UH/US440i:01

1 Documentação Elétrica Pasta 1

2 Manual do Operador Pasta 1

3 Catálogo de Peças Sobressalentes Pasta 1

4 Manual de Transporte e Comissionamento Pasta 1

5 Catálogo de Peças de Desgaste Pasta 1

6 Documentação do Produto Pasta 2

7
8
9
10
11
12
13
14
15
PASTA 2
16
Transport &
Commissioning
Manual 17
18
19
20
 UH/US440i:01
1 Sistema hidráulico

2 Diagrama do sistema hidráulico

3
4 Unidade de força – motor diesel, Volvo

Unidade de força – Engrenagem para

5 tomada de força, OMKA

6 Unidade de força – acoplamento do fluido KPTO

7 Unidade de trilhos

8 Transmissão por correia S 281.841 pt-BR

9
10 Transportador de alimentação

11
12
13
14
15
16
PD 1/2
17
Documentação do Produto
Product Documentation

S281.829 pt-BR Ver.3

18
20090304
19
20
Este documento é válido por:

Nº de série / Nº da máquina Assinatura

Sandvik UH440i / US440i

© Copyright 2009 Sandvik SRP AB.
Todos os direitos reservados. Nenhum parte deste documento pode
ser reproduzida ou copiada de nenhuma forma ou por qualquer meio,
sem a permissão por escrito da Sandvik SRP AB. Todos os dados e
informações contidos neste manual podem ser alterados sem aviso
prévio. Reservamo-nos o direito de corrigir eventuais erros de
impressão.

Número do documento: S281.829 pt-BR

Publicação: 20090304
Versão: 3

Sandvik SRP AB
Stationsplan, SE-233 81 Svedala, Suécia
Tel: +46 40-40 90 00, Fax: +46 40-40 92 60
www.sandvik.com
 UH/US440i:01
1
2
3
4
5
6
7
8
9
10
11 Detector de metal

12 Transportador de descarga

13 Aquecedor do motor (temporizador)

14
15
16 Unidade de força – motor diesel, Caterpillar

PD 2/2
17 Controle remoto por rádio (opção) S 281.842 pt-BR

Documentação do Produto
Product Documentation

S281.829 pt-BR Ver.3

18 Filtro anti-poeira (opção)

20090304
19
20
Este documento é válido por:

Nº de série / Nº da máquina Assinatura

Sandvik UH440i / US440i

© Copyright 2009 Sandvik SRP AB.
Todos os direitos reservados. Nenhum parte deste documento pode
ser reproduzida ou copiada de nenhuma forma ou por qualquer meio,
sem a permissão por escrito da Sandvik SRP AB. Todos os dados e
informações contidos neste manual podem ser alterados sem aviso
prévio. Reservamo-nos o direito de corrigir eventuais erros de
impressão.

Número do documento: S281.829 pt-BR

Publicação: 20090304
Versão: 3

Sandvik SRP AB
Stationsplan, SE-233 81 Svedala, Suécia
Tel: +46 40-40 90 00, Fax: +46 40-40 92 60
www.sandvik.com
 UH/US440i
Hydraulic system

1.1 Main pumps and main valves

1.2 A10VO pump
1.3 Main valve M4-15
1.4 Crawler
1.5 Feeder
1.6 Discharge conveyor
1.7 Hydroset system
1.8 Lubrication system crusher
1.9 Lubrication system crusher
1.10 Cooling fans Hydraulic Transmission
1.11 Cooling fan Lubrication system
1.12 Filter, Indicators
1.13 Cooling fan diesel engine
1.14 Return conveyor closed circuit (option)
1.15 Dust filter (option)
1.16
1.17
1.18
1.19
1.20 Hydraulic oils
 1.1 Huvudpumpar, huvudventiler / Main pumps, main valves

1 1

LS

LS

RH
LH X
PP
MPP LS
H1-B14 67
MT

MLS MP T
2
T P
P

MP MLS
P
MT
T
X

67 LS
LSz PP

H1-B15

UH/US440i
 1.2 A10VO pump

DR 310bar
FR 30bar

LS

FR 30bar

DR 310bar

Tools: Spanner 17, Allen key 3

UH/US440i
 1.3 Huvudventil / Main valve

A B
A, Q

B, Q
B

A, Q

5 On-off, blue
4 Proportional, black

A, P B, P

Tools: Spanner 13 Allen key 4

UH/US440i
 1.4 Larv / Crawler

LH

H1-Y2:A H1-Y2:B

14 A

RH

H1-Y1:B H1-Y1:A

B
A 14

23, 30

H1-Y4

UH/US440i
 1.5 Matartransportör / Feeder conveyor B1

48 A

69 20

B
A

LH

B1-Y1:A

B
A

15

B1-Y2:B

B1-Y2:A

MP MLS

21

UH/US440i
 1.6 Utlastningstransportör / Discharge conveyor B2

RH

H1-Y7:B B2-Y1:A
A 19

A
48

B2-Y2:B

A B

B2-Y2:A

18

B
B

UH/US440i
 1.7 Hydroset system

A B A B

31

32

K1-Y3:B

33

K1-Y3:A

UH/US440i
 1.8 Smörjsystem kross/ Lubrication system crusher

72

35
17

34
A

70

H1-Y8:B
A

K1-Y5:A

26

36

MLU
27
34
Ø 1,3 71

UH/US440i
 1.9 Smörjsystem kross/ Lubrication system crusher

66 28
66

73

78 79

UH/US440i
 1.10 Kylfläktar Hydraulik Transmission / Cooling fans Hydraulic Transmission

MCH H1-Y3

K1-Y2

80

HYDRAULIC TRANSMISSION

T P

P
D

13
D
12
T

RH
22, 23
MCT

24

UH/US440i
 1.11 Kylfläkt Smörjsystem / Cooling fan Lubrication system

16
T P

74

25

Ø 11,0

MP MLS

K1-Y4:A

UH/US440i
 1.12 Filter, givare / Filters, indicators
RH LH
H1-B12
68
H1-B11
68
7

11 50

H1-B9

50
H1-B13

51, 56

H1-B6

66

10

H1-B8

UH/US440i
 1.13 Kylfläkt dieselmotor / Cooling fan diesel engine

81

DM1-Y2

MCD

80

UH/US440i
 1.14 Returconveyor / Return conveyor B5

82

48

T P

T
P

B5-Y1:A

UH/US440i
 1.15 Dammfilter / Dust filter DF1 (Option)

80

MDF P

B A
39

DF1-Y1:A 40, 41 DF1-Y1:B

37
B

38

UH/US440i
 1.20 Hydraulic oils

Hydraulic oil on a mineral oil base: type HVLP ref. to DIN 51524 part 3,
SS155434 AV, SMR-norm

Viscosity Index VI: min 150

Viscosity Grade: ISO VG 68 ISO VG 46 ISO VG 32

Ambient air temp: -5 to +45 C -15 to +35 C -25 to +25 C
Max permissible viscosity, min temp 1000 cSt -5 C -15 C -25 C
in oil tank - start-up:
Min permissible viscosity, max temp 10 cSt +90 C +80 C +70 C
in oil tank - short term:
Optimal operating viscosity, temp oil 16 – 36 cSt +55 to +75 C +45 to +65 C +35 to +55 C
tank:

Applicable hydraulic oil, for example:

Statoil Hydra Way HVXA 32, HVXA 46, HVXA 68
Shell Tellus Oil TX32, Oil TX46, Oil TX68
Q8 Händel 32, 46, 68

General
Filling of hydraulic oil should be done through the filler cap on top of the return
filter to avoid contamination.
When repairing, be careful when opening hose and valve connections to avoid
contamination coming into the system. Clean up with compressed air first.
Do not let oil seep into the ground when repairing. Use a collecting vessel.
Store hydraulic oil in a proper way to avoid water and contamination to enter the
oil.
Before mixing hydraulic oil from different manufacturer, check with your oil supplier.
Do not mix oil made from different bases as this can cause filter clogging and other
problems.
Current official regulations must be observed when disposing old used oil.

Oil products present environmental and fire risks and can

Warning !!! cause injury if inhaled or brought into contact with the skin.
Follow your supplier's instructions and safety directions.

Hydraulic oil under high pressure leaking out from small

Warning !!! holes can penetrate unprotected skin causing serious
injures. Do not touch the leak with your bare hands. Consult
a doctor if injured.

Before disconnecting hoses be sure that the system

Caution !! pressure has been relieved. Use a vacuum pump to
minimize the spillage.

UH/US440i
 SEBU7901-01
February 2006

Operation and
Maintenance
Manual
C11 and C13 Industrial Engines
LGK1-Up (Engine)
GLS1-Up (Engine)
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SEBU7901-01 3
Table of Contents

Table of Contents Warranty Section

Warranty Information ............................................ 89
Foreword ................................................................. 4
Reference Information Section
Safety Section
Engine Ratings ..................................................... 91
Safety Messages .................................................... 6
Customer Service ................................................. 92
General Hazard Information ................................... 8
Reference Materials .............................................. 94
Burn Prevention .................................................... 10
Index Section
Fire Prevention and Explosion Prevention ............ 10
Index ..................................................................... 98
Crushing Prevention and Cutting Prevention ........ 12

Mounting and Dismounting ................................... 13

Before Starting Engine .......................................... 13

Engine Starting ..................................................... 13

Engine Stopping ................................................... 13

Electrical System .................................................. 14

Engine Electronics ................................................ 15

Product Information Section

General Information .............................................. 16

Model Views ......................................................... 17

Product Identification Information ........................ 21

Operation Section
Lifting and Storage ................................................ 23

Gauges and Indicators .......................................... 24

Features and Controls .......................................... 26

Engine Diagnostics ............................................... 30

Engine Starting ..................................................... 35

Engine Operation .................................................. 38

Engine Stopping ................................................... 40

Cold Weather Operation ....................................... 42

Maintenance Section
Refill Capacities .................................................... 44

Maintenance Interval Schedule ............................ 51

4 SEBU7901-01
Foreword
Foreword
Literature Information
This manual contains safety, operation instructions,
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literature holder or literature storage area. Read,
study and keep it with the literature and engine
information.
English is the primary language for all Caterpillar
publications. The English used facilitates translation
and consistency in electronic media delivery.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Caterpillar dealer for the latest
available information.
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
warning situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on this product.
Operation
Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by fuel consumption, service hours and/or calendar
time maintenance intervals. Items in the maintenance
schedule are referenced to detailed instructions that
follow.
Use fuel consumption or service hours to determine
intervals. Calendar intervals shown (daily, annually,
etc.) may be used instead of service meter intervals
if they provide more convenient schedules and
approximate the indicated service meter reading.
Recommended service should be performed at the
appropriate intervals as indicated in the Maintenance
Interval Schedule. The actual operating environment
of the engine also governs the Maintenance Interval
Schedule. Therefore, under extremely severe,
dusty, wet or freezing cold operating conditions,
more frequent lubrication and maintenance than is
specified in the Maintenance Interval Schedule may
be necessary.
The maintenance schedule items are organized for
a preventive maintenance management program. If
the preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation and application. We recommend that
the maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engine’s permanent record.
See the section in the Operation and Maintenance
Manual, “Maintenance Records” for information
regarding documents that are generally accepted
as proof of maintenance or repair. Your authorized
Caterpillar dealer can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.
Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
programs. If you experience a major engine failure,
there are also numerous after failure overhaul options
available from your Caterpillar dealer. Consult with
your dealer for information regarding these options.
SEBU7901-01 5
Foreword

California Proposition 65 Warning

Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.

Battery posts, terminals and related accessories

contain lead and lead compounds. Wash hands
after handling.
6 SEBU7901-01
Safety Section
Safety Messages

Safety Section
i02491938

Safety Messages
SMCS Code: 1000; 7405

g01245645
Illustration 1
Location of safety messages on C11 engine
SEBU7901-01 7
Safety Section
Safety Messages

g01245647
Illustration 2
Location of safety messages on C13 engine

There may be several specific safety messages on

your engine. The exact location and a description of
the safety messages are reviewed in this section.
Please become familiar with all safety messages.

Ensure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if the words cannot be read or if the
illustrations are not visible. Use a cloth, water,
and soap to clean the safety messages. Do not
use solvents, gasoline, or other harsh chemicals.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages. The
safety messages that are loosened could drop off
of the engine. g00934493
Illustration 3
Replace any safety message that is damaged or
missing. If a safety message is attached to a part
of the engine that is replaced, install a new safety
message on the replacement part. Your Caterpillar Do not operate or work on this engine unless you
dealer can provide new safety messages. have read and understand the instructions and
warnings in the Operation and Maintenance Man-
Universal Warning (1) ual. Failure to follow the instructions or heed the
warnings could result in injury or death. Contact
The safety messages for the universal warning are any Caterpillar dealer for replacement manuals.
located toward the front of the engine on both sides Proper care is your responsibility.
of the valve cover base.
8 SEBU7901-01
Safety Section
General Hazard Information
i02327617
General Hazard Information
SMCS Code: 1000; 7405
g00104545
Illustration 4
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar
dealer. Attach the warning tags to the engine and to
each operator control station. When it is appropriate,
disconnect the starting controls.
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
• Filler caps
• Grease fittings
• Pressure taps
• Breathers
• Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.
g00702020
Illustration 5
• Wear a hard hat, protective glasses, and other
protective equipment, as required.
• When work is performed around an engine that is
operating, wear protective devices for ears in order
to help prevent damage to hearing.
• Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the engine.
• Ensure that all protective guards and all covers are
secured in place on the engine.
• Never put maintenance fluids into glass containers.
Glass containers can break.
• Use all cleaning solutions with care.
• Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:
• The engine is stopped. Ensure that the engine
cannot be started.
• Disconnect the batteries when maintenance
is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
• Do not attempt any repairs that are not understood.
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
Pressurized Air and Water
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
personal injury.
SEBU7901-01
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).
Fluid Penetration
Illustration 6
g00687600
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for the following items:
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids
Obey all local regulations for the disposal of liquids.
9
Safety Section
General Hazard Information
Asbestos Information
g00702022
Illustration 7
Caterpillar equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning.
• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
10 SEBU7901-01
Safety Section
Burn Prevention

• Comply with applicable rules and regulations
for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal
of asbestos.
• Stay away from areas that might have asbestos
particles in the air.
Dispose of Waste Properly
Check the coolant level after the engine has stopped
and the engine has been allowed to cool. Ensure
that the filler cap is cool before removing the filler
cap. The filler cap must be cool enough to touch with
a bare hand. Remove the filler cap slowly in order
to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil or hot components
to contact the skin.

If the application has a makeup tank, remove the cap

for the makeup tank after the engine has stopped.
The filler cap must be cool to the touch.

Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.

g00706404 Do not smoke while checking the battery electrolyte

Illustration 8
levels. Batteries give off flammable fumes which can
explode.
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
Always wear protective glasses when you work with
disposed of according to local regulations.
batteries. Wash hands after touching batteries. The
use of gloves is recommended.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water. i02469590

Fire Prevention and Explosion

Prevention
i02088921

Burn Prevention
SMCS Code: 1000; 7405
SMCS Code: 1000; 7405

Do not touch any part of an operating engine.

Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure in
the appropriate system before any lines, fittings or
related items are disconnected.

Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. Any contact with
hot coolant or with steam can cause severe burns. Illustration 9
g00704000
Allow cooling system components to cool before the
cooling system is drained. All fuels, most lubricants, and some coolant mixtures
are flammable.
SEBU7901-01 11
Safety Section
Fire Prevention and Explosion Prevention

Flammable fluids that are leaking or spilled onto hot Inspect all lines and hoses for wear or for
surfaces or onto electrical components can cause deterioration. The hoses must be properly routed.
a fire. Fire may cause personal injury and property The lines and hoses must have adequate support
damage. and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after Oil filters and fuel filters must be properly installed.
an emergency shutdown. The filter housings must be tightened to the proper
torque.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.

If the application involves the presence of combustible

gases, consult your Caterpillar dealer for additional
information about suitable protection devices.

Remove all flammable materials such as fuel, oil, and

debris from the engine. Do not allow any flammable
materials to accumulate on the engine.

Store fuels and lubricants in properly marked

containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.

Do not expose the engine to any flame.

g00704059
Illustration 10
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
Use caution when you are refueling an engine. Do
a tube, or a seal failure. Exhaust shields must be
not smoke while you are refueling an engine. Do not
installed correctly.
refuel an engine near open flames or sparks. Always
stop the engine before refueling.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines or tanks that contain
flammable fluid. Clean any such lines or tanks
thoroughly with a nonflammable solvent prior to
welding or flame cutting.

Wiring must be kept in good condition. All electrical

wires must be properly routed and securely attached.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.

Eliminate all wiring that is unattached or unnecessary.

Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.

Arcing or sparking could cause a fire. Secure

connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
g00704135
Illustration 11
12
Safety Section
Crushing Prevention and Cutting Prevention
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.
Improper jumper cable connections can cause an
explosion that can result in injury. Refer to this
Operation and Maintenance Manual, “Starting with
Jump Start Cables” for specific instructions.
Do not charge a frozen battery. This may cause an
explosion.
The batteries must be kept clean. The covers
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Ether
Ether is flammable and poisonous.
Use ether in well ventilated areas. Do not smoke
while you are replacing an ether cylinder or while you
are using an ether spray.
Do not store ether cylinders in living areas or in the
engine compartment. Do not store ether cylinders
in direct sunlight or in temperatures above 49 °C
(120 °F). Keep ether cylinders away from open
flames or sparks.
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
Do not spray ether into an engine if the engine is
equipped with a thermal starting aid for cold weather
starting.
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
SEBU7901-01
Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.
• Flexible part of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.
i01359666
Crushing Prevention and
Cutting Prevention
SMCS Code: 1000; 7405
Support the component properly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
SEBU7901-01
i01372247
Mounting and Dismounting
SMCS Code: 1000; 7405
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items in good repair.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
controls as handholds.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
i00911989
Before Starting Engine
SMCS Code: 1000
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. All protective
guards and all protective covers must be installed
if the engine must be started in order to perform
service procedures. To help prevent an accident that
is caused by parts in rotation, work around the parts
carefully.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.
On the initial start-up of a new engine or an engine
that has been serviced, prepare to stop the engine
if an overspeed condition occurs. This may be
accomplished by shutting off the fuel supply to the
engine and/or shutting off the air supply to the engine.
See the Service Manual for repairs and for
adjustments.
13
Safety Section
Mounting and Dismounting
i02136012
Engine Starting
SMCS Code: 1000
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
If there is a possibility that unburned gas remains in
the exhaust system, refer to the purge procedure in
this Operation and Maintenance Manual, “Engine
Starting” topic in the Operation Section.
Start the engine from the operator’s compartment or
from the engine start switch.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature and the oil
temperature during heater operation.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
i01462046
Engine Stopping
SMCS Code: 1000
Stop the engine according to the procedure in
the Operation and Maintenance Manual, “Engine
Stopping (Operation Section)” in order to avoid
overheating of the engine and accelerated wear of
the engine components.
14 SEBU7901-01
Safety Section
Electrical System

Use the Emergency Stop Button (if equipped) ONLY Grounding Practices
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
corrected.

Stop the engine if an overspeed condition occurs

during the initial start-up of a new engine or an engine
that has been overhauled. This may be accomplished
by shutting off the fuel supply to the engine and/or
shutting off the air supply to the engine.

To stop an electronically controlled engine, cut the

power to the engine.

i02469632

Electrical System
SMCS Code: 1000; 1400

Never disconnect any charging unit circuit or battery

circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.

To help prevent sparks from igniting combustible

gases that are produced by some batteries, the g00771448
negative “−” jump start cable should be connected Illustration 12
last from the external power source to the negative Typical example
“−” terminal of the starting motor. If the starting motor Grounding Stud To Battery Ground
is not equipped with a negative “−” terminal, connect
the jump start cable to the engine block.

Check the electrical wires daily for wires that are

loose or frayed. Tighten all loose electrical wires
before the engine is started. Repair all frayed
electrical wires before the engine is started. Refer to
the “Engine Starting” section of this Operation and
Maintenance Manual for specific starting instructions.
SEBU7901-01
g00771487
Illustration 13
Typical example
Alternate Grounding Stud To Battery Ground
Proper grounding for the engine electrical system
is necessary for optimum engine performance
and reliability. Improper grounding will result in
uncontrolled electrical circuit paths and in unreliable
electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft bearing
journal surfaces, and to aluminum components.
Engines that are installed without engine-to-frame
ground straps can be damaged by electrical
discharge.
To ensure that the engine and the engine electrical
systems function properly, an engine-to-frame ground
strap with a direct path to the battery must be used.
This path may be provided by way of a starting motor
ground, a starting motor ground to the frame, or a
direct engine ground to the frame.
All grounds should be tight and free of corrosion. The
engine alternator must be grounded to the negative
“-” battery terminal with a wire that is adequate to
handle the full charging current of the alternator.
15
Safety Section
Engine Electronics
i01563743
Engine Electronics
SMCS Code: 1000; 1400; 1900
Tampering with the electronic system installation
or the OEM wiring installation can be dangerous
and could result in personal injury or death and/or
engine damage.
This engine has a comprehensive, programmable
Engine Monitoring System. The Engine Control
Module (ECM) has the ability to monitor the engine
operating conditions. If any of the engine parameters
extend outside an allowable range, the ECM will
initiate an immediate action.
The following actions are available for engine
monitoring control: WARNING, DERATE, and
SHUTDOWN. These engine monitoring modes have
the ability to limit engine speed and/or the engine
power.
Many of the parameters that are monitored by the
ECM can be programmed for the engine monitoring
functions. The following parameters can be monitored
as a part of the Engine Monitoring System:
• Operating Altitude
• Engine Coolant Level
• Engine Coolant Temperature
• Engine Oil Pressure
• Engine Speed
• Fuel Temperature
• Intake Manifold Air Temperature
• System Voltage
The Engine Monitoring package can vary for different
engine models and different engine applications.
However, the monitoring system and the engine
monitoring control will be similar for all engines.
Note: Many of the engine control systems and display
modules that are available for Caterpillar Engines will
work in unison with the Engine Monitoring System.
Together, the two controls will provide the engine
monitoring function for the specific engine application.
Refer to the Electronic Troubleshooting Manual for
more information on the Engine Monitoring System.
16 SEBU7901-01
Product Information Section
General Information

Product Information
Section

General Information
i01472899

Welding on Engines with

Electronic Controls
SMCS Code: 1000

NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.

To help avoid damage to the electronic controls,

proper welding procedures are necessary. Before
you weld on equipment with electronic controls,
observe the following precautions:

1. Turn off the engine. Place the engine control

switch in the OFF position.

2. If the engine has a battery disconnect switch, open

the switch. Otherwise, disconnect the negative “-”
battery cable from the battery of the equipment.

NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other com-
ponents.

Clamp the ground cable from the welder to the com-

ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.

3. Clamp the ground cable from the welder to the

component that will be welded. Place the clamp
as close as possible to the weld.

4. Protect wiring harnesses from welding debris and

from spatter. Use proper welding procedures.
SEBU7901-01 17
Product Information Section
Model Views

Model Views
i02490267

Model View Illustrations

SMCS Code: 1000

g01244135
Illustration 14
Left side view of C11 and C13 industrial engine
(1) Oil filler (5) Air inlet from aftercooler (9) Heater inlet
(2) Lifting eye (6) Fuel priming pump (10) Oil drain
(3) Water outlet (7) ECM (11) Fuel inlet
(4) Oil level gauge (8) Fuel filter
18 SEBU7901-01
Product Information Section
Model Views

g01244139
Illustration 15
Right side view of C11 and C13 industrial engine
(1) Oil pressure connection and location for (4) Air inlet (8) Oil drain
oil sampling (5) Air outlet to aftercooler (9) Mounting block for an oil filter bypass
(2) Lifting eye (6) Water inlet (10) Oil filter
(3) Jacket water heater (7) Heater inlet for lubrication

i02094174 Table 2

Engine Description C13 Engine Specifications

Cylinders and Arrangement In-line six cylinder
SMCS Code: 1000
Bore 130 mm (5.2 inch)
Table 1
Stroke 157 mm (6.2 inch)
C11 Engine Specifications
Displacement 12.5 L (763 in3)
Cylinders and Arrangement In-line six cylinder
Firing Order 1-5-3-6-2-4
Bore 130 mm (5.2 inch)
Rotation (flywheel end) Counterclockwise
Stroke 140 mm (5.5 inch)
Displacement 11.1 L (677 in3) The electronic engines that are covered by this
manual have the following characteristics: direct fuel
Firing Order 1-5-3-6-2-4
injection, electronic unit injection that is mechanically
Rotation (flywheel end) Counterclockwise actuated, turbocharged, and air-to-air aftercooled
(ATAAC).

The electronic engine control system provides the

following functions: electronic governing, automatic
air to fuel ratio control, torque rise shaping, injection
timing control, and system diagnostics.
SEBU7901-01
An electronic governor controls the output of the unit
injectors in order to maintain the engine rpm that
is desired. The functions of the governor include a
programmable low idle and a 20 rpm to 200 rpm
governor overrun.
Very high injection pressures are produced by
electronically controlled, mechanically actuated unit
injectors. The injectors combine the pumping and the
electronic fuel metering (duration and timing) during
injection. The unit injectors accurately control smoke
limiting, white smoke, and engine acceleration rates.
There is one unit injector per cylinder. Individual unit
injectors meter the fuel. The individual unit injectors
also pump the fuel. The metering and the pumping is
done under high pressure. High injection pressures
help to reduce fuel consumption and emissions.
The use of this type of unit injector provides total
electronic control of injection timing. The injection
timing varies with engine operating conditions. The
engine performance is optimized in the following
areas:
• Starting
• Emissions
• Noise
• Fuel consumption
The timing advance is achieved through precise
control of the injector firing. Engine speed is
controlled by adjusting the firing duration. The
information is provided to the Electronic Control
Module (ECM) by a engine speed/timing sensor. The
information is for detection of cylinder position and
engine speed.
The engines have built-in diagnostics in order to
ensure that all of the components are functioning
and operating properly. In the event of a system
component deviation from the programmed limits,
the operator will be alerted to the condition by a
DIAGNOSTIC lamp that is mounted on the control
panel. An electronic service tool that is provided by
Caterpillar may be used to read the numerical code
of the diagnostic flash code. There are three types of
diagnostic codes: ACTIVE, LOGGED, and EVENT.
These codes are logged and stored in the ECM.
Refer to the Operation and Maintenance Manual,
“Engine Diagnostics” for additional information.
The cooling system consists of the following items:
a centrifugal pump that is driven by a gear, water
temperature regulator, an oil cooler, and a radiator
that incorporates a shunt system.
19
Product Information Section
Model Views
The engine lubricating oil is supplied by a gear
type pump. The engine lubricating oil is cooled and
filtered. Bypass valves provide unrestricted flow
of lubrication oil to the engine parts when the oil
viscosity is high or if either the oil cooler or the oil
filter elements (paper cartridge) become plugged.
Engine efficiency, efficiency of emission controls, and
engine performance depend on adherence to proper
operation and maintenance recommendations. This
includes the use of recommended fuels, coolants
and lubrication oils.
Aftermarket Products and
Caterpillar Engines
NOTICE
In order to maximize fuel system life and prevent
premature wear out from abrasive particles in the
fuel, a two micron absolute high efficiency fuel filter
is required for all Caterpillar Electronic Unit Injectors.
Caterpillar High Efficiency Fuel Filters meet these
requirements. Consult your Caterpillar dealer for the
proper part numbers.
When auxiliary devices, accessories, or consumables
(filters, additives, catalysts, etc) which are made
by other manufacturers are used on Caterpillar
products, the Caterpillar warranty is not affected
simply because of such use.
However, failures that result from the installation
or use of other manufacturers’ devices,
accessories, or consumables are NOT Caterpillar
defects. Therefore, the defects are NOT covered
under the Caterpillar warranty.
Welding and Caterpillar Electronic
Engines
NOTICE
Because the strength of the frame may decrease,
some manufacturers do not recommend welding onto
a chassis frame or rail. Consult the OEM of the equip-
ment or your Caterpillar dealer regarding welding on
a chassis frame or rail.
To help avoid damage to the electronic controls,
proper welding procedures are necessary. Before
welding on a vehicle that is equipped with an
electronic engine, observe the following precautions:
1. Turn off the engine. Place the key start switch in
the OFF position.
20 SEBU7901-01
Product Information Section
Model Views

2. If the application has a battery disconnect switch,

open the switch. Otherwise, disconnect the
negative “-” battery cable from the battery of the
vehicle.

NOTICE
Do not ground the welder to electrical components
such as the ECM or sensors. Improper grounding can
cause damage to the drive train bearings, hydraulic
components, electrical components, and other com-
ponents.

Clamp the ground cable from the welder to the com-

ponent that will be welded. Place the clamp as close
as possible to the weld. This will help reduce the pos-
sibility of damage.

3. Clamp the ground cable from the welder to the

component that will be welded. Place the clamp
as close as possible to the weld.

4. Protect wiring harnesses from welding debris and

from spatter. Use proper welding procedures.
SEBU7901-01 21
Product Information Section
Product Identification Information

Product Identification Engine Arrangement Number ___________________________

Information Engine Modification Number ____________________________

The engine identification plate also contains other

i02495907 important information about the engine.
Plate Locations and Film
Locations i02164876

SMCS Code: 1000

Reference Numbers
SMCS Code: 1000

Information for the following items may be needed to

order parts. Locate the information for your engine.
Record the information in the appropriate space.
Make a copy of this list for a record. Keep the
information for future reference.

Record for Reference

Engine Model _______________________________________________

Engine Serial number _____________________________________

Engine Low Idle rpm ______________________________________

Engine Full Load rpm _____________________________________

Primary Fuel Filter _________________________________________

g01247995 Water Separator Element ________________________________

Illustration 16

Secondary Fuel Filter Element __________________________

Caterpillar engines are identified by serial numbers
and by arrangement numbers. These numbers are
Lubrication Oil Filter Element ___________________________
shown on the engine serial number plate and on the
engine information plate. Caterpillar dealers need
Auxiliary Oil Filter Element _______________________________
these numbers in order to determine the components
that were included with the engine. This permits
Total Lubrication System Capacity _____________________
accurate identification of replacement part numbers.
Total Cooling System Capacity _________________________
Serial Number Plate (1)
Air Cleaner Element _______________________________________
The engine serial number plate is located on the rear
right side of the engine block. Fan Drive Belt ______________________________________________

Engine serial number _____________________________________ Alternator Belt ______________________________________________

Engine model _______________________________________________

Arrangement number _____________________________________

Information Plate (2)

The engine information plate is located on the intake
manifold near the front of the right side of the engine.

Engine Serial Number ____________________________________

22 SEBU7901-01
Product Information Section
Product Identification Information

i00844066 Engine Parameters

Emissions Certification Film • Top Engine Limit (TEL) at 100 percent load (If
Applicable) _______________________________________________
SMCS Code: 1000; 7405
• Torque Limit ______________________________________________
• High Idle (If Applicable) ________________________________
• Low Idle ___________________________________________________
• Intermediate Speed ____________________________________
g00284658
Illustration 17 Engine Monitoring Mode
EPA Emissions Certification Film
• “OFF” ______________________________________________________
• “Warning” _________________________________________________
• “Warning/Derate” ________________________________________
• “Warning/Derate/Shutdown” __________________________
• “Coolant Level Sensor Enable/Disable” ____________
• “Fuel Pressure Sensor Enable/Disable” ___________
• “Inlet Manifold Air Temperature Sensor
Enable/Disable” _________________________________________
g00415538
Illustration 18 Equipment ID
European Emissions Certification Film
Maintenance Indicator
The EPA Emissions Certification Film (if equipped)
and/or the European Emissions Certification Film (if • Manual-Hours
equipped) is located on the side of the engine.
• Auto-Hours
i02238153
• Manual-Fuel
Customer Specified • Auto-Fuel
Parameters
Auxiliary Pressure
SMCS Code: 1000
• High Warning Set Point ________________________________
To record programmed specifications, use the
following blanks. Auxiliary Temperature

Customer Passwords • High Warning Set Point ________________________________

• First Password ___________________________________________
• Second Password ______________________________________
Power Rating (hp at rpm) ______________________________

Rating Selection (A-E) __________________________________

PTO Governor Parameters

• PTO Engine Speed Ramp Rate __________ rpm/sec

SEBU7901-01
Operation Section
Lifting and Storage
i01988813
Product Lifting
SMCS Code: 1000; 1404; 7002
g00103219
Illustration 19
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.
When it is necessary to remove a component at an
angle, only use a link bracket that is properly rated for
the weight.
Use a hoist to remove heavy components. Use
an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.
Some removals require lifting the fixtures in order to
obtain proper balance and safety.
To remove the engine ONLY, use the lifting eyes that
are on the engine.
Lifting eyes are designed and installed for the specific
engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures
for proper engine lifting.
23
Operation Section
Lifting and Storage
i02068367
Product Storage
SMCS Code: 1000; 1404; 7002
If the engine will not be started for several weeks, the
lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
liner surface. Rust on the cylinder liner surface will
cause increased engine wear and a reduction in
engine service life.
To help prevent excessive engine wear, use the
following guidelines:
• Complete all of the lubrication recommendations
that are listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
(Maintenance Section).
• If freezing temperatures are expected, check the
cooling system for adequate protection against
freezing. See this Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
(Maintenance Section).
If an engine is out of operation and if use of the engine
is not planned, special precautions should be made.
If the engine will be stored for more than one month,
a complete protection procedure is recommended.
For more detailed information on engine storage, see
Special Instruction, SEHS9031, “Storage Procedure
For Caterpillar Products”.
Your Caterpillar dealer can assist in preparing the
engine for extended storage periods.
24
Operation Section
Gauges and Indicators
Gauges and Indicators
i01465281
Gauges and Indicators
SMCS Code: 1900; 7450
Your engine may not have the same gauges or all of
the gauges that are described. For more information
about the gauge package, see the literature that is
provided by the OEM.
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing
the gauges over a period of time.
Noticeable changes in gauge readings indicate
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change
even if the readings are within specifications.
Determine the cause of any significant change in the
readings. Then, correct any cause of any significant
change in the readings. Consult your Caterpillar
dealer for assistance.
Caterpillar requires one lamp in addition to the gauge
package that is normally provided. The “Diagnostic”
lamp is yellow or amber. The “Diagnostic” lamp will
communicate the status of the engine’s electronic
system. The optional red “Warning” lamp is also
available. This red “Warning” lamp warns the operator
of engine problems.
The following conditions are some examples of the
engine problems:
• Low oil pressure
• High coolant temperature
• Low coolant level
• High inlet air temperature
Engine Oil Pressure – Typical oil
pressure for an engine at rated speed
with SAE 10W30 or with SAE 15W40 is
240 to 480 kPa (35 to 70 psi).
A lower oil pressure is normal at low idle. If the load
is stable and the gauge reading changes, perform
the following procedure:
1. Remove the load.
2. Reduce engine speed to low idle.
SEBU7901-01
3. Check the oil level. Maintain the oil level at the
proper amount.
If the gauge continues to fluctuate, consult your
Caterpillar dealer.
The diagnostic lamp will turn on if the oil pressure
drops below 35 kPa (5 psi) at low idle rpm. The
diagnostic code will be logged in the Engine Control
Module (ECM).
Engine Oil Temperature – This gauge
indicates the engine oil temperature. An
oil temperature that is higher than normal
indicates a heat problem in the lubrication system
and/or the cooling system. This problem can damage
the cylinder heads, the cylinder liners, the pistons,
and the crankshaft bearings.
Jacket Water Coolant Temperature –
Typical temperature range is 88 to 102 °C
(190 to 215 °F). The maximum allowable
temperature with the pressurized cooling system is
105 °C (220 °F). Higher temperatures may occur
under certain conditions. The water temperature
reading may vary according to load. The reading
should never exceed the boiling point for the
pressurized system that is being used.
If the engine is operating above the normal range
or steam becomes apparent, perform the following
procedure:
1. Reduce the load and the engine rpm.
2. Inspect the cooling system for leaks.
3. Determine if the engine must be shut down
immediately or if the engine can be cooled by
reducing the load.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
4. Check the coolant level.
Tachometer – This gauge indicates engine
speed. When the throttle control lever is
moved to the full throttle position without
load, the engine is running at high idle. The engine is
running at the full load rpm when the throttle control
lever is at the full throttle position with maximum
rated load.
SEBU7901-01 25
Operation Section
Gauges and Indicators

Note: The default high idle rpm and the full load rpm
are stamped on the Information Plate.

Ammeter – This gauge indicates the

amount of charge or of discharge in the
battery charging circuit. Operation of the
indicator should be to the right side of “0”(zero).

Service Hour Meter – This gauge

indicates the total number of clock hours
of engine operation. Hours of operation
are logged in the ECM. A service tool is needed to
retrieve the hours from the ECM. A Service Hour
Meter may be installed on the engine.

Fuel Pressure – This gauge indicates fuel

pressure to the electronic unit injectors from
the fuel filter. The indicator should indicate
the “NORMAL” range. A decrease in fuel pressure
usually indicates a plugged fuel filter.

Fuel Level – This gauge indicates the

level of fuel in the fuel tank. The fuel level
gauge registers the fuel level only when the
ignition switch is in the ON position.
26
Operation Section
Features and Controls
Features and Controls
i02441160
Monitoring System
SMCS Code: 1900; 7400; 7402; 7450; 7451
The Monitoring System is designed to alert the
operator to an immediate problem with any of the
engine systems that are monitored. The Monitoring
System is also designed to alert the operator to an
impending problem with any of the engine systems
that are monitored.
Indicators and Gauges
g01063079
Illustration 20
Gauge cluster and indicators
Diagnostic Lamp (1) – The diagnostic
lamp is used to indicate the existence
of a fault by flashing a fault code. For a
more detailed discussion of the diagnostic lamp,
please see this Operation and Maintenance Manual,
“Diagnostic Lamp” topic.
Engine Oil Pressure (2) – The oil pressure
should be greatest after a cold engine is
started. The pressure will decrease as
the engine warms up. The pressure will increase
when the engine rpm is increased. The pressure will
stabilize when the engine rpm is stable.
A lower oil pressure is normal at low idle. If the load
is stable and the gauge reading changes, perform
the following procedure:
1. Remove the load.
SEBU7901-01
2. Reduce engine speed to low idle.
3. Check and maintain the oil level.
Tachometer (3) – This gauge indicates
engine speed (rpm). When the throttle
control lever is moved to the full throttle
position without load, the engine is running at high
idle. The engine is running at the full load rpm when
the throttle control lever is at the full throttle position
with maximum rated load.
NOTICE
To help prevent engine damage, never exceed the
high idle rpm. Overspeeding can result in serious
damage to the engine. The engine can be operated
at high idle without damage, but should never be
allowed to exceed high idle rpm.
Note: The high idle rpm and the full load rpm are
stamped on the Information Plate.
Coolant Temperature (4) – When the
coolant temperature is above the normal
operating value, the coolant temperature
gauge will be in the red zone. Refer to the Messenger
display for any additional information that may be
available.
Warning Lamp (5) – There is a general
fault in the engine. Refer to the Messenger
display for any additional information that
may be available.
Fuel Pressure (6) – This gauge indicates
fuel pressure to the fuel injection pump from
the fuel filter. A decrease in fuel pressure
usually indicates a dirty fuel filter or a plugged fuel
filter. As the fuel filter becomes plugged, there will be
a noticeable reduction in the engine’s performance.
System Voltage (7) – This gauge indicates
the voltage of the electrical system.
Circuit Breaker (8) – Reset the circuit breaker if
a circuit breaker trips. Press the button in order to
reset the circuit breaker. If the electrical system is
working properly, the button will remain pressed. If
the button does not remain pressed or if the circuit
breaker trips soon after being reset, check the
appropriate electrical circuit. Repair the electrical
circuit, if necessary.
SEBU7901-01
Start Switch (9) – The start switch has three
positions: OFF, RUN, and START. When the start
switch is turned clockwise to the RUN position, the
lamps will flash for five seconds during the system
test. The lamps will then shut off. In the RUN position,
the ECM and electronic systems are powered up.
Idle Speed Switch (10) – When the switch
is in the up position, the engine speed
increases to HIGH IDLE. When the switch
is in the down position, the engine speed decreases
to LOW IDLE.
Maintenance Lamp (11) – The ECM
records data that is related to equipment
maintenance. The ECM will activate
the maintenance indicator lamp when scheduled
maintenance is due. The maintenance indicator
lamp can be reset by actuating the maintenance
clear switch. The maintenance interval may be
based on operating hours or fuel consumption.
The ECM provides information that pertains to
maintenance intervals and the last maintenance that
was performed.
Maintenance Clear Switch (12) – The
maintenance clear switch is required
to reset the maintenance lamp after
maintenance on the engine is performed.
Shutdown Switch (13) – Use the engine
shutdown switch in order to stop the
engine. Push the shutdown switch in order
to put the switch in the OFF position. This will stop
the engine. After the engine stops, turn the knob
clockwise. This will reset the engine shutdown switch
to the ON position.
Service Tool Connector (14) – For more information
regarding the use of Caterpillar Electronic Technician
(ET) and the PC requirements for Cat ET, refer to
the documentation that accompanies your Cat ET
software.
27
Operation Section
Features and Controls
Caterpillar Messenger Display
g01063102
Illustration 21
Digital display area (15) – The Messenger system
shows information on the digital display area.
Previous button (16) – Use the previous button to
return to information that was previously shown on
the digital display area.
“Scroll up/scroll left button” (17) – This button is
used to scroll up through information that is shown
on the display area. The button can also be used to
scroll to the left through information that is shown on
the display area.
“Scroll down/scroll right button” (18) – This
button is used to scroll down through information that
is shown on the display area. The button can also be
used to scroll to the right through information that is
shown on the display area.
OK button (19) – This button may be used in order
to confirm the selections that were selected with
the“scroll up/scroll left” buttonand with the “scroll
down/scroll right” button.
Performance Monitor Screen
The following options are available through the
performance monitor screen:
Engine Speed – When you scroll to this option, the
performance monitor screen will show the engine
RPM.
Engine Coolant Temperature – When you scroll to
this option, the performance monitor screen will show
the engine coolant temperature in degrees fahrenheit
or in degrees celsius.
Fuel Level – When you scroll to this option, the
performance monitor screen will show the amount of
fuel that remains in the fuel tank as a percentage of
a full tank.
28
Operation Section
Features and Controls
Display Screen for Totals
The following information is available through the
display:
Service Hours – When you scroll to this option, the
display shows the total amount of service hours that
the engine has accumulated.
Total Time – When you scroll to this option, the
display shows the total hours for the engine ECM.
Total Fuel – When you scroll to this option, the
display shows the total amount of fuel that has been
consumed.
Display Screen for Settings
The following options are available through the
payload display:
Language – Select this option in order to change
the language that is shown on the display.
Units – Select this option in order to choose the
desired system of measurement. The choices are
metric or English.
Adjust Contrast – Select this option in order to
adjust the contrast of the display so that visibility will
be improved.
Adjust the Backlight – Select this option in order to
adjust the backlighting of the display so that visibility
will be improved.
Equipment ID – Select this option in order to view
the product identification number.
Product Identification – Select this option in order
to view the product identification number.
Service Display
The following options are password protection.
You must enter a password in order to change the
settings.
View – Select this option in order to view events that
have been logged by the monitoring system. If you
use an authorized password, you can clear individual
events.
Clear All Diagnostics – If you use an authorized
password, you can select this option in order to clear
all logged events.
SYSTEM PARAMETERS
MONITORING SYSTEM
SEBU7901-01
• Battery Voltage When you scroll to this option, the
battery voltage is displayed.
• Fuel Level When you scroll to this option, the fuel
level is displayed.
• Status of the Alternator When you scroll to this
option, the status of the alternator is displayed.
• Engine Speed When you scroll to this option, the
engine RPM is displayed.
• Desired Engine Speed When you scroll to this
option, the desired engine speed is displayed.
This parameter is used by the Automatic Retarder
Control to prevent the engine from overspeeding. If
you have an approved password, you can change
this parameter.
• Throttle Position When you scroll to this option,
the throttle position is displayed.
• Coolant Temperature When you scroll to this
option, the coolant temperature is displayed.
• Coolant Flow When you scroll to this option, the
amount of coolant flow is displayed.
• Boost Pressure When you scroll to this option,
the boost pressure is displayed.
• Atmospheric Pressure When you scroll to this
option, the atmospheric pressure is displayed.
• Turbocharger Inlet Pressure When you scroll
to this option, the turbocharger inlet pressure is
displayed.
• Oil Pressure When you scroll to this option, the
absolute engine oil pressure is displayed.
• Oil Pressure When you scroll to this option, the
engine oil pressure gauge is displayed.
• Fuel Temperature When you scroll to this option,
the fuel temperature is displayed.
SYSTEMS TESTS
“SYSTEM SELF TEST”
If you select this option, the monitoring system will
initiate the self test. The self test is similar to the
functional test that occurs when you turn the start
switch from the OFF position to the ON position.
INFORMATION on MONITORING and ENGINE
SYSTEMS
MONITORING SYSTEM
SEBU7901-01 29
Operation Section
Features and Controls

• Software Part Number When you scroll to this

option, the software part number is displayed.

• ECM Part Number When you scroll to this option,

the ECM part number is displayed.

• “Software Release Date” When you scroll to

this option, the release date of the software is
displayed.

• “Software Description” When you scroll to this

option, the description of the software is displayed.

ENGINE

• ECM Serial Number When you scroll to this

option, the ECM serial number is displayed.

• Software Part Number When you scroll to this

option, the software part number is displayed.

• “Software Release Date” When you scroll to

this option, the release date of the software is
displayed.

• “Software Description” When you scroll to this

option, the description of the software is displayed.

• Engine Serial Number When you scroll to this

option, the engine serial number is displayed.

TATTLETALE

• “Full Tattletale Readout” When this option is

selected, all displays and gauges will display the
maximum values that have been reached during
operation.

• Engine Coolant Temperature When this option is

selected, all indicators will display the maximum
values that have been reached during operation.
The engine coolant temperature gauge will also
show the maximum value that was reached during
operation.

• Tachometer When this option is selected, all

indicators will display the maximum values
that have been reached during operation. The
tachometer will also show the maximum value that
was reached during operation.

• Fuel Level When this option is selected, all

indicators will display the maximum values that
were reached during operation. The fuel level
gauge will also show the minimum value that was
reached during operation.

• Clear If you have an approved password, you can

clear the maximum values that have been stored
by the monitoring system.
30
Operation Section
Engine Diagnostics
Engine Diagnostics
i01563934
Self-Diagnostics
SMCS Code: 1000; 1900; 1901; 1902
Caterpillar Electronic Engines have the capability to
perform a self-diagnostics test. When the system
detects an active problem, the “DIAGNOSTIC”
lamp is activated. Diagnostic codes will be stored in
permanent memory in the Electronic Control Module
(ECM). The diagnostic codes can be retrieved by
using the following components:
• Caterpillar electronic service tools
• “DIAGNOSTIC” lamp
Note: The “DIAGNOSTIC” lamp must be installed by
the OEM or by the customer.
Some installations have electronic displays that
provide direct readouts of the engine diagnostic
codes. Refer to the manual that is provided by the
OEM for more information on retrieving engine
diagnostic codes.
Active codes represent problems that currently exist.
These problems should be investigated first. If a code
is active, the “DIAGNOSTIC” lamp will flash the flash
code at five second intervals.
Logged codes represent the following items:
• Intermittent problems
• Recorded events
• Performance history
The problems may have been repaired since the
logging of the code. These codes do not indicate that
a repair is needed. The codes are guides or signals
when a situation exists. Codes may be helpful to
troubleshoot problems.
When the problems have been corrected, the
corresponding logged fault codes should be cleared.
SEBU7901-01
i01463253
Diagnostic Lamp
SMCS Code: 1000; 1900; 1901; 1902; 7451
The “DIAGNOSTIC” lamp is used to indicate the
existence of an active fault by flashing codes.
When the ignition switch is first turned on, the
“DIAGNOSTIC” lamp will go through the following
procedure:
• The “DIAGNOSTIC” lamp will come on and
the “DIAGNOSTIC” lamp will remain on for five
seconds. This checks the operation of the lamp.
• The “DIAGNOSTIC” lamp will turn off.
• The “DIAGNOSTIC” lamp will come on again and
the “DIAGNOSTIC” lamp will flash codes for any
active diagnostic codes. Not all diagnostic codes
have a unique flash code.
• The “DIAGNOSTIC” lamp will turn off for five
seconds.
• The “DIAGNOSTIC” lamp repeats all active
diagnostic codes.
A fault diagnostic code will remain active until the
problem is repaired. The electronic control module
will continue flashing the flash code at five second
intervals until the problem is repaired.
i02496338
Diagnostic Flash Code
Retrieval
SMCS Code: 1000; 1900; 1901; 1902
Problems with the electronic control system are
reported via these types of codes: flash codes,
SPN/FMI codes, diagnostic codes, and event codes.
SEBU7901-01 31
Operation Section
Engine Diagnostics

Table 3
Cross Reference for Diagnostic Codes
Diagnostic Code
Flash Code SPN(1)/FMI Code or Description of Code
Event Code
1387-15 High Auxiliary Pressure Warning
1387-16 E443(2) High Auxiliary Pressure Derate
1387-00 High Auxiliary Pressure Shutdown
0441-15 High Auxiliary Temperature Warning
0441-16 E445(2) High Auxiliary Temperature Derate
0441-00 High Auxiliary Temperature Shutdown
545-05 Ether Start Relay open/short to +batt
626-05
N/A 2417-05 Ether Injection Control Solenoid open/short to +batt
545-06 Ether Start Relay short to ground
626-06
2417-06 Ether Injection Control Solenoid short to ground
1835-03 1835-03 Auxiliary Pressure Sensor open/short to +batt
1835-04 1835-04 Auxiliary Pressure Sensor short to ground
1836-03 1836-03 Auxiliary Temperature Sensor open/short to +batt
1836-04 1836-04 Auxiliary Temperature Sensor short to ground
111-02 111-02 Engine Coolant Level Sensor Loss of Signal
174-03 174-03 Fuel Temperature open/short to +batt
13
174-04 174-04 Fuel Temperature short to ground
678-03 41-03 8 Volt DC Supply short to +batt
678-04 41-04 8 Volt DC Supply short to ground
620-03
21 262-03 5 Volt Sensor DC Power Supply short to +batt
1079-03
620-04
262-04 5 Volt Sensor DC Power Supply short to ground
1079-04
100-03 100-03 Engine Oil Pressure open/short to +batt
24 100-04 100-04 Engine Oil Pressure short to ground
100-10 100-10 Engine Oil Pressure abnormal rate of change
102-03 102-03 Boost Pressure Sensor short to +batt
25 102-04 102-04 Boost Pressure Sensor short to ground
102-10 102-10 Boost Pressure Sensor abnormal rate of change
108-03 274-03 Atmospheric Pressure open/short to +batt
26
108-04 274-04 Atmospheric Pressure short to ground
110-03 110-03 Engine Coolant Temperature open/short to +batt
27
110-04 110-04 Engine Coolant Temperature short to ground
28 91-13 91-13 Throttle Position calibration required
32 91-08 91-08 Throttle Position signal abnormal
(continued)
32 SEBU7901-01
Operation Section
Engine Diagnostics

(Table 3, contd)
Cross Reference for Diagnostic Codes
Diagnostic Code
Flash Code SPN(1)/FMI Code or Description of Code
Event Code
190-08 190-08 Engine Speed signal abnormal
34
723-08 342-08 Secondary Engine Speed signal abnormal
190-15 Engine Overspeed Warning
35 E362(2)
190-00 Engine Overspeed Shutdown
94-03 94-03 Fuel Pressure open/short to +batt
37
94-04 94-04 Fuel Pressure short to ground
105-03 172-03 Intake Manifold Air Temp open/short to +batt
38
105-04 172-04 Intake Manifold Air Temp short to ground
42 637-13 261-13 Engine Timing calibration required
100-17 Low Engine Oil Pressure Warning
46 100-18 E360(2) Low Engine Oil Pressure Derate
100-01 Low Engine Oil Pressure Shutdown
168-00 168-00 System Voltage high
51 168-01 168-01 System Voltage low
168-02 168-02 System Voltage intermittent/erratic
56 630-02 268-02 Check Programmable Parameters
58 639-09 247-09 J1939 Data Link communications
110-15 High Engine Coolant Temperature Warning
61 110-16 E361(2) High Engine Coolant Temperature Derate
110-00 High Engine Coolant Temperature Shutdown
111-17 Low Engine Coolant Level Warning
62 111-18 E2143(2) Low Engine Coolant Level Derate
111-01 Low Engine Coolant Level Shutdown
63 94-15 E096 High Fuel Pressure Warning
1636-15 High Inlet Air Temperature Warning
64 E539(2)
1636-00 High Inlet Air Temperature Shutdown
174-15 High Fuel Temperature Warning
65 174-16 E363(2) High Fuel Temperature Derate
174-00 High Fuel Temperature Shutdown
651-05 001-05 Injector Cylinder 1 open circuit
71 651-06 001-06 Injector Cylinder 1 short
651-11 001-11 Injector Cylinder #1 fault
652-05 002-05 Injector Cylinder 2 open circuit
72 652-06 002-06 Injector Cylinder 2 short
652-11 002-11 Injector Cylinder #2 fault
(continued)
SEBU7901-01 33
Operation Section
Engine Diagnostics

(Table 3, contd)
Cross Reference for Diagnostic Codes
Diagnostic Code
Flash Code SPN(1)/FMI Code or Description of Code
Event Code
653-05 003-05 Injector Cylinder 3 open circuit
73 653-06 003-06 Injector Cylinder 3 short
653-11 003-11 Injector Cylinder #3 fault
654-05 004-05 Injector Cylinder 4 open circuit
74 654-06 004-06 Injector Cylinder 4 short
654-11 004-11 Injector Cylinder #4 fault
75 655-05 005-05 Injector Cylinder 5 open circuit
655-06 005-06 Injector Cylinder 5 short
655-11 005-11 Injector Cylinder #5 fault
656-05 006-05 Injector Cylinder 6 open circuit
76 656-06 006-06 Injector Cylinder 6 short
656-11 006-11 Injector Cylinder #6 fault
(1) Suspect Parameter Number
(2) Caterpillar Electronic Technician (ET) will display the number 1, 2, or 3 after the event code in order to designate a warning, a derate,
or a shutdown.

For further information, see the troubleshooting guide i01797045

for your engine.
Engine Operation with Active
i01463504
Diagnostic Codes
Fault Logging SMCS Code: 1000; 1900; 1901; 1902

SMCS Code: 1000; 1900; 1901; 1902
The system provides the capability of Fault Logging.
When the Electronic Control Module (ECM)
generates an active diagnostic code, the code will be
logged in the memory of the ECM. The codes that
have been logged in the memory of the ECM can
be retrieved with Caterpillar electronic service tools.
The codes that have been logged can be cleared
with Caterpillar electronic service tools. The codes
that have been logged in the memory of the ECM
will be automatically cleared from the memory after
100 hours. The following faults can not be cleared
from the memory of the ECM without using a factory
password: overspeed, low engine oil pressure, and
high engine coolant temperature.
If a diagnostic lamp illuminates during normal engine
operation, the system has identified a situation that is
not within the specification. Use Caterpillar electronic
service tools to check the active diagnostic codes.
Note: If the customer has selected “DERATE” and if
there is a low oil pressure condition, the Electronic
Control Module (ECM) will limit the engine power
until the problem is corrected. If the oil pressure is
within the normal range, the engine may be operated
at the rated speed and load. However, maintenance
should be performed as soon as possible.
The active diagnostic code should be investigated.
The cause of the problem should be corrected as
soon as possible. If the cause of the active diagnostic
code is repaired and there is only one active
diagnostic code, the diagnostic lamp will turn off.

Operation of the engine and performance of the

engine can be limited as a result of the active
diagnostic code that is generated. Acceleration
rates may be significantly slower. Refer to the
Troubleshooting Guide for more information on the
relationship between these active diagnostic codes
and engine performance.
34 SEBU7901-01
Operation Section
Engine Diagnostics

i01456915 i01801152

Engine Operation with Customer Specified

Intermittent Diagnostic Codes Parameters
SMCS Code: 1000; 1900; 1901; 1902 SMCS Code: 1000; 1900; 1901; 1902

If the diagnostic lamp starts to flash codes during
normal engine operation and the diagnostic lamp
shuts off, an intermittent fault may have occurred. If
a fault has occurred, the fault will be logged into the
memory of the Electronic Control Module (ECM).
In most cases, it is not necessary to stop the engine
because of an intermittent code. However, the
operator should retrieve the logged fault codes
and the operator should reference the appropriate
information in order to identify the nature of the event.
The operator should log any observation that could
have caused the lamp to light.
• Low power
• Limits of the engine speed
• Excessive smoke, etc
This information can be useful to help troubleshoot
the situation. The information can also be used for
future reference. For more information on diagnostic
codes, refer to the Troubleshooting Guide for this
engine.
Customer specified parameters that will enhance
the fuel efficiency and the operator’s convenience
can be programmed into the Electronic Control
Module (ECM). Some parameters may affect
engine operation. This may lead to complaints from
the operator about power or about performance.
The following engine related parameters may be
programmed by the customer by using Caterpillar
electronic service tools in order to influence the
operation of the engine:
• Customer Passwords
• Power Rating (hp at rpm)
• Rating Selection
• Air/Fuel Ratio
• PTO Ramp Rate
• Low Idle
• High Idle
• Top Engine Limit
• Torque Limit
• Intermediate Speed
• Engine Monitoring Mode
• Equipment ID
• Maintenance Indicator
• Parameter Lockout
The customer specified parameters can be changed
as often as needed. Password protection is provided
so that the customer can change the parameters. The
customer can authorize someone else to change the
parameters. Ensure that a record of the parameters
is kept in the Operation and Maintenance Manual.
For detailed instructions on programming the engine
for optimum performance and for optimum fuel
economy, consult your Caterpillar dealer.
SEBU7901-01
Engine Starting
i02109067
Before Starting Engine
SMCS Code: 1000; 1400; 1450
Perform the required daily maintenance and other
periodic maintenance before the engine is started.
Inspect the engine compartment. This inspection can
help prevent major repairs at a later date. Refer to the
Operation and Maintenance Manual, “Maintenance
Interval Schedule” for more information.
• For the maximum service life of the engine, make
a thorough inspection before the engine is started.
Look for the following items: oil leaks, coolant
leaks, loose bolts, and trash buildup. Remove trash
buildup and arrange for repairs, as needed.
• Inspect the aftercooler for loose connections and
for debris buildup.
• Inspect the cooling system hoses for cracks and
for loose clamps.
• Inspect the alternator and accessory drive belts for
cracks, breaks, and other damage.
• Inspect the wiring for loose connections and for
worn wires or frayed wires.
• Check the fuel supply. Drain water from the water
separator (if equipped). Open the fuel supply valve.
NOTICE
All valves in the fuel return line must be open before
and during engine operation to help prevent high fuel
pressure. High fuel pressure may cause filter housing
failure or other damage.
If the engine has not been started for several weeks,
fuel may have drained from the fuel system. Air
may have entered the filter housing. Also, when fuel
filters have been changed, some air pockets will be
trapped in the engine. In these instances, prime the
fuel system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information
on priming the fuel system.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
35
Operation Section
Engine Starting
• Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or
to the controls.
• Ensure that the areas around the rotating parts are
clear.
• All of the guards must be put in place. Check for
damaged guards or for missing guards. Repair
any damaged guards. Replace damaged guards
and/or missing guards.
• Disconnect any battery chargers that are not
protected against the high current drain that
is created when the electric starting motor (if
equipped) is engaged. Check electrical cables
and check the battery for poor connections and
for corrosion.
• Reset all of the shutoffs or alarm components.
• Check the engine lubrication oil level. Maintain the
oil level between the “ADD” mark and the “FULL”
mark on the oil level gauge.
• Check the coolant level. Observe the coolant level
in the coolant recovery tank (if equipped). Maintain
the coolant level to the “FULL” mark on the coolant
recovery tank.
• If the engine is not equipped with a coolant
recovery tank maintain the coolant level within
13 mm (0.5 inch) of the bottom of the filler pipe. If
the engine is equipped with a sight glass, maintain
the coolant level in the sight glass.
• Observe the air cleaner service indicator (if
equipped). Service the air cleaner when the yellow
diaphragm enters the red zone, or when the red
piston locks in the visible position.
• Ensure that any driven equipment has been
disengaged. Minimize electrical loads or remove
any electrical loads.
i01903151
Starting the Engine
SMCS Code: 1000; 1450
Note: Do not adjust the engine speed control during
start-up. The electronic control module (ECM) will
control the engine speed during start-up.
Starting a Cold Engine
1. Disengage any equipment that is driven by the
engine.
36
Operation Section
Engine Starting
2. Turn the keyswitch to the RUN position. Leave the
keyswitch in the RUN position for 15 seconds.
3. Turn the keyswitch to the START position in order
to engage the electric starting motor and crank
the engine.
NOTICE
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
start the engine again.
4. Allow the keyswitch to return to the RUN position
after the engine starts.
5. Repeat step 2 through step 4 if the engine fails
to start.
Starting a Warm Engine
1. Disengage any equipment that is driven by the
engine.
2. Turn the keyswitch to the START position in order
to engage the electric starting motor and crank
the engine.
NOTICE
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
start the engine again.
3. Allow the keyswitch to return to the RUN position
after the engine starts.
4. Repeat step 2 and step 3 if the engine fails to start.
i01797227
Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
SEBU7901-01
Startability will be improved at temperatures below
−18 °C (0 °F) from the use of a jacket water heater
or extra battery capacity.
When No. 2 diesel fuel is used, the following items
provide a means of minimizing starting problems
and fuel problems in cold weather: engine oil pan
heaters, jacket water heaters, fuel heaters, and fuel
line insulation.
Use the procedure that follows for cold weather
starting.
Note: Do not adjust the engine speed control during
start-up. The electronic control module (ECM) will
control the engine speed during start-up.
1. Disengage any driven equipment.
2. Turn the keyswitch to the RUN position. Leave the
keyswitch in the RUN position for 20 seconds.
NOTICE
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
start the engine again.
3. Turn the keyswitch to the START position in order
to engage the starting motor and crank the engine.
4. Allow the keyswitch to return to the RUN position
after the engine starts.
5. Repeat step 2 through step 4 if the engine fails
to start.
6. Allow the engine to idle for three to five minutes, or
allow the engine to idle until the water temperature
indicator begins to rise. The engine should run
at low idle smoothly until speed is gradually
increased to high idle. Allow the white smoke to
disperse before proceeding with normal operation.
7. Operate the engine at low load until all systems
reach operating temperature. Check the gauges
during the warm-up period.
SEBU7901-01
i01934760
Starting with Jump Start
Cables
SMCS Code: 1000; 1401; 1402; 1900
Improper jump start cable connections can cause
an explosion resulting in personal injury.
Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
If the installation is not equipped with a backup
battery system, it may be necessary to start the
engine from an external electrical source.
NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.
Do not reverse the battery cables. The alternator can
be damaged. Attach ground cable last and remove
first.
When using an external electrical source to start the
engine, turn the generator set control switch to the
“OFF” position. Turn all electrical accessories OFF be-
fore attaching the jump start cables.
Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en-
gine being started.
1. Turn the start switch to the OFF position. Turn off
all accessories.
2. Connect one positive end of the jump start cable
to the positive cable terminal of the discharged
battery. Connect the other positive end of the jump
start cable to the positive cable terminal of the
electrical source.
3. Connect one negative end of the jump start cable
to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
that are produced by some batteries.
4. Start the engine.
37
Operation Section
Engine Starting
5. Immediately after the stalled engine is started,
disconnect the jump start cables in reverse order.
Note: If there is a problem with the alternator or the
battery charger, the engine will not continue to run
after starting, unless the power to the engine control
module is supplied by a separate source.
i01646248
After Starting Engine
SMCS Code: 1000
Note: In temperatures from 0 to 60°C (32 to 140°F),
the warm-up time is approximately three minutes. In
temperatures below 0°C (32°F), additional warm-up
time may be required.
Note: Ensure that the self test for the monitoring
system (if equipped) is completed before operating
the engine under load.
When the engine idles during warm-up, observe the
following conditions:
• Check for any fluid or for any air leaks at idle rpm
and at one-half full rpm (no load on the engine)
before operating the engine under load. This is not
possible in some applications.
• Operate the engine at low idle until all systems
achieve operating temperatures. Check all gauges
during the warm-up period.
Note: Gauge readings should be observed and
the data should be recorded frequently while the
engine is operating. Comparing the data over time
will help to determine normal readings for each
gauge. Comparing data over time will also help
detect abnormal operating developments. Significant
changes in the readings should be investigated.
38
Operation Section
Engine Operation
Engine Operation
i02176671
Engine Operation
SMCS Code: 1000
Correct operation and maintenance are key factors
in obtaining the maximum life and economy of
the engine. If the directions in the Operation and
Maintenance Manual are followed, costs can be
minimized and engine service life can be maximized.
The engine can be operated at the rated rpm after the
engine reaches operating temperature. The engine
will reach normal operating temperature sooner
during a low engine speed (rpm) and during a low
power demand. This procedure is more effective than
idling the engine at no load. The engine should reach
operating temperature in a few minutes.
Gauge readings should be observed and the data
should be recorded frequently while the engine
is operating. Comparing the data over time will
help to determine normal readings for each gauge.
Comparing data over time will also help detect
abnormal operating developments. Significant
changes in the readings should be investigated.
i00808595
Engine Warm-up
SMCS Code: 1000
1. Run the engine at low idle for three to five minutes,
or run the engine at low idle until the jacket water
temperature starts to rise.
More time may be necessary when the
temperature is below −18° C (0° F).
2. Check all of the gauges during the warm-up
period.
3. Perform another walk-around inspection. Check
the engine for fluid leaks and air leaks.
4. Increase the rpm to the rated rpm. Check for fluid
leaks and air leaks. The engine may be operated
at full rated rpm and at full load when the engine
oil temperature reaches 60° C (140° F).
SEBU7901-01
i01196062
Engaging the Driven
Equipment
SMCS Code: 1000
If the load varies, or if the load is cyclic, the governor
will adjust the engine rpm, as needed.
Extended operation at low idle or extended
operation at a reduced load may cause increased
oil consumption and carbon buildup in the cylinders.
This carbon buildup results in a loss of power and/or
poor performance. When the engine is operated at
a reduced load, the engine should be fully loaded
at every four hours in order to burn excess carbon
from the cylinders.
Industrial Engines
1. When the engine is operating, check the engine
gauges. The engine gauges should be in the
normal range before you engage the driven
equipment.
2. Engage the driven equipment. Begin operating the
engine at low load. Check the gauges and check
the equipment for proper operation. Check the
gauges and check the equipment frequently while
the engine is operating under load.
i01878039
Fuel Conservation Practices
SMCS Code: 1000; 1250
The efficiency of the engine can affect the fuel
economy. Caterpillar’s design and technology in
manufacturing provides maximum fuel efficiency in
all applications. Follow the recommended procedures
in order to attain optimum performance for the life
of the engine.
• Avoid spilling fuel.
Fuel expands when the fuel is warmed up. The fuel
may overflow from the fuel tank. Inspect fuel lines for
leaks. Repair the fuel lines, as needed.
• Be aware of the properties of the different fuels.
Use only the recommended fuels.
• Avoid unnecessary operation at no load.
Shut off the engine instead of operating the engine
at no load for long periods of time.
SEBU7901-01 39
Operation Section
Engine Operation

• Observe the service indicator for the air cleaner

frequently, if equipped. Keep the air cleaner
elements clean.

• Maintain a good electrical system.

One bad battery cell will overwork the alternator. This
will consume excess power and excess fuel.

• Ensure that the belts are properly adjusted. The

belts should be in good condition.

• Ensure that all of the connections of the hoses are

tight. The connections should not leak.

• Ensure that the driven equipment is in good

working order.

• Cold engines consume excess fuel. Keep cooling

system components clean and keep cooling
system components in good repair. Never operate
the engine without water temperature regulators.
All of these items will help maintain operating
temperatures.

• Settings for the fuel system and the limits for the
operating altitude are stamped on the Engine
Information Plate. If an engine is moved to a
higher altitude, the settings must be changed by a
Caterpillar dealer. Changing the settings will help
to provide the maximum efficiency for the engine.
Engines can be operated safely at higher altitudes,
but the engines will deliver less horsepower. The
fuel settings should be changed by a Caterpillar
dealer in order to obtain the rated horsepower.
40 SEBU7901-01
Operation Section
Engine Stopping

Engine Stopping i01646416

Manual Stop Procedure

i02255774
SMCS Code: 1000
Emergency Stopping
Note: Individual applications will have different
SMCS Code: 1000; 7418 control systems. Ensure that the shutoff procedures
are understood. Use the following general guidelines
NOTICE in order to stop the engine.
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or 1. Remove the load, when possible. Reduce the
controls for normal stopping procedure. engine speed (rpm) to low idle.

2. Increase the engine speed (rpm) to no more than

Ensure that any components for the external system one-half of the rated rpm. Perform this procedure
that support the engine operation are secured after for three to five minutes in order to cool the engine.
the engine is stopped. Reduce the engine speed (rpm) to low idle.

3. After the cool down period, turn the key switch to

Emergency Stop Button the OFF position.

g00104303
Illustration 22
Typical emergency stop button

The emergency stop button is in the OUT position for

normal engine operation. Push the emergency stop
button. The engine will not start when the button is
locked. Turn the button clockwise in order to reset.

Refer to Operation and Maintenance Manual,

“Features and Controls” for the location and the
operation of the emergency stop button.
SEBU7901-01 41
Operation Section
Engine Stopping

i02069570

After Stopping Engine

SMCS Code: 1000

Note: Before you check the engine oil, do not operate

the engine for at least 10 minutes in order to allow
the engine oil to return to the oil pan.

• Check the crankcase oil level. Maintain the oil level

between the “ADD” mark and the “FULL” mark on
the oil level gauge.

Note: Only use oil that is recommended in

this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” article. Failure to
do so may result in engine damage.

• If necessary, perform minor adjustments. Repair

any leaks and tighten any loose bolts.

• Note the service hour meter reading. Perform

the maintenance that is in the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.

• Fill the fuel tank in order to help prevent

accumulation of moisture in the fuel. Do not overfill
the fuel tank.

• Allow the engine to cool. Check the coolant level.

Maintain the cooling system at 13 mm (0.5 inch)
from the bottom of the pipe for filling.

Note: Only use coolant that is recommended in

this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” article. Failure to
do so may result in engine damage.

• If freezing temperatures are expected, check

the coolant for proper antifreeze protection. The
cooling system must be protected against freezing
to the lowest expected outside temperature. Add
the proper coolant/water mixture, if necessary.

• Perform all required periodic maintenance on all

driven equipment. This maintenance is outlined in
the instructions from the OEM.
42 SEBU7901-01
Operation Section
Cold Weather Operation

Cold Weather Operation i01872912

Fuel and the Effect from Cold

i01646447 Weather
Radiator Restrictions SMCS Code: 1000; 1250
SMCS Code: 1353; 1396
The following fuels are the grades that are available
for Caterpillar engines:
Caterpillar discourages the use of airflow restriction
devices that are mounted in front of radiators. Airflow
restriction can cause the following conditions: • No. 1

• High exhaust temperatures • No. 2

• Power loss • Blend of No. 1 and No. 2

No. 2 diesel fuel is the most commonly used fuel.
• Excessive fan usage Either No. 1 diesel fuel or a blend of No. 1 and No. 2
is best suited for cold weather operation.
• Reduction in fuel economy
Quantities of No. 1 diesel fuel are limited. No. 1 diesel
If an airflow restriction device must be used, the
fuels are usually available during the months of the
device should have a permanent opening directly
winter in the colder climates. During cold weather
in line with the fan hub. A centered opening that is
operation, if No. 1 diesel fuel is not available, use No.
directly in line with the fan hub is specified in order
2 diesel fuel, if necessary.
to prevent an interrupted airflow on the fan blades.
Interrupted airflow on the fan blades could cause a
There are three major differences between No. 1 and
fan failure.
No. 2 diesel fuel. No. 1 diesel fuel has the following
properties:
Caterpillar recommends a warning device for the
inlet manifold temperature and/or the installation of
an inlet air temperature gauge. The warning device • Lower cloud point
for the inlet manifold temperature should be set at
75 °C (167 °F). The inlet manifold air temperature • Lower pour point
should not exceed 75 °C (167 °F). Temperatures that
exceed this limit can cause power loss and potential • Lower rating of kJ (BTU) per unit volume of fuel
engine damage.
When No. 1 diesel fuel is used, a decrease in power
and in fuel efficiency may be noticed. Other operating
effects should not be experienced.

The cloud point is the temperature when a cloud of

wax crystals begins to form in the fuel. These crystals
can cause the fuel filters to plug. The pour point is
the temperature when diesel fuel will thicken. The
diesel fuel becomes more resistant to flow through
fuel pumps and through fuel lines.

Be aware of these values when diesel fuel is

purchased. Anticipate the average ambient
temperature for the engine area. Engines that are
fueled in one climate may not operate well if the
engines are moved to another climate. Problems can
result due to changes in temperature.

Before troubleshooting for low power or for poor

performance during cold weather, check the type of
fuel that is being used.
SEBU7901-01 43
Operation Section
Cold Weather Operation

i02469608 Note: Fuel heaters that are controlled by the water

temperature regulator or self-regulating fuel heaters
Fuel Related Components in should be used with this engine. Fuel heaters that
Cold Weather are not controlled by the water temperature regulator
can heat the fuel in excess of 65°C (149°F). A loss of
SMCS Code: 1000; 1250 engine power can occur if the fuel supply temperature
exceeds 37°C (100°F).
Fuel Tanks Note: Heat exchanger type fuel heaters should have
a bypass provision in order to prevent overheating of
Condensation can form in partially filled fuel tanks. the fuel in warm weather operation.
Top off the fuel tanks after you operate the engine.

Fuel tanks should contain some provision for draining

water and sediment from the bottom of the tanks.
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe.

Some fuel tanks use supply lines that take fuel

directly from the bottom of the tank. If the engine is
equipped with this system, regular maintenance of
the fuel system filter is important.

Drain the water and sediment from any fuel storage

tank at the following intervals: weekly, oil changes,
and refueling of the fuel tank. This will help prevent
water and/or sediment from being pumped from the
fuel storage tank and into the engine fuel tank.

Fuel Filters
It is possible that a primary fuel filter is installed
between the fuel tank and the engine fuel inlet. After
you change the fuel filter, always prime the fuel
system in order to remove air bubbles from the fuel
system. Refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for more information.

The micron rating and the location of a primary fuel

filter is important in cold weather operation. The
primary fuel filter and the fuel supply line are the most
common components that are affected by cold fuel.

Fuel Heaters
Fuel heaters help to prevent fuel filters from plugging
in cold weather due to waxing. A fuel heater should
be installed in the fuel system before the primary
fuel filter.

For further information on fuel heaters, consult your

Caterpillar dealer.

Disconnect the fuel heater in warm weather.

44
Maintenance Section
Refill Capacities
Maintenance Section
Refill Capacities
i02466201
Refill Capacities and
Recommendations
SMCS Code: 1348; 1395; 7560
NOTICE
Every attempt is made to provide accurate, up-to-date
information. By the use of this document, you agree
that Caterpillar Inc. is not responsible for errors or
omissions.
NOTICE
These recommendations are subject to change with-
out prior notice. Contact your Caterpillar dealer for the
most up to date recommendations.
Lubrication System
NOTICE
The Engine Crankcase Fluid - 1 (ECF-1) specifica-
tion has been introducedby Caterpillar in order to pro-
vide additional performance to the oils that are mar-
keted under the American Petroleum Institute (API)
categories of oil. The API Engine Oil Licensing and
Certification System is recognized by Caterpillar. For
detailed information about this system, see the lat-
estedition of the “API publication No. 1509”. Engine
oils that bear the API symbol are authorized by API.
The ECF-1 specification is applicable to those oil man-
ufacturers whose products meet the specification re-
quirements.
Caterpillar Diesel Engine Oil (DEO)
Caterpillar oils have been developed and tested in
order to provide the full performance and service
life that has been designed and built into Caterpillar
engines. Cat DEO exceeds the requirements of
the ECF-1 specification by passing four additional
proprietary tests of diesel engine oil. Caterpillar
oils are currently used to fill diesel engines at the
factory. These oils are offered by Caterpillar dealers
for continued use when the engine oil is changed.
Consult your Caterpillar dealer for more information
on these oils.
Due to significant variations in the quality and in
the performance of commercially available oils,
Caterpillar makes the following recommendations:
SEBU7901-01
• Cat DEO (Diesel Engine Oil) (SAE 10W-30)
• Cat DEO (Diesel Engine Oil) (SAE 15W-40)
Cat DEO multigrade oil is formulated with the correct
amounts of detergents, dispersants, and alkalinity in
order to provide superior performance in Caterpillar
diesel engines.
Cat DEO multigrade oil is available in various
viscosity grades that include SAE 10W-30 and
SAE 15W-40. Choose the correct oil viscosity for
the ambient temperature by referring to table 4.
Multigrade oils provide the correct viscosity for a
broad range of operating temperatures.
Multigrade oils are effective in maintaining low oil
consumption and low levels of piston deposits.
Consult your Caterpillar dealer for part numbers and
for available sizes of containers.
Note: Cat multigrade DEO exceeds the requirements
of the ECF-1 specification. Cat DEO SAE 15W-40
exceeds the performance requirements for the
following API classifications: API CI-4, API CI-4
PLUS, API CH-4, API CG-4, and API CF. Cat DEO
SAE 15W-40 oil also passes additional proprietary
tests that include the following tests: sticking of the
piston ring, stable oil control, tests for wear, and tests
for soot. Proprietary tests help ensure that Caterpillar
multigrade oil provides superior performance in
Caterpillardiesel engines. In addition, Caterpillar
multigrade oil exceeds many of the performance
requirements of other manufacturers of diesel
engines. Therefore, this oil is an excellent choice for
many mixed fleets. True high performance oil is
produced by using a combination of the following
factors: industry standard tests, proprietary
tests, field tests, and prior experience with similar
formulations. The design and the development
of Caterpillar lubricants that are both high
performance and high quality are based on these
factors.
Commercial Oils
Engine Crankcase Fluid Recommendations for all
Caterpillar Diesel Engines
Note: Commercial oils that conform to the
requirements of the Caterpillar ECF-1 specification
are acceptable but these oils are not preferred.
• Only commercial oils that meet the requirements
of Caterpillar’s ECF-1 (Engine Crankcase Fluid
specification - 1) are acceptable for use in
Caterpillar commercial diesel engines. API CH-4,
API CI-4, and API CI-4 PLUS oils that have not
met the requirements of Caterpillar’s ECF-1
specification may cause reduced engine life.
SEBU7901-01 45
Maintenance Section
Refill Capacities

• API CG-4 multigrade oils are acceptable for all Table 4

Caterpillar commercial diesel engines. When API Lubricant Viscosities for Ambient Temperatures
CG-4 oils are used, do not exceed the standard oil
drain interval. Refer to the engine’s Operation and Ambient Temperature
Maintenance Manual for the oil drain interval. Viscosity Grade Minimum Maximum
Note: Do not use API CF-4 oils in Caterpillar SAE 0W-20 −40 °C (−40 °F) 10 °C (50 °F)
diesel engines.
SAE 0W-30 −40 °C (−40 °F) 30 °C (86 °F)
SAE 0W-40 −40 °C (−40 °F) 40 °C (104 °F)
NOTICE
Failure to follow these oil recommendations can cause SAE 5W-30 −30 °C (−22 °F) 30 °C (86 °F)
shortened engine service life due to deposits and/or
excessive wear. SAE 5W-40 −30 °C (−22 °F) 50 °C (122 °F)
SAE 10W-30(2) −18 °C (0 °F) 40 °C (104 °F)
Refer to Special Publication, SEBU6251, “Caterpillar SAE 10W-40 −18 °C (0 °F) 50 °C (122 °F)
Commercial Engine Fluids Recommendations” for
more information about choosing the correct oils for SAE 15W-40 −9.5 °C (15 °F) 50 °C (122 °F)
your Caterpillar diesel engine. (2) SAE 10W-30 is the preferred viscosity grade for the 3116, 3126,
C7, and C9 diesel engines when the ambient temperature is
above −18 °C (0 °F) and below 40 °C (104 °F).
Lubricant Viscosity Recommendations
Note: Supplemental heat is recommended for
The proper SAE viscosity grade of oil is determined
cold-soaked starts below the minimum ambient
by the minimum ambient temperature during
temperature. Supplemental heat may be required
cold engine start-up, and the maximum ambient
for cold-soaked starts that are above the minimum
temperature during engine operation.
temperature that is stated, depending on the parasitic
load and other factors. Cold-soaked starts occur
Refer to Table 4 (minimum temperature) in order to
when the engine has not been operated for a period
determine the required oil viscosity for starting a cold
of time and when the cooler ambient temperatures
engine.
allow the oil to become more viscous.
Refer to Table 4(maximum temperature) in order to
select the oil viscosity for engine operation at the S·O·S Services Oil Analysis
highest ambient temperature that is anticipated.
Caterpillar has developed a tool for maintenance
Note: Generally, use the highest oil viscosity that is management that evaluates oil degradation and the
available to meet the requirement for the temperature tool also detects the early signs of wear on internal
at start-up. components. The Caterpillar tool for oil analysis is
called S·O·S oil analysis and the tool is part of the
If ambient temperature conditions at engine start-up S·O·S Services program. S·O·S oil analysis divides
require the use of multigrade SAE 0W oil, SAE oil analysis into three categories:
0W-40 viscosity grade is generally preferred over
SAE 0W-20 or SAE 0W-30. • Component wear rate

Note: SAE 10W-30 is the preferred viscosity grade • Contamination of oil

for this engine when the ambient temperature is
above −18 °C (0 °F) and below 40 °C (104 °F).
• Condition of oil
• Identification of oil
Note: Refer to Special Publication, SEBU6251,
“Caterpillar Commercial Diesel Engine Fluid
Recommendations” or contact your local Caterpillar
dealer for additional information concerning the
S·O·S oil analysis program.
46 SEBU7901-01
Maintenance Section
Refill Capacities

Refill Capacities (Engine Oil) Table 5

Approximate Refill Capacities of the Engine
The capacity of the engine lubrication system Lubrication System
includes the capacity of the oil filters that are installed
at the factory. Auxiliary oil filter systems (if equipped) Compartment
C11 C13
will require additional oil. Refer to the specifications or System
that are provided by the OEM of the auxiliary oil filter Standard Oil
system. 34 L (36 qt)
Pan(1)
Deep Oil Pan(1) 40 L (42 qt)
Capacity of the
Auxiliary Oil
Filter System(2)
Total Capacity
of the
Lubrication
System(3)
(1) Approximate sump capacity of the crankcase includes the
standard oil filters that are factory installed. Engines with
auxiliary oil filters will require additional oil. Optional bypass
oil filters that are supplied by Caterpillar require an additional
3 L (3.2 qt)of oil. If the engine is equipped with another type
of auxiliary oil filter, refer to the OEM specifications for the
g01011620 capacity of the auxiliary oil filter.
Illustration 23 (2) Fill in the capacity of the auxiliary oil filter system (if equipped)
C11 and C13 standard oil pan in the space that is provided.
(3) Fill in the total capacity of the lubrication system. Add the
auxiliary oil filter system to the correct capacity of the oil sump
in order to find the total capacity of the lubrication system.

g01011683
Illustration 24
C11 and C13 deep oil pan
Note: Refer to Special Publication, SEBU6251,
“CaterpillarCommercial Diesel Engine Fluid
Recommendations” for additional information that
relates to lubrication for your engine.
Lubricating Grease
Caterpillar provides various greases that vary in
performance from a moderate performance to an
extremely high performance. These greases service
the entire line of Caterpillar products in the wide
variety of climates throughout the world. You can find
a Caterpillar grease that will exceed the performance
requirements of any original equipment manufacturer
(OEM).
Before selecting a specific grease, the performance
requirements must be determined. Consult the
recommendations for grease that are given by the
OEM for the equipment. Consult with your Caterpillar
dealer for a list of greases that meet or exceed the
performance requirements.
Note: Always choose a grease that meets or exceeds
the recommendations of an equipment manufacturer.
SEBU7901-01
If it is necessary to choose a single grease,
always choose a grease that meets or exceeds the
requirements of the most demanding application.
Remember that lubricants that barely meet the
minimum performance requirements can be expected
to barely meet the minimum life of the part. False
economy is being used if a grease is purchased with
the lowest cost as the only consideration. Instead,
use the grease that yields the lowest total operating
cost. This cost should be based on an analysis that
includes the costs of parts, labor, downtime, and the
cost of the amount of grease that is required.
Because some greases are not chemically
compatible, purge all of the old grease from a joint
when the following conditions exist.
• The grease in a joint is changed from one type of
grease to another type of grease.
• The grease that will be used in the joint will be
supplied by a supplier that did not supply the
grease that is currently in the joint.
Consult your supplier in order to determine if the
greases are compatible.
If in doubt, Purge!
Note: All Caterpillar greases are compatible with
each other.
Fuel
In North America, diesel fuel that is identified as
No. 1-D or No. 2-D in “ASTM D975” with the S15
designation generally meet the specifications.
Caterpillar recommends diesel fuels that are distilled
from crude oil. Diesel fuels from other sources could
exhibit detrimental properties that are not defined or
controlled by this specification.
In the USA, 0.05 percent diesel fuels have been
used in all on-highway truck engines since 1 January
1994. This low sulfur diesel fuel was mandated as a
means of directly reducing particulate emissions from
diesel truck engines. This low sulfur fuel will also be
used in Caterpillar commercial diesel engines and
in Caterpillar machine engines. This diesel fuel will
be used when low emissions are required. This fuel
will be used when the fuel supplier can provide this
type of fuel. Caterpillar has not seen any detrimental
effects with 0.05 percent sulfur fuel in Caterpillar
diesel engines.
47
Maintenance Section
Refill Capacities
NOTICE
Operating with fuels that do not meet Caterpillar’s rec-
ommendations can cause the following effects: start-
ing difficulty, poor combustion, deposits in the fuel in-
jectors, reduced service life of the fuel system, de-
posits in the combustion chamber, and reduced ser-
vice life of the engine.
NOTICE
Heavy Fuel Oil (HFO), Residual fuel, or Blended fuel
must NOT be used in Caterpillar diesel engines (ex-
cept in 3600 Series HFO engines). Blended fuel is
residual fuel that has been diluted with a lighter fuel
(cutter stock) so that they will flow. Blended fuels are
also referred to as heavy fuel oils. Severe component
wear and component failures will result if HFO type
fuels are used in engines that are configured to use
distillate fuel.
In extreme cold ambient conditions, you may use the
distillate fuels that are specified in Table 6. However,
the fuel that is selected must meet the requirements
that are specified in Table 6. These fuels are intended
to be used in operating temperatures that are down
to −54 °C (−65 °F).
Table 6
Distillate Fuels (1)
Specification Grade
“MIL-DUL-5624T” JP-5
“ASTM D1655-05” Jet-A-1
“MIL-DTL-83133E” JP-8
(1) The fuels that are listed in this table may not meet all of the
requirements that are specified in this table . Consult the
supplier for the recommended additives in order to maintain
the proper fuel lubricity.
These fuels are lighter than the No. 2 grades of fuel.
The cetane number of the fuels in Table 6 must be
at least 40. If the viscosity is below 1.4 cSt at 40 °C
(104 °F), use the fuel only in temperatures below
0 °C (32 °F). Do not use any fuels with a viscosity of
less than 1.2 cSt at 40 °C (104 °F).
Note: Fuel cooling may be required in order to
maintain the minimum viscosity of 1.4 cSt at the fuel
injection pump.
There are many other diesel fuel specifications that
are published by governments and by technological
societies. Usually, those specifications do not
review all the requirements that are addressed
in this specification. To ensure optimum engine
performance, a complete fuel analysis should be
obtained before engine operation.
48 SEBU7901-01
Maintenance Section
Refill Capacities

Note: Refer to Special Publication, SEBU6251, Table 7

“Caterpillar Commercial Diesel Engine Fluids Coolant Service Life
Recommendations” for the Caterpillar Specification
for distillate fuel and for additional information that Coolant Service Life(1)(2)
relates to fuel for your engine. Cat® ELC 965,606 kilometers
(600,000 miles), 12000
Refill Capacities (Fuel System) hours, or 6 years(3)
Commercial coolant that 482,803 kilometers
Refer to the “Operation and Maintenance Manual” meets the Caterpillar EC-1 (300,000 miles), 6000
that is provided by the OEM for capacities of the fuel specification hours, or 6 years(4)
system.
CAT® DEAC 321,869 kilometers
(200,000 miles), 3000
Cooling System hours, or 3 years

The following types of coolants may be used in Commercial Heavy-Duty 241,402 kilometers
Caterpillar diesel engines: coolant that meets “ASTM (150,000 miles), 3000
D6210” hours, or 2 years
Preferred – Cat ELC (Extended Life Coolant) or Commercial Heavy-Duty 241,402 kilometers
a commercial extended life coolant that meets the coolant that meets “ASTM (150,000 miles), 3000
Caterpillar EC-1 specification D4985” hours, or 1 year
(1) Use the interval that occurs first.
Acceptable – Cat DEAC (Diesel Engine (2) Refer to this Operation and Maintenance Manual, “Maintenance
Antifreeze/Coolant) or a commercial heavy-duty Interval Schedule” in order to find the correct interval for
coolant that meets “ASTM D4985”, or “ASTM D6210” replacing the water temperature regulator.
(3) Cat ELC Extender must be added at 6000 service hours or one
specifications
half of the service life of the ELC.
(4) An extender must be added at 3000 service hours or one half
Note: Cat DEAC does not require a treatment with of the service life of the coolant.
an SCA (Supplemental Coolant Additive) at the
initial fill. However, a commercial heavy-duty coolant Note: These coolant change intervals are only
that only meets the “ASTM D4985” specification achievable with annual S·O·S Services Level 2
WILL require a treatment with an SCA at the initial coolant sampling and analysis.
fill. A commercial heavy-duty coolant that meets
the “ASTM D6210” specification will NOT require Distilled water or deionized water is
a treatment with an SCA at the initial fill. Read the recommended for use in engine cooling systems.
label or the instructions that are provided by the
manufacturer of the commercial heavy-duty coolant. If distilled water or deionized water is not available,
use water that meets or exceeds the properties that
Note: These coolants WILL require a treatment with are listed in 8.
a supplemental coolant additive on a maintenance
basis.

NOTICE
Do not use a commercial coolant/antifreeze that on-
ly meets the ASTM D3306 specification. This type of
coolant/antifreeze is made for light duty automotive
applications.

Caterpillar recommends a 1:1 mixture of water and

glycol. This mixture of water and glycol will provide
optimum heavy-duty performance as a coolant.

NOTICE
All Caterpillar diesel engines equipped with air-to-air
aftercooling (ATAAC) require a minimum of 30 percent
glycol to prevent water pump cavitation.
SEBU7901-01 49
Maintenance Section
Refill Capacities

Table 8 Table 9
Caterpillar Minimum Acceptable Water Requirements Ethylene Glycol
Property Maximum Limit ASTM Test Freeze Boil
Concentration
Protection Protection(1)
40 mg/L “D512”,
Chloride (Cl)
(2.4 grains/US gal) “D4327” 50 Percent −37 °C (−34 °F) 106 °C (223 °F)
100 mg/L 60 Percent −52 °C (−62 °F) 111 °C (232 °F)
Sulfate (SO4) “D516”
(5.9 grains/US gal) (1) Protection from boiling is increased with the use of a
170 mg/L pressurized radiator.
Total Hardness “D1126”
(10 grains/US gal)
“Federal NOTICE
340 mg/L Do not use propylene glycol in concentrations that ex-
Total Solids Method
(20 grain/US gal) ceed 50 percent glycol because of propylene glycol’s
2540B”(1)
reduced heat transfer capability. Use ethylene glycol
Acidity pH of 5.5 to 9.0 “D1293” in conditions that require additional protection against
(1) Total dissolved solids dried at 103 - 105ºC, “Standard Method boiling or freezing.
for the Examination of Water and Wastewater”, American
Public Health Association, et al, 1015 15th Street, N.W.
Washington, DC 20005 Table 10

DO NOT use the following types of water in cooling
systems: hard water, softened water that has been
conditioned with salt, and sea water.
Glycol
Glycol in the coolant helps to provide protection
against the following conditions:
• Boiling
• Freezing
• Cavitation of the water pump and cylinder liners
For optimum performance, Caterpillar recommends a
1:1 mixture of a water/glycol solution.
Note: Use a mixture that will provide protection
against the lowest ambient temperature.
Propylene Glycol
Freeze Boil
Concentration
Protection Protection
50 Percent −32 °C (−26 °F) 106 °C (223 °F)
To check the concentration of glycol, use 245-5829
Coolant Test Kit . The testers give readings that are
immediate and accurate. The testers can be used
with ethylene or propylene glycol.
Note: Propylene glycol coolant that is used in
Caterpillar diesel engine cooling systems must meet
ASTM D6210-04, “Fully-Formulated Propylene
Glycol-Based Engine Coolant for Heavy-Duty
Engines” standards. When Propylene glycol is used
in heavy-duty diesel engines, Supplemental Coolant
Additive (SCA) must be added regularly for protection
for the liner cavitation. Consult your Caterpillar dealer
for more information.

Note: 100 percent pure glycol will freeze at a
temperature of −23 °C (−9 °F).
Most conventional heavy-duty coolants use ethylene
glycol. Propylene glycol may also be used. In a 1:1
mixture with water, ethylene and propylene glycol
provide similar protection against freezing and
boiling.
Refer to Tables 9 and 10 for additional information.
S·O·S Services Coolant Analysis
Testing the engine coolant is important to ensure that
the engine is protected from internal cavitation and
from corrosion. The analysis also tests the ability of
the coolant to protect the engine from boiling and
from freezing. The S·O·S coolant analysis can be
done at your Caterpillar dealer. Caterpillar S·O·S
coolant analysis is the best way to monitor the
condition of your coolant and your cooling system.
S·O·S coolant analysis is a program that is based
on periodic samples.
50 SEBU7901-01
Maintenance Section
Refill Capacities

Refill Capacity (Coolant System)

To maintain the cooling system, the total cooling
system capacity must be known. The capacity of
the total cooling system will vary. The capacity will
depend on the size of the radiator (capacity) that is
provided by the vehicle manufacturer. Table 11should
be completed by the customer for the maintenance
of the cooling system.

Table 11
Approximate Capacity of the Cooling System
Compartment
Liters Quarts
or System
Total Cooling
System(1)
(1) The total cooling system capacity includes the following
components:the engine block, the radiator, and all coolant
hoses and lines.

Note: Refer to Special Publication, SEBU6251,

“Caterpillar Commercial Diesel Engine Fluids
Recommendations” for additional information that
relates to coolant for your engine.
SEBU7901-01
i02433183
Maintenance Interval Schedule
SMCS Code: 1000; 7500
Ensure that all safety information, warnings, and
instructions are read and understood before any
operation or any maintenance procedures are
performed.
The user is responsible for the performance of
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. The
performance of this product may be diminished if
proper maintenance intervals and procedures are not
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures
are not followed.
Use fuel consumption, service hours, or calendar
time, WHICH EVER OCCURS FIRST, in order to
determine the maintenance intervals. Products that
operate in severe operating conditions may require
more frequent maintenance.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
When Required
Battery - Replace .................................................. 54
Battery or Battery Cable - Disconnect .................. 55
Engine Air Cleaner Element (Dual Element) -
Clean/Replace .................................................... 66
Engine Storage Procedure - Check ...................... 75
Fuel System - Prime ............................................. 76
Severe Service Application - Check ..................... 85
Daily
Cooling System Coolant Level - Check ................ 61
Engine Air Cleaner Service Indicator - Inspect ..... 69
Engine Oil Level - Check ...................................... 71
Fuel System Primary Filter/Water Separator -
Drain ................................................................... 78
Power Take-Off Clutch - Check/Adjust/Lubricate .. 84
Walk-Around Inspection ........................................ 87
Every Week
Fuel Tank Water and Sediment - Drain ................. 80
Jacket Water Heater - Check ................................ 82
Every 250 Service Hours
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add ................................................. 62
Engine Oil and Filter - Change ............................. 72
Fuel Tank Water and Sediment - Drain ................. 80
51
Maintenance Section
Maintenance Interval Schedule
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 62
Every 500 Service Hours
Belts - Inspect/Adjust/Replace .............................. 55
Cooling System Coolant Sample (Level 1) -
Obtain ................................................................. 61
Starting Motor - Inspect ........................................ 86
Turbocharger - Inspect .......................................... 86
Water Pump - Inspect ........................................... 88
Every 500 Service Hours or 6 Months
Engine Protective Devices - Check ...................... 74
Every 2000 Service Hours or 1 Year
Alternator - Inspect ............................................... 53
Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 62
Every 3000 Service Hours or 3 Years
Cooling System Coolant (DEAC) - Change .......... 56
Cooling System Coolant Extender (ELC) - Add .... 60
Cooling System Water Temperature Regulator -
Replace ............................................................... 63
Every 8000 Service Hours or 3 Years
Driven Equipment - Check .................................... 64
Every 12 000 Service Hours or 6 Years
Cooling System Coolant (ELC) - Change ............. 58
Every 14 400 L (3750 US gal) of Fuel or 250
Service Hours or 1 Year
Battery Electrolyte Level - Check .......................... 54
Electronics Grounding Stud - Inspect/Clean/
Tighten ................................................................ 65
Engine Crankcase Breather - Clean ..................... 70
Engine Oil Sample - Obtain .................................. 72
Fuel System Primary Filter (Water Separator)
Element - Replace .............................................. 78
Fuel System Secondary Filter - Replace .............. 79
Hoses and Clamps - Inspect/Replace .................. 81
Radiator - Clean .................................................... 85
Every 28 500 L (7500 US gal) of Fuel or 500
Service Hours or 1 Year (Deep Sump)
Engine Oil and Filter - Change ............................. 72
52 SEBU7901-01
Maintenance Section
Maintenance Interval Schedule

Every 114 000 L (30 000 US gal) of Fuel or

3000 Service Hours
Aftercooler Core - Clean/Test ............................... 53

Every 170 400 L (45 000 US gal) of Fuel or

3000 Service Hours
Crankshaft Vibration Damper - Inspect ................. 64
Electronic Unit Injector - Inspect/Adjust ................ 65
Engine - Clean ...................................................... 66
Engine Mounts - Inspect ....................................... 71
Engine Speed/Timing Sensors - Check/Clean/
Calibrate .............................................................. 74
Engine Valve Lash - Inspect/Adjust ...................... 75
Engine Valve Rotators - Inspect ........................... 76
Fan Drive Bearing - Lubricate ............................... 76

Every 380 000 L (100 000 US gal) of Fuel or

10 000 Service Hours
Overhaul Considerations ...................................... 82

Overhaul
Fan Drive Bearing - Replace ................................ 76
SEBU7901-01
i01188617
Aftercooler Core - Clean/Test
(Air-To-Air Aftercooler)
SMCS Code: 1064-070; 1064-081
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the cooling air side of the aftercooler for these
items: damaged fins, corrosion, dirt, grease, insects,
leaves, oil, and other debris. Clean the cooling air
side of the aftercooler, if necessary.
For air-to-air aftercoolers, use the same methods that
are used for cleaning the outside of radiators.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
of the fan’s air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move the
air nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
After cleaning, start the engine and accelerate the
engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.
Inspect the fins for damage. Bent fins may be opened
with a “comb”.
53
Maintenance Section
Aftercooler Core - Clean/Test
Note: If parts of the aftercooler system are repaired
or replaced, a leak test is highly recommended. The
FT1984 Aftercooler Testing Group is used to perform
leak tests on the aftercooler. Refer to the Systems
Operation/Testing and Adjusting, “Aftercooler - Test”
and the Special Instruction, SEHS8622 for the proper
testing procedure.
Inspect these items for good condition: welds,
mounting brackets, air lines, connections, clamps,
and seals. Make repairs, if necessary.
For more detailed information on cleaning and
inspection, see Special Publication, SEBD0518,
“Know Your Cooling System”.
i00072207
Alternator - Inspect
SMCS Code: 1405-040
Caterpillar recommends a scheduled inspection
of the alternator. Inspect the alternator for loose
connections and proper battery charging. Inspect the
ammeter (if equipped) during engine operation in
order to ensure proper battery performance and/or
proper performance of the electrical system. Make
repairs, as required. Refer to the Service Manual.
Check the alternator and the battery charger for
proper operation. If the batteries are properly
charged, the ammeter reading should be very near
zero. All batteries should be kept charged. The
batteries should be kept warm because temperature
affects the cranking power. If the battery is too cold,
the battery will not crank the engine. The battery will
not crank the engine, even if the engine is warm.
When the engine is not run for long periods of time
or if the engine is run for short periods, the batteries
may not fully charge. A battery with a low charge will
freeze more easily than a battery with a full charge.
54
Maintenance Section
Battery - Replace
i01878164
Battery - Replace
SMCS Code: 1401-510
Batteries give off combustible gases which can
explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
jury or death.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Switch the engine to the OFF position. Remove
all electrical loads.
2. Turn off any battery chargers. Disconnect any
battery chargers.
3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the NEGATIVE “-” terminal
on the starter motor. Disconnect the cable from
the NEGATIVE “-” battery terminal.
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the POSITIVE “+” terminal
on the starting motor. Disconnect the cable from
the POSITIVE “+” battery terminal.
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
recycling facility.
5. Remove the used battery.
6. Install the new battery.
Note: Before the cables are connected, ensure that
the engine start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
SEBU7901-01
8. Connect the cable from the NEGATIVE “-” terminal
on the starter motor to the NEGATIVE “-” battery
terminal.
i02340858
Battery Electrolyte Level -
Check
SMCS Code: 1401-535
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing. If batteries
are properly charged, ammeter reading should be
very near zero, when the engine is in operation.
All lead-acid batteries contain sulfuric acid which
can burn the skin and clothing. Always wear a face
shield and protective clothing when working on or
near batteries.
1. Remove the filler caps. Maintain the electrolyte
level to the “FULL” mark on the battery.
If the addition of water is necessary, use distilled
water. If distilled water is not available use clean
water that is low in minerals. Do not use artificially
softened water.
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
3. Keep the batteries clean.
Clean the battery case with one of the following
cleaning solutions:
• A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water
Thoroughly rinse the battery case with clean water.
Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
SEBU7901-01
i01492654
Battery or Battery Cable -
Disconnect
SMCS Code: 1402-029
The battery cables or the batteries should not be
removed with the battery cover in place. The bat-
tery cover should be removed before any servic-
ing is attempted.
Removing the battery cables or the batteries with
the cover in place may cause a battery explosion
resulting in personal injury.
1. Turn the start switch to the OFF position. Turn the
ignition switch (if equipped) to the OFF position
and remove the key and all electrical loads.
2. Disconnect the negative battery terminal at the
battery that goes to the start switch. Ensure that
the cable cannot contact the terminal. When four
12 volt batteries are involved, the negative side of
two batteries must be disconnected.
3. Tape the leads in order to help prevent accidental
starting.
4. Proceed with necessary system repairs. Reverse
the steps in order to reconnect all of the cables.
i02042962
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
Inspection
Inspect the alternator belt and the fan drive belts for
wear and for cracking. Replace the belts if the belts
are not in good condition.
Check the belt tension according to the information in
the Service Manual, “Specifications”.
Slippage of loose belts can reduce the efficiency
of the driven components. Vibration of loose belts
can cause unnecessary wear on the following
components:
• Belts
• Pulleys
• Bearings
55
Maintenance Section
Battery or Battery Cable - Disconnect
If the belts are too tight, unnecessary stress is placed
on the components. This reduces the service life of
the components.
Replacement
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail.
Alternator Belt Adjustment
g00788814
Illustration 25
1. Remove the belt guard.
2. Loosen mounting bolts (1) and adjusting bolt (2).
3. Move the assembly in order to increase or
decrease the belt tension.
4. Tighten adjusting bolt (2). Tighten mounting bolts
(1).
5. Reinstall the belt guard.
If new drive belts are installed, check the drive belt
tension again after 30 minutes of engine operation
at the rated rpm.
Adjustment of the Fan Drive Belt
1. Remove the belt guard.
2. Loosen the mounting bolt for the pulley.
3. Loosen the adjusting nut for the pulley.
4. Move the pulley in order to adjust the belt tension.
5. Tighten the adjusting nut.
6. Tighten the mounting bolt.
56
Maintenance Section
Cooling System Coolant (DEAC) - Change
7. Reinstall the belt guard.
If new drive belts are installed, check the drive belt
tension again after 30 minutes of engine operation
at the rated rpm.
i02070334
Cooling System Coolant
(DEAC) - Change
SMCS Code: 1350-070; 1395-044
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.
• Foaming of the coolant
• The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the
coolant is contaminated.
NOTICE
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
Drain
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain
valve, remove one of the drain plugs.
SEBU7901-01
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tools:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to the
Specifications Manual for your particular engine for
more specific information on the proper torques.
Refer to the Specifications, SENR3130, “Torque
Specifications” for more general information on
the proper torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap.
4. Start the engine and run the engine at low idle for a
minimum of 30 minutes. The coolant temperature
should be at least 82 °C (180 °F).
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
SEBU7901-01
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
plugs. Refer to the Specifications Manual for your
particular engine for more specific information on
the proper torques. Refer to the Specifications,
SENR3130, “Torque Specifications” for more
general information on the proper torques.
Cooling Systems with Heavy
Deposits or Plugging
Note: For the following procedure to be effective,
there must be some active flow through the cooling
system components.
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to the
Specifications Manual for your particular engine for
more specific information on the proper torques.
Refer to the Specifications, SENR3130, “Torque
Specifications” for more general information on
the proper torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add .5 L (1 pint) of cleaner per 3.8 to 7.6 L
(1 to 2 US gal) of the cooling system capacity.
Install the cooling system filler cap.
4. Start the engine and run the engine at low idle for a
minimum of 90 minutes. The coolant temperature
should be at least 82 °C (180 °F).
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
57
Maintenance Section
Cooling System Coolant (DEAC) - Change
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
plugs. Refer to the Specifications Manual for your
particular engine for more specific information on
the proper torques. Refer to the Specifications,
SENR3130, “Torque Specifications” for more
general information on the proper torques.
Fill
Refer to the Operation and Maintenance Manual,
“Refill Capacities and Recommendations” topic for
the capacity of the engine’s system and for coolant
recommendations.
Engines that are Equipped with a Coolant
Recovery Tank
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
1. Fill the cooling system with coolant/antifreeze.
Refer to the Operation and Maintenance Manual,
“Refill Capacities and Recommendations” topic
(Maintenance Section) for more information on
cooling system specifications. Do not install the
cooling system filler cap.
2. Start the engine and run the engine at low idle.
Increase the engine rpm to high idle. Run the
engine at high idle for one minute in order to purge
the air from the cavities of the engine block. Stop
the engine.
3. Add coolant to the cooling system until the cooling
system is full.
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap.
If the gasket that is on the cooling system filler
cap is not damaged, perform a pressure test. A
9S-8140 Pressurizing Pump is used to perform
the pressure test. The correct pressure for the
cooling system filler cap is stamped on the face of
the cooling system filler cap. If the cooling system
filler cap does not retain the correct pressure,
install a new cooling system filler cap.
58
Maintenance Section
Cooling System Coolant (ELC) - Change
5. Loosen the cap for the coolant recovery tank
slowly in order to relieve any pressure. Remove
the cap for the coolant recovery tank.
6. Pour coolant into the coolant recovery tank until
the coolant reaches the “COLD FULL” mark.
DO NOT fill the coolant recovery tank above the
“COLD FULL” mark.
7. Clean the cap for the coolant recovery tank. Install
the cap for the coolant recovery tank.
8. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
Engines that are Not Equipped with a
Coolant Recovery Tank
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
1. Fill the cooling system with coolant/antifreeze.
Refer to the Operation and Maintenance Manual,
“Refill Capacities and Recommendations” topic
(Maintenance Section) for more information on
cooling system specifications. Do not install the
cooling system filler cap.
2. Start the engine and run the engine at low idle.
Increase the engine rpm to high idle. Run the
engine at high idle for one minute in order to purge
the air from the cavities of the engine block. Stop
the engine.
3. Check the coolant level. Maintain the coolant level
within 13 mm (.5 inch) below the bottom of the
pipe for filling. Maintain the coolant level within
13 mm (.5 inch) to the proper level on the sight
glass (if equipped).
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap.
If the gasket that is on the cooling system filler
cap is not damaged, perform a pressure test. A
9S-8140 Pressurizing Pump is used to perform
the pressure test. The correct pressure for the
cooling system filler cap is stamped on the face of
the cooling system filler cap. If the cooling system
filler cap does not retain the correct pressure,
install a new cooling system filler cap.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
SEBU7901-01
i02070355
Cooling System Coolant (ELC)
- Change
SMCS Code: 1350-070; 1395-044
Clean the cooling system and flush the cooling
system before the recommended maintenance
interval if the following conditions exist:
• The engine overheats frequently.
• Foaming of the coolant
• The oil has entered the cooling system and the
coolant is contaminated.
• The fuel has entered the cooling system and the
coolant is contaminated.
Note: When the cooling system is cleaned, only
clean water is needed when the ELC is drained and
replaced.
Note: Inspect the water pump and the water
temperature regulator after the cooling system has
been drained. This is a good opportunity to replace
the water pump, the water temperature regulator and
the hoses, if necessary.
Drain
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
2. Open the cooling system drain valve (if equipped).
If the cooling system is not equipped with a drain
valve, remove the cooling system drain plugs.
Allow the coolant to drain.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
SEBU7901-01
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tools:
Outside Illinois: 1-800-542-TOOL
Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL
Flush
1. Flush the cooling system with clean water in order
to remove any debris.
2. Close the drain valve (if equipped). Clean the
drain plugs. Install the drain plugs. Refer to the
Specifications Manual for your particular engine for
more specific information on the proper torques.
Refer to the Specifications, SENR3130, “Torque
Specifications” for more general information on
the proper torques.
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with clean water. Install the
cooling system filler cap.
4. Start the engine and run the engine at low
idle until the temperature reaches 49 to 66 °C
(120 to 150 °F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly
in order to relieve any pressure. Remove the
cooling system filler cap. Open the drain valve (if
equipped) or remove the cooling system drain
plugs. Allow the water to drain. Flush the cooling
system with clean water. Close the drain valve (if
equipped). Clean the drain plugs. Install the drain
plugs. Refer to the Specifications Manual for your
particular engine for more specific information on
the proper torques. Refer to the Specifications,
SENR3130, “Torque Specifications” for more
general information on the proper torques.
Fill
Engines that are Equipped with a Coolant
Recovery Tank
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
59
Maintenance Section
Cooling System Coolant (ELC) - Change
1. Fill the cooling system with Extended Life Coolant
(ELC). Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
topic (Maintenance Section) for more information
on cooling system specifications. Do not install the
cooling system filler cap.
2. Start the engine and operate the engine at low
idle. Increase the engine rpm to high idle. Operate
the engine at high idle for one minute in order to
purge air from the cavities of the engine block.
Stop the engine.
3. Pour more ELC into the cooling system until the
cooling system is full.
4. Clean the cooling system filler cap. Inspect the
gasket that is on the cooling system filler cap. If
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
cap and install a new cooling system filler cap. If
the gasket that is on the cooling system filler cap is
not damaged, use a 9S-8140 Pressurizing Pump
in order to pressure test the cooling system filler
cap. The correct pressure for the cooling system
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new
cooling system filler cap.
5. Loosen the cap for the coolant recovery tank
slowly in order to relieve any pressure. Remove
the cap for the coolant recovery tank.
6. Pour Extended Life Coolant (ELC) into the coolant
recovery tank until the coolant reaches the “COLD
FULL” mark. DO NOT fill the coolant recovery
tank above the “COLD FULL” mark.
7. Clean the cap for the coolant recovery tank. Install
the cap for the coolant recovery tank.
8. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
Engines that are NOT Equipped with a
Coolant Recovery Tank
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
1. Fill the cooling system with Extended Life Coolant
(ELC). Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
topic (Maintenance Section) for more information
on cooling system specifications. Do not install the
cooling system filler cap.
60 SEBU7901-01
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

2. Start the engine and operate the engine at low

idle. Increase the engine rpm to high idle. Operate
the engine at high idle for one minute in order to
Personal injury can result from hot coolant, steam
purge air from the cavities of the engine block.
and alkali.
Stop the engine.
At operating temperature, engine coolant is hot
3. Check the coolant level. Maintain the coolant level
and under pressure. The radiator and all lines
within 13 mm (.5 inch) below the bottom of the
to heaters or the engine contain hot coolant or
pipe for filling. Maintain the coolant level within
steam. Any contact can cause severe burns.
13 mm (.5 inch) to the proper level on the sight
glass (if equipped).
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
4. Clean the cooling system filler cap. Inspect the
cooling system pressure cap is cool enough to
gasket that is on the cooling system filler cap. If
touch with your bare hand.
the gasket that is on the cooling system filler cap
is damaged, discard the old cooling system filler
Do not attempt to tighten hose connections when
cap and install a new cooling system filler cap. If
the coolant is hot, the hose can come off causing
the gasket that is on the cooling system filler cap is
burns.
not damaged, use a 9S-8140 Pressurizing Pump
in order to pressure test the cooling system filler
Cooling System Coolant Additive contains alkali.
cap. The correct pressure for the cooling system
Avoid contact with skin and eyes.
filler cap is stamped on the face of the cooling
system filler cap. If the cooling system filler cap
does not retain the correct pressure, install a new NOTICE
cooling system filler cap. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
5. Start the engine. Inspect the cooling system for ing, adjusting and repair of the product. Be prepared to
leaks and for proper operating temperature. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
i02482066
nent containing fluids.

Cooling System Coolant Refer to Special Publication, NENG2500, “Caterpillar

Extender (ELC) - Add
SMCS Code: 1352-045; 1395-081
Cat ELC (Extended Life Coolant) does not require
the frequent additions of any supplemental cooling
additives which are associated with the present
conventional coolants. The Cat ELC Extender only
needs to be added once.
NOTICE
Use only Cat Extended Life Coolant (ELC) Extender
with Cat ELC.
Do NOT use conventional supplemental coolant addi-
tive (SCA) with Cat ELC. Mixing Cat ELC with conven-
tional coolants and/or conventional SCA reduces the
Cat ELC service life.
Check the cooling system only when the engine is
stopped and cool.
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
1. Loosen the cooling system filler cap slowly in
order to relieve pressure. Remove the cooling
system filler cap.
2. It may be necessary to drain enough coolant from
the cooling system in order to add the Cat ELC
Extender.
3. Add Cat ELC Extender according to the
requirements for your engine’s cooling system
capacity. Refer to the Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
article for more information.
4. Clean the cooling system filler cap. Inspect the
gaskets on the cooling system filler cap. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
SEBU7901-01 61
Maintenance Section
Cooling System Coolant Level - Check

i01197583 3. Clean the cooling system filler cap and check the
condition of the filler cap gaskets. Replace the
Cooling System Coolant Level cooling system filler cap if the filler cap gaskets are
- Check damaged. Reinstall the cooling system filler cap.

SMCS Code: 1395-082 4. Inspect the cooling system for leaks.

Check the coolant level when the engine is stopped i02326688

and cool.
Cooling System Coolant
Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542

Note: Obtaining a Coolant Sample (Level 1) is

optional if the cooling system is filled with Cat
ELC (Extended Life Coolant). Cooling systems that
are filled with Cat ELC should have a Coolant Sample
(Level 2) that is obtained at the recommended interval
that is stated in the Maintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if the

cooling system is filled with any other coolant
g00285520 instead of Cat ELC. This includes the following
Illustration 26
Cooling system filler cap types of coolants.

Table 12
Recommended Interval
Pressurized System: Hot coolant can cause seri- Type of Coolant Level 1 Level 2
ous burns. To open the cooling system filler cap, Every 250
stop the engine and wait until the cooling system Cat DEAC Yearly(1)(2)
Hours(1)
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres- Cat ELC Optional(2) Yearly(2)
sure. (1) This is the recommended interval for coolant samples for all
conventional heavy-duty coolant/antifreeze. This is also the
recommended interval for coolant samples of commercial
1. Remove the cooling system filler cap slowly in coolants that meet the Cat EC-1 specification for engine
order to relieve pressure. coolant.
(2) The Level 2 Coolant Analysis should be performed sooner if a
2. Maintain the coolant level within 13 mm (0.5 inch) problem is suspected or identified.
of the bottom of the filler pipe. If the engine is
equipped with a sight glass, maintain the coolant • Commercial long life coolants that meet the
level to the proper level in the sight glass. Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1)

• Cat DEAC (Diesel Engine Antifreeze/Coolant)

• Commercial heavy-duty coolant/antifreeze

NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
g00103639
Illustration 27
Note: Level 1 results may indicate a need for
Typical filler cap gaskets
Level 2 Analysis.
62
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Use the following guidelines for proper sampling of
the coolant:
• Complete the information on the label for the
sampling bottle before you begin to take the
samples.
• Keep the unused sampling bottles stored in plastic
bags.
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
• Keep the lids on empty sampling bottles until you
are ready to collect the sample.
• Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
contamination.
• Never collect samples from expansion bottles.
• Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
For additional information about coolant analysis,
see Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids Recommendations”
or consult your Caterpillar dealer.
i01987714
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant.
SEBU7901-01
Submit the sample for Level 2 analysis.
For additional information about coolant
analysis, see Special Publication, SEBU6251,
“Caterpillar Commercial Diesel Engines Fluids
Recommendations” or consult your Caterpillar dealer.
i02417522
Cooling System Supplemental
Coolant Additive (SCA) -
Test/Add
SMCS Code: 1352-045; 1395-081
This maintenance procedure is required for
conventional coolants such as DEAC and for
mixtures of water and SCA. This maintenance is
NOT required for cooling systems that are filled
with Extended Life Coolant.
Cooling system coolant additive contains alkali.
To help prevent personal injury, avoid contact with
the skin and eyes. Do not drink cooling system
coolant additive.
Note: Caterpillar recommends an S·O·S coolant
analysis (Level 1).
Test the Concentration of the SCA
Coolant/Antifreeze and SCA
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit.
Water and SCA
NOTICE
Do not exceed the recommended eight percent sup-
plemental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Use the instructions
that follow:
1. Fill the syringe to the “1.0 ml” mark with the
coolant.
2. Dispense the 1.0 mL coolant sample from the
syringe into the empty mixing bottle.
SEBU7901-01 63
Maintenance Section
Cooling System Water Temperature Regulator - Replace

3. Add tap water to the mixing bottle in order to bring

the level up to the “10 ml” mark. Place the cap on
the bottle and shake the bottle.
4. Add 2 to 3 drops of the “NITRITE INDICATOR
SOLUTION B” to the mixing bottle. Move the bottle
in a circular motion in order to mix the solution.
5. Add 1 drop of “NITRITE TEST SOLUTION A” to
the mixing bottle. Move the bottle in a circular
motion in order to mix the solution.
6. Repeat 5 until the solution changes color from red
to light gray, green, or blue. Record the number of
drops of “NITRITE TEST SOLUTION A” that were
required to cause the color change.
NOTICE
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
faces of the cooling system, reducing the engine’s
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat exchang-
er, overheating, and/or accelerated wear of the water
pump seal.
Do not exceed the recommended amount of supple-
mental coolant additive concentration.

7. Use Table 13 to interpret the results.

3. Add the proper amount of SCA. For the
Table 13 proper amount of SCA, refer to this Operation
and Maintenance Manual, “Refill Capacities
Number of Concentration Maintenance and Recommendations” topic. The proper
Drops of SCA Required
concentration of SCA depends on the type of
Less than 25 Less than the Add SCA. coolant that is used. For the proper concentration
recommended Retest the of SCA, refer to Special Publication, SEBU6251,
concentration of coolant. “Caterpillar Commercial Diesel Engine Fluids
SCA Recommendations”.
25 to 30 The None
recommended 4. Clean the cooling system filler cap. Install the
concentration of cooling system filler cap.
SCA
More than 30 More than the Remove the i00912898
recommended coolant.
concentration of Replace with Cooling System Water
SCA water only
Retest the Temperature Regulator -
coolant. Replace
SMCS Code: 1355-510
Add the SCA, If Necessary
Replace the water temperature regulator before
the water temperature regulator fails. This is a
recommended preventive maintenance practice.
Pressurized System: Hot coolant can cause seri- Replacing the water temperature regulator reduces
ous burns. To open the cooling system filler cap, the chances for unscheduled downtime.
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system A water temperature regulator that fails in a
pressure cap slowly in order to relieve the pres- partially opened position can cause overheating or
sure. overcooling of the engine.

A water temperature regulator that fails in the closed

1. Remove the cooling system filler cap slowly. position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
Note: Always dispose of fluids according to local head or piston seizure problems.
regulations.

2. If necessary, drain some coolant in order to allow

space for the addition of the SCA.
64 SEBU7901-01
Maintenance Section
Crankshaft Vibration Damper - Inspect

A water temperature regulator that fails in the open
position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner.
NOTICE
Failure to replace your water temperature regulator
on a regularly scheduled basis could cause severe
engine damage.
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a water
temperature regulator installed.
If the water temperature regulator is installed incor-
rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position. Ensure that
the water temperature regulator vent hole is open.
Do not use liquid gasket material on the gasket or
cylinder head surface.
Refer to the Service Manual for the replacement
procedure of the water temperature regulator, or
consult your Caterpillar dealer.
Inspect the damper for evidence of fluid leaks. If
a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone. Silicone has
the following characteristics: transparent, viscous,
smooth, and difficult to remove from surfaces.
If the fluid leak is oil, inspect the crankshaft seals for
leaks. If a leak is observed, replace the crankshaft
seals.
Inspect the damper and repair or replace the damper
for any of the following reasons:
• The damper is dented, cracked, or leaking.
• The paint on the damper is discolored from heat.
• The engine has had a failure because of a broken
crankshaft.
• Analysis of the oil has revealed that the front main
bearing is badly worn.
• There is a large amount of gear train wear that is
not caused by a lack of oil.
Refer to the Service Manual or consult your
Caterpillar dealer for information about damper
replacement.
i00934883

Note: If only the water temperature regulators are

replaced, drain the coolant from the cooling system to
Driven Equipment - Check
a level that is below the water temperature regulator SMCS Code: 3279-535
housing.
Check the Alignment
i00934535
To minimize bearing problems and vibration of the
Crankshaft Vibration Damper engine crankshaft and the driven equipment, the
- Inspect alignment between the engine and driven equipment
must be properly maintained.
SMCS Code: 1205-040
Check the alignment according to the instructions
Damage to the crankshaft vibration damper or failure that are provided by the following manufacturers:
of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to • Caterpillar
the crankshaft and to other engine components. A
damper that is damaged can cause excessive gear • OEM of the drive coupling
train noise at variable points in the speed range.
• OEM of the driven equipment
The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the Torque all of the fasteners to the proper specifications.
engine.

Visconic Damper
The visconic damper has a weight that is located
inside a fluid filled case. The weight moves in the
case in order to limit torsional vibration.
SEBU7901-01
Inspect the Drive Coupling
Inspect the drive coupling according to the
instructions that are provided by the OEM of the
coupling. For the following service information, see
the literature that is provided by the OEM of the
coupling:
• Lubrication requirements
• Specifications for the end play
• “Reusability Guidelines”
• Replacement instructions
Inspect the Rear Gear Train
Inspect the crankshaft gear. If excessive wear is
found, replace the crankshaft gear and the large
cluster idler.
If any gear causes damage to other gears through
failure, replace the entire rear gear train.
For the correct parts, see the Parts Manual for the
engine. For removal and replacement instructions,
see the Service Manual, “Disassembly and
Assembly” module. Consult your Caterpillar dealer
for assistance.
i02070777
Electronic Unit Injector -
Inspect/Adjust
SMCS Code: 1251-025; 1251-040; 1290-025;
1290-040
Be sure the engine cannot be started while this
maintenance is being performed. To prevent pos-
sible injury, do not use the starting motor to turn
the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
suring/adjusting the unit injectors.
The electronic unit injectors use high voltage. Dis-
connect the unit injector enable circuit connector
in order to prevent personal injury. Do not come
in contact with the injector terminals while the en-
gine is running.
65
Maintenance Section
Electronic Unit Injector - Inspect/Adjust
The operation of Caterpillar engines with improper
adjustments of the electronic unit injector can reduce
engine efficiency. This reduced efficiency could result
in excessive fuel usage and/or shortened engine
component life.
Only qualified service personnel should perform
this maintenance. Refer to the following topics
for your engine for the correct procedure: Refer
to the Systems Operation, Testing and Adjusting,
“Electronic Unit Injector - Test” for the test procedure,
and Systems Operation, Testing and Adjusting,
“Electronic Unit Injector - Adjust” for the correct
procedure for adjusting the injectors.
NOTICE
The camshafts must be correctly timed with the crank-
shaft before an adjustment of the lash for the fuel in-
jector is made. The timing pins must be removed from
the camshafts before the crankshaft is turned or dam-
age to the cylinder block will be the result.
i02052170
Electronics Grounding Stud -
Inspect/Clean/Tighten
SMCS Code: 7423-040; 7423-070; 7423-079
The connection of battery cables to a battery and
the disconnection of battery cables from a battery
may cause an explosion which may result in injury
or death. The connection and the disconnection
of other electrical equipment may also cause an
explosion which may result in injury or death. The
procedures for the connection and the disconnec-
tion of battery cables and other electrical equip-
ment should only be performed in a nonexplosive
atmosphere.
66
Maintenance Section
Engine - Clean
Illustration 28
g00765094
Electronics grounding stud (side view)
Inspect the OEM harness for good connections.
Inspect the condition of the OEM harness.
The electronics grounding stud must have a wire
ground to the battery. Tighten the electronics
grounding stud at every oil change. Ground wires
and straps should be combined at engine grounds.
All grounds should be tight and free of corrosion.
• Clean the electronics grounding stud and the
terminals for the electronics ground strap with a
clean cloth.
• If the connections are corroded, clean the
connections with a solution of baking soda and
water.
• Keep the electronics grounding stud and the strap
clean and coated with MPGM grease or petroleum
jelly.
SEBU7901-01
i01646701
Engine - Clean
SMCS Code: 1000-070
Personal injury or death can result from high volt-
age.
Moisture can create paths of electrical conductiv-
ity.
Make sure that the electrical system is OFF. Lock
out the starting controls and tag the controls “DO
NOT OPERATE”.
NOTICE
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.
Periodic cleaning of the engine is recommended.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits:
• Easy detection of fluid leaks
• Maximum heat transfer characteristics
• Ease of maintenance
Note: Caution must be used in order to prevent
electrical components from being damaged by
excessive water when you clean the engine. Avoid
electrical components such as the alternator, the
starter, and the ECM.
i01553486
Engine Air Cleaner Element
(Dual Element) - Clean/Replace
SMCS Code: 1054-037; 1054-510
NOTICE
Never run the engine without an air cleaner element
installed. Never run the engine with a damaged air
cleaner element. Do not use air cleaner elements with
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.
SEBU7901-01 67
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air
can split the material of the air cleaner element.
Unfiltered air will drastically accelerate internal engine
wear. Your Caterpillar dealer has the proper air
cleaner elements for your application. Consult your
Caterpillar dealer for the correct air cleaner element.
g00736431
Illustration 29
• Check the precleaner (if equipped) daily for (1) Cover
accumulation of dirt and debris. Remove any dirt (2) Primary air cleaner element
and debris, as needed. (3) Secondary air cleaner element
(4) Turbocharger air inlet
• Operating conditions (dust, dirt and debris) may
require more frequent service of the air cleaner 1. Remove the cover. Remove the primary air
element. cleaner element.

• The air cleaner element may be cleaned up to 2. The secondary air cleaner element should be
six times if the element is properly cleaned and removed and discarded for every three cleanings
inspected. of the primary air cleaner element.

• The air cleaner element should be replaced at least Note: Refer to “Cleaning the Primary Air Cleaner
one time per year. This replacement should be Elements”.
performed regardless of the number of cleanings.
3. Cover the turbocharger air inlet with tape in order
Replace the dirty paper air cleaner elements with to keep dirt out.
clean air cleaner elements. Before installation, the
air cleaner elements should be thoroughly checked 4. Clean the inside of the air cleaner cover and body
for tears and/or holes in the filter material. Inspect with a clean, dry cloth.
the gasket or the seal of the air cleaner element for
damage. Maintain a supply of suitable air cleaner 5. Remove the tape for the turbocharger air inlet.
elements for replacement purposes. Install the secondary air cleaner element. Install a
primary air cleaner element that is new or cleaned.
Dual Element Air Cleaners
6. Install the air cleaner cover.
The dual element air cleaner contains a primary
air cleaner element and a secondary air cleaner 7. Reset the air cleaner service indicator.
element. The primary air cleaner element can be
used up to six times if the element is properly cleaned
and inspected. The primary air cleaner element
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.

The secondary air cleaner element is not serviceable

or washable. The secondary air cleaner element
should be removed and discarded for every three
cleanings of the primary air cleaner element. When
the engine is operating in environments that are
dusty or dirty, air cleaner elements may require more
frequent replacement.
68 SEBU7901-01
Maintenance Section
Engine Air Cleaner Element (Dual Element) - Clean/Replace

Cleaning the Primary Air Cleaner Pressurized Air

Elements
NOTICE
Caterpillar recommends certified air filter cleaning ser-
vices that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
Pressurized air can be used to clean primary air
cleaner elements that have not been cleaned more
than two times. Pressurized air will not remove
deposits of carbon and oil. Use filtered, dry air with a
maximum pressure of 207 kPa (30 psi).

Observe the following guidelines if you attempt to

clean the filter element:

Do not tap or strike the filter element in order to re-

move dust.

Do not wash the filter element.

Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
engine components.
Illustration 30
g00281692
Note: When the primary air cleaner elements are
cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
(outside).

The primary air cleaner element can be used up Aim the hose so that the air flows inside the element
to six times if the element is properly cleaned and along the length of the filter in order to help prevent
inspected. When the primary air cleaner element is damage to the paper pleats. Do not aim the stream
cleaned, check for rips or tears in the filter material. of air directly at the primary air cleaner element. Dirt
The primary air cleaner element should be replaced could be forced further into the pleats.
at least one time per year. This replacement should
be performed regardless of the number of cleanings. Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
Use clean primary air cleaner elements while dirty
elements are being cleaned. Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
NOTICE
primary air cleaner elements which require daily
Do not clean the air cleaner elements by bumping or
cleaning because of a dry, dusty environment.
tapping. This could damage the seals. Do not use el-
Cleaning with pressurized air is recommended prior
ements with damaged pleats, gaskets or seals. Dam-
to vacuum cleaning. Vacuum cleaning will not remove
aged elements will allow dirt to pass through. Engine
deposits of carbon and oil.
damage could result.
Note: Refer to “Inspecting the Primary Air Cleaner
Visually inspect the primary air cleaner elements Elements”.
before cleaning. Inspect the air cleaner elements for
damage to the seal, the gaskets, and the outer cover.
Discard any damaged air cleaner elements.

There are two common methods that are used to

clean primary air cleaner elements:

• Pressurized air
• Vacuum cleaning
SEBU7901-01
Inspecting the Primary Air Cleaner
Elements
g00281693
Illustration 31
Inspect the clean, dry primary air cleaner element.
Use a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air cleaner
element. Rotate the primary air cleaner element.
Inspect the primary air cleaner element for tears
and/or holes. Inspect the primary air cleaner element
for light that may show through the filter material. If it
is necessary in order to confirm the result, compare
the primary air cleaner element to a new primary air
cleaner element that has the same part number.
Do not use a primary air cleaner element that has
any tears and/or holes in the filter material. Do not
use a primary air cleaner element with damaged
pleats, gaskets or seals. Discard damaged primary
air cleaner elements.
Storing Primary Air Cleaner Elements
If a primary air cleaner element that passes inspection
will not be used, the primary air cleaner element can
be stored for future use.
g00281694
Illustration 32
69
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air cleaner elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the primary air cleaner element into a box
for storage. For identification, mark the outside of
the box and mark the primary air cleaner element.
Include the following information:
• Date of cleaning
• Number of cleanings
Store the box in a dry location.
i01900118
Engine Air Cleaner Service
Indicator - Inspect
(If Equipped)
SMCS Code: 7452-040
Some engines may be equipped with a different
service indicator.
Some engines are equipped with a differential gauge
for inlet air pressure. The differential gauge for inlet
air pressure displays the difference in the pressure
that is measured before the air cleaner element and
the pressure that is measured after the air cleaner
element. As the air cleaner element becomes dirty,
the pressure differential rises. If your engine is
equipped with a different type of service indicator,
follow the OEM recommendations in order to service
the air cleaner service indicator.
The service indicator may be mounted on the air
cleaner housing or in a remote location.
g00103777
Illustration 33
Typical service indicator
70
Maintenance Section
Engine Crankcase Breather - Clean
Observe the service indicator. The air cleaner
element should be cleaned or the air cleaner element
should be replaced when one of the following
conditions occur:
• The yellow diaphragm enters the red zone.
• The red piston locks in the visible position.
Test the Service Indicator
Service indicators are important instruments.
• Check for ease of resetting. The service indicator
should reset in less than three pushes.
• Check the movement of the yellow core when the
engine is accelerated to the engine rated speed.
The yellow core should latch approximately at the
greatest vacuum that is attained.
If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
the service indicator should be replaced. If the new
service indicator will not reset, the hole for the service
indicator may be plugged.
The service indicator may need to be replaced
frequently in environments that are severely dusty, if
necessary. Replace the service indicator annually
regardless of the operating conditions. Replace the
service indicator when the engine is overhauled, and
whenever major engine components are replaced.
Note: When a new service indicator is installed,
excessive force may crack the top of the service
indicator. Tighten the service indicator to a torque
of 2 N·m (18 lb in).
SEBU7901-01
i01848984
Engine Crankcase Breather -
Clean
SMCS Code: 1317-070
g00485291
Illustration 34
(1) Bolts. (2) Hose clamp. (3) Breather cover.
NOTICE
Perform this maintenance with the engine stopped.
If the crankcase breather is not maintained on a
regular basis, the crankcase breather will become
plugged. A plugged crankcase breather will cause
excessive crankcase pressure that may cause
crankshaft seal leakage.
1. Loosen hose clamp (2) and remove the hose from
breather cover (3).
2. Loosen four bolts (1) for the breather cover and
remove breather cover (3).
3. Remove the breather element and wash the
breather element in solvent that is clean and
nonflammable. Allow the breather element to dry.
4. Install a breather element that is clean and dry.
Install breather cover (3) and install bolts (1).
Refer to the Specifications, SENR3130 in order to
locate the proper torques.
5. Install the hose. Install hose clamp (2). Refer to
the Specifications, SENR3130 in order to locate
the proper torques.
SEBU7901-01 71
Maintenance Section
Engine Mounts - Inspect

i02139969

Engine Mounts - Inspect

SMCS Code: 1152-040

Inspect the engine mounts for deterioration and for

proper bolt torque. Engine vibration can be caused
by the following conditions: Illustration 36
g00110310

(Y) “ADD” mark

• Improper mounting of the engine (X) “FULL” mark

• Deterioration of the engine mounts

Any engine mount that shows deterioration should
be replaced. Refer to the Specifications Manual,
SENR3130, “Torque Specifications”. Refer to your
Caterpillar dealer for more information.
i02073191
Engine Oil Level - Check
SMCS Code: 1348-535-FLV
NOTICE
Perform this maintenance with the engine stopped.
1. Maintain the oil level between “ADD” mark (Y) and
“FULL” mark (X) on oil level gauge (1). Do not fill
the crankcase above “FULL” mark (X).
NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge (dip-
stick).

An overfull crankcase can enable the crankshaft to

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
dip into the oil. This will reduce the power that is de-
veloped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oil’s ability to lubricate, reduction of oil
pressure, inadequate cooling of the pistons, oil blow-
ing out of the crankcase breathers, and excessive oil
consumption.

Excessive oil consumption will enable deposits to form

on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.

If the oil level is above the “FULL” mark on the oil level
gauge, drain some of the oil immediately.

2. Remove oil filler cap (2) and add oil, if necessary.

For the correct oil to use, see this Operation
and Maintenance Manual, “Refill Capacities and
Recommendations” topic (Maintenance Section).
Do not fill the crankcase above “FULL” mark (X)
on the oil level gauge. Clean the oil filler cap.
Install the oil filler cap.

Illustration 35
g00622328 3. Record the amount of oil that is added. For the
(1) Oil level gauge
next oil sample and analysis, include the total
(2) Oil filler cap amount of oil that has been added since the
previous sample. This will help to provide the most
accurate oil analysis.
72
Maintenance Section
Engine Oil Sample - Obtain
i01935337
Engine Oil Sample - Obtain
SMCS Code: 1000-008; 1348-554-SM;
7542-554-OC, SM
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regularly scheduled intervals in order
to monitor the condition of the engine and the
maintenance requirements of the engine. S·O·S oil
analysis provides infrared analysis, which is required
for determining nitration and oxidation levels.
Obtain the Sample and the Analysis
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Before you take the oil sample, complete the Label,
PEEP5031 for identification of the sample. In order
to help obtain the most accurate analysis, provide
the following information:
• Engine model
• Service hours on the engine
• The number of hours that have accumulated since
the last oil change
• The amount of oil that has been added since the
last oil change
To ensure that the sample is representative of the
oil in the crankcase, obtain a warm, well mixed oil
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
Caterpillar recommends using the sampling valve
in order to obtain oil samples. The quality and the
consistency of the samples are better when the
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
obtained during normal engine operation.
The 169-8373 Fluid Sampling Bottle is
recommended for use with the sampling valve. The
fluid sampling bottle includes the parts that are
needed for obtaining oil samples. Instructions are
also provided.
SEBU7901-01
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
If the engine is not equipped with a sampling valve,
use the 1U-5718 Vacuum Pump. The pump is
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion
into the sump.
For instructions, see Special Publication, PEHP6001,
“How To Take A Good Oil Sample”. Consult your
Caterpillar dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
i02107152
Engine Oil and Filter - Change
SMCS Code: 1318-510; 1348-044
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Do not drain the oil when the engine is cold. As the oil
cools, suspended waste particles settle on the bottom
of the oil pan. The waste particles are not removed
with the draining cold oil. Drain the crankcase with
the engine stopped. Drain the crankcase with the
oil warm. This draining method allows the waste
particles that are suspended in the oil to be drained
properly.
Failure to follow this recommended procedure will
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
Drain the Engine Oil
After the engine has been run at the normal operating
temperature, stop the engine. Use one of the
following methods to drain the engine crankcase oil:
• If the engine is equipped with a drain valve, turn the
drain valve knob counterclockwise in order to drain
the oil. After the oil has drained, turn the drain valve
knob clockwise in order to close the drain valve.
SEBU7901-01
• If the engine is not equipped with a drain valve,
remove the oil drain plug in order to allow the oil
to drain. If the engine is equipped with a shallow
sump, remove the bottom oil drain plugs from both
ends of the oil pan.
After the oil has drained, the oil drain plugs should
be cleaned and installed.
Replace the Oil Filter
NOTICE
Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.
1. Remove the oil filter with a 1U-8760 Chain
Wrench.
2. Cut the oil filter open with a 175-7546 Oil Filter
Cutter Gp. Break apart the pleats and inspect the
oil filter for metal debris. An excessive amount
of metal debris in the oil filter may indicate early
wear or a pending failure.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
Due to normal wear and friction, it is not
uncommon to find small amounts of debris in the
oil filter. Consult your Caterpillar dealer in order
to arrange for a further analysis if an excessive
amount of debris is found in the oil filter.
73
Maintenance Section
Engine Oil and Filter - Change
g00103713
Illustration 37
Typical filter mounting base and filter gasket
3. Clean the sealing surface of the filter mounting
base. Ensure that all of the old oil filter gasket is
removed.
4. Apply clean engine oil to the new oil filter gasket.
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to
engine components.
5. Install the oil filter. Tighten the oil filter until the
oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that are
shown on the oil filter. Do not overtighten the oil
filter.
Fill the Engine Crankcase
1. Remove the oil filler cap. Refer to the Operation
and Maintenance Manual, “Refill Capacities and
Recommendations” for more information.
NOTICE
If equipped with an auxiliary oil filter system or a re-
mote oil filter system, follow the OEM or filter manu-
facturer’s recommendations. Under filling or overfilling
the crankcase with oil can cause engine damage.
NOTICE
To prevent crankshaft bearing damage, crank the en-
gine with the fuel OFF. This will fill the oil filters before
starting the engine. Do not crank the engine for more
than 30 seconds.
2. Start the engine and run the engine at “LOW
IDLE” for two minutes. Perform this procedure in
order to ensure that the lubrication system has
oil and that the oil filters are filled. Inspect the oil
filter for oil leaks.
74 SEBU7901-01
Maintenance Section
Engine Protective Devices - Check

3. Stop the engine and allow the oil to drain back to i01464654
the sump for a minimum of ten minutes.
Engine Speed/Timing Sensors
4. Remove the oil level gauge in order to check the
oil level. Maintain the oil level between the “ADD”
- Check/Clean/Calibrate
and “FULL” marks on the oil level gauge. SMCS Code: 1912-040; 1912-070; 1912-524

i00626013

Engine Protective Devices -

Check
SMCS Code: 7400-535

Alarms and shutoffs must function properly. Alarms

provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices.

A calibration check of the engine protective devices

will ensure that the alarms and shutoffs activate
at the setpoints. Ensure that the engine protective
devices are functioning properly.
g00765246
Illustration 38
NOTICE
Left side view
During testing, abnormal operating conditions must be
simulated. (1) Secondary speed/timing sensor
(2) Primary speed/timing sensor

The tests must be performed correctly in order to pre-

1. Remove the speed/timing sensors from the front
vent possible damage to the engine.
housing. Check the condition of the plastic end
of the speed/timing sensors for wear and/or
To prevent damage to the engine, only authorized contaminants.
service personnel or your Caterpillar dealer should
perform the tests. 2. Clean the metal shavings and other debris from
the face of the speed/timing sensors. Use the
procedure in the Service Manual in order to
Visual Inspection calibrate the speed/timing sensors.
Visually check the condition of all gauges, sensors
Refer to the Service Manual for more information on
and wiring. Look for wiring and components that
the speed/timing sensors.
are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced
immediately.
SEBU7901-01
i01458399
Engine Storage Procedure -
Check
SMCS Code: 1000-535
The oil change interval may be extended to 12
months for a vehicle that is operated seasonally
and placed in storage for the remainder of the year
by using the required storage procedures and the
required start-up procedures. This extension is
permitted if the following categories for oil change
intervals in the Operation and Maintenance Manual,
“Maintenance Interval Schedule” have not been
reached:
• Mileage
• Operating hours
• Fuel consumption
If an engine is out of operation and if use of the
engine is not planned, special precautions should
be made. If the engine will be stored for more than
three months, a complete protection procedure is
recommended. For more detailed information on
engine storage, see Special Instruction, SEHS9031,
“Storage Procedure For Caterpillar Products”.
If the engine will not be started for several weeks, the
lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
liner surface. Rust on the cylinder liner surface will
cause increased engine wear and a reduction in
engine service life. Caterpillar recommends the
use of volatile corrosion inhibitor (VCI) oil in order
to prevent internal engine damage due to moisture
during storage. These inhibitors in the VCI oil act by
evaporating inside the engine. The inhibitors then
condense over the inside surfaces of the engine. The
evaporation process and the condensing process
offers full protection to surfaces that cannot be
reached with preservatives. 0.9 L (1.0 qt) of 4C-6792
VCI oil will treat 28.4 L (30.0 qt) of engine oil. This
will give a 3 percent concentration of VCI oil. The
engine must be completely sealed when the engine
is stored in order for the VCI oil to function properly.
The VCI oil is easily cleaned from the engine when
you remove the engine from storage. The volatile
vapors are removed by simply running the engine
to operating temperature. A mineral oil base is left
behind after the volatile vapors are removed.
75
Maintenance Section
Engine Storage Procedure - Check
i01849001
Engine Valve Lash -
Inspect/Adjust
SMCS Code: 1102-025
The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The
adjustment is necessary due to the initial wear of
the valve train components and to the seating of the
valve train components.
This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.
Ensure that the engine can not be started while
this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.
Ensure that the engine is stopped before measuring
the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance is
performed.
The following components should be inspected and
adjusted when the valves are inspected and adjusted.
• Valve actuators
• Injectors
• Compression brakes
Refer to the Service Manual for more information.
76 SEBU7901-01
Maintenance Section
Engine Valve Rotators - Inspect

i01597115

Engine Valve Rotators - Inspect

SMCS Code: 1109-040

When inspecting the valve rotators, protective

glasses or face shield and protective clothing
must be worn, to help prevent being burned by
hot oil or spray.

Engine valve rotators rotate the valves when the

engine runs. This helps to prevent deposits from
building up on the valves and the valve seats.
Perform the following steps after the engine valve
lash is set, but before the valve covers are installed:
1. Start the engine according to Operation and
Maintenance Manual, “Engine Starting” (Operation
Section) for the procedure.
2. Operate the engine at low idle.
3. Observe the top surface of each valve rotator.
The valve rotators should turn slightly when the
valves close.
g00746166
Illustration 39
Typical location of the grease fitting (if equipped) that is for the fan
drive bearing
The pulley is shown with the belt guards that have been removed.
Lubricate the grease fitting that is on the fan drive
bearing with Bearing Lubricant or the equivalent.
Inspect the fan drive pulley assembly for wear or for
damage. If the shaft is loose, an inspection of the
internal components should be performed. Refer to
the Service Manual for additional information.
i02053753

NOTICE
Fan Drive Bearing - Replace
A valve rotator which does not operate properly will SMCS Code: 1359-510-BD
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not replaced, 1. Remove Bearings. Refer to Disassembly and
valve face guttering could result and cause pieces of Assembly, “Bearing Removal”.
the valve to fall into the cylinder. This can cause piston
and cylinder head damage. 2. Measure the bearing housings for roundness and
for proper size.
If a valve fails to rotate, consult your Caterpillar
dealer. 3. Replace the bearings.

i02239650 i02075183

Fan Drive Bearing - Lubricate Fuel System - Prime

SMCS Code: 1359-086-BD SMCS Code: 1258-548

Some of the fan drives have grease fittings and some The Secondary Fuel Filter Has
of the fan drives do not have grease fittings. If there is
no grease fitting, periodic lubrication is not required. Been Replaced
The fan drive requires grease only if the fan drive
is equipped with a zerk.

Fuel leaked or spilled onto hot surfaces or elec-

trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
SEBU7901-01
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
Note: Refer to Operation and Maintenance Manual,
“Fuel System Secondary Filter - Replace” for
information on replacing the filter.
1. Turn the ignition switch to the “OFF” position.
g00975199
Illustration 40
(1) Fuel priming pump
(2) Air purge screw
(3) Priming valve (If Equipped)
2. Turn the priming valve (3) (If Equipped) to the
“Closed (Prime)” position in order to prime the fuel
system.
3. Open air purge screw (2) for the fuel filter by three
full turns. Do not remove the air purge screw.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Start the engine. The engine should start and the
engine should run smoothly.
Note: You may use the fuel priming pump for the fuel
filter (IF EQUIPPED) instead of starting the engine
and running the engine.
5. While the engine is running, observe air purge
screw (2). When a small drop of fuel appears
at the threads of the air purge screw, close and
tighten air purge screw (2).
77
Maintenance Section
Fuel System - Prime
Note: There may be a noticeable change in the
sound of the running engine when the air purge
screw is tightened. The change in the sound of the
engine is normal.
Note: Failure to tighten all fittings could result in
serious fuel leaks.
6. Clean any residual fuel from the engine
components.
7. After the engine has operated smoothly for 30
seconds, turn the priming valve (3) to the “Open
(Run)” position.
Note: Shortened injector life may occur if the priming
valve (3) is left in the “Closed (Prime)” position.
The Engine Has Been Run Out of
Fuel
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
1. Turn the ignition switch to the “OFF” position.
2. Fill the fuel tank(s) with clean diesel fuel.
Illustration 41
g00975199
(1) Fuel priming pump
(2) Air purge screw
(3) Priming valve (If Equipped)
3. Turn the priming valve (3) (If Equipped) to the
“Closed (Prime)” position in order to prime the fuel
system.
78 SEBU7901-01
Maintenance Section
Fuel System Primary Filter/Water Separator - Drain

4. Open air purge screw (2) for the fuel filter by three
full turns. Do not remove the air purge screw.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.

5. Crank the engine for 30 seconds. Use a suitable

container to catch the fuel while you crank the
engine. Allow the starter motor to cool for 2
minutes.

Note: You may use the fuel priming pump (1) (IF
EQUIPPED) for the fuel filter instead of cranking the
engine.

6. Crank the engine for 30 seconds. Allow the starter

motor to cool for 2 minutes.

7. Repeat Step 6 until the engine starts and the g00709596

Illustration 42
engine runs.
(1) Element
(2) Bowl
Note: Failure to tighten all fittings could result in (3) Drain
serious fuel leaks.
Bowl (2) should be monitored daily for signs of water.
8. After the engine has operated smoothly for 30 If water is present, drain the water from the bowl.
seconds, turn the priming valve (3) to the “Open
(Run)” position. 1. Open drain (3). The drain is a self-ventilated drain.
Catch the draining water in a suitable container.
Note: Shortened injector life may occur if the priming Dispose of the water properly.
valve (3) is left in the “Closed (Prime)” position.
2. Close drain (3).
9. Clean any residual fuel from the engine
components.
NOTICE
The water separator is under suction during normal
i01341997 engine operation. Ensure that the drain valve is tight-
ened securely to help prevent air from entering the fuel
Fuel System Primary system.
Filter/Water Separator - Drain
SMCS Code: 1260-543; 1263-543 i02053433

Fuel System Primary Filter

Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
Water in the fuel can cause the engine to run rough.
Water in the fuel may cause a electronic unit injector
to fail. If the fuel has been contaminated with water,
the element should be changed before the regularly
scheduled interval.
SEBU7901-01
The primary filter/water separator also provides
filtration in order to help extend the life of the
secondary fuel filter. The element should be changed
regularly. If a vacuum gauge is installed, the
primary filter/water separator should be changed at
50 to 70 kPa (15 to 20 inches Hg).
Replace the Element
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
1. Close the main fuel supply valve.
g00104012
Illustration 43
Element (1), Bowl (2), and Drain (3)
2. Remove element (1) from the element mounting
base while bowl (2) is attached.
3. Dispose of the contents of the filter. Remove bowl
(2) from element (1). The bowl is reusable. Do not
discard the bowl. Dispose of the used element.
4. Remove the O-ring from the gland of the bowl.
Clean the following components:
• Bowl
• O-ring
• Mounting base
Inspect the O-ring for damage and for
deterioration. Replace the O-ring, if necessary.
5. Lubricate the O-ring with clean diesel fuel.
6. Install bowl (2) on a new element. Tighten the
bowl by hand. Do not use tools in order to tighten
the bowl.
79
Maintenance Section
Fuel System Secondary Filter - Replace
NOTICE
The primary filter/water separator may be prefilled with
fuel to avoid rough running/stalling of the engine due
to air. Do not fill the secondary filter with fuel before
installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause accel-
erated wear to fuel system parts.
7. Lubricate the top seal of element (1) with clean
diesel fuel. The element may be filled with fuel at
this time. Install the new element on the mounting
base. Tighten the element by hand.
NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is tight-
ened securely to help prevent air from entering the fu-
el system.
8. Open the main fuel supply valve.
9. Start the engine and check for leaks. Run the
engine for one minute. Stop the engine and check
for leaks again.
Detecting leaks is difficult while the engine is
running. The primary filter/water separator is
under suction. A leak will allow air to enter the fuel.
The air in the fuel can cause low power due to
aeration of the fuel. If air enters the fuel, check the
components for overtightening or undertightening.
i01776046
Fuel System Secondary Filter -
Replace
SMCS Code: 1261-510-SE
Fuel leaked or spilled onto hot surfaces or elec-
trical components can cause a fire. To help pre-
vent possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any dis-
connected fuel system components.
80
Maintenance Section
Fuel Tank Water and Sediment - Drain
NOTICE
Use a suitable container to catch any fuel that might
spill. Clean up any spilled fuel immediately.
1. Stop the engine. Turn the ignition switch to the
OFF position or disconnect the battery. Refer to
the Operation and Maintenance Manual, “Battery
or Battery Cable - Disconnect” topic (Maintenance
Section) for more information. Shut off the fuel
supply valve (if equipped).
2. It may be necessary to relieve residual fuel
pressure from the fuel system before the fuel
filter is removed. Wait for one to five minutes until
the fuel pressure has lowered. Use a suitable
container in order to catch any fuel that may spill.
3. Remove the used fuel filter and discard the used
fuel filter.
4. Clean the gasket sealing surface of the fuel filter
base. Ensure that all of the old gasket is removed.
5. Apply clean diesel fuel to the new fuel filter gasket.
NOTICE
Do not fill the secondary fuel filter with fuel before in-
stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
NOTICE
In order to maximize fuel system life and prevent pre-
mature wear out from abrasive particles in the fuel, a
two micron high efficiency fuel filter is required for all
Caterpillar Electronic Unit Injectors. Caterpillar High
Efficiency Fuel Filters meet these requirements. Con-
sult your Caterpillar dealer for the proper part num-
bers.
6. Install the new fuel filter. Spin the fuel filter onto
the fuel filter base until the gasket contacts the
base. Use the rotation index marks on the filters
as a guide for proper tightening. Tighten the filter
according to the instructions that are on the fuel
filter. Do not overtighten the filter.
7. Open the fuel supply valve. The engine will need
to be purged of air. Refer to the Operation and
Maintenance Manual, “Fuel System - Prime” topic
(Maintenance Section) for more information.
SEBU7901-01
i02436696
Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543-M&S
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Fuel Tank
Fuel quality is critical to the performance and to the
service life of the engine. Water in the fuel can cause
excessive wear to the fuel system. Condensation
occurs during the heating and cooling of fuel. The
condensation occurs as the fuel passes through the
fuel system and the fuel returns to the fuel tank. This
causes water to accumulate in fuel tanks. Draining
the fuel tank regularly and obtaining fuel from reliable
sources can help to eliminate water in the fuel.
Drain the Water and the Sediment
Fuel tanks should contain some provision for draining
water and draining sediment from the bottom of the
fuel tanks.
Open the drain valve on the bottom of the fuel tank
in order to drain the water and the sediment. Close
the drain valve.
Check the fuel daily. Drain the water and sediment
from the fuel tank after operating the engine or drain
the water and sediment from the fuel tank after the
fuel tank has been filled. Allow five to ten minutes
before performing this procedure.
Fill the fuel tank after operating the engine in
order to drive out moist air. This will help prevent
condensation. Do not fill the tank to the top. The
fuel expands as the fuel gets warm. The tank may
overflow.
SEBU7901-01
Some fuel tanks use supply pipes that allow water
and sediment to settle below the end of the fuel
supply pipe. Some fuel tanks use supply lines that
take fuel directly from the bottom of the tank. If
the engine is equipped with this system, regular
maintenance of the fuel system filter is important.
Fuel Storage Tanks
Drain the water and the sediment from the fuel
storage tank during the following conditions:
• Weekly
• Oil change
• Refill of the tank
This will help prevent water or sediment from being
pumped from the storage tank into the engine fuel
tank. A 2 micron filter for the breather vent on the
fuel tank is also recommended. Refer to Special
Publication, SENR9620, “Improving Fuel System
Durablity”.
If a bulk storage tank has been refilled or moved
recently, allow adequate time for the sediment to
settle before filling the engine fuel tank. Internal
baffles in the bulk storage tank will also help trap
sediment. Filtering fuel that is pumped from the
storage tank helps to ensure the quality of the fuel.
When possible, water separators should be used.
i02121526
Hoses and Clamps -
Inspect/Replace
SMCS Code: 7554-040; 7554-510
Inspect all hoses for leaks that are caused by the
following conditions:
• Cracking
• Softness
• Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
NOTICE
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec-
ommended torque.
81
Maintenance Section
Hoses and Clamps - Inspect/Replace
Check for the following conditions:
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
A constant torque hose clamp can be used in place
of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
clamp.
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
Each installation application can be different. The
differences depend on the following factors:
• Type of hose
• Type of fitting material
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the
fittings
Replace the Hoses and the Clamps
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Stop the engine. Allow the engine to cool.
2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
4. Remove the hose clamps.
82
Maintenance Section
Jacket Water Heater - Check
5. Disconnect the old hose.
6. Replace the old hose with a new hose.
7. Install the hose clamps with a torque wrench.
Note: Refer to the Specifications, SENR3130,
“Torque Specifications” in order to locate the proper
torques.
8. Refill the cooling system.
9. Clean the cooling system filler cap. Inspect the
cooling system filler cap’s gaskets. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
10. Start the engine. Inspect the cooling system for
leaks.
i02486400
Jacket Water Heater - Check
SMCS Code: 1383-535
Jacket water heaters help to improve startability in
ambient temperatures that are below 21 °C (70 °F).
All installations that require automatic starting should
have jacket water heaters.
Check the operation of the jacket water heater. For
an ambient temperature of 0 °C (32 °F), the heater
should maintain the jacket water coolant temperature
at approximately 32 °C (90 °F).
i01848653
Overhaul Considerations
SMCS Code: 7595-043
Reduced hours of operation at full load will result in a
lower average power demand. A decreased average
power demand should increase both the engine
service life and the overhaul interval.
The need for an overhaul is generally indicated by
increased fuel consumption and by reduced power.
The following factors are important when a decision
is being made on the proper time for an engine
overhaul:
• The need for preventive maintenance
• The quality of the fuel that is being used
• The operating conditions
• The results of the S·O·S analysis
SEBU7901-01
Oil Consumption as an Overhaul
Indicator
Oil consumption, fuel consumption, and maintenance
information can be used to estimate the total
operating cost for your Caterpillar engine. Oil
consumption can also be used to estimate the
required capacity of a makeup oil tank that is suitable
for the maintenance intervals.
Oil consumption is in proportion to the percentage
of the rated engine load. As the percentage of the
engine load is increased, the amount of oil that is
consumed per hour also increases.
The oil consumption rate (brake specific oil
consumption) is measured in grams per kW/h (lb per
bhp). The brake specific oil consumption (BSOC)
depends on the engine load. Consult your Caterpillar
dealer for assistance in determining the typical oil
consumption rate for your engine.
When an engine’s oil consumption has risen to three
times the original oil consumption rate due to normal
wear, an engine overhaul should be scheduled.
There may be a corresponding increase in blowby
and a slight increase in fuel consumption.
Overhaul Options
Before Failure Overhaul
A planned overhaul before failure may be the best
value for the following reasons:
• Costly unplanned downtime can be avoided.
• Many original parts can be reused according to the
standards for reusable parts.
• The engine service life can be extended without the
risk of a major catastrophe due to engine failure.
• The best cost/value relationship per hour of
extended life can be attained.
After Failure Overhaul
If a major engine failure occurs and the engine
must be removed, many options are available. An
overhaul should be performed if the engine block or
the crankshaft needs to be repaired.
If the engine block is repairable and/or the crankshaft
is repairable, the overhaul cost should be between 40
percent and 50 percent of the cost of a new engine
with a similar exchange core.
This lower cost can be attributed to three aspects:
• Specially designed Caterpillar engine features
SEBU7901-01 83
Maintenance Section
Overhaul Considerations

• Caterpillar dealer exchange components • Unscheduled downtime

• Caterpillar Inc. remanufactured exchange
components
Overhaul Recommendation
To minimize downtime, a scheduled engine overhaul
by your Caterpillar dealer is recommended. This will
provide you with the best cost/value relationship.
Note: Overhaul programs vary according to the
engine application and according to the dealer that
performs the overhaul. Consult your Caterpillar
dealer for specific information about the available
overhaul programs and about overhaul services for
extending the engine life.
If an overhaul is performed without overhaul service
from your Caterpillar dealer, be aware of the following
maintenance recommendations.
Unit Fuel Injector
Clean the fuel injector body and replace the O-rings.
Replace the O-rings and the gasket on the injector
sleeve. Clean the area around the injector seating
in the injector sleeve. Refer to the Service Manual
for the complete procedure, or consult with your
Caterpillar dealer for assistance.
Rebuild or Exchange
Cylinder Head Assembly, Connecting Rods,
Pistons, Cylinder Liners, Turbocharger, Cylinder
Packs, Oil Pump, and Fuel Transfer Pump
These components should be inspected according to
the instructions that are found in various Caterpillar
reusability publications. The Special Publication,
SEBF8029 lists the reusability publications that are
needed for inspecting the engine parts.
If the parts comply with the established inspection
specifications that are expressed in the reusable
parts guideline, the parts should be reused.
Parts that are not within the established inspection
specifications should be dealt with in one of the
following manners:
• Salvaging
• Repairing
• Replacing
Parts that do not comply with the established
inspection specifications can result in the following
problems:
• Costly repairs
• Damage to other engine parts
• Reduced engine efficiency
• Increased fuel consumption
Reduced engine efficiency and increased fuel
consumption translates into higher operating costs.
Therefore, Caterpillar Inc. recommends repairing
out-of-spec parts or replacing out-of-spec parts.
Inspection and/or Replacement
Piston Rings, Crankshaft Bearings, Valve
Rotators, and Crankshaft Seals
The following components may not last until the
second overhaul.
• Thrust bearings
• Main bearings
• Rod bearings
• Valve rotators
• Crankshaft seals
Caterpillar Inc. recommends the installation of new
parts at each overhaul period.
Inspect these parts while the engine is disassembled
for an overhaul.
Inspect the crankshaft for any of the following
conditions:
• Deflection
• Damage to the journals
• Bearing material that has seized to the journals
Check the journal taper and the profile of the
crankshaft journals. Check these components by
interpreting the wear patterns on the following
components:
• Rod bearing
• Main bearings
Note: If the crankshaft is removed for any reason,
use the magnetic particle inspection process to check
for cracks in the crankshaft.
84
Maintenance Section
Power Take-Off Clutch - Check/Adjust/Lubricate
Inspect the camshaft for damage to the journals and
to the lobes.
Note: If the camshaft is removed for any reason, use
the magnetic particle inspection process to check for
cracks in the camshaft.
Inspect the following components for signs of wear or
for signs of scuffing:
• Camshaft bearings
• Camshaft followers
Caterpillar Inc. recommends replacing the crankshaft
vibration damper.
Oil Cooler Core and Aftercooler Core
During an overhaul, the removal of the oil cooler
core and the aftercooler core is recommended. The
oil cooler core and the aftercooler core should be
cleaned and pressure tested.
NOTICE
Do not use caustic cleaners to clean the core.
Caustic cleaners can attack the internal metals of the
core and cause leakage.
Obtain Coolant Analysis
The concentration of supplemental coolant additive
(SCA) should be checked regularly with test kits
or with S·O·S Coolant Analysis (Level 1). Further
coolant analysis is recommended when the engine
is overhauled.
A coolant analysis can be conducted in order to verify
the condition of the water that is being used in the
cooling system. A full water analysis can be obtained
by consulting your local water utility company or
an agricultural agent. Private laboratories are also
available for water analysis.
Caterpillar Inc. recommends an S·O·S Coolant
Analysis (Level 2).
S·O·S Coolant Analysis (Level 2)
An S·O·S Coolant Analysis (Level 2) is a
comprehensive coolant analysis which completely
analyzes the coolant and the effects on the cooling
system. An S·O·S Coolant Analysis (Level 2) provides
the following information:
• Complete S·O·S Coolant Analysis (Level 2)
• Visual inspection of properties
SEBU7901-01
• Identification of metal corrosion
• Identification of contaminants
• Identification of built up impurities (corrosion and
scale)
S·O·S Coolant Analysis (Level 2) provides a report of
the results of both the analysis and the maintenance
recommendations.
For more information about coolant analysis, consult
your Caterpillar dealer.
i01506009
Power Take-Off Clutch -
Check/Adjust/Lubricate
SMCS Code: 3055-036; 3055-086
NOTICE
New power take-offs should have the clutch adjust-
ment checked before being placed into service. The
clutch adjustment should be checked again after the
first ten hours of operation. New clutch plates have a
“wear in” period, and the clutch may require several
adjustments until the new plates are “worn in”.
Illustration 44
g00781502
(1) Instruction plate
(2) Serial number plate
Check the clutch adjustment regularly after “wear in”.
Heavy-duty applications which have engagements
that are frequent and relatively long periods of
clutch slippage require more frequent adjustment
than light-duty applications. The operating torque
should be measured in order to determine if a clutch
adjustment is required.
Refer to the OEM information and instruction plate
(1) for instructions on lubrication, adjustment, and
other recommendations for service. Perform the
maintenance that is specified on the instruction plate.
SEBU7901-01
Do not operate the engine with the Instruction
Plate cover removed from the clutch. Personal
injury may result.
If the clutch is damaged to the point of burst fail-
ure, expelled pieces can cause personal injury to
anyone in the immediate area. Proper safeguards
must be followed to help prevent accidents.
i01604510
Radiator - Clean
SMCS Code: 1353-070
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
of the fan’s air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move the
air nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
After cleaning, start the engine and accelerate the
engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.
85
Maintenance Section
Radiator - Clean
Inspect the fins for damage. Bent fins may be opened
with a “comb”. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.
For more detailed information on cleaning and
inspection, refer to Special Publication, SEBD0518,
“Know Your Cooling System”.
i00151038
Severe Service Application -
Check
SMCS Code: 1000-535
Severe service is an application of an engine that
exceeds current published standards for that engine.
Caterpillar maintains standards for the following
engine parameters:
• Performance (power range, speed range, and fuel
consumption)
• Fuel quality
• Altitude range
• Maintenance intervals
• Oil selection and maintenance
• Coolant selection and maintenance
• Environmental qualities
• Installation
Refer to the standards for the engine or consult with
your Caterpillar dealer in order to determine if the
engine is operating within the defined parameters.
Severe service operation can accelerate component
wear. Engines that operate under severe conditions
may need more frequent maintenance intervals in
order to ensure maximum reliability and retention of
full service life.
Due to individual applications, it is not possible to
identify all of the factors which can contribute to
severe service operation. Consult your Caterpillar
dealer for the unique maintenance that is necessary
for the engine.
The operating environment, improper operating
procedures and improper maintenance procedures
can be factors which contribute to severe service
conditions.
86
Maintenance Section
Starting Motor - Inspect
Environmental Factors
Ambient temperatures – The engine may be
exposed to extended operation in extremely
cold environments or hot environments. Valve
components can be damaged by carbon buildup if
the engine is frequently started and stopped in very
cold temperatures. Extremely hot inlet air reduces
engine performance.
Air Quality – The engine may be exposed to
extended operation in an environment that is dirty
or dusty, unless the equipment is cleaned regularly.
Mud, dirt and dust can encase components.
Maintenance can be very difficult. The buildup can
contain corrosive chemicals.
Buildup – Compounds, elements, corrosive
chemicals and salt can damage some components.
Altitude – Problems can arise when the engine is
operated at altitudes that are higher than the intended
settings for that application. Necessary adjustments
should be made.
Improper Operating Procedures
• Extended operation at low idle
• Frequent hot shutdowns
• Operating at excessive loads
• Operating at excessive speeds
• Operating outside the intended application
Improper Maintenance Procedures
• Extending the maintenance intervals
• Failure to use recommended fuel, lubricants and
coolant/antifreeze
i00651416
Starting Motor - Inspect
SMCS Code: 1451-040; 1453-040
Caterpillar Inc. recommends a scheduled inspection
of the starting motor. If the starting motor fails, the
engine may not start in an emergency situation.
Check the starting motor for proper operation. Check
the electrical connections and clean the electrical
connections. Refer to the Service Manual for more
information on the checking procedure and for
specifications or consult your Caterpillar dealer for
assistance.
SEBU7901-01
i01539769
Turbocharger - Inspect
SMCS Code: 1052-040; 1052
Periodic inspection and cleaning is recommended
for the turbocharger compressor housing (inlet side).
Any fumes from the crankcase are filtered through
the air inlet system. Therefore, by-products from oil
and from combustion can collect in the turbocharger
compressor housing. Over time, this buildup can
contribute to loss of engine power, increased black
smoke and overall loss of engine efficiency.
If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the
turbocharger compressor wheel can cause additional
damage to the pistons, the valves, and the cylinder
head.
NOTICE
Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.
Minor leakage of a turbocharger housing under ex-
tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc-
curred.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
An inspection of the turbocharger can minimize
unscheduled downtime. An inspection of the
turbocharger can also reduce the chance for potential
damage to other engine parts.
Note: Turbocharger components require precision
clearances. The turbocharger cartridge must
be balanced due to high rpm. Severe Service
Applications can accelerate component wear.
Severe Service Applications require more frequent
inspections of the cartridge.
Removal and Installation
For options regarding the removal, installation, repair
and replacement, consult your Caterpillar dealer.
Refer to the Service Manual for this engine for the
procedure and specifications.
SEBU7901-01
Cleaning and Inspecting
1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil. Clean
the interior of the pipes in order to prevent dirt
from entering during reassembly.
2. Turn the compressor wheel and the turbine wheel
by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There
should not be any visible signs of contact between
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
the turbocharger must be reconditioned.
3. Check the compressor wheel for cleanliness.
If only the blade side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering
system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger
oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line
for the inlet air (plugged air filters), which causes
the turbocharger to slobber.
4. Use a dial indicator to check the end clearance
on the shaft. If the measured end play is greater
than the Service Manual specifications, the
turbocharger should be repaired or replaced.
An end play measurement that is less than the
minimum Service Manual specifications could
indicate carbon buildup on the turbine wheel. The
turbocharger should be disassembled for cleaning
and for inspection if the measured end play is less
than the minimum Service Manual specifications.
5. Inspect the bore of the turbine housing for
corrosion.
6. Clean the turbocharger housing with standard
shop solvents and a soft bristle brush.
7. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
87
Maintenance Section
Walk-Around Inspection
i01185304
Walk-Around Inspection
SMCS Code: 1000-040
Inspect the Engine for Leaks and
for Loose Connections
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
For maximum engine service life, make a thorough
inspection of the engine compartment before starting
the engine. Look for items such as oil leaks or coolant
leaks, loose bolts, worn belts, loose connections and
trash buildup. Make repairs, as needed:
• The guards must be in the proper place. Repair
damaged guards or replace missing guards.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
• Ensure that the cooling lines are properly clamped
and that the cooling lines are tight. Check for leaks.
Check the condition of all pipes.
• Inspect the water pumps for coolant leaks.
Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount
of leakage to occur as the engine cools down and
the parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For the removal of
water pumps and the installation of water pumps
and/or seals, refer to the Service Manual for the
engine or consult your Caterpillar dealer.
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve cover.
88 SEBU7901-01
Maintenance Section
Water Pump - Inspect

• Inspect the fuel system for leaks. Look for loose Note: Refer to the Service Manual or consult your
fuel line clamps or for loose fuel line tie-wraps. Caterpillar dealer if any repair is needed or any
replacement is needed.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps. Ensure
that hoses and tubes are not contacting other
hoses, tubes, wiring harnesses, etc.

• Inspect the alternator belt and the accessory drive

belts for cracks, breaks or other damage.

Belts for multiple groove pulleys must be replaced as

matched sets. If only one belt is replaced, the belt will
carry more load than the belts that are not replaced.
The older belts are stretched. The additional load on
the new belt could cause the belt to break.

• Drain the water and the sediment from fuel tanks

on a daily basis in order to ensure that only clean
fuel enters the fuel system.

• Inspect the wiring and the wiring harnesses for

loose connections and for worn wires or frayed
wires.

• Inspect the ground strap for a good connection and

for good condition.

• Inspect the ECM to the cylinder head ground strap

for a good connection and for good condition.

• Disconnect any battery chargers that are not

protected against the current drain of the starting
motor. Check the condition and the electrolyte level
of the batteries, unless the engine is equipped with
a maintenance free battery.

• Check the condition of the gauges. Replace any

gauges that are cracked. Replace any gauge that
can not be calibrated.

i01057943

Water Pump - Inspect

SMCS Code: 1361-040; 1361

A failed water pump might cause severe engine

overheating problems that could result in the following
conditions:

• Cracks in the cylinder head

• A piston seizure
• Other potential damage to the engine
Visually inspect the water pump for leaks. If any
leaking is observed, replace the water pump seal
or the water pump assembly. Refer to the Service
Manual for the disassembly and assembly procedure.
SEBU7901-01
Warranty Section
Warranty Information
i02212087
Emissions Warranty
Information
SMCS Code: 1000
Maintenance Recommendations
Caterpillar Inc. engines are certified by the United
States Environmental Protection Agency (EPA) in
order to comply with exhaust emission standards and
gaseous emission standards that are prescribed by
Federal laws at the time of manufacture.
Efficiency of the emission control and the engine
performance depends on adherence to proper
operation and maintenance recommendations and
use of recommended fuels and lubricating oils.
According to recommendations, major adjustments
and repairs should be made by your authorized
Caterpillar dealer.
Various chemical fuel additives which claim to reduce
visible smoke are available commercially. Although
additives have been used to solve some isolated
smoke problems in the field, additives are not
recommended for general use. The engines should
be certified without smoke depressants according to
federal smoke regulations.
Take corrective steps immediately after worn parts
which may affect emission levels are discovered in
order to ensure the proper operation of the emission
control systems. The use of genuine Caterpillar parts
is recommended. Suppliers of non-Caterpillar parts
must ensure the owner that the use of such parts will
not adversely affect emission levels.
Regular maintenance intervals with a special
emphasis on the following items are necessary in
order to keep exhaust emissions within acceptable
limits for the useful life of the engine. Refer to the
Operation and Maintenance Manual, “Severe Service
Application - Check” topic (Maintenance Section).
If the engine is operating under severe conditions,
adjust the maintenance schedule accordingly.
See your authorized Caterpillar dealer in order to
help analyze your specific application, operating
environment and maintenance schedule adjustments.
89
Warranty Section
Warranty Information
The following information is an explanation of
maintenance items for emission related components.
See the Operation and Maintenance Manual,
“Maintenance Interval Schedule” (Maintenance
Section) for the specific interval for the following
items.
EXHAUST AFTERTREATMENT SYSTEM –
Aftertreatment devices are sensitive to the type of
fuel that is used and the operating schedule. Low
quality fuel may cause increases in exhaust back
pressure or clogging resulting in loss of power. An
authorized Caterpillar dealer can determine if the
aftertreatment device needs service.
UNIT INJECTORS – Unit injectors are subject to tip
wear as a result of fuel contamination. This damage
can cause the following conditions: an increase in
fuel consumption, black smoke, misfire, and rough
running engine. The unit injector should be inspected,
tested and replaced, if necessary. Unit injectors can
be tested by an authorized Caterpillar dealer.
TURBOCHARGER – Check for any unusual sound
or vibration in the turbocharger. Inspect the inlet
piping and connections and inspect the exhaust
piping and connections. Check the condition of
the bearing. Perform the maintenance that is
described in the Operation and Maintenance Manual,
“Maintenance Interval Schedule” (Maintenance
Section).
ELECTRONIC ENGINE CONTROL – This
component is a device that is designed to control
engine operation with respect to the amount of fuel
injected, the injection timing as well as controlling
the black smoke emission of the engine during the
engine’s operation when low inlet manifold pressure
exists.
Any erratic engine behavior may indicate a need
for replacement or repair. Your Caterpillar dealer is
equipped with the necessary tools, personnel and
procedures in order to perform this service.
The owner is encouraged to keep adequate
maintenance records. However, the absence of such
records will not invalidate the warranty. Refer to the
Operation and Maintenance Manual, “Maintenance
Log” (Reference Materials Section).
The owner may perform routine maintenance, repairs
and other work that is outside of the warranty. The
work may be done at any repair facility. Such work
does not need to be performed at a designated
station that is determined by the warranty in order for
the warranty to remain in force.
90 SEBU7901-01
Warranty Section
Warranty Information

Customer Assistance (Emission

Control Systems Warranty)
Caterpillar Inc. intends to ensure that the Emission
Control Systems warranty is properly administered. If
you do not receive adequate warranty service under
the Emission Control Systems Warranty, call or write
to the following address:

Caterpillar Inc.
Manager, Engine Business
P.O. Box 0600 Mossville, IL 61552

Authorized dealers are recommended for major

maintenance and for repair work. Authorized dealers
are staffed with trained personnel and proper
tools. Authorized dealers are aware of the latest
maintenance methods and procedures. If owners or
other persons desire to perform the work, a Service
Manual should be purchased and current service
information should be obtained from a Caterpillar
dealer.
SEBU7901-01
Reference Information
Section
Engine Ratings
i01097462
Engine Rating Conditions
SMCS Code: 1000
All engine ratings are based on“SAE J1349”.
Ratings relate to the standard conditions of “AS1501”,
of “ISO3046/1”, of “DIN6271”, and of “BS5514”.
The engine ratings are gross output ratings.
Gross Output Ratings – The total output capability
of the engine that is equipped with standard
accessories.
Standard accessories include the following
components:
• Oil pumps
• Fuel pumps
• Water pumps
Subtract the power that is required to drive auxiliary
components from the gross output. This will produce
the net power that is available for the external load
(flywheel).
i00819749
Engine Rating Definitions
SMCS Code: 1000
It is important to know the use of the engine so
that the rating will match the operating profile. The
proper rating selection is also important so that the
customer’s perception of price and value is realized.
In selecting a rating for a specific application, the
most important consideration is the time that is spent
at full throttle. These rating definitions identify the
percent of time at full throttle. The definitions also
identify the corresponding times below rated rpm.
Note: The examples of the applications are only
for reference. For an exact determination of the
appropriate rating, follow the OEM specifications or
consult your Caterpillar dealer.
91
Reference Information Section
Engine Ratings
A Rating – This rating is used for heavy-duty
applications that are operated at rated load and at
rated rpm up to 100 percent. This rating is used for
engines that operate without interruption of load
cycling. Typical applications include the following
examples: pipeline pumping and ventilation.
B Rating – This rating is used when power and/or
rpm are cyclic. The engine should be run at full load.
The engine should not exceed 80 percent of the
duty cycle. Typical applications include the following
examples: irrigation, operation where normal pump
demand is 85 percent of the engine rating, oil
pumping/drilling, field mechanical pumping/drilling,
and stationary/plant air compressors.
C Rating – This rating is used when power and/or
rpm are cyclic. The horsepower and the rpm of the
engine can be utilized continuously for one hour. This
is followed by one hour of operation at the A rating
or below the A rating. The engine should be run at
full load. The engine should not exceed 50 percent
of the duty cycle. Typical applications include the
following examples: agricultural tractors, harvesters
and combines, off-highway trucks, fire pumps, blast
hole drills, rock curshers, wood chippers with high
torque rise, and oil field hoisting.
D Rating – This rating is used when rated power
is required for periodic overloads. The maximum
horsepower and the rpm of the engine can be utilized
continuously for a maximum of 30 minutes. This is
followed by one hour of operation at the C rating. The
engine should be run at full load. The engine should
not exceed 10 percent of the duty cycle. Typical
applications include the following examples: offshore
cranes, runway snow blowers, water well drills,
portable air compressors, and fire pump certification
power.
E Rating – This rating is used when rated power
is required for a short time for initial starting or
for sudden overload. The rating is also used for
emergency service when standard power is not
available. The horsepower and the rpm of the engine
can be utilized continuously for a maximum of 15
minutes. This is followed by one hour of operation
at the C rating or by the duration of the emergency.
The engine should be run at full load. The engine
should not exceed 5 percent of the duty cycle. Typical
applications include the following examples: standby
centrifugal water pumps, oil field well servicing, crash
trucks, portable air compressors, and gas turbine
starting motors.
NOTICE
Operating engines above the rating definitions can re-
sult in shorter service life before overhaul.
92 SEBU7901-01
Reference Information Section
Customer Service

Customer Service Latin America, Mexico, Carribean

Caterpillar Americas Co.
701 Waterford Way, Suite 200
i02097871 Miami, FL 33126-4670
USA
Customer Assistance Phone: 305-476-6800
Fax: 305-476-6801
SMCS Code: 1000
Europe, Africa, and Middle East
USA and Canada Caterpillar Overseas S.A.
76 Route de Frontenex
When a problem arises concerning the operation of P.O. Box 6000
an engine or concerning the service of an engine, CH-1211 Geneva 6
the problem will normally be managed by the dealer Switzerland
in your area. Phone: 22-849-4444
Fax: 22-849-4544
Your satisfaction is a primary concern to Caterpillar
and to Caterpillar dealers. If you have a problem that Far East
has not been handled to your complete satisfaction, Caterpillar Asia Pte. Ltd.
follow these steps: 7 Tractor Road
Jurong, Singapore 627968
1. Discuss your problem with a manager from the Republic of Singapore
dealership. Phone: 65-662-8333
Fax: 65-662-8302
2. If your problem cannot be resolved at the dealer
level without additional assistance, use the phone China
number that is listed below to talk with a Field Caterpillar China Ltd.
Service Coordinator: 37/F., The Lee Gardens
33 Hysan Avenue
1-800-447-4986 Causeway Bay
G.P.O. Box 3069
The normal hours are from 8:00 to 4:30 Monday Hong Kong
through Friday Central Standard Time. Phone: 852-2848-0333
Fax: 852-2848-0440
3. If your needs have not been met still, submit the
matter in writing to the following address: Japan
Shin Caterpillar Mitsubishi Ltd.
Caterpillar Inc. SBS Tower
Manager, Customer Service, Engine Division 10-1, Yoga 4-Chome
Mossville Bldg AC Setagaya-Ku, Tokyo 158-8530
P.O. Box 610 Japan
Mossville, Illinois 61552-0610 Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Please keep in mind: probably, your problem will
ultimately be solved at the dealership, using the Japan
dealership’s facilities, equipment, and personnel. Caterpillar Power Systems, Inc.
Therefore, follow the steps in sequence when a SBS Tower (14th floor)
problem is experienced. 4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Phone: 81-3-5797-4300
Outside of the USA and of Canada Fax: 81-3-5797-4359
If a problem arises outside the USA and outside Australia and New Zealand
Canada, and if the problem cannot be resolved at the Caterpillar of Australia Ltd.
dealer level, consult the appropriate Caterpillar office. 1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: 03-9953-9333
Fax: 03-9335-3366
SEBU7901-01 93
Reference Information Section
Customer Service

i01028392

Ordering Replacement Parts

SMCS Code: 7567

When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers’ parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.

When you order parts, please specify the following

information:

• Part number
• Part name
• Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.

When a Caterpillar engine requires maintenance

and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).

Discuss the problem with the dealer. Inform the

dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
94 SEBU7901-01
Reference Information Section
Reference Materials

Reference Materials Lubricants

• Special Publication, PEDP7035, “Optimizing Oil
i02469344 Change Intervals”
Reference Material • Data Sheet, PEHJ0008, “Cat Arctic DEO SYN”
SMCS Code: 1000
• Data Sheet, PEHJ0021, “Product Data Sheet for
Cat DEO (Diesel Engine Oil) APD, EAME, LACD
The following literature can be obtained through any Only”
Caterpillar dealer.
• Data Sheet, PEHJ0059, “Cat DEO (for North
Coolants America)”

• Data Sheet, PEHJ0067, “Cat ELC (Extended Life
Coolant) (Worldwide Formulation)”
• Data Sheet, PEHP9554, “Diesel Engine
Antifreeze/Coolant (DEAC)”
• Special Publication, PMEP5027, “Label - ELC
Radiator Label”
• Special Publication, SEBD0518, “Know Your
Cooling System”
• Special Publication, SEBD0970, “Coolant and Your
Engine”
• Data Sheet, PEHJ0072, “Cat DEO (Brazil Only)”
• Data Sheet, PEHJ0091, “Cat DEO (Egypt and
Saudi Arabia)”
• Special Publication, PEHP6001, “How To Take A
Good Oil Sample”
• Data Sheet, PEHP7062, “Full Synthetic Diesel
Engine Oil Data Sheet”
• Special Publication, PELJ0179, “FLU03-02
Caterpillar Engine Crankcase Fluid-1
Specifications (All World Market Areas)”

Fuels • Special Publication, SEBD0640, “Oil and Your

Engine”
• Special Publication, SEBD0717, “Diesel Fuels and
Your Engine” S·O·S Services
• Special Publication, SENR9620, “Improving Fuel • Data Sheet, NEHP6013, “S·O·S Fluids Analysis
System Durability” Products”

Greases • Special Publication, PEDP7036, “S·O·S Fluids

Analysis Cornerstone”
• Data Sheet, NEHP6010, “Cat Ultra 5Moly Grease” • Special Publication, PEHP7057, “S·O·S Coolant
Analysis”
• Data Sheet, NEHP6011, “Arctic Platinum Grease
Spec Sheet”
• Special Publication, PEHP7076, “Understanding
S·O·S Services Tests”
• Data Sheet, NEHP6012, “Cat Desert Gold Grease”
• Data Sheet, NEHP6015, “Cat Special Purpose Miscellaneous
Grease”
• Special Publication, NEHS0526, “Service
• Special Publication, PEGJ0035, “Grease Selection Technology Application Guide”
Guide”
• Special Instruction, NENG2500, “Caterpillar Dealer
• Data Sheet, PEHJ0088, “Cat Multipurpose Grease” Service Tool Catalog”

• Data Sheet, PEHP0002, “Molybdenum Grease • Special Publication, PECP9067, “One Safe
Data Sheet” Source”

• Data Sheet, PEHP6002, “Cat Advanced 3Moly • Special Instruction, REHS0354, “Charging System
Grease” Troubleshooting for All Engines”
SEBU7901-01
• Special Instruction, REHS0871, “Electronic
Installation Guide”.
• Special Publication, SEBF8029, “Index to
Guidelines for Reusable Parts and Salvage
Operations”
• Special Publication, SEBF8062, “Guideline for
Reusable Parts - Procedure to Inspect and Clean
Air Filters”
• Special Publication, SEBU6251, “Caterpillar
Commercial Diesel Engine Fluids
Recommendations”
• Special Instruction, SEHS7332, “Warning Tag -
Danger Do Not Operate”
• Special Instruction, SEHS7633, “Battery Test
Procedure”
• Special Instruction, SEHS8622, “Using the
FT-1984 Aftercooler Testing Group”
• Special Instruction, SEHS9031, “Storage
Procedure for Caterpillar Products”
• Specifications, SENR3130, “Torque Specifications
Module”
• Service Manual, SENR9850, “C11 and C13
Industrial Engines”
• Special Instruction, SMHS7001, “Assembly of Fan
Drive Pulley Assemblies”
Additional Reference Material
The “Engine Fluids Data Book” can be obtained from
the following locations: local technological society,
local library, and local college. If necessary, consult
EMA at the following address:
Engine Manufacturers Associaton
Two North LaSalle Street, Suite 2200
Chicago, IL, USA 60602
E-mail: ema@enginemanufacturers.org
Telephone: (312) 827-8700
Facsimile: (312) 827-8737
The “Society of Automotive Engineers (SAE)
Specifications” can be found in your SAE handbook.
This publication can also be obtained from the
following locations: local technological society, local
library, and local college. If necessary, consult SAE
at the following address:
SAE International
400 Commonwealth Drive
Warrendale, PA, USA 15096-0001
Telephone: (724) 776-4841
95
Reference Information Section
Reference Materials
The “American Petroleum Institute Publication No.
1509” can be obtained from the following locations:
local technological society, local library, and local
college. If necessary, consult API at the following
address:
American Petroleum Institute
1220 L St. N.W.
Washington, DC, USA 20005
Telephone: (202) 682-8000
The International Organization for Standardization
(ISO) offers information and customer service
regarding international standards and standardizing
activities. ISO can also supply information on the
following subjects that are not controlled by ISO:
national standards, local standards, regulations,
certification, and related activities. Consult the
member of ISO in your country.
International Organization for Standardization
(ISO)
1, rue de Varembé
Case postale 56
CH-1211 Genève 20
Switzerland
Telephone: +41 22 749 01 11
Facsimile: +41 22 733 34 30
E-mail: central@iso.ch
Web site: http://www.iso.ch
European classifications are established by the
Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Engines).
CIMAC Central Secretariat
Lyoner Strasse 18
60528 Frankfurt
Germany
Telephone: +49 69 6603 1567
Facsimile: +49 69 6603 1566
i00912149
Maintenance Records
SMCS Code: 1000
Caterpillar Inc. recommends the retention of accurate
maintenance records. Accurate maintenance records
can be used for the following purposes:
• Determine operating costs.
• Establish maintenance schedules for other engines
that are operated in the same environment.
• Show compliance with the required maintenance
practices and maintenance intervals.
96 SEBU7901-01
Reference Information Section
Reference Materials

Maintenance records can be used for a variety of

other business decisions that are related to engine
maintenance.

Maintenance records are a key element of a

maintenance program that is well managed. Accurate
maintenance records can help your Caterpillar dealer
to fine tune the recommended maintenance intervals
in order to meet the specific operating situation. This
should result in a lower engine operating cost.

Records should be kept for the following items:

Fuel Consumption – A record of fuel consumption

is essential in order to determine when the load
sensitive components should be inspected or
repaired. Fuel consumption also determines overhaul
intervals.

Service Hours – A record of service hours is

essential to determine when the speed sensitive
components should be inspected or repaired.

Documents – These items should be easy to

obtain, and these items should be kept in the engine
history file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number, and engine serial number. The following
types of documents should be kept as proof of
maintenance or repair for warranty:

Keep the following types of documents as proof of

maintenance for warranty. Also, keep these types of
documents as proof of repair for warranty:

• Dealer work orders and itemized bills

• Owner’s repair costs
• Owner’s receipts
• Maintenance log
SEBU7901-01 97
Reference Information Section
Reference Materials

i01176304

Maintenance Log
SMCS Code: 1000

Table 14
Engine Model Customer Identifier
Serial Number Arrangement Number
Service Quantity
Service Item Date Authorization
Hours Of Fuel
98
Index Section
Index
A Customer Service .................................................. 92
After Starting Engine .............................................
After Stopping Engine............................................
Aftercooler Core - Clean/Test (Air-To-Air
Aftercooler) ..........................................................
Alternator - Inspect ................................................
B Check the Alignment..........................................
Battery - Replace................................................... 54
Battery Electrolyte Level - Check .......................... 54
Battery or Battery Cable - Disconnect ................... 55
Before Starting Engine .................................... 13, 35
Belts - Inspect/Adjust/Replace............................... 55
Adjustment of the Fan Drive Belt ....................... 55
Alternator Belt Adjustment ................................. 55
Inspection........................................................... 55
Replacement...................................................... 55
Burn Prevention..................................................... 10
Batteries............................................................. 10
Coolant............................................................... 10
Oils..................................................................... 10
C Warranty) ......................................................... 90
Cold Weather Operation........................................
Cold Weather Starting ...........................................
Cooling System Coolant (DEAC) - Change...........
Cooling Systems with Heavy Deposits or
Plugging ...........................................................
Drain ..................................................................
Fill ......................................................................
Flush ..................................................................
Cooling System Coolant (ELC) - Change..............
Drain ..................................................................
Fill ......................................................................
Flush ..................................................................
Cooling System Coolant Extender (ELC) - Add.....
Cooling System Coolant Level - Check .................
Cooling System Coolant Sample (Level 1) -
Obtain ..................................................................
Cooling System Coolant Sample (Level 2) -
Obtain ..................................................................
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add..................................................
Add the SCA, If Necessary ................................
Test the Concentration of the SCA.....................
Cooling System Water Temperature Regulator -
Replace................................................................
Crankshaft Vibration Damper - Inspect .................
Visconic Damper................................................
Crushing Prevention and Cutting Prevention ........
Customer Assistance.............................................
Outside of the USA and of Canada....................
USA and Canada ...............................................
SEBU7901-01
Customer Specified Parameters...................... 22, 34
37
41
D
53
53 Diagnostic Flash Code Retrieval ........................... 30
Diagnostic Lamp.................................................... 30
Driven Equipment - Check..................................... 64
64
Inspect the Drive Coupling................................. 65
Inspect the Rear Gear Train .............................. 65
E
Electrical System ................................................... 14
Grounding Practices .......................................... 14
Electronic Unit Injector - Inspect/Adjust................. 65
Electronics Grounding Stud - Inspect/Clean/
Tighten................................................................. 65
Emergency Stopping ............................................. 40
Emergency Stop Button ..................................... 40
Emissions Certification Film .................................. 22
Emissions Warranty Information............................ 89
Customer Assistance (Emission Control Systems
Maintenance Recommendations ....................... 89
42 Engaging the Driven Equipment............................ 38
36 Industrial Engines .............................................. 38
56 Engine - Clean....................................................... 66
Engine Air Cleaner Element (Dual Element) -
57 Clean/Replace ..................................................... 66
56 Cleaning the Primary Air Cleaner Elements ...... 68
57 Servicing the Air Cleaner Elements ................... 67
56 Engine Air Cleaner Service Indicator - Inspect (If
58 Equipped) ............................................................ 69
58 Test the Service Indicator................................... 70
59 Engine Crankcase Breather - Clean...................... 70
59 Engine Description ................................................ 18
60 Aftermarket Products and Caterpillar Engines... 19
61 Welding and Caterpillar Electronic Engines....... 19
Engine Diagnostics................................................ 30
61 Engine Electronics................................................. 15
Engine Mounts - Inspect........................................ 71
62 Engine Oil and Filter - Change .............................. 72
Drain the Engine Oil........................................... 72
62 Fill the Engine Crankcase .................................. 73
63 Replace the Oil Filter ......................................... 73
62 Engine Oil Level - Check ....................................... 71
Engine Oil Sample - Obtain ................................... 72
63 Obtain the Sample and the Analysis.................. 72
64 Engine Operation................................................... 38
64 Engine Operation with Active Diagnostic Codes ... 33
12 Engine Operation with Intermittent Diagnostic
92 Codes .................................................................. 34
92 Engine Protective Devices - Check ....................... 74
92 Visual Inspection................................................ 74
SEBU7901-01 99
Index Section

Engine Rating Conditions ...................................... 91 General Information............................................... 16

Engine Rating Definitions ...................................... 91
Engine Ratings ...................................................... 91
Engine Speed/Timing Sensors - Check/Clean/ H
Calibrate .............................................................. 74
Engine Starting ................................................ 13, 35 Hoses and Clamps - Inspect/Replace ................... 81
Engine Stopping .............................................. 13, 40 Replace the Hoses and the Clamps .................. 81
Engine Storage Procedure - Check....................... 75
Engine Valve Lash - Inspect/Adjust ....................... 75
Engine Valve Rotators - Inspect ............................ 76 I
Engine Warm-up.................................................... 38
Important Safety Information ................................... 2

F
J
Fan Drive Bearing - Lubricate................................ 76
Fan Drive Bearing - Replace ................................. 76 Jacket Water Heater - Check ................................ 82
Fault Logging......................................................... 33
Features and Controls ........................................... 26
Fire Prevention and Explosion Prevention ............ 10 L
Ether .................................................................. 12
Fire Extinguisher ................................................ 12 Lifting and Storage ................................................ 23
Lines, Tubes and Hoses .................................... 12
Foreword ................................................................. 5
California Proposition 65 Warning ....................... 5 M
Literature Information........................................... 4
Maintenance ........................................................ 4 Maintenance Interval Schedule ............................. 51
Maintenance Intervals.......................................... 4 Maintenance Log ................................................... 97
Operation ............................................................. 4 Maintenance Records............................................ 95
Overhaul .............................................................. 4 Maintenance Section ............................................. 44
Safety................................................................... 4 Manual Stop Procedure......................................... 40
Fuel and the Effect from Cold Weather ................. 42 Model View Illustrations......................................... 17
Fuel Conservation Practices.................................. 38 Model Views .......................................................... 17
Fuel Related Components in Cold Weather .......... 43 Monitoring System................................................. 26
Fuel Filters ......................................................... 43 Caterpillar Messenger Display ........................... 27
Fuel Heaters ...................................................... 43 Indicators and Gauges....................................... 26
Fuel Tanks.......................................................... 43 Mounting and Dismounting.................................... 13
Fuel System - Prime .............................................. 76
The Engine Has Been Run Out of Fuel ............. 77
The Secondary Fuel Filter Has Been Replaced.. 76 O
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................... 78 Operation Section.................................................. 23
Replace the Element.......................................... 79 Ordering Replacement Parts ................................. 93
Fuel System Primary Filter/Water Separator - Overhaul Considerations ....................................... 82
Drain .................................................................... 78 Oil Consumption as an Overhaul Indicator ........ 82
Fuel System Secondary Filter - Replace ............... 79 Overhaul Recommendation ............................... 83
Fuel Tank Water and Sediment - Drain ................. 80
Drain the Water and the Sediment..................... 80
Fuel Storage Tanks ............................................ 81 P
Fuel Tank ........................................................... 80
Plate Locations and Film Locations....................... 21
Information Plate (2) .......................................... 21
G Serial Number Plate (1) ..................................... 21
Power Take-Off Clutch - Check/Adjust/Lubricate .. 84
Gauges and Indicators .......................................... 24 Product Identification Information .......................... 21
General Hazard Information .................................... 8 Product Information Section .................................. 16
Asbestos Information ........................................... 9 Product Lifting........................................................ 23
Containing Fluid Spillage ..................................... 9 Product Storage..................................................... 23
Dispose of Waste Properly ................................ 10
Fluid Penetration.................................................. 9
Pressurized Air and Water ................................... 8
100 SEBU7901-01
Index Section

Radiator - Clean .................................................... 85

Radiator Restrictions ............................................. 42
Reference Information Section .............................. 91
Reference Material ................................................ 94
Additional Reference Material............................ 95
Coolants............................................................. 94
Fuels .................................................................. 94
Greases ............................................................. 94
Lubricants .......................................................... 94
Miscellaneous .................................................... 94
S·O·S Services................................................... 94
Reference Materials .............................................. 94
Reference Numbers .............................................. 21
Record for Reference......................................... 21
Refill Capacities..................................................... 44
Refill Capacities and Recommendations............... 44
Cooling System.................................................. 48
Fuel .................................................................... 47
Lubricating Grease............................................. 46
Lubrication System ............................................ 44

Safety Messages ..................................................... 6

Universal Warning (1) .......................................... 7
Safety Section ......................................................... 6
Self-Diagnostics..................................................... 30
Severe Service Application - Check ...................... 85
Environmental Factors ....................................... 86
Improper Maintenance Procedures.................... 86
Improper Operating Procedures ........................ 86
Starting Motor - Inspect ......................................... 86
Starting the Engine ................................................ 35
Starting a Cold Engine ....................................... 35
Starting a Warm Engine..................................... 36
Starting with Jump Start Cables ............................ 37

Table of Contents..................................................... 3
Turbocharger - Inspect .......................................... 86
Cleaning and Inspecting .................................... 87
Removal and Installation.................................... 86

Walk-Around Inspection ........................................ 87

Inspect the Engine for Leaks and for Loose
Connections ..................................................... 87
Warranty Information ............................................. 89
Warranty Section ................................................... 89
Water Pump - Inspect............................................ 88
Welding on Engines with Electronic Controls ........ 16
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
©2006 Caterpillar
All Rights Reserved Printed in U.S.A.
 Cross Reference for Diagnostic Codes
Diagnostic
Diagnostic Code
Code
Flash Code SPN(1)/FMI Code or Description of Code Flash Code SPN(1)/FMI Code Description of Code
or
Event Code
Event Code
1835-15 High Auxiliary Pressure Warning 42 637-13 261-13 Engine Timing calibration required

1835-16 E443(2) High Auxiliary Pressure Derate 100-17 Low Engine Oil Pressure Warning

1835-00 High Auxiliary Pressure Shutdown 46 100-18 E360(2) Low Engine Oil Pressure Derate

1836-15 High Auxiliary Temperature Warning 100-01 Low Engine Oil Pressure Shutdown

1836-16 E445(2) High Auxiliary Temperature Derate 168-00 168-00 System Voltage high

1836-00 High Auxiliary Temperature Shutdown 51 168-01 168-01 System Voltage low

545-05 Ether Start Relay open/short to +batt 168-02 168-02 System Voltage intermittent/erratic
626-05
N/A 2417-05 Ether Injection Control Solenoid open/short to +batt 56 630-02 268-02 Check Programmable Parameters

545-06 Ether Start Relay short to ground 58 639-09 247-09 J1939 Data Link communications
626-06
2417-06 Ether Injection Control Solenoid short to ground 110-15 High Engine Coolant Temperature Warning

1835-03 1835-03 Auxiliary Pressure Sensor open/short to +batt 61 110-16 E361(2) High Engine Coolant Temperature Derate

1835-04 1835-04 Auxiliary Pressure Sensor short to ground 110-00 High Engine Coolant Temperature Shutdown

1836-03 1836-03 Auxiliary Temperature Sensor open/short to +batt 111-17 E059 Low Engine Coolant Level Warning

1836-04 1836-04 Auxiliary Temperature Sensor short to ground 111-18 E057 Low Engine Coolant Level Derate

111-02 111-02 Engine Coolant Level Sensor Loss of Signal 111-01 E058 Low Engine Coolant Level Shutdown
62
174-03 174-03 Fuel Temperature open/short to +batt 111-17 Low Engine Coolant Level Warning
13
174-04 174-04 Fuel Temperature short to ground 111-18 E2143(2) Low Engine Coolant Level Derate

678-03 41-03 8 Volt DC Supply short to +batt 111-01 Low Engine Coolant Level Shutdown

678-04 41-04 8 Volt DC Supply short to ground 63 94-15 E096 High Fuel Pressure Warning

620-03 1636-15 High Inlet Air Temperature Warning

21 262-03 5 Volt Sensor DC Power Supply short to +batt 64 E539(2)
1079-03 1636-00 High Inlet Air Temperature Shutdown

620-04 174-15 High Fuel Temperature Warning

262-04 5 Volt Sensor DC Power Supply short to ground
1079-04 65 174-16 E363(2) High Fuel Temperature Derate

100-03 100-03 Engine Oil Pressure open/short to +batt 174-00 High Fuel Temperature Shutdown

24 100-04 100-04 Engine Oil Pressure short to ground 651-05 001-05 Injector Cylinder 1 open circuit

100-10 100-10 Engine Oil Pressure abnormal rate of change 71 651-06 001-06 Injector Cylinder 1 short

102-03 102-03 Boost Pressure Sensor short to +batt 651-11 001-11 Injector Cylinder #1 fault

25 102-04 102-04 Boost Pressure Sensor short to ground 652-05 002-05 Injector Cylinder 2 open circuit

102-10 102-10 Boost Pressure Sensor abnormal rate of change 72 652-06 002-06 Injector Cylinder 2 short

108-03 274-03 Atmospheric Pressure open/short to +batt 652-11 002-11 Injector Cylinder #2 fault
26
108-04 274-04 Atmospheric Pressure short to ground 653-05 003-05 Injector Cylinder 3 open circuit

110-03 110-03 Engine Coolant Temperature open/short to +batt 73 653-06 003-06 Injector Cylinder 3 short
27
110-04 110-04 Engine Coolant Temperature short to ground 653-11 003-11 Injector Cylinder #3 fault

28 91-13 91-13 Throttle Position calibration required 654-05 004-05 Injector Cylinder 4 open circuit

32 91-08 91-08 Throttle Position signal abnormal 74 654-06 004-06 Injector Cylinder 4 short

190-08 190-08 Engine Speed signal abnormal 654-11 004-11 Injector Cylinder #4 fault
34
723-08 342-08 Secondary Engine Speed signal abnormal 655-05 005-05 Injector Cylinder 5 open circuit

190-15 Engine Overspeed Warning 75 655-06 005-06 Injector Cylinder 5 short N

35 E362(2)
190-00 Engine Overspeed Shutdown 655-11 005-11 Injector Cylinder #5 fault N
N
94-03 94-03 Fuel Pressure open/short to +batt 656-05 006-05 Injector Cylinder 6 open circuit
N
37 N
94-04 94-04 Fuel Pressure short to ground 76 656-06 006-06 Injector Cylinder 6 short
N
105-03 172-03 Intake Manifold Air Temp open/short to +batt 656-11 006-11 Injector Cylinder #6 fault
38
105-04 172-04 Intake Manifold Air Temp short to ground N

(1) Suspect Parameter Number N

(2) Caterpillar Electronic Technician (ET) will display the number 1, 2, or 3 after the event code in order
to designate a warning, a derate, or a shutdown.
 Servicing of air cleaners
The pressure in the air cleaner are continuously supervised. Once the air
filter isn’t operating properly, the air filter indicator, which is shown on the
display, see OM:11, will be lit. Then, the air filter element must be
immediately replaced.

The air cleaner is designed as a two stage air cleaner, the first stage is the
tangential inlet that creates a rotating movement of the air. This forces the
particles to be centrifuged and transported to the end cover where the ejector
evacuates the dust from the air cleaner. This pre cleaning device takes care of
75% to 80% of the dust that enters the cleaner. Adding an optional pre
cleaner adds restriction and will not increase the lifetime of the elements.
The media in the elements are produced of cellulose fibres creating a filter
paper. This paper has openings to let the air through to the engine. The
openings are uneven in shape due to the nature of the fibres. A new element
needs to be "runned in" before it reaches its final efficiency. The initial dust
entering the element helps to build up the uneven shape of the openings and
increases the efficiency of the element.
Therefore it is very important not to clean or change the element before it
comes to the end of its lifetime as this again will open up the media and let
dust particles pass trough the air cleaner into the engine.

UH/US440i, UJ440i © Sandvik SRP AB – Doc. no. S 281.898 en Ver. 1 1

Servicing of air cleaners

The element is designed for a long lifetime, (up to 1000 hours, depending on
the dust content in the air) and should not be changed in advance. The
manufacturer has set the final pressure drop allowed over the dirty air
cleaner. This level is checked by a filter indicator. The best way to achieve
the optimum economical and technical result is to change the element only
when the indicator indicates filter change.
It is not possible to visually detect the dirt level of an element; a perfect
working element could be loaded with dust to the level where the pleats no
longer are visible.
One element with a clean weight of 3.5 kg could reach a total weight of
13.5 kg before it needs to be changed.
The safety element mounted inside the main element must never be cleaned
as this element is as a safety device and will protect the engine from damage
if the main element fails. This element needs to be changed only every
second or third time of the main element change.
If there is doubt regarding the function of the indicator, it is possible to
disassemble the rain cap and carefully and slowly choke the intake of the air
cleaner while the engine is running. There should be a signal from the
indicator long before the engine starts to drop in rpm. This is not
recommended and should only be done if there is serious doubt in the
function of the indicator.
Use only original elements. Elements from other suppliers than Sandvik
must not be used as they can cause severe damage of the engine.
When servicing the air cleaner according to these instructions there will be
fewer elements needed, less work for the maintenance people and the best
protection of the engine.
• Use only orig inal spare parts
• Never change elements before they reach the final pressure drop (signal
from the indicator)
• Always change elements only by indication from the indicator.
• It is not possible to visually detect the dirt level of the element.
• Never clean the elements as this can cause failure of the media.
• No need for an optional pre cleaner
• Change safety element every second or third the main elements is
changed.
NOTE! Never clean the safety element.

2 © Sandvik SRP AB – Doc. no. S 281.898 en Ver. 1 UH/US440i, UJ440i

OPERATOR’S MANUAL p

Industrial engines
12 liter (EMS 2)
Foreword
Volvo Penta industrial engines are relied upon throughout the world,
in both mobile and stationary applications, under some of the most
rigorous conditions imaginable. This is not by chance.
After more than 90 years of producing engines the name Volvo Penta
has come to symbolize reliability, technical ingenuity, first-class perfor-
mance and longevity. We believe that these characteristics are also
ultimately your requirements and expectations for new Volvo Penta
industrial engines.
To make certain that your expectations are matched, we ask that
you read carefully through the instruction book before starting
the engine.
Sincerely
AB VOLVO PENTA

Engine data
Engine designation ........................... Product number ....................................

Serial number .........................................................................................................

Clutch, type/nr. .......................................................................................................

Nearest Volvo Penta service location

Name .......................................................................... Telephone ....................

Address ...................................................................................................................

© 2006 AB VOLVO PENTA

Volvo reserves the right to make changes
Printed on environmentally friendly paper
 Contents

Safety information .................................................. 2 Maintenance schedule ......................................... 29

Safety instructions for operation and
maintenance ......................................................... 3 Maintenance ......................................................... 31
Engine, general ................................................... 31
Introduction ............................................................ 6 Lubrication system .............................................. 34
Environmental care ............................................... 6 Cooling system ................................................... 37
Running-in ............................................................. 6 Fuel system ........................................................ 43
Fuel and oils ......................................................... 6 Electric system ................................................... 46
Maintenance and replacement parts ...................... 6
Certified engines ................................................... 7 Preparations for storage ...................................... 49
Warranty ............................................................... 7 Conservation ....................................................... 49
Removing conservation preparations ................... 50
Presentation ........................................................... 8
Technical description ............................................ 8 Troubleshooting ................................................... 51
Identification numbers ........................................... 9 Symptoms and possible causes ......................... 51
Orientation .......................................................... 10
Location of sensors ............................................. 11 Diagnostic function .............................................. 52
Instrument, EMS 2 .............................................. 14 Message regarding disturbance ........................... 52
DCU (Display Control Unit) .................................. 15 Effect on engine .................................................. 52
Operation ............................................................ 53
Starting the engine ............................................... 21
Before starting .................................................... 21
Fault codes ........................................................... 55
Starting procedure EMS 2 ................................... 22
Volvo Penta start lock ......................................... 23
Technical data ...................................................... 64
Start-up under extreme cold ................................ 24
General ............................................................... 64
Never use starting spray ..................................... 25
Lubrication system .............................................. 64
Start with booster batteries ................................. 25
Fuel system ........................................................ 65
Cooling system ................................................... 65
Operation .............................................................. 26
Electric system ................................................... 66
Checking instruments ......................................... 26
Fault indication .................................................... 26
Operation at low load .......................................... 26

Stopping the engine ............................................ 27

Before shutdown ................................................. 27
Stop .................................................................... 27
After shutdown .................................................... 28
Extra stop ........................................................... 28

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known to
the State of California to cause cancer, birth defects, and other
reproductive harm.
Safety information
Read this chapter very carefully. It concerns your safety .How safety information is presented in the instruction
book and on the product is described here. You will also find an overall picture of the basic safety procedures for
operation of the engine.
Make sure that you have the correct instruction book before reading any further. If you do not, please con-
tact your Volvo Penta dealer.

Incorrect operation can lead to injuries and/or product or property damage. It is therefore impor-
tant to read through the instruction book very carefully before you start the engine or perform
maintenance or service work. If there is anything that you are unclear on or unsure about even af-
ter reading the book, please contact your Volvo Penta dealer for assistance.

This symbol is used in the instruction book and on the product to let you know that it con-
cerns safety information. Always read this information very carefully.

In the instruction book warning texts are handled according to the following priority system:

WARNING! Warns of risk of injury, extensive damage to the product or other property, or
that serious functional problems can occur if the instruction is not followed.

IMPORTANT! Used to call attention to things that can cause damage or functional
problems to the product or property.

NOTE! Used to call attention to important information that can make the work process or opera-
tion go more smoothly.

This symbol is used in certain cases on our products and refers to important information in
the instruction book. Make sure that warning and information symbols on the engine and trans-
mission are always visible and legible. Replace symbols that have been damaged or painted
over.

2

Safety instructions for operation and maintenance
Daily checks
Make a habit of always visually checking the engine
and engine compartment prior to operation (before
starting the engine) and after operation (after shut-
ting down the engine). This will help you to quickly
notice if fuel, coolant or oil leaks or any other abnor-
mal conditions have occurred or are occurring.
Fuel filling
There is a risk of fire and explosion when filling tanks
with fuel. Smoking is forbidden and the engine must
be stopped.
Never overfill the tank. Make sure that the cap is cor-
rectly closed.
Use only the fuel recommended in the instruction
book. Fuel of the wrong grade can cause the engine to
run incorrectly or not at all. On a diesel engine it can
also lead to seizure of the injection system and over-
revving the engine, putting both the machine and near-
by people at risk.
Carbon monoxide poisoning
Only start the engine in a well-ventilated space. Dur-
ing operation in an enclosed space both exhaust and
crankcase gases must be properly vented.
Operation
The engine should not be operated in environments
with surrounding explosive substances due to the fact
that the electrical and mechanical components can
cause sparks.
Getting close to a running engine is a safety risk.
Hair, fingers, loose-fitting clothing or a dropped tool
can get caught in rotating parts causing severe injury.
If the engine has been delivered without protective
coverings, all rotating parts and hot surfaces should
be covered as necessary following installation to in-
sure personal safety.
Safety information
Starting lock
If the instrument panel does not have a key switch
the engine compartment should be lockable to pre-
vent unauthorized personnel from starting the engine.
A lockable main switch may be used as an alterna-
tive.
Maintenance and service
tasks
Knowledge
In the instruction book you will find instructions for
how the most common maintenance and service
tasks can be carried out in a safe and correct man-
ner. Read the instructions carefully before initiating
work.
Literature covering more extensive work is available
from your Volvo Penta dealer.
Never attempt a procedure if you are not completely
certain regarding how it should be performed. Contact
your Volvo Penta dealer for assistance.
Shut down the engine
Shut down the engine before opening or removing the
engine access panel/hood. Maintenance and service
procedures should be carried out on a stopped en-
gine unless otherwise specified.
Prevent an undesired start-up by removing the start-
ing key and disconnecting the electricity with the
main switch and locking it in the disconnected posi-
tion. A warning notice should also be placed at the
operating station advising that work is being carried
out.
Working with or getting close to a running engine is a
safety risk. Hair, fingers, loose-fitting clothing or a
dropped tool can get caught in rotating parts causing
severe injury. Volvo Penta recommends that all ser-
vice work that requires that the engine be running be
assigned to an authorized Volvo Penta repair facility.
3
Safety information
Safety instructions for operation and maintenance (cont.)
Lifting the engine
When lifting the engine use the lifting eyes that are
mounted on the engine. Always make sure that the
lifting device is in good condition and has sufficient
capacity for the lift (the weight of the engine as well
as all necessary extra equipment). For safe handling
the engine should be lifted with an adjustable lifting
boom. All chains or cables should run parallel to each
other and as possible at right angles to the upper sur-
face of the engine. Note that extra equipment that is
mounted on the engine can change its center of gravi-
ty. Special lifting equipment may be necessary to in-
sure correct balance and safe handling. Never perform
work on a motor that is only hanging in a lifting de-
vice.
Before starting
Reinstall all protective covers that have been removed
prior to starting the engine. Make sure that no tools or
other objects have been left near the engine.
An engine with a turbocharger may never be started
without the air filter being mounted. The rotating com-
pressor wheel in the turbo can cause severe injuries.
There is also a risk that foreign objects can be sucked
in causing damage to the machine.
Fire and explosion
Fuel and lubricating oil
All fuels, most lubricating substances and many
chemicals are flammable. Always read and follow all
instructions listed on the packaging.
Work on the fuel system must be performed on a cold
engine. Fuel leakage and spillage onto hot surfaces or
electrical components can cause a fire.
Store oil and fuel-soaked rags and other flammable
material in a fire-safe manner. Oil-soaked rags can
spontaneously ignite under certain conditions.
Never smoke while filling with fuel or lubricating oil, in
proximity to the filling station or in the engine compart-
ment.
Non-original parts
Components of the fuel and electrical systems on Vol-
vo Penta engines are designed and manufactured to
minimize the risk of explosion or fire according to ap-
plicable requirements.
Use of non-original parts can result in explosion or
fire.
4
Batteries
Batteries contain and develop oxyhydrogen gas, espe-
cially while charging. Oxyhydrogen gas is easily flam-
mable and very explosive.
Smoking, open fire or sparks must never be allowed
near batteries or the battery compartment.
An improper connection of a battery cable or booster
cable can cause a spark that can in turn cause the
battery to explode.
Starting fluid
Never use starting spray or other similar substances
to help start an engine with air preheating (glow plugs/
starting coil). This could cause an explosion in the in-
take tract. This poses a risk of injury.
Hot surfaces and fluids
A warm engine always creates a risk for burns. Be
careful of hot surfaces. For example: exhaust pipes,
turbo, oil sump, turbo pressure pipe, heating coil, hot
coolant and warm lubricating oil in lines and hoses.
Chemicals
Most chemicals, for example glycol, rust prevention
substances, preserving oils, degreasers, etc. are haz-
ardous to your health. Always read and follow the di-
rections on the packaging.
Certain chemicals, for example preserving oils are
flammable and also hazardous if inhaled. Make sure
that you have good ventilation and use a protective
mask when spraying. Always read and follow the di-
rections on the packaging.
Keep chemicals and other hazardous materials out of
reach of children. Bring leftover or used chemicals to
an environmental station for destruction.
Lubrication system
Warm oil can cause burns. Avoid skin contact with
warm oil. Make sure that the lubrication system is not
pressurized prior to performing service. Never start or
operate the engine without the oil filler cap in place
due to risk of oil being thrown out.
 Safety information

Cooling system Electric welding

Avoid opening the coolant filler cap when the engine is
warm. Steam or hot coolant can squirt out causing
burns.
If the filler cap, coolant lines, taps or so on must be
opened or removed while the motor is warm the filler
cap must be opened slowly and carefully so that pres-
sure is released before the cap is completely removed
and work is started. Note that the coolant can still be
hot and cause burns.
Remove the positive and negative cables from the
batteries. Next, remove all connections to the genera-
tor.
Always connect the welding clamp to the component
to be welded and as close to the place to be welded
as possible. The clamp must never be attached to the
engine or so that the current can pass through any
bearings.
When finished welding: Always connect all connec-
tions to the generator before the battery cables are re-
connected.

Fuel system
Always protect your hands when searching for leaks.
Streaming pressurized liquids can make their way into
body tissues causing serious injuries. There is a risk
of blood poisoning.
Always cover the generator if it is placed under the
fuel filter. A fuel spill can damage the generator.

Electrical system
Disconnect the power
Before servicing the electrical system the engine
should be stopped and the electrical power switched
off using the main switch/breakers. External power to
the engine heater, battery charger or other equipment
mounted on the engine must be switched off.
Batteries
Batteries contain a very strong corrosive electrolyte.
Protect your eyes, skin and clothing during charging
or other handling of batteries. Always use safety
glasses and gloves.
In case of skin contact, wash with soap and large
quantities of water. In case of eye contact rinse im-
mediately with large quantities of water and contact a
doctor as soon as possible.

5
Introduction
This instruction book has been compiled to give you the best possible use of your Volvo Penta industrial engine.
It contains the information you need to operate and take care of the engine in a safe and correct manner. We
therefore ask you to read the instruction book carefully and to learn to handle the engine, controls and additional
equipment in a safe manner before you start the engine.

IMPORTANT! The instruction book describes the engine and equipment that are sold by Volvo Penta. In cer-
tain applications there can be variations of for example controls and instrumentation that concern both ap-
pearance and function. In these cases we refer you to the instruction book for the application in question.

Environmental care Fuel and oils

We all want to live in a pure and healthy environment
where we can breathe fresh air, see healthy trees,
have clean water in our lakes and oceans and where
we can enjoy the sunshine without fearing for our
health. Unfortunately this is not always the case today
but it is a situation that we all must work to preserve
and protect.
As an engine manufacturer Volvo Penta has a special
responsibility, therefore care for the environment is a
core value in our product development. Today Volvo
Penta has a broad engine line where large steps have
been taken towards reducing exhaust emissions and
improving fuel economy, engine noise and so on.
We hope that you will be careful to preserve these
qualities. Always follow the advice in the instruction
book regarding fuel quality, operation and mainte-
nance so that you can avoid unnecessary damage to
the environment. Contact your Volvo Penta dealer if
you notice changes such as decreased fuel economy
or increased exhaust smoke.
Only use fuel and oils of a grade matching that recom-
mended in the instruction book (see the chapter on
”Maintenance” under the fuel and lubricating system
headings). Other grades can cause problems with op-
eration, decreased fuel economy and in the long run
even a shortened lifetime of the engine.
Always change the oil, oil and fuel filters according to
the prescribed intervals.
Maintenance and replacement
parts
Volvo Penta engines are constructed for maximal de-
pendability and longevity. They are built to survive in
demanding environments but also to have the mini-
mum possible impact on the environment within which
they operate. Regular maintenance and use of Volvo
Penta original parts will preserve these properties.

Remember to always bring hazardous waste such as Volvo Penta has a worldwide network of authorized
drained oil, coolant, used batteries etc. to an environ- dealers. They are specialists on Volvo Penta products
mental station for destruction. and have accessories, original parts, test equipment
and the special tools that are necessary for high-quali-
Through our mutual efforts we can make a valuable ty service and repair work.
contribution to the environment.
Always adhere to the maintenance schedules list-
ed in the instruction book and remember to pro-
vide the engine/transmission identification num-
ber when ordering service and parts.
Running-in
The engine should be ”run-in” during the first
10 hours of operation according to the following:
Run the engine as with normal operation. Full-throttle
operation should not occur for more than short peri-
ods. Do not run the engine for long periods of time at
steady RPM during the run-in period.
An increase in the consumption of lubricating oil is
normal during the first 100–200 hours of operation. It
is therefore important to check the oil level more often
that is normally recommended.
When a clutch is mounted it should be inspected more
frequently during the first days of operation. Adjust-
ment may be required to compensate for initial wear of
the plates.

6
 Introduction

Certified engines
For those of you who own an emissions-certified
engine that is used in an area where exhaust emis-
sions are legally regulated, it is important to rec-
ognize the following:
A certification signifies that an engine type has been
inspected and approved by the authorities in question.
The manufacturer of the engine guarantees that all en-
gines of the same type will match the engine that was
certified.
This places the following special requirements
upon the maintenance and service that you per-
form on your engine:
• Maintenance and service intervals recommended
by Volvo Penta must be followed.
• Only Volvo Penta original parts may be used.
• Service on the injector pumps, pump settings and
injectors must always be performed by an autho-
rized Volvo Penta repair facility.
• The engine may not be rebuilt or modified with the
exception of accessories and service kits devel-
oped by Volvo Penta for the engine.
• No changes may be made to the engine’s exhaust
or intake air systems.
• No seals may be broken by non-authorized per-
sonnel.
In all other cases follow the advice in the instruction
book regarding operation, maintenance and service.
IMPORTANT! In cases of neglected or deficient
maintenance/service as well as use of non-origi-
nal parts AB Volvo Penta will no longer be able
to assure that the engine meets conditions of
certification.
Volvo Penta will not settle damages and/or costs
associated with such instances.

Warranty
Your new Volvo Penta industrial engine is covered by a limited warranty according to the conditions
and instructions that are contained in the Warranty and Service book.
Note that AB Volvo Penta’s responsibility is limited to that which is named in the Warranty and Service
book. Read it carefully immediately following delivery. It contains vital information on subjects such as
the warranty card,
services, and maintenance that is your responsibility as the owner to be aware of, check on and per-
form. AB Volvo Penta may otherwise completely or partially deny warranty claims.
Contact your Volvo Penta dealer if you do not have a Warranty and Service book as well as a
customer copy of the warranty card.

7
Presentation
TAD1250VE, TAD1251VE and TAD1252VE are in-line, direct-injected, 6-cylinder industrial diesel engines with
switchable internal EGR (Exhaust Gas Recirculation).
They are equipped with electronically controlled fuel management, turbochargers, intercoolers and thermostatically
regulated cooling systems and electronic RPM regulation.

Technical description
Engine and cylinder block Lubrication system
– Cylinder block and cylinder head of alloyed cast – Water-cooled oil cooler
iron
– Gear-driven oil pump
– Seven main bearing induction hardened crank-
– Full flow and bypass oil filters of spin-on type
shaft
– Wet replaceable cylinder liners Intake air compression system
– Steel pistons – Turbocharger

– Three piston rings, the top of which is of the ”key- Cooling system
stone” variety – Cooler with expansion tank (option)
– Induction hardened overhead camshaft with roller – Air-cooled intercooler (option)
rocker arms
– Four valves per cylinder Electrical system
– Replaceable valve seats and valve guides – 24V electric system with generator (80A) with
charging sensor
Fuel system
– Microprocessor-based control unit for fuel delivery
(EMS 2)
– Gear-driven feeder pump
– Centrally placed unit injector with electromagneti-
cally controlled fuel valves
– Fuel filter of spin-on type and a water separating
filter
– EMS 2 (Electronic Management System). See
separate description

8
 Presentation

Identification numbers
Location of engine plates

The plate above shows: The plate above shows:

1 Engine designation 1 Engine designation
2 Serial number 2 Specification number
3 Specification number 3 Serial number engine block
(last six digits)

The plate shows:

A Engine designation
B Net engine output (without fan)
C Max. rpm
D Main software
E Computer kit number
F Product number

The above plate shows:

(K) Engine family
(J) Swept volume Explanation of engine designation:
(A) Engine designation Ex. TAD1250VE
(F1) Valve clearance, inlet T – Turbo
(F2) Valve clearance, outlet A – Air-to-air Charge air cooler
(I) Emission Control devices D – Diesel engine
(P) Only constant RPM 12 – Swept volume, liter
(E) Part number – decal 5 – Generation
(B) Engine code (in engine family) 0 – Version
(C) Output/RPM V – Stationary and mobile operation
(D) Fuel quantity E – Emissions check
(M) Engine speed
(H) Certification approval number (EU)

9
 Presentation

Orientation

1 2 3 4 5

6 7 8 9 10

1. Expansion tank 6. Cooling package

2. Alternator 7. Oil dipstick
3. Control unit, EMS 2 8. Oil filler
4. Starter motor 9. Fuel filter with fuel pressure sensor
5. Air filter 10. Fuel pre-filter with water sensor

10
 Presentation

Location of sensors

1 2 3 4 5 6 7

20

19

10
11

18 17 16 15 14 13 12

1. Coolant level sensor 11. Position sensor, flywheel

2. Position sensor, camshaft 12. Connector for diagnostic tool, 6-pin
3. Unit injector (one for each cylinder) 13. 8-pin connector engine interface
4. Extra stop 14. Water in fuel, fuel filter
5. Charge pressure and temperature sensor 15. Control unit
6. Main relay 16. OiI temperature and level sensor
7. Fuel pressure sensor 17. Crankcase pressure
8. Coolant temperature sensor 18. Oil pressure sensor
9. Starter motor 19. Main fuse 10 A
10. Starter motor relay 20. Alternator

11
 Presentation

21

22

21. Air filter indicator

22. Piston cooling pressure

12
 Presentation

EMS 2
EMS 2 (Engine Management System) is an electronic system with CAN communication (Controller Area Network)
for diesel engine control. The system has been developed by Volvo and includes fuel control and diagnostic func-
tion.

Summary Fuel control

The system includes sensors, control unit and unit in-
jectors. The sensors send input signals to the control
unit, which controls the unit injectors in its turn.
Information from the sensors provides exact informa-
tion about current operation conditions and allows the
processor in the control unit to calculate the correct
fuel injection volume and timing, check engine status
etc.
The engine fuel requirement is analyzed up to 100
times per second. The amount of fuel injected into the
engine and the injection advance are fully electronical-
ly controlled, via fuel valves and the unit injectors.
This means that the engine always receives the cor-
rect volume of fuel in all operating conditions, which
offers lower fuel consumption, minimal exhaust emis-
sions etc.

Input signals Diagnostic function

The control unit receives input signals about engine The task of the diagnostic function is to discover and
operating conditions etc. from the following compo- localize any malfunctions in the EMS 2 system, to
nents: protect the engine and to ensure operation in the event
of serious malfunction.
– coolant temperature sensor
If a malfunction is discovered, this is announced by
– charge pressure / charge temperature sensor
warning lamps, a flashing diagnostic lamp or in plain
– crankcase pressure sensor language on the instrument panel, depending on the
– position sensor, camshaft equipment used. If a fault code is obtained as a flash-
ing code or in plain language, this is used for guidance
– speed sensor, flywheel in any fault tracing. Fault codes can also be read by
– piston cooling pressure sensor Volvo’s VODIA tool at authorized Volvo Penta work-
shops.
– coolant level sensor
If there is a serious malfunction, the engine will be
– oil pressure sensor shut down altogether, or the control unit will reduce the
– oil level and oil temperature sensor power delivered (depending on application). Once
again, a fault code is set for guidance in any fault trac-
– fuel pressure sensor ing.
– water in fuel indicator
– air filter indicator.

Output signals
The control unit controls the following components on
the basis of the input signals received:
– unit injectors
– starter motor
– main relay
– preheating relay

13
 Presentation

Instrument, EMS 2
NOTE! All instruments are accessories.

CIU - Control Interface Unit

The CIU is the “translator” between the EMS 2 control
unit and the customer’s own control panel. The CIU
has two serial communication links, a fast one and a
slow one.
The fast one is a so-called CAN link. All data related
to instruments, indication lamps, connectors and po-
tentiometers is controlled by this link.
The slow link manages diagnostic information for
flashing codes etc.

DU - Display Unit
The DU is an instrument panel which shows engine
working values graphically on an LCD screen. It con-
sists of an computerised unit for permanent installa-
tion in a control panel.
The DU is connected between the engine control unit
and the CIU or DCU.

Easy Link instrument

(only together with a CIU)
The following “Easy Link” instruments are available:
– Engine speed / hours counter (fault codes are also
displayed on the tachometer display when the di-
agnostic button is pressed)
– Coolant temperature
– Oil pressure
– Oil temperature
– Battery voltage
– Alarm panel
– Charge pressure

14
 Presentation

DCU (Display Control Unit)

The DCU (Diesel Control System) control panel is available as an optional accessory for the EMS (Engine Man-
agement System) electronic control system. The DCU is a digital instrument panel which communicates with the
engine control unit. DCU has several functions, such as: engine control, monitoring, diagnostics and parameter
setting.
The menus in the DCU system can be used to check, and in some cases to set a number of different functions in
the EMS system.
NOTE! The menus and illustrations shown here are the English version. The language can be changed, however.
Please refer to the “Setup” menu.

10 9 8

1 2 3 4 5 6

1. LED display 6. ON/OFF. Starts and stops the system

2. START. Starts the engine 7. Scroll downwards in menus
3. SPEED -. Reduces engine speed 8. SEL. Selects in menus
4. SPEED +. Increases engine speed 9. Scroll upwards in menus
5. STOP. Stops the engine 10. ESC. Return to previous menu selection

Start
When the DCU panel is started up, the “Engine Data” menu is displayed. Press “ESC” to come to the main menu.

15
 Presentation

Menus
There are several sub-menus under each main menu.
There is not space for all the menu choices on the
display. To scroll through the menus, use the “7” and
“9” buttons on the display. Press the “SEL” button, no.
“8” to make a selection. Please refer to the illustration
on the previous page.
NOTE! The “Setup” menu can be used to select the
language that you want to use on the display.

Main menu
 Engine data, relevant engine data.
 Preheat, manual activation of pre-heating
 Governor mode, activation of droop.
 Diagnostics, shows fault codes in plain language.
 Trip reset, resets trip data
 Setup, parameter setting
 Information, shows the data for the applicable
hardware, software, data set and engine identifica-
tion of the engine and DCU

Engine data
shows relevant engine data.
• Engine speed, can be controlled with the “SPEED +”
and “SPEED –” buttons (rpm)
• Charge pressure (kPa)
• Coolant temperature (°C)
• Charge air temperature (°C)
• Oil pressure (kPa)
• Oil temperature (°C)
• Engine hours (h)
• Battery voltage (V)
• Fuel consumption (l/h)
• Instantaneous fuel consumption (trip fuel) (l)

16
 Presentation

Preheat
manual activation of pre-heating. When it is activated,
the EMS system senses when started if pre-heating is
needed. For automatic pre-heating, please refer to the
“Setup” / “Pre-heat on ignition” menu.
The pre-heating time is adjusted to suit the engine
temperature, and can last for up to 50 seconds both
before and after starting. Also refer to “Starting proce-
dure, EMS 2”.
• Press “SEL”, the text “Preheat requested” is dis-
played.
• The display automatically returns to the “Engine
Data” menu.

Governor mode
activates/shuts off droop. To set the droop level,
please refer to the “Setup” / “Governor gradient” or
“Governor droop” menus.
• Select “Isochronous mode” or “Droop mode” with
the SEL button.

Diagnostics
shows the error list containing the 10 latest active and
inactive faults. The fault code are shown as text on
the display.
• Scroll through the error list with the arrow keys.

Trip reset
resets trip data, such as fuel consumption.
• Press the SEL button to reset trip data.

17
 Presentation

Setup
parameter setting in the engine’s control systems. Dif-
ferent menus appear under “Customer parameter”, de-
pending on whether you select “Versatile” or “Genset”
from “Set application”.
The parameters that can be set / selected (choice is
made with the SEL button) are:
• Set application, setting of “Versatile” or “Genset”.
Different menus appear under “Customer param-
eter”, depending on what is chosen here.
• Unit, selection of units of measurement (metric or
US units)
• Language, selection of the language shown in the
display. You can choose between English,
French, German and Spanish.
• Stop energized to, setting for the external stop
input. Activated at “Stop” or “Run”.
“Stop”: The stop input must be connected to
voltage to stop the engine.
“Run”: The stop input must be connected to volt-
age to run the engine.
• Customer parameter, alarm limit setting. Please
refer to “Customer parameter / Versatile” and
“Customer parameter / Genset”.
• Throttle input setting, setting of speed control
and voltage limits. See “Throttle input setting”.
• Display setting, display setting. See “Display set-
ting”.

Customer parameter / Versatile

• Idle engine speed - setting idling speed.
• Preheat on ignition - activation of automatic pre-
heating. The engine control system senses if pre-
heating is needed and activates it directly when
switched on.
• Governor gradient (Nm/rpm) - setting the droop
level, when this has been activated. Please refer
to “Governor droop” in the main menu for activa-
tion.
• Oil temp warning limit (°C) - setting the alarm
limit for the oil temperature.
• Coolant temp warning limit (°C) - setting the
alarm limit for the coolant temperature.

18
 Presentation

Customer parameter / Genset

• Primary engine speed - selection of engine
speed, 1500 or 1800 rpm.
• Preheat on ignition - activation of automatic pre-
heating. The engine control system senses if pre-
heating is needed and activates it directly when
switched on.
• Governor droop (%) - setting the droop level,
when this has been activated. Please refer to
“Governor droop” in the main menu for activation.
• Overspeed limit (%) - setting the speed for the
excess speed alarm, % of set engine speed.
• Overspeed shutdown - activation of engine shut
down when the excess speed alarm is activated.
Please refer to “Overspeed limit” to activate the
alarm limit for the excess speed alarm.
• Oil temp warning limit (°C) - setting the alarm
limit for the oil temperature.
• Coolant temp limit (°C) - setting the alarm limit
for the coolant temperature.

Throttle input setting

speed control setting (throttle operation).
• Set throttle mode-
“OFF” - engine speed is controlled via the DCU
panel.
“ext throttle input” - engine speed is controlled
with a potentiometer (accelerator).
“ext voltage input” - engine speed is controlled by
an external unit.
• Set idle voltage (V) - setting the voltage level at
idle.
• Set max voltage (V) - setting the voltage level at
maximum speed.

Potentiometer Potentiometer
value (%) value (%)

100 100

0 0
Voltage (V) Voltage (V)
Idling Max Max Idling

19
 Presentation

Display setting
settings for the display. Adjustment is done with the
“7” and “9” buttons, please refer to the DCU panel in
the illustration.
• Set contrast (%) - display contrast adjustment.
• Set backlight time (sec) - sets the time (in sec-
onds) for background illumination in the display.
The light is then switched off if the panel is not
used.
• Set backlight brightness - adjustment of illumi-
nation strength in the display.

Information
shows the data for the engine and DCU.
• Engine hardware ID - part number of the engine
control module
• Engine software ID - part number of the software
in the engine control module
• Engine dataset1 ID - part number of engine data
set 1.
• Engine dataset2 ID - part number of engine data
set 2.
• Vehicle ID - chassis number
• DCU hardware ID - part number of the DCU.
• DCU software ID - part number of the software in
the DCU.
• DCU dataset1 ID - part number of DCU data set 1.
• DCU dataset2 ID - part number of DCU data set 2.

20
Starting the engine
Make a habit of always visually checking the engine and engine compartment prior to starting the engine. This will
help you to quickly notice if any abnormal conditions have occurred or are occurring. Check also to verify that the
instruments show normal values after start-up.

Before starting
• Check that the oil level is between the MIN and
MAX marks on the oil dipstick (1). See the chap-
ter ”Maintenance, lubrication system”.

• Open the fuel cocks.

• Make sure that there is no leakage of coolant, fuel

or oil.

• Check the air filter’s pressure drop indicator (op-

tion). See the chapter ”Maintenance, Engine, gen-
eral”.

• Check the coolant levels and that the radiator is

not blocked on the outside. See the chapter
”Maintenance, cooling system”.

WARNING! Do not open the coolant filler cap (1)

when the engine is warm. Steam or hot coolant
can squirt out
Do not open the pressure cap (2).

• Turn on the main switches.

IMPORTANT! Never switch off the power with

the main switch while the engine is running. The
generator can be damaged.

• Set the throttle to idle and disengage the clutch/

put the transmission in neutral.

21
Starting the engine

Starting method EMS 2

The pre-heating time is adjusted to suit the engine
temperature, and can last for up to 50 seconds both
before and after starting.
The starter motor connection time is maximized to 30
seconds. After that, the starter motor circuit is cut for
80 seconds to protect the starter motor against over-
heating.
NOTE! Preheating must be activated at temperattures
below 0°.

9
7

2
With pre-heating
1. Press the “ON/OFF” button (6).
2. Press the “SEL” button (7) to come to the main
menu.
3. Scroll down to Preheat with button (9). Press the
“SEL” button (7).
4. In the pre-heat menu, press the “SEL” button (7)
to select pre-heating. The text “Preheat active
please wait” is shown in the display.
5. Wait until the text has gone out and then press
the “START” button (2).

Without pre-heating
1. Press the “ON/OFF” button (6).
2. Press the “START” button (2).
Leave the engine to idle for the first 10 seconds. Then
warm the engine up at low speed and under low load.

IMPORTANT! Never race the engine when it is

cold.

22
 Starting the engine

Volvo Penta start lock

NOTE! Preheating is option.
1. Turn the key to the ”I” position and check the indi-
cator lamps.
2. Position ”II”. Preheating is activated. Wait until the
preheating indicator lamp goes out. Preheating
time is dependent upon engine temperature.
3. Start the engine with position “III”. Let the key re-
turn to position ”I” immediately once the engine
has started.

NOTE! The engine has a built-in starter motor inter-

lock to prevent inadvertent activation of the starter
motor while the engine is running. The key must be
turned to the “O” position before attempting to start
again.

Let the engine run at 500–700 rpm for the first 10 sec-
onds. Following this, warm up the engine using low
rpm and low loading.

IMPORTANT! Never rev-up the engine when it is

cold.

Alternative preheating:
1. Turn the key to the ”I” position and check the indi-
cator lamps. Preheating activates automatically.
Preheating time is dependent upon engine tem-
perature.
2. Start the engine with position ”III”. Let the key re-
turn to position ”I” immediately once the engine
has started.

23
Starting the engine

Start-up under extreme cold

To facilitate and in certain cases allow start-up under
extremely cold conditions certain procedures must be
followed:
Use a winter fuel (from a well-known supplier) that has
been approved for the temperature in question. This
minimizes the risk of wax precipitation in the fuel sys-
tem. During extremely low temperatures use of a fuel
heater is recommended.
In order to insure sufficient lubrication we recommend
use of synthetic oil of the recommended viscosity for
the temperature in question (see chapter ”Mainte-
nance, lubrication system). Synthetic oils retain their
lubricating properties over a wider range of tempera-
tures than mineral oils.
Preheat the coolant by using a separately mounted
electric engine heater. In extreme cases it can be
necessary to use a diesel-powered engine heater.
Consult your Volvo Penta dealer.

IMPORTANT! Make sure that the cooling sys-

tem is filled with a glycol mixture. See the chap-
ter ”Maintenance, cooling system”.

The batteries must be in good condition. Cold reduces

the capacity of the batteries. Increasing the total bat-
tery capacity may be necessary.

24
 Starting the engine

Never use starting spray

WARNING! Never use starting spray or other
similar substances to help start an engine. This
could cause an explosion in the intake tract. This
poses a risk of injury.

Start with booster batteries

WARNING! Batteries (especially booster batter-
ies) contain oxyhydrogen gas that is very explo-
sive. A spark, which can occur if the booster bat-
teries are improperly connected, can be suffi-
cient to cause a battery to explode causing dam-
age and/or injury.

1. Make sure that the booster batteries are con-

nected (in series or in parallel) so that the ground
voltage corresponds to the engine’s system volt-
age.
2. First connect the red booster cable (+) to the
booster battery and then to the dead battery. Then
connect the black booster cable (-) to the booster
battery, then to a place that is a distance away
from the dead battery, e.g. next to the main
switch on the negative wiring or at the negative
cable’s connection to the starter motor.
3. Start the engine.

WARNING! Do not disturb the connections while

attempting to start the engine (risk for creating
sparks) and do not lean over any of the batteries.

4. Remove the cables in reverse order.

WARNING! The normal cables to the standard

batteries must absolutely not be modified.

25
Operation
Correct operation technique is very important for both fuel economy and engine life. Always let the engine warm
up to normal operating temperature before operating at full power. Avoid sudden throttle openings and operation at
high engine speeds.
Checking instruments
Check all instruments directly after starting, and then
regularly during operation.
IMPORTANT! On engines which operate continu-
ously, the lubrication oil level must be checked,
at least every 24 hours. Please refer to the
“Maintenance, lubrication system” chapter.
Fault indication
If the EMS 2 system receives abnormal signals from
the engine, the control unit generates fault codes and
alarms, in the form of lamps and audible warnings.
This is done by means of CAN signals to the instru-
ment.
More information about fault codes and fault tracing is
found in the “Diagnostic function” chapter.
26
Operation at low load
Avoid long-term operation at idle or at low load, since
this can lead to increased oil consumption and even-
tually to oil leakage from the exhaust manifold, since
oil will seep past the turbocharger seals and accompa-
ny the induction air into the inlet manifold at low turbo
boost pressure.
One consequence of this is that carbon builds up on
valves, piston crowns, exhaust ports and the exhaust
turbine.
At low load, the combustion temperature is so low that
full combustion of the fuel can not be ensured, which
means that the lubrication oil can be diluted by diesel
fuel, and the exhaust manifold will eventually leak oil.
If the following points are done as a complement
to normal maintenance, there will be no risk of
malfunctions caused by operation at low load.:
• Reduce operation at low load to a minimum. If the
engine is regularly test run without load once a
week, operation duration should be limited to 5
minutes.
• Run the engine at full load for about 4 hours once
a year. Carbon deposits in the engine and exhaust
pipe can then be burned off.
Stopping the engine
In case of extended time between uses the engine should be run until warm at least once every 14 days. This pre-
vents corrosion of the engine. If the engine will not be used for more than two months preservation should be per-
formed. See the chapter ”Storage”.

IMPORTANT! In case of freezing temperatures liquid in the cooling system must have sufficient antifreeze.
See the chapter ”Maintenance, cooling system”. A poorly charged battery can freeze and break.

Before shutdown
Allow the engine to run a few minutes with no load be-
fore it is shut down. This permits an evening out of
temperatures within the engine, which prevents ”after-
boiling” as well as cooling the turbocharger somewhat.
This contributes to a lengthened useful life without
disruptions.

Stop
• Disengage the clutch (if possible).

• Depress the “STOP” button / turn the key to "S".

27
Stopping the engine

After shutdown
• Check the engine with respect to possible leak-
age.

• Switch off the main switch during extended peri-

ods without use.

Extra stop
The extra stop (AUX STOP) is located on the left side
of the engine, above the control unit.

WARNING! Approaching or working on a running

engine is a safety risk. Beware of rotating parts
and hot surfaces.

28
Maintenance schedule
General
Your Volvo Penta engine and its equipment are built to provide a high degree of reliability and a long useful life.
They are built to have the minimum possible effect upon the environment. Preventative maintenance according to
the maintenance schedule and use of original Volvo Penta parts will preserve these qualities and help to avoid un-
necessary operational disturbances.

MAINTENANCE SCHEDULE
WARNING! Prior to starting maintenance work the chapter ”Maintenance” should be
read carefully. In it you will find instructions for how the work can be carried out in a
safe and correct manner

IMPORTANT! When both operational and calendar times are given maintenance should
be performed in accordance with the first interval to arrive. Maintenance points marked
with should be performed by an authorized Volvo Penta service facility.

Daily, before the first start-up

• Engine and engine compartment, general inspection ......................................page 31
• Air filter indicator, check 1) .............................................................................page 33
• Oil level, check and add ................................................................................. page 35
•
1)
Coolant level, check level .............................................................................. page 39
Change the air filter at least every 12th month.

Every 50th operational hour / at least every 12th month

• Fuel filter. Drain water/impurities ....................................................................page 45

After the first 150 operational hours

•
1)
Engine oil, change 1) ......................................................................................page 35
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.

Every 50–600 operational hours / at least every 12th month

• Engine oil, change 1), 2) ....................................................................................page 35
•
1)
Oil filter/Bypass filter, change 2) .....................................................................page 36
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.

Every 400th operational hour / at least every 12th month

• Fuel tank (sludge collector), drain. ............................................................. not shown
• Alternator belt, check/adjust ..........................................................................page 32
• Batteries, check electrolyte level ...................................................................page 47

29
Maintenance schedule

Every 800th operational hour / at least every 12th month

• Charge air pipes, check for leaks ...................................................................page 31
• Fuel pre-filter, change ....................................................................................page 44
• Fuel filter, change ..........................................................................................page 45
• Fuel pre-filter. Check .................................................................................. not shown

Every 1000 operational hours / at least every 6th month

•
1)
Coolant filter, change 1) ..................................................................................page 42
Not concurrent with the change of coolant.

Every 2000 operational hours

Turbocharger, check .................................................................................. not shown
Valve play/Double rocker (IEGR), check/adjust ......................................... not shown

Every 12th month

EDC system. Check with diagnosis tool .................................................... not shown
Engine, general check ................................................................................ not shown
• Air filter element, change ........................................................................... not shown
• Engine, cleaning/painting ........................................................................... not shown
• Air Filter, tank ventilation, change. ............................................................. not shown
• Air filter, air compressor, change. .............................................................. not shown

Every 48th month or every 10,000 operational hours

Cooling system, check/cleaning .....................................................................page 41
Coolant, change ........................................................................................ page 39-40

Newly rebuilt engine:

After the first 250 hours of operation
Valve play, adjust ...................................................................................... not shown
Maintenance
This chapter contains general technical information and instructions detailing how the recommended maintenance
should be performed. Read carefully through the instructions before starting the task. The time frames for when
each maintenance point should be performed are given in the previous chapter: Maintenance schedule.

WARNING! Read through the safety instructions for maintenance and service work in the chapter: Safety in-
formation, before starting to work.

WARNING! Maintenance and service work shall be performed on a stopped engine if not otherwise indicated.
Stop the engine before the engine cover/hood is opened or removed. Make inadvertent start-up impossible
by removing the starting key and disconnect the power using the main switch.

Engine, general

General inspection
Get in the habit of giving the engine and engine com-
partment a visual inspection before starting the en-
gine and after operation when the engine has
stopped. This will help you to quickly realize if some-
thing unusual has happened or is happening.
Look especially carefully for oil, fuel and coolant leak-
age, loose screws, worn or loose drive belts, loose
connections or damaged hoses and wires. The in-
spection only takes a few minutes but can mean that
serious service interruptions and costly repairs can be
avoided.

WARNING! Puddles of fuel, oil or grease on the

engine or in the engine compartment are a fire
hazard and must be removed as soon as they
are noticed.

IMPORTANT! If leakage of oil, fuel or coolant is

detected the cause must be determined and the
problem resolved before the engine is started.

IMPORTANT! When cleaning with a high-pres-

sure sprayer the following instructions must be
kept in mind: Never point the spray at seals, rub-
ber hoses or electric components.

Charge air pipes, check

Check the condition of the charge air pipes and
clamps looking for leaks or other damage.
Change as needed. Tighten the clamp with the torque
that is stated on the clamps.

31
Maintenance

Alternator drive belt, check/adjust.

Inspection should be done after operation, when the
belt is hot.
The alternator belt have an automatic belt tensioner
and do not need to be adjusted.
Check the condition of the drive belt. It should be pos-
sible to press the alternator belt down about 3-4 mm
(0,118-0,157 ") between the pulleys.
Change as necessary, please refer to “Alternator belt,
change”.

Alternator belt, change

IMPORTANT! Always change a drive belt which
appears worn or cracked.

1. Disconnect the main switch(es) and check that

the engine is not connected to system voltage.
2. Remove the fan guard and fan ring round the cool-
ing fan.
3. Remove the belt guard.
4. Insert a 1/2” square wrench in the belt tensioner.
Turn the tensioner away with the wrench and lift
the alternator belt off.
5. Check that the pulleys are clean and undamaged.
6. Turn the tensioner away with the 1/2” wrench and
install the new alternator drive belt.
7. Install the belt guards.
8. Install the fan guard and fan ring round the cooling
fan.
9. Start the engine and do a function check.

32
 Maintenance

Air filter Check/change. (Option)

The engine is equipped with electronic air filter indica-
tion. A pressure drop in the air filter provides an output
signal which is announced as a warning on the instru-
ment panel. The air filter then needs to be checked
and possibly changed.
NOTE! Scrap the old filter. No cleaning or reuse is
permissible.

IMPORTANT! In continuous operation, the filter

should be checked every 8 hours.
Driving in extremely contaminated environments
such as coal mines or rock crushers requires
special air filters.

33
Maintenance

Lubrication system
Oil change intervals can vary between 50–600 hours depending upon the grade of the oil and the sulfur 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 manu-
facturer of the oil by regular testing.
NOTE! Oil filter must be changed with every oil change.

Sulfur content in fuel, by weight

< 0.3 % 0.3 – 0.5 % > 0.5 %1)
Oil grade Oil change interval: Reached first in operation

VDS-3 600 hours / 12 month 300 hours / 12 month 150 hours / 12 month

VDS-2 and ACEA E7 2) 400 hours / 12 month 200 hours / 12 month 100 hours / 12 month
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)

VDS and ACEA E3 2) 200 hours / 12 month 100 hours / 12 month 50 hours / 12 month
ACEA: E7, E5, E4
API: CI-4, CH-4, CG-4
1)
If 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.

VDS = Volvo Drain Specification

ACEA = Association des Constructeurs Européenne d’Automobiles
Global DHD = Global Diesel Heavy Duty
API = American Petroleum Institute
TBN = Total Base Number

Viscosity
Viscosity should be chosen using the adjoining table.
Note! The temperature values refer to steady outside
air temperature.
* Refers to synthetic or partially synthetic oil

Oil change amount

See chapter ”Technical Data”.

34
 Maintenance

Oil level, check and add

The oil level should be within the marked area on the
dipstick (1) and should be checked daily before the
first start.
Add oil using the filler opening (2) on the side of the
engine.
Check that the correct level is reached. Wait a few
minutes so that the oil has time to run down into the
oil pan.

IMPORTANT! Do not fill over the maximum oil

level. Only use oil of the recommended grade
(see previous page).

1 2

Engine oil, change

WARNING! Hot oil can cause severe burns.

NOTE! Oil should be changed while the engine is

warm.

1. Connect the drain hose to the oil bilge pump and

make sure that leakage can not occur.
2. Pump out the oil (or remove the drain plug and
drain the oil).

NOTE! Collect all the used oil and deliver it to a used

oil collection facility.

3. Remove the drain hose (or replace the drain plug).

4 . Fill with new oil.

35
Maintenance

Oil filter / Bypass filter, change

WARNING! Hot oil can cause severe burns.

1. Clean the oil filter housing.

2. Remove all oil filters using appropriate filter
wrenches (1).
3. Clean the sealing surface on the filter housing,
making sure that no gasket residue remains.
4. Spread a thin layer of engine oil on the new filter’s
sealing rings.
5. Install the new oil filter. The two full-flow filters
should be tightened 1/2 to 3/4 turn following seal
contact. The bypass filter should be tightened 3/4
to 1 turn following seal contact.
6. Fill with oil, start the engine and operate it for
20-30 seconds.
7. Shut off the engine, check the oil level and fill
with oil as needed.
8. Check the seals around the oil filters.

36
 Maintenance

Cooling system
The cooling system ensures that the engine operates at the correct temperature. It is a closed circuit system and
must always be filled with a mixture of at least 40 % concentrated coolant and 60 % water to protect against inter-
nal corrosion, cavitation and damage caused by freezing.
We recommend that you use “Volvo Penta Coolant, Ready Mixed”, alternatively “Volvo Penta Coolant” (con-
centrated) mixed with pure water according to spec, see “Coolant. Mixture”. Only coolant of this quality is suited
too and approved by Volvo Penta.
The coolant should contain ethylene glycol of a good quality with a suitable chemical consistency for an adequate
protection of the engine. Using anticorrosion additive exclusively is not permitted in Volvo Penta’s engines. Never
use water by itself as coolant.

IMPORTANT! Coolant, with a suitable consistency, must be used all year round. This applies even if there is
never any risk for frost , to ensure that the engine has an adequate protection against corrosion.
Future warranty claims on the engine and additional equipment may be rejected if an unsuitable coolant has
been used or if the instructions concerning coolant mixing have not been followed.

NOTE! The anticorrosive agents become less effective after a time, which means that the coolant must be re-
placed, see “Maintenance schedule”. The cooling system should be flushed out at the same time as the coolant is
replaced, see “Cooling system. Cleaning”.

“Volvo Penta Coolant” is a concentrated coolant

that is to be mixed with water. It has been developed
to function optimally with Volvo Penta’s engines and
provides excellent protection against corrosion, cavi-
tation and frost damage.

“Volvo Penta Coolant, Ready Mixed” is a ready-

mixed coolant, 40% “Volvo Penta Coolant” and 60%
water. This concentration protects the engine against
corrosion, cavitation damage and freezing conditions
down to -28 °C (18°F).

37
Maintenance

Coolant. Mixture
WARNING! All glycol is hazardous and harmful
to the environment. Do not consume!
Glycol is flammable.

IMPORTANT! Ethylene glycol must not be

mixed with other types of glycol.

Mix:
40 % “Volvo Penta Coolant” (conc. coolant)
60 % water
This mixture protects the engine against internal cor-
rosion, cavitation and frost damage down to -28°C
(-18°F). (Using 60 % glycol lowers the freezing point
to -54 °C (65°F)). Never mix more than 60 % concen-
trate (Volvo Penta Coolant) in the cooling liquid, this
will give reduced cooling effect and increase the risk
of overheating, and will give reduced freezing protec-
tion.

IMPORTANT! Coolant must be mixed with pure

water, use distilled - deionized water. The wa-
ter must fulfill the requirements specified by Vol-
vo Penta, see “Water quality”.

IMPORTANT! It is extremely important that the

correct concentration of coolant is added to the
system. Mix in a separate, clean vessel before
adding into the cooling system. Ensure that the
liquids mix properly.

Water quality

ASTM D4985:
Total solid particles ...................................... < 340 ppm
Total hardness: ............................................ < 9.5° dH
Chloride ......................................................... < 40 ppm
Sulfate ........................................................... < 100 ppm
pH value ........................................................ 5,5– 9
Silica (acc. ASTM D859) .............................. < 20 mg SiO2/l
Iron (acc. ASTM D1068) .............................. < 0.10 ppm
Manganese (acc. ASTM D858) ................... < 0.05 ppm
Conductivity (acc. ASTM D1125) ................ < 500 µS/cm
Organic content, CODMn (acc. ISO8467) .... < 15 mg KMnO4/l

38
 Maintenance

Coolant level, check

WARNING! Do not open the coolant filler cap (1)
when the engine is warm. Steam or hot coolant
can squirt out as pressure is released.

NOTE! Only open the filler cap (1). Do not open the
pressure cap.

The coolant level should be above the MIN mark. Add

coolant as needed according to the description in
”Adding, cooling system”.

Adding, cooling system

WARNING! Do not open the coolant filler cap (1)
when the engine is warm. Steam or hot coolant
can squirt out as pressure is released.

NOTE! Do not open the pressure cap.

1. Open the filler cap (1).

NOTE! Use only Volvo Penta recommended coolant

and mixtures.

2. Mix the correct amount of coolant ahead of time

(see the table below) so that it can be assured
that the system has been filled.
Filling must not be done so quickly that air pock-
ets form in the system. Air must be given the
chance to flow out through the filler opening and
drain valves.
When adding coolant, the coolant level should be
between the MIN and MAX markings.
3. Start the engine when the cooling system has
been bled of air and filled completely. If there is a
heater attached to the engine’s cooling system
the heater control valve should be opened and the
unit should also be bled of air during filling.
4. Stop the engine after approximately 1 hour, check
the coolant level and add coolant as needed.

39
Maintenance

Draining, cooling system

WARNING! Do not open the coolant filler cap (1)
when the engine is warm. Steam or hot coolant
can squirt out.

1. Remove the filler cap (1).

2. Open all of the drain valves. Drain the coolant
from the radiator. Use drain hose that can be or-
dered from Volvo Penta, the drain cock (P) is lo-
cated under the radiator.
3. Make sure that all coolant runs out. Deposits may
exist just inside of the cocks/plugs that must be
cleaned away. If this is not done there is a risk
that coolant will be left in the engine where it can
cause serious damage.
Check to see if the installation has additional
cocks or plugs at the lowest points of the coolant
system.
4. Close the cocks and replace any plugs.

P = Coolant drain cock/plug

40
 Maintenance

Cooling system, cleaning

IMPORTANT! Cleaning must not be done if
there is a risk of freezing in the cooling system,
since the cleaning solution does not have any
frost protection properties.

NOTE! If the cooling system is flushed regularly, for

example by draining and refilling with rust-preventative
fluid, a smaller amount of flushing additive or simple
rinsing with clean water can be sufficient.

1. Drain the cooling system, see “Draining, cooling

system”.
2. Rinse the cooling system clean with water.
3. Fill the cooling system with radiator flushing
agent, follow the instructions on the package.
4. Run the engine until normal operating temperature
has been reached and then for another 2 hours.

NOTE! As an alternative the cooling system can be

filled with 15–20% concentrated coolant which is
drained after 1–2 days of operation.

5. Carefully flush the system at once with hot water

to prevent any dirt from settling back on the inte-
rior surfaces, and to remove any traces of acid.
Make sure that any heater controls are set to full
heat during emptying.
NOTE! To prevent dissolved dirt etc. from settling in
the cooling system the emptying must be done quick-
ly, within 10 minutes, without leaving the engine sta-
tionary for a long time before emptying. Remove the
filler cap and the lower radiator hose, if fitted, to in-
crease the rate of emptying.
6. Fill the system with Volvo Penta neutralizing mix-
ture, follow the instructions on the package.
Neutralize the residual cleaner for 10-15 minutes
at normal working temperature.
7. Carefully flush the system at once with hot water.
8. When the cooling system is completely clean, fill
it with new coolant that is recommended by Volvo
Penta.

IMPORTANT! It is extremely important that the

correct concentration of coolant is added to the
system. Mix in a separate, clean vessel before
adding into the cooling system. Ensure that the
liquids mix properly.

41
Maintenance

Coolant filter, change

1. Turn the valve (1) 90° to stop the flow through the
coolant filter.
2. Remove the coolant filter using an appropriate fil-
ter wrench. Make sure that no residue from the old
gasket remains on the housing.
3. Spread a thin layer of engine oil on the new cool-
ant filter’s gasket. Tighten the coolant filter by
hand until the rubber seal contacts the sealing
surface on the filter bracket. Tighten the coolant
filter 1/2 turn.
4. Turn the valve (1) 90° to start the flow through the
coolant filter again.
5. Start the engine and check for leaks.
6. Shut-off the engine and check the coolant level,
see ”Coolant level, check”.

42
 Maintenance

Fuel system
Only use fuel of the recommended grade according to the fuel specification below. Always make sure to maintain
a high level of cleanliness when fueling and when working with the fuel system.
All work involving the engine’s unit injectors must be performed by an authorized service location.

WARNING! Risk of fire. Work on the fuel system must be performed on a cold engine. Fuel leakage and
spillage onto hot surfaces or electrical components can cause a fire. Store fuel-soaked rags in a fire-safe
manner.

Fuel specification
The fuel must at least satisfy national and interna-
tional standards for market fuel, for example:
EN 590 (with nationally adjusted environmental and
temperature
requirements)
ASTM-D975-No. 1-D, 2-D
JIS KK 2204
Sulfur content: According to legal requirements in
each respective country. If the sulfur content ex-
ceeds 0.5 percent by weight oil change intervals
must be changed, see “Lubrication system”.
Note that low-density fuel (urban diesel in Sweden
and citydiesel in Finland) can cause a power reduc-
tion of approximately 5% and a decrease in fuel
economy of approximately 2–3%.

43
Maintenance

Fuel filter, change

NOTE! Do not fill the new fuel filter with fuel before as-
sembly. There is a risk that contamination could get
into the system and cause malfunctions or damage.

WARNING! The fuel filter must be changed when

the engine is cold, to avoid the risk of fire due to
spilled fuel on hot surfaces.

1. Clean round the fuel filter.

2. Remove the filter with a suitable filter remover.
Collect any spilled fuel in a collection vessel.
3. Clean the filter mating surface on the filter
bracket.
4. Lubricate the seal with diesel fuel and install the
new fuel filter. Tighten the fuel filter in accordance
with the instructions on the fuel filter.
5. If necessary, vent the fuel system, please refer to
“Fuel System, Venting”.

NOTE! If a water trap is installed: change the filter in

it at the same time as the fuel filter, and clean the wa-
ter trap in the plastic bowl under the filter with a soft
rag.

44
 Maintenance

Fuel pre-filter, change

1. Undo the cable from the water trap sensor.
2. Remove the water trap filter from the filter bracket.
Collect any spilled fuel in a collection vessel.
3. Remove the lower part of the water trap from the
filter.
4. Clean the lower part of the water trap with a soft
rag. Check that the drain hole in the lower part is
not blocked.
5. Install a new seal on the lower part and lubricate
the seal with diesel fuel. Reinstall the lower part of
the filter.
6. Lubricate the seal with diesel fuel. Screw the filter
onto the filter bracket by hand until the rubber seal
just touches the mating surface. Then tighten a
further half turn, no more.
7. Connect the cable to the water trap sensor.
8. If necessary, vent the fuel system, please refer to
“Fuel System, Venting”.

Draining condensate, fuel system

NOTE! Put a collection vessel under the fuel filter to
collect the condensate and fuel.

1. Open the drain nipple (1) in the base of the pri-

mary fuel filter.
2. Tighten the drain tap (1) when fuel without water
starts to run out.

1
Venting the fuel system
The system does not need to be vented unless it has
been run completely dry. Venting is then done with the
hand pump on the fuel filter bracket.

45
Maintenance

Electrical system

The engine is equipped with a 2-pole electric system and with an alternator. System voltage is 24V.

WARNING! Before performing service on the electric system the engine should be stopped and the power
disconnected at the main switch. All connections to battery chargers or other equipment must be discon-
nected.

Main switch
The main switch must never be switched off before
the engine has been stopped. If the circuit between
the generator and the battery is broken while the en-
gine is running the generator and the electronics can
be damaged. For the same reason reconnecting of the
charging circuits must never be carried out while the
engine is running.

IMPORTANT! Never switch off the power with

the main switch while the engine is running.

Fuses
The engine is equipped with a 10A fuse that shuts off
the power in case of an overload in the electrical sys-
tem.
The fuse is placed adjacent to the engine control unit
on the engine’s left side.

Note! The engine will stop if the fuse blows out.

If the fuse blows out often an authorized Volvo Penta

repair facility should be contacted to investigate the
cause of the overload.

Electrical connections
Check that electrical connections are dry, free from
oxide and that they are securely tightened. Spray
these connections as necessary with water-repellent
spray (Volvo Penta universal oil).

46
 Maintenance

Batteries, maintenance
WARNING! Fire and explosion risk. Batteries
may never be exposed to open flame or sparks.

WARNING! Never confuse the plus and minus

poles of the batteries. Risk of causing sparks
and explosion.

WARNING! Battery electrolytes is strongly corro-

sive. Protect eyes, skin and clothing during all
handling of batteries.

WARNING! Always use safety glasses and

gloves. In case of skin contact, wash with soap
and large quantities of water.

WARNING! In case of eye contact rinse immedi-

ately with large quantities of water and contact a
doctor as soon as possible.

Connection and disconnection

When connecting batteries first connect the + cable
(red) to the battery’s + pole. Then connect the – cable
(black) to the battery’s – pole.
When disconnecting batteries disconnect the – cable
(black) first, then the + cable (red).

Cleaning
Keep the batteries dry and clean. Contamination and
oxidation on the battery and the battery poles can
cause current leaks, a reduction in voltage and dis-
charge, especially during times of humid weather.
Clean oxidation from the battery poles and cable ends
using a brass brush. Tighten the cable ends and pro-
tect them using pole grease or Vaseline.

Electrolyte level
The Electrolyte level should be 5–10 mm over the cell
plates in the battery. Add battery water as needed.
After filling the batteries should be charged by being
connected to a battery charger, or by running the en-
gine in normal operation for at least 30 minutes.

NOTE! Certain maintenance-free batteries have spe-

cial instructions that must be followed.

IMPORTANT! Never switch the batteries + pole

and - pole.

47
Maintenance

Batteries, charging
WARNING! Explosion risk. During charging oxy-
hydrogen gas is formed. Short-circuits, open
flame or sparks can cause a powerful explosion.
Ventilate well.

WARNING! Battery electrolyte is strongly corro-

sive. Protect eyes, skin and clothing. Always
use safety glasses and gloves. In case of skin
contact, wash with soap and large quantities of
water. In case of eye contact rinse immediately
with large quantities of water and contact a doc-
tor as soon as possible.

Charge batteries if they have become discharged. If

the engine is not used for an extended period the bat-
teries should be fully charged initially and receive peri-
odic maintenance charging (see the battery manufac-
turers recommendations). A discharged state
damages batteries and they can also freeze and break
during cold weather.

IMPORTANT! Carefully follow all instructions for

the battery charger. To avoid risk for electro-
chemical corrosion when using an external
charger when an external charger is used the
battery cables should be removed from the bat-
tery before the charger is connected.

During charging the cell plugs should be unscrewed

but remain in the plugholes. Ventilate well, especially
if the battery is being charged in an enclosed space.

WARNING! Always turn off the charger before

loosening the charging clamps. Never confuse
the + and - poles of the batteries. Risk of caus-
ing sparks and explosion.

There are special instructions for so-called quick-

charging. Quick-charging can shorten the useful life
of the battery and should therefore be avoided.

48
Preparation for storage
To prevent the engine and other equipment from suffering damage during periods of storage exceeding two
months a preservation procedure should be performed. It is important that this be done correctly and that no part
of it be forgotten. We have therefore created a checklist covering the most important points.
Before the engine is taken out of service for an extended period an authorized Volvo Penta service facility should
perform a check.
Problems should be addressed at this point so that the equipment will be ready for use when needed next.

WARNING! Prior to starting maintenance work the chapter ”Maintenance” should be read carefully. In it you
will find instructions for how the work can be carried out in a safe and correct manner

WARNING! Certain preservation oils are flammable. Some even produce dangerous fumes. Make sure that
there is good ventilation. Use a protective mask when spraying.

IMPORTANT! When cleaning with a high-pressure sprayer the following instructions must be kept in mind:
Never point the spray at seals, rubber hoses or electric components. Never use the high-pressure function
while cleaning the engine.

Conservation
• For periods of storage up to 8 months:
Change the engine oil and oil filter and then run until
warm.
For periods of storage longer than 8 months:
Preserve the lubrication and fuel systems with pres-
ervation oil. See instructions on next page.

• Make sure that the coolant’s freeze protection is

sufficient. Supplement as needed. As an alternative
the coolant can be drained (drain also the coolant
filter).

• Drain off any water and contamination from the fuel

filter and the fuel tank. Fill the tank completely full
with fuel to avoid building of condensation.

• Disconnect the battery cables and clean and charge

the batteries. Maintenance charge the batteries peri-
odically during the storage period. A poorly
charged battery can freeze and break.

• Clean the engine externally. Do not use high-pres-

sure spray when cleaning the engine. Touch-up
paint damage using Volvo Penta original paint.

• Spray the electrical system’s components with a

water displacing spray.

• Check and treat control cables using rust-preventa-

tive.

• Affix a note on the engine showing the date, type of

preservation and type of preservation oil is pro-
vided.

• Cover the air filter, exhaust pipe and the engine if

called for.

49
Preparation for storage

Removing conservation
preparations
• Remove any covers from the engine, air filter and • Close the drain valves and replace any drain
plugs.
exhaust pipe.

• Fill the engine with the proper grade of lubricating
oil as needed. Mount a new oil filter if a filter
change was not performed in conjunction with the
preservation process.
• Mount a new fuel filter and purge the fuel system.
• Check the coolant levels. Add as needed.
• Connect the fully charged batteries.
• Start the engine and run until warm at a high idle
speed prior to apply load to the engine.

• Check the drive belt/s. • Check that no leakage of oil, fuel or coolant
occurs.
• Check the condition of the hoses and check-
tighten the hose clamps.

Preservation of lubrication and fuel systems for storage exceeding 8 months:

• Drain the oil from the engine and fill it with pre-
serving oil* to just over the MIN marking on the
dipstick.
• Connect the suction and return fuel lines to a
container filled with 1/3 preservation oil* and
2/3 diesel fuel.
• Bleed the fuel system.
• Start the engine and operate at a high idle
speed until approximately two liters have been
used. Shut off the engine and connect the nor-
mal fuel lines.
• Empty the preservation oil from the engine.
• Follow otherwise the instructions on the previ-
ous page.

*Preservation oil is distributed by oil manufacturers.

50
Troubleshooting
A number of symptoms and possible causes for engine problems are described in the table below. Always contact
your Volvo Penta dealer if problems occur that you are not able to solve on your own.

WARNING! Read through the safety instructions for maintenance and service work in the chapter ”Safety in-
formation” before starting to work.

Symptoms and possible causes

Diagnostic button’s indicator is blinking See the chapter ”Diagnostic function”.
The engine can not be stopped 2, 5
The starter motor does not turn over 1, 2, 3, 4, 5, 6, 7, 8, 25
The starter motor turns slowly 1, 2
The starter motor turns normally but the engine does not start 9, 10, 11, 12,13
The engine starts but stops again 9, 10, 11, 12, 14
The engine does not reach the correct
operational RPM with full throttle 10, 11, 12, 13, 14, 15, 22, 26, 27, 28
The engine does not run smoothly 11, 12, 13
Poor fuel economy 13, 14, 16, 26
Black exhaust smoke 13, 14
Blue or white exhaust smoke 15, 16, 23
Insufficient lubricating oil pressure 17
Excessive coolant temperature 18, 19, 20, 21
Insufficient coolant temperature 21
Absent or poor charging 2, 24

1. Discharged batteries
2. Poor connection/broken wires
3. Main switch turned off
4. Fuse on the wiring box blown
5. Malfunctioning start lock
6. Malfunctioning main relay
7. Malfunctioning starter motor
relay
8. Malfunctioning starter motor/
solenoid
9. Out of fuel:
- fuel valves closed
- fuel tank empty/wrong tank
connected
10. Blocked fuel filter/pre-filter
(because of contamination or
paraffin condensation in the
fuel at low temperatures)
11. Air in the fuel system
12. Water/contamination in the
fuel
13. Malfunctioning injector
(injectors)
14. Insufficient air to the engine:
- blocked air filter
- air leakage between the
turbo and the engine intake
plenum
- contaminated compressor
section in the turbocharger
- malfunctioning turbocharger
- poor engine compartment
ventilation
15. Excessive coolant tempera-
ture
16. Insufficient coolant tempera-
ture
17. Insufficient lubrication oil level
18. Low coolant level
19. Air in the fresh water coolant
system
20. Malfunctioning circulation
pump
21. Defective thermostat
22. Blocked intercooler
23. Excessive lubricating oil level
24. Generator drive belt slippage
25. Water inside the engine
26. High backpressure in the
exhaust system
27. High oil temperature
28. High charge-air temperature

51
Diagnostic function
The diagnostic function monitors and checks that the EMS 2 system functions normally.
The diagnostic function has the following tasks:
• Discover and localize malfunctions
• Notify that malfunctions have been discovered
• Give advice in fault finding

Message regarding disturbance

If the diagnostic function discovers a malfunction in
the EMS-2 system, this is reported by means of fault
codes/fault messages on the instruments.
Both active (un-mended) and passive (mended) faults
are stored in the control unit.
Please refer to the “Operation” heading for reading
fault codes/fault messages.
• Fault codes can also be read by means of the
VODIA tool. Please refer to the “VODIA User’s
Guide” for advice on use.
At the same time, the fault is stored in the control unit
memory. When the fault has been attended to and the
ignition is switched off and on again, the fault disap-
pears as active.

All fault codes and fault messages are found in the

fault code list, with information about the reason, reac-
tion and measures to be taken. Please refer to the
“Fault codes” chapter.
NOTE! All instruments are optional
Active faults
DCU (Display Control Unit)
• text “!! ENGINE WARNING !!” is shown on the
display.
NOTE! It’s possible to choose which language the in-
formation will be presented in.
CIU (Control Interface Unit)
• the diagnostic lamp starts to flash.
• “Easy Link” instrument (only with CIU)
- the relevant lamp on the alarm panel lights up
- after the diagnostic button has been pressed,
the fault code is shown as text on the tachometer
display.
DU (Display Unit)
• Either “WARNING!” or “ALARM STOP” (a horn
sounds) will be shown on the display, depending
on the severity of the fault.
NOTE! You can choose the language that the informa-
tion is presented in.
Inactive faults
• DCU - the fault is indicated as passive
• CIU - the diagnostic lamp goes out
• DU - the fault message disappears (inactive faults
can not be read out)
• “Easy Link” - the lamp on the alarm panel goes out
Effect on engine
Engines are affected differently, depending on the se-
verity of the fault discovered by the diagnostic function.
A fault message in the form of a fault code is always
generated when a malfunction is discovered by the di-
agnostic function.
Engines are affected differently, depending on the se-
verity of the fault.
• The engine is not affected
• Engine idles
• Engine torque is restricted to a certain amount
• Engine is stopped

52
 Diagnostic function

Operation
When a malfunction has occurred and the diagnostic Reading fault codes via the DU (Display
system has generated one or more fault codes, these Unit)
are read out differently, depending on the equipment
Depending on the severity of the fault, the following text
used. Please refer to “Fault codes”.
will appear on the display: “WARNING!” or “ALARM
If the system indicates that a fault code has been set: STOP” (a horn sounds).
1. Cut engine speed to idle, or shut the engine off. 1. Press any button to come to the fault list.
2. For DCU/DU The fault list shows:
Read the fault code that has been set from the - Operation hours
display, please refer to “Reading fault codes via - Fault message
the DCU” or “Reading fault codes via the DU”.
2. Look up the fault code in the “Fault Code” chapter
For CIU and take the recommended measures.
press the diagnostic button and read the fault
code that has been set, by observing the flashing 3. Press ACK to confirm the fault code. The display
of the diagnostic lamp. Please refer to “Reading background will change color (the buzzer stops
fault codes via the diagnostic lamp, CIU” sounding).

3. Look up the fault code in the “Fault Code” chapter 4. Press EXIT to leave the fault list.
and take the recommended measures.

Reading fault causes via the DCU

(Display Control Unit)
When a fault code is set, the following text is shown
on the display:
“!! ENGINE WARNING !!”
alternated with
“Press SEL for information”.
NOTE! You can choose the language used for the in-
formation presented on the.
Read the fault code as follows:
1. Press the SEL button (to come to the fault list.
The fault list shows:
- Operation hours
- Fault message
- Active/inactive
2. Look up the fault code in the “Fault Code” chapter
and take the recommended measures.
3. Press the ESC button to leave the fault list.
NOTE! To enter the fault list when no fault code has
been set, press the SEL button and select “Diagnos-
tics” from the menu.

53
Diagnostic function

Reading fault codes via the diagnostic Reading the fault codes via an “Easy
lamp on the instrument panel, CIU link” instrument (only with a CIU)
When the system has discovered a malfunction, the When the system has discovered a malfunction, this
diagnostic lamp starts to flash. If the diagnostic but- is reported by the diagnostic lamp which starts to
ton is depressed and then released, a fault code is flash.
flashed out. 1. Press the diagnostic button. The fault code is
The fault code consists of two groups of flashes, sep- shown as text on the tachometer display.
arated by a pause of two seconds. A fault code is ob-
tained by counting the number of flashes in each 2. Look up the fault code in the “Fault Code” chapter
group. and take the recommended measures.
Example: pause = Fault code 2.4 3. When the fault has been rectified, the fault code
disappears from the display and the diagnostic
The fault code is stored and can be read as long as lamp goes out.
the malfunction remains. You can find information
about cause, reaction and actions in the “Fault Code”
chapter.
Read the fault code as follows:
1. Press the diagnostic button.
Erasing fault codes
2. Release the diagnostic button and make a note of
the fault that is flashed out. Fault codes must be erased by means of the VODIA
tool.
3. Repeat items 1-2. A new fault code is flashed out
if more are stored. Repeat until the first fault code
is repeated.
NOTE! When the first fault code is repeated, all fault
codes have been read out.
If the diagnostic button is pressed after the fault has
been mended and the fault codes have been erased,
code 1.1 “No fault” will be displayed.

54
Fault codes
WARNING! Read through the safety advice for care and maintenance work in the ”Safety information” chap-
ter before you start work.

NOTE! Reading the fault codes below, such as Code 2.1, PID 97 means that 2.1 is the flashing code indicated by
the diagnostic lamp. PID 97 is read with the VODIA diagnostic tool. With the use of DCU or DU the fault mes-
sage will be shown as text in the display.

NOTE! Please refer to ”Wiring schedule CIU and DCU” for references to the sleeves in the electrical connectors
on the engine control unit.

Code 1.1 No faults Code 2.4, SID22 / SPN 637

Flywheel speed sensor
There are no active faults.
Cause:
Code 2.1, PID / SPN 97. Water in fuel
• No signal.
Cause:
• Abnormal frequency.
• Water in fuel.
• “Intermittent” signal from the sensor.
Reaction:
• Fault in sensor.
• None.
Reaction:
Remedy:
• Engine is very difficult to start and runs roughly
• Empty the primary fuel filter.
when it starts.
Code 2.2, PID / SPN 111. Coolant level Remedy:
Cause: • Check that the sensor connector is correctly in-
stalled.
• Low coolant level.
• Check that the engine speed sensor cable is not
Reaction:
damaged.
• Engine control module reduces engine power (un- Check that the engine speed sensor is correctly
less the protection has been shut off with the •
installed in the flywheelhousing.
VODIA diagnostic tool).
• Check engine speed sensor function.
• Engine stopped.
Code 2.5, SID21 / SPN 636
Remedy:
Camshaft drive speed sensor
• Check the coolant level.
Cause:
• Check coolant level monitor function.
• No signal.
Code 2.3, PID / SPN 111. Coolant level sensor • Abnormal frequency.
Cause: • Fault in sensor.
• Short circuit to positive (+). Reaction:
• Fault in sensor. • Engine takes longer to start than normal. Engine
Reaction: runs normally when running.
Remedy:
• None.
Remedy: • Check that the engine speed sensor connector is
correctly installed.
• Check that the coolant level sensor cable is not
• Check that the engine speed sensor cable is not
damaged.
damaged.
• Check coolant level sensor function. Check that the engine speed sensor is correctly
•
installed in the upper timing gear cover.
• Check engine speed sensor function.

55
Fault codes

Code 2.6, PID / SPN 190. Engine speed Code 3.1, PID / SPN 100. Oil pressure sensor
Cause: Cause:
• Engine speed too high. • Short circuit to positive (+) or earth (ground) (–).
Reaction: • Open circuit.
• None. Reaction:
Remedy: • None.
• After the engine has stopped, look for the reason Remedy:
for the high speed.
• Check that the oil pressure sensor cable is not
damaged.
Code 2.8, PPID 132 / SPN 608
Speed potentiometer connected to CIU • Check that the oil pressure sensor is correctly
connected.
Cause:
• Shorted to plus (+) or minus (-). Code 3.2, PID / SPN 105
Boost temperature sensor
• Fault in sensor.
Cause:
Reaction:
• Short circuit to positive (+) or earth (ground) (–).
• Engine goes to idle.
• Open circuit.
• If you release the accelerator first, and the press
it down again, the engine can be forced to run us- Reaction:
ing the idle contact. • None.
Remedy: Remedy:
• Check that the potentiometer has been connected • Check that the boost temperature sensor connec-
correctly. tor is correctly installed.
• Check that the cable harness to the potentiometer • Check that the boost temperature sensor cable is
has not been damaged. not damaged.
• Check the potentiometer function. • Check that the boost temperature sensor is cor-
rectly installed.
Code 2.9, PID / SPN 97 • Check boost temperature sensor function.
Indicator for water in fuel
Cause: Code 3.3, PID / SPN 110
Coolant temperature sensor
• Short circuit
Cause:
• Open circuit.
• Short circuit to positive (+) or earth (ground) (–).
• Fault in indicator.
• Open circuit.
Reaction:
Reaction:
• None.
• Preheating is also activated when the engine is hot.
Remedy:
Remedy:
• Check the indicator cables for breaks and short
circuits. • Check that the coolant temperature sensor con-
nector is correctly installed.
• Check indicator function. Change indicator as nec-
• Check that the coolant temperature sensor cable
essary
is not damaged.
• Check that the coolant temperature sensor is cor-
rectly installed.
• Check coolant temperature sensor function.

56
 Fault codes

Code 3.4, PID / SPN 106 Code 3.7, PID / SPN 175. Oil temperature sensor
Boost pressure sensor
Cause:
Cause: • Shorted to plus (+) or minus (-).
• Short circuit to positive (+) or earth (ground) (–). • Break.
• Open circuit. Reaction:
Reaction: • None.
• Engine smokes more than normally during accel- Remedy:
eration/load increase.
• Check that the cable harness to the oil tempera-
Remedy: ture sensor has not been damaged.
• Check that the boost pressure sensor connector Check that the oil temperature sensor has been
•
is correctly installed. connected correctly.
• Check that the boost pressure sensor cable is not
damaged. Code 3.8, PID / SPN 94. Fuel pressure

• Check that the boost pressure sensor is correctly Cause:

installed. • Low supply pressure.
• Check boost pressure sensor function. Reaction:
Code 3.5, PID / SPN 10. Boost pressure • None.
Cause: Remedy:
• Boost pressure too high • Check if it is possible to build up pressure with
the hand pump.
Reaction:
• Check the fuel filter.
• Engine control module reduces engine power (un-
less the protection has been shut off with the • Check the fuel pre-filter.
VODIA diagnostic tool).
Code 3.9, PID / SPN 158. Battery voltage, EMS
Remedy:
Cause:
• Check turbocharger compressor function.
• Faulty alternator.
• Check boost pressure sensor function.
• Faulty battery, battery cables.
• Check fuel volume/injector. Reaction:
Code 3.6, PID / SPN 94. Fuel pressure sensor • None.
Cause: Remedy:
• Short circuit to positive (+) or earth (ground) (–). • Check the supply voltage from the control unit.
• Open circuit. Code 4.6, PPID 3 / SPN 677
Reaction: Start output / Start motor relay
• None. Cause:
Remedy: • Shorted to plus (+) or minus (-).
• Check that the fuel pressure sensor connector is
• Activated for too long.
correctly installed.
Reaction:
• Check that the fuel pressure sensor cable is not
damaged. • The engine cannot be started.
• Check that the fuel pressure sensor is correctly • The engine starts immediately when ignition is tur-
installed. ned on.
• Check fuel pressure sensor function. Remedy:

• Check that connections to the ignition key have

not been damaged.
• Check that the cable harness to the ignition key
has not been damaged.

57
Fault codes

Code 4.8, PPID 6/ SPN 520195. Stop input EMS Code 5.4, PID 45/ SPN 626. Preheating relay
Cause: Cause:
• Short circuit to negative (-). • Short circuit to positive (+) or earth (ground) (–).
• Open circuit. • Open circuit.
Reaction: Reaction:
• Engine can only be stopped with the auxiliary • Preheating can not be activated.
stop. • Preheating is constantly connected.
Remedy: Remedy:
• Check that the starter switch connections are not • Check that the relay input cable is not damaged.
damaged.
• Check relay function.
Code 5.2, PPID 4 / SPN 520194. Starter input CIU
Code 5.5, PID / SPN 107, Air filter pressure
Cause:
Reason:
• Shorted to minus (-).
• Too large pressure drop across filter.
• Activated for too long.
Reaction:
Reaction:
• Less good response from engine.
• The engine cannot be started.
Action:
• The engine starts immediately when ignition is tur-
ned on. • Check the air filter.

Remedy: Code 5.6, PID/SPN 107. Air filter sensor

• Check that connections to the ignition key have Cause:
not been damaged.
• Shorted to plus (+) or minus (-).
• Check that the cable harness to the ignition key
has not been damaged. • Break.
Reaction:
Code 5.3, PPID 6/ SPN 970. Stop input CIU
• None
Cause:
Remedy:
• Short circuit to negative (-).
• Check that the air filter sensor contact is correctly
• Open circuit. installed.
• Activated for too long time. • Check that the cable harness to air filter sensor
Reaction: has not been damaged.

• Engine can only be stopped with the auxiliary stop • Check the air filter sensor functionality.
(AUX STOP) on engine.
Code 5.7. PID / SPN 98, Oil level
• Engine stops. A fault code is displayed for 40 Cause:
seconds and the engine can not be started during
this time. When a fault code is active, the engine • Oil level is too low.
can be started but not stopped. Reaction:
Remedy: • Warning indication.
• Check that the starter switch connections are not Remedy:
damaged.
• Check the oil level.
• Check that the ignition switch cable is not
damaged.

58

Code 5.8, PID / SPN 175. Oil temperature
Cause:
• Oil temperature is too high
Reaction:
• Warning indication.
• The engine control module limits engine output
(unless protection has been turned off with the
diagnosis tool VODIA).
Remedy:
• Check the oil level.
• Check the oil temperature.
• Check the oil temperature sensor function.
Code 5.9, PID / SPN 98. Oil level sensor
Cause:
• Shorted to plus (+) or minus (-).
• Break.
Reaction:
• None.
Remedy:
• Check that the cable harness to the oil level sen-
sor has not been damaged.
• Check the oil level sensor function.
Code 6.1, PID / SPN 110. Coolant temperature
Cause:
• Coolant temperature is too high.
Reaction:
• Engine control module reduces engine power (un-
less the protection has been shut off with the
VODIA diagnostic tool).
Remedy:
• Check the coolant level.
• Check the intercooler (cleanliness).
• Check if there is air in the cooling system.
• Check the pressure cap on the expansion tank.
• Check coolant temperature sensor function.
• Check thermostat function.
Fault codes
Code 6.2, PID / SPN 105. Boost temperature
Cause:
• Boost temperature is too high.
Reaction:
• Engine control module reduces engine power (un-
less the protection has been shut off with the
VODIA diagnostic tool).
Remedy:
• Check the coolant level.
• Check the intercooler (cleanliness).
• Check boost temperature sensor function.
• Check the function of the thermostat.
Code 6.4, PPID 231 / SPN 639, Data link (CAN),
CIU
Cause:
• Faulty data link (CAN), CIU.
Reaction:
• Instruments and warning lamps stop working.
Remedy:
• Check that the 8-pin connector is not damaged.
• Check that the cables between the CIU and the
engine management unit are not damaged.
Code 6.5, PPID 231 / SPN 639, 2017 / PSID 201
Data link (CAN), EMS 2
Cause:
• Internal fault in control module.
Reaction:
• Engine not operating: engine can not be started.
Engine operating: engine idles and can only be
stopped with the auxiliary stop (AUX-stop).
Remedy:
• Check that the 8-pin connector is not damaged.
• Check that the cables between the CIU and the
engine management unit are not damaged.
• Check that sleeves 11 and 12 in the connector on
the CIU are not damaged.
59
Fault codes

Code 6.6, PID / SPN 100, Oil pressure Code 6.9, PID / SPN 158, Battery voltage, CIU
Cause: Cause:
• Oil pressure is too low. • Short circuit to negative (-).
Reaction: • Faulty alternator.
• Engine control module reduces engine power (un- • Faulty battery, battery cables.
less the protection has been shut off with the
Reaction:
VODIA diagnostic tool).
• Problems in engine starting.
Remedy:
Remedy:
• Check oil level.
• Check the supply voltage from the control unit.
• Check that the air filters are not blocked.
• Check system pressure valves and safety valves • Check the battery.
in the oil system. • Check the alternator.
• Check oil pressure sensor function. • Check the 8-pin contact.
Code 6.7, PPID 8 / SPN 520192, Code 7.1, SID 1 / SPN 651
Piston cooling pressure Injector, cylinder #1
Cause: Cause:
• Piston cooling pressure is too low. • Electrical fault.
Reaction: • Faulty compression or injector.
• Engine stopped. The fault code is de-activated at Reaction:
engine speeds below 1000 rpm. • Engine runs on 5 cylinders.
Remedy:
• Abnormal sound.
• Check that the oil pressure in the engine exceeds
• Reduced performance.
175 kPa (25.4 psi).
Remedy:
Code 6.8, PPID 8 / SPN 520192, • Check that the injector cables are not damaged.
Piston cooling pressure sensor
• Check that the injector connections are not dam-
Cause: aged.
• Shorted to plus (+) or minus (-). • Check fuel supply pressure.
• Break. • Check the valve clearance.
Reaction: • Do a compression test and check cylinder #1.
• None.
Remedy:

• Check that the piston cooling pressure sensor

contact is correctly installed.
• Check that the cable harness to the piston cooling
pressure sensor has not been damaged.
• Check the piston cooling pressure sensor func-
tionality.

60
 Fault codes

Code 7.2, SID 2 / SPN 652 Code 7.4, SID 4 / SPN 654
Injector, cylinder #2 Injector, cylinder #4

Cause:
• Electrical fault.
• Faulty compression or injector.
Reaction:
• Engine runs on 5 cylinders.
• Abnormal sound.
• Reduced performance.
Remedy:
• Check that the injector cables are not damaged.
• Check that the injector connections are not dam-
aged.
• Check fuel supply pressure.
• Check the valve clearance.
• Do a compression test and check cylinder #2.
Cause:
• Electrical fault.
• Faulty compression or injector.
Reaction:
• Engine runs on 5 cylinders.
• Abnormal sound.
• Reduced performance.
Remedy:
• Check that the injector cables are not damaged.
• Check that the injector connections are not dam-
aged.
• Check fuel supply pressure.
• Check the valve clearance.
• Do a compression test and check cylinder #4.

Code 7.3, SID 3 / SPN 653 Code 7.5, SID 5 / SPN 655
Injector, cylinder #3 Injector, cylinder #5
Cause:
Cause:
• Electrical fault.
• Electrical fault.
• Faulty compression or injector.
• Faulty compression or injector.
Reaction:
Reaction:
• Engine runs on 5 cylinders.
• Engine runs on 5 cylinders.
• Abnormal sound.
• Abnormal sound.
• Reduced performance.
• Reduced performance.
Remedy:
Remedy:
• Check that the injector cables are not damaged.
• Check that the injector cables are not damaged.
• Check that the injector connections are not dam-
• Check that the injector connections are not dam-
aged.
aged.
• Check fuel supply pressure.
• Check fuel supply pressure.
• Check the valve clearance.
• Check the valve clearance.
• Do a compression test and check cylinder #5.
• Do a compression test and check cylinder #3.

61
Fault codes

Code 7.6, SID 6 / SPN 656 Code 7.9, PID / SPN 172
Injector, cylinder #6 Air temperature sensor, inlet
Cause: Cause:
• Electrical fault. • Shorted to plus (+) or minus (-).
• Faulty compression or injector. • Break.
Reaction: Reaction:
• Engine runs on 5 cylinders. • None.
• Abnormal sound. Remedy:

• Reduced performance. • Check that the air temperature sensor contact is

Remedy:
• Check that the injector cables are not damaged.
• Check that the injector connections are not dam-
aged.
• Check fuel supply pressure.
• Check the valve clearance.
• Do a compression test and check cylinder #6.
correctly installed.
• Check that the cable harness to the air tempera-
ture sensor has not been damaged.
• Check the air temperature sensor functionality.
Code 8.5, PPID 19 / SPN 2791. Internal EGR
Cause:
• Fault in cable harness (boost pressure sensor).

Code 7.7, PID / SPN 153 • Mechanical fault on the IEGR

Crankcase ventilation pressure Reaction:
Cause: • Engine control module reduces engine power.
• Crankcase ventilation pressure too high. Remedy:
Reaction: • Check cable harness (boost pressure sensor).
• The engine is shut down (if the protection has not • Check the IEGR.
been shut off by the parameter tool).
Remedy: Code 9.3, 232 / SPN 620/1079
Power supply to sensor
• Check whether the crankcase ventilation is bloc-
ked. Cause:

• Check whether cylinder liner, piston or piston rings • Shortcut.

are worn or damaged. • Fault in sensor.
Reaction:
Code 7.8, PID / SPN 153
Crankcase ventilation pressure sensor • Faulty values in oil pressure and boost pressure
sensors.
Cause:
• Shorted to plus (+) or minus (-). • Fault code for oil pressure- and boost pressure
sensor.
• Break.
• Low engine output.
Reaction:
• The instrument shows zero oil pressure and boost
• None. pressure.
Remedy: Remedy:

• Check that the crankcase ventilation pressure • Check that the cable harness to oil pressure and
sensor contact is correctly installed. boost pressure sensor has not been damaged.
• Check that the cable harness to the crankcase • Check oil pressure and boost pressure sensors.
ventilation pressure sensor has not been dam-
aged.
• Check crankcase ventilation pressure sensor
function.

62
 Fault codes

Code 9.8, SID 253 / SPN 630 Code 9.9, SID 253 / SPN 630
Data set memory EEPROM, CIU Data set memory EEPROM, EMS
Cause: Cause:
• Internal fault in control module • Internal fault in control module
• Programming faulty. • Programming faulty.
Reaction: Reaction:
• Engine does not start. • Engine does not start.
Remedy: Remedy:
• Re-program the control module. If the fault re- • Re-program the control module. If the fault re-
mains, change the control module. mains, change the control module.

Code 9.8, SID 254 / SPN 629 Code 9.9, SID 254 / SPN 629
Fault in control unit, CIU Control module EMS
Cause: Cause:
• Faulty EEPROM, CIU. • Internal fault in control module.
• Faulty flash memory, CIU. Reaction:
• Fault in control module, CIU • Engine misfires.
Reaction: • Engine does not start.
• CIU returns to factory setting. Remedy:
• Engine goes to idle. • Change engine control unit.
• Engine can not be started.
Remedy:
• Re- program the unit
• Change CIU unit.

Code 9.9, SID 240 / SPN 639. Memory fault

Cause:
• Memory fault in engine management system.
Reaction:
• Engine might not start.
Remedy:
• Re-program the unit.

63
Technical Data

General
Type designation TAD1250VE TAD1251VE TAD1252VE

Power See sales literature

Torque See sales literature

Number of cylinders 6 6 6

Cylinder diameter 131 131 131

Stroke, mm inch 150 150 150

Displacement, dm3 12,13 12,13 12,13

Dry weight, kg lbs 1230 1230 1230

Wet weight, kg lbs 1270 1270 1270

Firing order 1-5-3-6-2-4 1-5-3-6-2-4 1-5-3-6-2-4

Compression ratio 18,1:1 18,1:1 18,1:1

Low idle, rpm 700 700 700

High idle, rpm 1900 1900 1900

Lubrication system
Oil
Change volume including change of three filters:
With horizontal installation ......................................... 35 liter

Oil pressure
at Operational speed 1100 rpm or higher .................... 400–550 kPa
Idle, min ..................................................................... 175 kPa

Oil grade .................................................................... See chapter ”Lubrication system”.

Viscosity .................................................................... See chapter ”Lubrication system”.

Oil filter
Number ...................................................................... 3
Full-flow filter
(tightened 1/2–3/4 turn after sealing surface contact) . 2
Bypass filter
(tightened 3/4–1 turn after sealing surface contact) .... 1

Oil pump
Type .......................................................................... Gear driven

64
 Technical data

Fuel system
Injection order
Injection order ............................................................ 1-5-3-6-2-4

Feed pump
Feed pressure after fuel filter at
1000 RPM, min. ......................................................... 350 kPa (51 psi)
Feed pressure after fuel filter at
full load, min. ............................................................. 350 kPa (51 psi)

Overflow valve
Opening pressure ....................................................... 400–450 kPa (58–65 psi)

Fuel specification
The fuel must at least satisfy national and international standards for market fuel, for example:
EN 590 (with nationally adjusted environmental and temperature requirements)
ASTM-D975 No. 1-D and 2-D
JIS KK 2204
Sulfur content: According to legal requirements in each respective country.
Low-density fuel (urban diesel in Sweden and citydiesel in Finland) can cause a power reduction of approximately 5%
and a decrease in fuel economy of approximately 2–3%.

Cooling system
Type .......................................................................... Overpressure, closed
Pressure valve opens at ............................................ 75 kPa (11 psi)
Volume (engine) ......................................................... 20 liters (5.3 US gal)
Volume (engine + radiator and hoses) ........................ 44 liters (11.6 US gal)

Thermostat
Type .......................................................................... Piston thermostat
Number ...................................................................... 1
Opening temperature .................................................. 82°C (180°F)

Coolant filter
Number ...................................................................... 1

65
Technical data

Electrical system
System voltage .......................................................... 24 V
Alternator:
voltage/max. current .............................................. 28 V/80 A
power approx. ........................................................ 2200W
Battery capacity ........................................................ 2 serial-connected 12 V, max. 220 Ah
Battery electrolyte density at +25°C:
fully charged battery .............................................. 1.28 g/cm3 (1.24 g/cm3)*
the battery discharges at ........................................ 1.24 g/cm3 (1.20 g/cm3)*
* Note! Applies to batteries with tropical electrolyte.

66
 Notes

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 ✂
Yes please,
I would like an operator’s manual in English at no charge.
Post or fax this coupon to: Publication number: 7745086

42200/615001/155099900192
Document & Distribution Center Name
Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg Address
Sweden
Fax: +46 31 545 772
Orders can also be placed via
the Internet:
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manual/coupon Country

Please note that this offer is valid for 12 months from the date of deliv-
ery of the engine, after this it is subject to availability.

✂
Ja danke,
ich will kostenlos eine Betriebsanleitung in deutscher Sprache erhalten.
Schicken Sie den Coupon Publikationsnummer: 7745087

42200/615001/155099900192
per Post oder als Fax an: Name
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Schweden
Fax: +46 31 545 772
Die Bestellung kann auch über
das Internet erfolgen:
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manual/coupon

Bitte beachten Sie, dass das Angebot für die Dauer von 12 Monaten ab dem
Lieferdatum des Motors gilt, danach nur noch bis zum Aufbrauchen des Lager-
bestandes.

Envoyez ou faxez le bon de
commande à:
✂
Oui merci,
Je souhaite recevoir un manuel d’instructions gratuit en français.
Numéro de publication: 7745088
42200/615001/155099900192

Document & Distribution Center Nom

Order Department
ARU2, Dept. 64620
SE-405 08 Göteborg Adresse
Suède
Fax: +46 31 545 772
Vous pouvez également passer
la commande par Internet:
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manual/coupon Pays

Noter que l’offre est valable 12 mois à partir de la date de livraison du

moteur, puis seulement dans la mesure des stocks disponibles.
 ✂
Sí gracias,
Franquear o enviar fax a: deseo recibir gratuitamente un libro de instrucciones en español.
Document & Distribution Center Número de publicación: 7745089

42200/615001/155099900192
Order Department Nombre
ARU2, Dept. 64620
SE-405 08 Göteborg
Suecia Direc
Fax: +46 31 545 772
El pedido puede hacerse tam-
bién por internet:
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manual/coupon
País

Observe que la oferta es válida durante 12 meses a partir de la fecha de entrega

del motor. A partir de la fecha de finalización de la oferta, la misma es válida siem-
pre que haya existencias.

✂
Sì, grazie,
Spedire il tagliando per posta o desidero ricevere gratuitamente un manuale d’istruzioni in lingua italiana.
per fax a: Public. No.: 7745091

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7745086 English 07-2006
 OMKA (10100075)

RESERVDELSKATALOG
SPARE PARTS CATALOGUE

SERVICE MANUAL
SERVICE MANUAL

MODELL / MODEL : OMKA

KOD / CODE No. : 10100075

M-TECH TRANSMISSIONS AB – Kvarsebovägen 124– S-618 93 KOLMÅRDEN (SWEDEN)

Tel. +46 (0)11 396 444, Fax. +46 (0)11 396 480
 OMKA

SERVICE MANUAL OMKA

(PTO PUMPDRIVE)

10100069
10100073
10100074
10100075

M-TECH TRANSMISSIONS AB – Kvarsebovägen 1242– S-618 93 KOLMÅRDEN (SWEDEN)

Tel. +46 (0)11 396 444, Fax. +46 (0)11 396 480
 OMKA POWER TAKE OFF 1/11
OPERATION AND MAINTENANCE MANUAL

INDEX

1. FIELD OF APPLICATION

2. TECHNICAL SPECIFICATIONS

3. UNIT WEIGHT

4. IDENTIFICATION PLATE

5. DESCRIPTION
5.1 Structure
5.2 Gearing

6. INSTALLATION
6.1 Mounting procedure to engine
6.2 Lubrication plumbing
6.3 Mounting of pumps
6.4 Wiring of pressure switch

7. RECOMMENDED OIL TYPE

8. INITIAL OPERATION
8.1 Oil fill
8.2 Starting of engine and inspection for proper lubrication
8.3 Purging the lubrication plumbing
8.4 Warning – breakdown system for lubrication pump

9. MAINTENANCE
9.1 Checking the oil level and filter blockage
9.2 Oil change and replacement of filter element
9.3 Heads nuts tightening checking

M -TECH TRANSMISSIONS AB, Kvarse b o v ä g e n 1 2 4 , S -6 1 8 9 3 K o l m ården (SWEDEN), T e l + 4 6 ( 0 ) 1 1 3 9 6 4 4 4 , F a x + 4 6 ( 0 ) 3 9 6 4 8 0

 OMKA POWER TAKE OFF 2/11
OPERATION AND MAINTENANCE MANUAL

Print
All rights reserved.
Copyright: M-TECH TRANSMISSIONS AB
Kvarsebovägen 124
S-618 93 KOLMÅRDEN
SWEDEN
Tel.: +46 (0)11 396 444
Fax: +46 (0)11 396 480

Omsi Trasmissioni S.p.A

Via S. Pietro 60
I-25077 Roé Volciano (BS)
ITALY
Tel. +39 (0365) 637 61
Fax +39 (0365) 637 43

This manual may be reproduced and copied in whole or in parts after a formal approval by
M-TECH TRANSMISSIONS AB.

We reserve the right of modifications without any prior notice.

Release 25/07/2000, Rev 00

M -TECH TRANSMISSIONS AB, K v a r s e b o v ä g e n 1 2 4 , S -6 1 8 9 3 K o l m ården (SWE DEN), T e l + 4 6 ( 0 ) 1 1 3 9 6 4 4 4 , F a x + 4 6 ( 0 ) 1 1 3 9 6 4 8 0

 OMKA POWER TAKE OFF 3/11
OPERATION AND MAINTENANCE MANUAL

1. FIELD OF APPLICATION

The OMKA power take-off is installed between a diesel engine and a fluid coupling with SAE1 mounting flange.
It allows the mounting of more hydraulic pumps of medium size for the operation of the various systems of the
unit.

2. TECHNICAL SPECIFICATIONS
MAIN DRIVE SHAFT

Ratio 1
Maximum input power 300 kW
Maximum input torque 2200 Nm
Maximum input speed 2500 RPM

POWER TAKE-OFF

Available ratios for each head 1.29729 (increase) 1.0666 (increase)

Maximum output instantaneous torque 950 Nm 1050 Nm
from a single head

INTERMITTENT working conditions

CURRENT USE OF TWO HEADS

Maximum output power from each head 120 kW 120 kW
Maximum output torque from each head 750 Nm 850 Nm
Maximum revolutions at PTO output 2600 RPM 2600 RPM

USE OF ONE SINGLE HEAD

Maximum output power from the head 150 kW 150 kW

Maximum output torque from the head 750 Nm 850 Nm
Maximum revolutions at PTO output 2600 RPM 2600 RPM

CONTINUOUS working conditions

CURRENT USE OF TWO HEADS

Maximum output power from each head 100 kW 100 kW

Maximum output torque from each head 550 Nm 650 Nm
Maximum revolutions at PTO output 2600 RPM 2600 RPM

M -TECH TRANSMISSIONS AB, K v a r s e b o v ä g e n 1 2 4 , S -6 1 8 9 3 K o l m ården (SWE DEN), T e l + 4 6 ( 0 ) 1 1 3 9 6 4 4 4 , F a x + 4 6 ( 0 ) 1 1 3 9 6 4 8 0

 OMKA POWER TAKE OFF 4/11
OPERATION AND MAINTENANCE MANUAL

USE OF ONE SINGLE HEAD

Maximum output power from the head 120 kW 120 kW
Maximum output torque from the head 550 Nm 650 Nm
Maximum revolutions at PTO output 2600 RPM 2600 RPM

3. UNIT WEIGHT

The approximate weight of the OMKA PTO with two heads and without oil is 225 Kg.

4. IDENTIFICATION PLATE

OMSI TRASMISSIONI S.P.A.

MODEL OMKA
PART No. 10100075
SERIAL No. 0700 0004
RATIO 1:1,07 OIL LT.7
SAE80W90MIL-2105BD-APIGL5

The nameplates are affixed as follows: 1 on the mid-section and 2 on the two heads, in order to always allow
the identification of the manufacturing date.

Photo 1 Photo 2

M -TECH TRANSMISSIONS AB, K v a r s e b o v ä g e n 1 2 4 , S -6 1 8 9 3 K o l m ården (SWEDEN), Tel + 4 6 ( 0 ) 1 1 3 9 6 4 4 4 , F a x + 4 6 ( 0 ) 1 1 3 9 6 4 8 0

 OMKA POWER TAKE OFF 5/11
OPERATION AND MAINTENANCE MANUAL

5. DESCRIPTION

5.1 - STRUCTURE OF THE POWER TAKE-OFF

The OMKA PTO is constructed of one standard main body and various head configurations.

The reduction ratio of the main body is fixed, while adapting heads with ratios of 1: 1.297 increase or 1:1.

The head flange and spline shaft for pump mounting must be selected in relation to the type of pump to be used
in the application.
The PTO can support the weight of the pumps but not the weight of the fluid coupling.

5.2 - GEARING

The drive torque of the diesel engine is transmitted to the main shaft of the power take-off through a rigid
coupling and subsequently through a second flywheel and a flexible coupling, its is transmitted to the fluid
coupling mounted at the output side of the power take-off.
The drive torque transmitted to the hydraulic pumps mounted at the lateral heads is through a common driving
wheel drawn from the main shaft and two quaternaries of cylindrical gears.
The gears are hardened and tempered, with helical configuration and ground profile.

5.3 - OIL SEALS

The main shaft incorporates two oil seals with dual lips. The outer lip is a wiper that prevents dust passage.
The oil seals are manufactured specifically for this application, with preferential direction of rotation.
The oil seals have different dimensions to avoid errors through the assembly process, and eliminating the
possibility of jeopardizing the actual sealing effect.
We do not recommend the use of other oil seals. In the case of maintenance, use only original oil seals,
supplied by OMSI Trasmissioni S.p.A. or by authorized sellers.
The oil seal between the heads and main body is obtained with liquid seal type Loctite 510.
In the case where the heads are removed, after cleaning the surfaces thoroughly, use the same liquid seal or
equivalent.
The same sealing element can be used also for the seal between the heads and at the moutning flnage of the
hydraulic pumps.
Other sealing points are made with rubber O’ring gaskets.

6. INSTALLATION

The PTO can support the weight of the pumps but not the weight of the fluid coupling.
A frame arrangement with flexible isolator mountings must support the diesel engine, power take-off and fluid
coupling.

6.1 - MOUNTING PROCEDURE TO ENGINE

M -TECH TRANSMISSIONS AB, K v a r s e b o v ä g e n 1 2 4 , S -6 1 8 9 3 K o l m ården (SWE DEN), T e l + 4 6 ( 0 ) 1 1 3 9 6 4 4 4 , F a x + 4 6 ( 0 ) 1 1 3 9 6 4 8 0

 OMKA POWER TAKE OFF 6/11
OPERATION AND MAINTENANCE MANUAL

6.1.1 - Mount the main shaft support bearing to the flywheel (Pos.3, Illustration 1). Be sure that the two rubber
O’rings 150 (40050256) and O’ring 165 (40050257) are positioned at the internal diameter of the bearing for the
retention of grease.
It is recommended to grease thoroughly the internal surface with Mobil Special Grease or equivalente with the
following characteristics:

• Multi-purpose Lithium grease with bisulphide of molybdenum

• Grade: ISO 150
• Penetration ASTM (m/10): 275 - 305
• Grade NLGI: 2
• Dropping point (C°): 180

6.1.2 - Mount the reduction ring 20120568 (Pos. 8, Illustration 1) on the flywheel with the correspondent
hardware 40210172 (Pos. 8, Illustration 1, TCCE 12.9 UNI5931 M12x30).
It is recommended to install the screws with thread lock type Loctite 242. Torque to 145 Nm +/- 10 Nm.

6.1.3 - Providing the proper support, proceed with the mounting of the power take-off with the side of the
rigid coupling to the engine.
For the attachment of the power take-off to the engine, we recommend the use of the original engine studs or
studs of class 10.9 or greater.
It is recommended the use of lock-nuts type Metal-Blok DIN 980 and conical washers DIN 6796.

6.1.4 - Remove the plugs 20060010 (Pos. 6, Illustration 2) by loosen screws 40210020 (Pos. 9, Illustration
2).

6.1.5 - Through the two openings, mount screws 40210521 (Pos. 10, Illustration 1, TE M12x25 10.9 UNI5739)
and proper wave washers d.13 UNI3545 (Pos. 9, Illustration 1) to lock the dragging discs against the reduction
ring.
It is recommended to install the screws with thread lock type Loctite 242. Torque to 120 Nm +/- 6 Nm.

6.1.6 - Following the operation of locking the dragging discs, proceed with the relocation of the plugs
20060010 (Pos. 6, Illustration 2) in order to avoid foreign materials to enter the PTO and engine, and to damage
the oil seals on the main shaft.

Fill/breather plug

Oil fill
port

Illustration 1 Illustration 2

M -TECH TRANSMISSIONS AB, K v a r s e b o v ä g e n 1 2 4 , S -6 1 8 9 3 K o l m ården (SWE DEN), T e l + 4 6 ( 0 ) 1 1 3 9 6 4 4 4 , F a x + 4 6 ( 0 ) 1 1 3 9 6 4 8 0

 OMKA POWER TAKE OFF 7/11
OPERATION AND MAINTENANCE MANUAL

6.2 - LUBRICATION PLUMBING

The OMKA PTO is furnished with partial lubrication plumbing because it is always installed with a heat
exchanger system. We highly recommend the installation of the external oil reservoir / level indicator (Pos. 8,
Illustration 3) to facilitate oil level inspection and re-filling when required.
Follow the diagram below for complete lubrication plumbing and connections.

6.2.1 - Connect the pump output with the inlet of the heat exchanger.

6.2.2 - Connect the outlet of the heat exchanger into two distribution blocks (Pos. 1 and 2, Illustration 3) on
both heads of the PTO.

6.2.3 - Install the external filter with the element mounted slightly higher than the oil level to avoid spillage
when replacing it.

6.2.4 - Connect the oil suction port under the main housing to the inlet of the oil filter. Install the furnished non-
return check valve (Pos. 4, Illustration 3) on this line as shown on the diagram below.

6.2.5 - Connect the outlet of the filter to the suction port of the hydraulic pump.

6.2.6 - We recommend the installation of a by-pass system at the heat exchanger ports with a check valve of ~
3 bar (Pos. 6, Illustration 3) to allow circulation of oil even in the event of blockage in the heat exchanger (Pos.
5 and 7, Illustration 3).

Fill/breather plug
6

5
1

2
3

8
Oil level
9

Oil drain plug 4

Illustration 3

M -TECH TRANSMISSIONS AB, K v a r s e b o v ä g e n 1 2 4 , S -6 1 8 9 3 K o l m ården (SWE DEN), T e l + 4 6 ( 0 ) 1 1 3 9 6 4 4 4 , F a x + 4 6 ( 0 ) 1 1 3 9 6 4 8 0

 OMKA POWER TAKE OFF 8/11
OPERATION AND MAINTENANCE MANUAL

IMPORTANT:
During the installation of the filter assembly, be sure to carefully follow the direction arrow on the aluminum
housing in relation to the flow path of the system (photo 3). Also the non-return check valve have a particular
direction to follow (photo 4).

Photo 3 Photo 4

6.2 - MOUNTING OF PUMPS

The power take-off is furnished complete with O’ring gaskets and spline adapters for the pump installation.
In the event that the O’ring gasket is not able to completely seal the oil between the housing and pump, use
liquid gasket Loctite 510 in addition to the gasket provided.

6.3 - WIRING OF PRESSURE SWITCH

Proceed with the electrical wiring (24V) of the pressure switch (Pos. 2, Illustration 4), mounted on the
lubricating pump to a light indicator visible to the operator at all times, or preferable to an audible alarm system.

7. RECOMMENDED TYPE OF OIL

The oil must be of the following type:
SAE80W90 for transmissions and differentials
Specifications Api GL-5
Military specs Mil-L 2105BD

The major characteristics of this oil are:

Viscosity at 40° C 130 cSt

Viscosity at 100° C 14 cSt
Pouring point -34° C
Viscosity index 105

As an alternative Mobil Oil SHC 75W90 (synthetic) or equivalent synthetic oil may be used in low temperature
environments.

The quantity of oil varies from the different types of PTO’s. Please, check on the gear identification plate the
approximate oil quantity. To fill the gear correctly please see chapter 9.1 in this manual.

M -TECH TRANSMISSIONS AB, K v a r s e b o v ä g e n 1 2 4 , S -6 1 8 9 3 K o lmården(SWEDEN), T e l + 4 6 ( 0 ) 1 1 3 9 6 4 4 4 , F a x + 4 6

(0 ) 1 1 3 9 6 4 8 0
 OMKA POWER TAKE OFF 9/11
OPERATION AND MAINTENANCE MANUAL

8. INITIAL OPERATION

8.1 - INITIAL OIL FILL

WARNING: The power take-off is shipped without oil.
Before the initial start up, follow these points:
• Remove the element of the oil filter, fill it with oil, and re-install it onto the filter housing and tighten
securely.
• Fill the power take-off with oil through the port where the breather plug is mounted (see note on illustration
2), until it reaches the proper level at the sight eyes on the heads ( Pos. 1, Illustration 5).

8.2 - STARTING OF ENGINE AND INSPECTION FOR PROPER LUBRICATION

Engage the power take-off and run for ~ 5 minutes at low revolutions.
Shut off engine, allow the oil to cover all internal surfaces and inspect level through the sight eye.
Add more oil as necessary.
This procedure must be followed in order to fill the entire plumbing of the lubrication system and heat exchanger
with oil.
To verify the proper connections and operation of the pressure switch, indicator light and/or alarm system,
provide power to the main electrical panel with the engine shut off. At this point, the indicator light and/or alarm
system should register lack of pressure in the system.

8.3 - PURGING THE LUBRICATION PLUMBING

If the indicator light and/or alarm system do not turn off after approximately 30 seconds from the first signal,
there is a possibility that air pockets are trapped within the system plumbing. To remove these pockets,
proceed with the following:

• Shut off the engine immediately.

• Remove the plug from the cross (Pos. 1, Illustration 4) mounted at the outlet port of the lubrication pump.
• Prepare a bucket to catch any oil that could get spilled.
• Start the engine briefly and check if oil squirts out.
• Shut off the engine and re-install the plug on the cross (Pos. 1, Illustration 4). Add more oil until it reaches
its proper level.
• Re-start the engine and check if the light and/or alarm system are off or interrupted.
• If the problem persists, review paragraph “B” of point 8.4 of this manual.

1 Illustration 5 Illustration 4

M -TECH TRANSMISSIONS AB, K v a r s e b o v ä g e n 1 2 4 , S -6 1 8 9 3 K o l m ården (SWE DEN), T e l + 4 6 ( 0 ) 1 1 3 9 6 4 4 4 , F a x + 4 6 ( 0 ) 1 1 3 9 6 4 8 0

 OMKA POWER TAKE OFF 10/11
OPERATION AND MAINTENANCE MANUAL

8.4 - WARNING – BREAKDOWN SYSTEM FOR LUBRICATION PUMP

If the system pressure decreases below 0.8 bar, the indicator light and/or alarm system will indicate a
malfunctioning in the system or lubrication pump. In this case, the operator must shut off the diesel engine
immediately. After verification that the oil level is at its proper level through the sight eye (Pos. 1, Illustration 5),
re-start the engine at low revolutions and loosen the connection after the non-return check valve (Pos. 2,
Illustration 5).

A - If oil does not come out, it is necessary to:
1) Loosen the plug (Pos 1, Illustration 4) to allow air to es
cape and then re-tighten.
2) If the problem persists shut off the engine and replace
the lubrication pump. After replacing the pump, repeat
The operation and check that oil circulates through the
plumbing.

B - If oil comes out correctly, it is necessary to: 1) Verify the operation of the pressure switch (Pos. 2,
Illustration 4). Replace it if necessary.
2) Verify the wiring between the pressure switch and
indicator light and/or alarm system.

9. MAINTENANCE

9.1 - CHECKING THE OIL LEVEL

The approximate capacity of oil of the power take-off is 7 liters, excluding the lubrication plumbing and heat
exchanger. The filter indicator must be checked for potential blockages within the element with the PTO in
working conditions. During the first week of operation, the oil level and filter indicator must be checked on a
daily basis with the machine on level ground. Subsequently, these checks must be performed on a weekly
basis. If during the inspection process, oil is not visible through the sight eye (Pos. 1, Illustration 5), or through
the external oil reservoir / level indicator (Pos. 8, Illustration 3), re-fill immediately through the external oil
reservoir / level indicator or through the fill / breather plug (refer to note on illustration 2). It is imperative to find
the source of leak and refer to paragraph 5.3 of this manual.
When re-filling to the proper oil level, always use the recommended oil type. Mixing of oils can be detrimental to
the lubrication system.
After re-filling, re-install the fill / breather plug.

9.2 - OIL CHANGE AND REPLACEMENT OF FILTER ELEMENT

Perform the oil change referring to paragraph 8 “Initial Operation”. The oil and filter element must be replaced
after the first 100 hours of operation. In order to facilitate the draining of the oil, it is recommended to proceed
with this operation when the oil is still warm. Pay very close attention to all safety procedures because the
OMKA PTO and the oil could reach very high temperatures.

Subsequent oil changes and filter element replacement should be performed every 500 hours of service or once
a year, whichever comes first.
After replacing the oil, start the engine and inspect the circulation of oil through every lubricating point.
Oil change instructions:
• Position a bucket large enough to collect the old oil under the PTO. Remove the drain plug (Pos. 9,
Illustration 3).
• Remove the fill / breather plug (refer to note on lilustration 2), in order to facilitate the draining of oil
completely.
• Re-install the drain plug (Pos. 9, Illustration 3).

M -TECH TRANSMISSIONS AB, K v a r s e b o v ä g e n 1 2 4 , S -6 1 8 9 3 K o l m ården (SWE DEN), T e l + 4 6 ( 0 ) 1 1 3 9 6 4 4 4 , F a x + 4 6 ( 0 ) 1 1 3 9 6 4 8 0

 OMKA POWER TAKE OFF 11/11
OPERATION AND MAINTENANCE MANUAL

• Fill the power take-off with oil (see paragraph 7) until it reaches the level sight eye (Pos. 1, Illustration 5) or
if applicable, to the sight eye at the external oil reservoir / level indicator (Pos. 8, Illustration 3).
•
• Engage the PTO and run for ~ 5 minutes at low revolutions. Shut off engine, allow oil to cover all internal
surfaces and inspect level through the sight eye. Add more oil as necessary.
• This procedure must be followed in order to fill the entire plumbing of the lubrication system and heat
exchanger with oil.
• Re-install the fill / breather plug (see note on illustration 2).

Important:
Use protective equipment during this process and when handling hot oil. AVOID INJURIES!
Disposal of old oil must be done following your local, state, and federal regulations.
DO NOT POLLUTE THE ENVIRONMENT!

9.3 - HEADS NUTS TIGHTENING CHECKING

We strongly recommend to inspect the torque of the nuts that support the two heads to the main body (Pos.7,
illustration 6) every 6 months.
Torque to 50 Nm.

Illustration 6

Maintenance table:
FIRST 100
MAINTENANCE INTERVALS
HOURS
SEE
MAINTENANCE INTERVENTIONS After Every Every
when Every 6 CHAPTERS
Daily 100 50 500 Yearly
necessary months
hours hours hours
Level checking X X 9.1
OIL
Oil change X X X 9.2
FILTER
Checking blockage X X 9.1
INDICATOR
FILTER Filter element replacement X X X X 9.2
SCREW
Checking X X X 9.3
TIGHTENING
SEALS Change X 5.3 / 9.1

M -TECH TRANSMISSIONS AB, K v a r s e b o v ä g e n 1 2 4 , S -6 1 8 9 3 K o l m ården (SWE DEN), T e l + 4 6 ( 0 ) 1 1 3 9 6 4 4 4 , F a x + 4 6 ( 0 ) 1 1 3 9 6 4 8 0

 OMKA (10100075)

RESERVDELSKATALOG
SPARE PARTS CATALOGUE

MODELL / MODEL : OMKA

KOD / CODE No. : 10100075

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 Allmän information och beställningsexempel OMKA 10100075
General information and ordering example
Rev. 01 Tab.

INTRODUKTION

Instruktioner, ritningar, tabeller och all annan information i denna manual är av teknisk karaktär och är därför
konfidentiell. Denna manual får ej, vare sig delvis eller i sin helhet kopieras och/eller lämnas till 3: e part utan
skriftligt godkännande av M-TECH TRANSMISSIONS AB eller av Omsi Trasmissioni som båda äger rätten till
denna manual. Vi förbehåller oss rätten till ändringar utan förvarning, på ett sådant sätt vi finner önskvärt.

HUR BESTÄLLA RESERVDELAR:

Följande information och beskrivning måste lämnas vid beställning av reservdelar.

1. TYP
2. SERIENUMMER FÖR AKTUELL VÄXEL (Omka)
3. TAB. NUMMER (denna manual)
4. KOD/ARTIKELNUMMER FÖR BESTÄLLD DETALJ
5. ÖNSKAT ANTAL
6. LEVERANSSÄTT, LEVERANSADRESS
7. BESTÄLLARENS ADRESS

FOREWORD
Instructions, drawings, tables and all other information in this manual are technical and strictly confidential. No
information may be reproduced or copied in parts or in whole without a formal and written approval by M-TECH
TRANSMISSION AB or Omsi Trasmissioni. We reserve the right s for modifications without any notice as we may
find appropriate.

HOW TO ORDER SPARE PARTS:

1. TYPE
2. SERIAL NUMBER OF THE ACTUAL GEAR (Omka)
3. TAB. NUMBER (TABELL)
4. CODE NUMBER OF ORDERED PARTS
5. ORDERED QUANTITY
6. WAY OF DELIVERY, DELIVERY ADDRESS
7. ADDRESS OF THE ORDERING FIRM

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 Detalj lista OMKA 10100075
Parts list
Rev. 01 Tab.

Kod Nr/Code No ANTAL/QTY Beskrivning / Description

20010330 2 PTO huvud för pump / PTO housing for pump
20010311 1 Växelhus aluminium / Gear housing aluminum
20030434 1 Fläns adapter för pump / Flange adaptor for pump
20040008 1 Fläns lagerhållare (6026) / Flange bearing carrier (6026)
20040061 2 Bussning / Bushing
20040062 2 Bussning / Bushing
20040168 1 Pilotlager bussning centrum / Pilot central bearing bushing
20060010 2 Lock montering / Cover mounting
20090011 1 Svänghjul utgående / Flywheel output
20120134 1 Tätning 140x165x15 / Seal 140x165x15
20120567 1 Lock tätning / Cover for seal
20120568 1 Övergång / Ring reduction
20120586 2 Ring centrering pump A10VO / Ring center pump A10VO
20130019 1 Splinesbussning 48x44 DIN 5482 / Bushing splines 48x44 DIN 5482
20150451 2 Axel bussning splines för pump / Shaft bushing for pump
20160779 2 Drev Z 53 / Gear ring Z 53
20160780 1 Drev Z 48 / Gear ring Z 48
20160784 2 Drev Z 44 / Gear ring Z 44
20160785 2 Drev Z 45 / Gear ring Z 45
20260022 2 Hållare för lock montering / Square for housing plug fixing
20280040 2 Låsning pinne / Locking pin
20280107 2 Axel för drev Z 48 / Shaft for gear ring Z 48
20290169 4 Distans för koniskt lager / Spacer for conical bearing
20290374 2 Distans för lager / Spacer for bearings
20290375 1 Distans för lager (6026) / Spacer for bearing (6026)
20300426 1 Fläns lock för pumputgång / Cover for pump output
20300430 1 Lock för oljetätning / Cover oils seal
20390020 2 Platta för pinne lås / Plate for locking pin
20390054 2 Låsplatta för pinne lås / Locking plate for locking pin
20400008 1 Nipple 1/2"-M.10x1 / Nipple 1/2"-M.10x1 for pressure switch
20440001 4 Kil låsning monteringspos. för PTO huvud/ Key for PTO head position
20470018 8 Skruv lås / Locking Screw
20500023 2 Distans M12x1,5-1/4"G för smörjoljeledning / Extension for lubrication pipe
21020027 1 Axel ingående / Input shaft
40010021 2 Lager SF 6213 / Bearing SF 6213
40010040 1 Lager SF 6026 / Bearing SF 6026
40010153 8 Lager koniskt rull 30308 / Bearing conical roller 30308
40010200 2 Lager SF 6313 / Bearing SF 6313
40030220 1 Tätning FKM 595 höger / Seal FKM 595 right
40030221 1 Tätning FKM 595 vänster / Seal FKM 595 left
40050023 4 O-ring 4131 / O-ring 4131
40050037 4 O-ring 167 / O-ring 167
40050045 1 O-ring 2100 / O-ring 2100
40050054 2 O-ring 3131 / O-ring 3131
40050072 2 O-ring 4350 / O-ring 4350
40050076 2 O-ring 4500 / O-ring 4500
40050077 1 O-ring 4775 / O-ring 4775
40050101 1 O-ring 4900 / O-ring 4900
40050105 2 O-ring 3181 / O-ring 3181
40050124 1 O-ring 3725 / O-ring 3725
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 Detalj lista OMKA 10100075
Parts list
Rev. 01 Tab.

Kod Nr/Code No ANTAL/QTY Beskrivning / Description

40050129 1 O-ring 3325 / O-ring 3325
40050144 2 O-ring 4550 / O-ring 4550
40050254 1 O-ring 4462 (Viton) / O-ring 4462 (Viton)
40050256 1 O-ring 150 / O-ring 150
40050257 1 O-ring 165 / O-ring 165
40060004 2 Låsring I 140 / Circlip I 140
40060006 1 Låsring I 45 / Circlip I 45
40060039 2 Låsring E 65 / Circlip E 65
40060064 1 Låsring I 200 / Circlip I 200
40060071 2 Låsring E 48 / Circlip E 48
40060084 4 Låsring JK 90 / Circlip JK 90
40060098 2 Låsring I 34 / Circlip I 34
40060154 1 Låsring I 16 / Circlip I 16
40160001 4 Plugg avtappnings TC3G 1/2" / Plug drain TC3G 1/2"
40160003 3 Plugg magnet TSCM3G 1/2" / Plug magnet TSCM3G 1/2"
40160012 1 Plugg avtappning TCE3G 1/2" / Plug drain TCE3G 1/2"
40160024 2 Plugg M12x1,5 / Plug M12x1,5
40160055 2 Plugg TCE2G 3/8" / Plug TCE2G 3/8"
40160125 1 Plugg nivå 38 B ½ ” GAS / Plug 38 B ½” GAS
40170051 2 Nippel M1/4"T.ACC.D. 8 E731-108L / Nipple M1/4"T.ACC.D. 8 E731-108L
40170061 2 Nippel vinklad M.1/4" / Nipple elbow M.1/4"
40170068 2 Anslutning vinkel (pump) 1/2" / Pipe fitting (pump) 1/2"
40170078 2 Anslutning 4 VIE M.3/8 / Pipe fitting 4 VIE M.3/8
40170086 4 Anslutning M.3/8"-1/4" / Pipe fitting M.3/8"-1/4"
40170090 1 Koppling "T" 1/2"2M.1F / Fitting "T" 1/2"2M.1F
40180011 1 Plugg avluftning TS/3G 1/2" / Plug air breathing TS/3G 1/2"
40190008 2 Stift P.P.UNI5923 M. 6x10 / Pin P.P.UNI5923 M. 6x10
40190010 2 Stift P.P.UNI5923 M.10x10 / Pin P.P.UNI5923 M.10x10
40200001 12 Mutter lås UNI7474 6S M 10 / Nut self-locking UNI7474 6S M 10
40200002 28 Mutter lås UNI7473 6S M 10 / Nut self-locking UNI7473 6S M 10
40200004 6 Mutter UNI5589 6S M 8 / Nut UNI5589 6S M 8
40200038 2 Mutter UNI5587 6S M 8 / Nut UNI5587 6S M 8
40210006 6 Skruv TE 8.8 5739 M 10x30 / Screw TE 8.8 5739 M 10x30
40210010 2 Skruv TE 8.8 5739 M 8x20 / Screw TE 8.8 5739 M 8x20
40210016 2 Skruv TE 8.8 5739 M 8x25 / Screw TE 8.8 5739 M 8x25
40210020 14 Skruv TE 8.8 5739 M 10x25 / Screw TE 8.8 5739 M 10x25
40210024 1 Skruv TE 8.8 5739 M 8x16 / Screw TE 8.8 5739 M 8x16
40210032 6 Skruv TCCE 8.8 5931 M 10x30 / Screw TCCE 8.8 5931 M 10x30
40210065 4 Skruv TCCE 8.8 5931 M 6x20 / Screw TCCE 8.8 5931 M 6x20
40210172 8 Skruv TCCE12.9 5931 M 12x30 / Screw TCCE12.9 5931 M 12x30
40210190 16 Skruv för svänghjul (Omsi) / Screw for flywheel (Omsi)
40210330 8 Skruv TE10.9 5739 M 12x40 / Screw TE10.9 5739 M 12x40
40210367 4 Skruv TCCE 8.8 5931 M 5x35 / Screw TCCE 8.8 5931 M 5x35
40210521 10 Skruv TE10.9 5739 M 12x25 / Screw TE10.9 5739 M 12x25
40220006 10 Bricka (koppar) D.12x18x1,5 / Washer (copper) D.12x18x1,5
40220018 4 Bricka konsik D. 6x12x1 / Washer conical D. 6x12x1
40220019 8 Bricka konisk D.12 13x24x3,2 / Washer conical D.12 13x24x3,2
40220020 16 Bricka konisk D.10 11x20x2,3 / Washer conical D.10 11x20x2,3
40220023 8 Bricka konisk D. 8x16x1,9 / Washer conical D. 8x16x1,9
40220066 11 Bricka (koppar) D.21x27x1,5 1/2" / Washer (copper) D.21x27x1,5 1/2"
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 Detalj lista OMKA 10100075
Parts list
Rev. 01 Tab.

Kod Nr/Code No ANTAL/QTY Beskrivning / Description

40220099 1 Bricka / Washer
40220108 10 Bricka elastisk D.13 UNI 3545 / Washer elastic
40260010 2 Shims 120 (119,5x105,5) 0,2 / Shims 120 (119,5x105,5) 0,2
40260023 2 Shims 120 (119,5x105,5) 0,3 / Shims 120 (119,5x105,5) 0,3
40260072 2 Shims 120 (119,5x105,5) 0,1 / Shims 120 (119,5x105,5) 0,1
40310024 1 Pump olje 10.4 DO-81 E1-LBB/BA-N / Pump oil 10.4 DO-81 E1-LBB/BA-N
40320003 1 Filter olje MPS.50 S M60 AGVS / Filter oil MPS.50 S M60 AGVS
40320007 1 Filter element olje CS.5 M69 / Filter cartridge oil CS.5 M69
40330014 1 Nippel M-F 1/2"-1/2" / Nipple M-F 1/2"-1/2"
40340091 2 Slang smörjolje pump / Lubrication pipe pump
40410003 24 Pinnbult PTO-huvud M.10x55 / Bolt stud PTO-head M.10x55
40410004 12 Pinnbult utg sida (koppling) M.10x72 / Bolt stud output side (coupling) M.10x72
40410005 16 Pinnbult PTO-huvud M.10x45 / Bolt stud PTO-head M.10x45
40440046 1 Bussning splines 16/32 dp Z 11 / Bushing splines 16/32 dp Z11
40440047 2 Bussning splines 12/24 dp Z 17 / Bushing splines 12/24 dp Z17
40460017 2 Ring / Ring disc
40500002 1 Ventil back “non-return” 1/2"GAS / Valve non-return 1/2"GAS
40500006 1 Tryckvakt 0,8 BAR M10x1 40.7073 / Switch pressure 0,8 BAR M10x1 40.7073

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 VÄXELHUS OMKA 10100075
Housing
Rev. 01 Tab. 01

POS. Kod / Code POS. Kod / Code POS. Kod / Code

1 20010311 18 40160003 35
2 40180011 19 36
3 40220066 20 37
4 40330014 21 38
5 40050072 22 39
6 20060010 23 40
7 20260022 24 41
8 40220023 25 42
9 40210010 26 43
10 40210016 27 44
11 40200038 28 45
12 40410004 29 46
13 40410005 30 47
14 40190008 31 48
15 20440001 32 49
16 40410003 33 50
17 40160001 34 51

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 Ingående axel med fast drivning OMKA 10100075
Input shaft with rigid driving plate
Rev. 01 Tab. 02.4

POS. Kod / Code POS. Kod / Code POS. Kod / Code

1 40210190 18 40410005 35
2 40050256 19 40200001 36
3 20040168 20 40030221 37
4 40050257 21 40060064 38
5 20120567 22 40050254 39
6 20120568 23 20290375 40
7 40460017 24 20090011 41
8 40210172 25 40220019 42
9 40220108 26 40210330 43
10 40210521 27 40050077 44
11 21020027 28 20120134 45
12 40200004 29 40010040 46
13 20300430 30 20160780 47
14 40030220 31 48
15 40050124 32 49
16 40050101 33 50
17 20040008 34 51
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 Axel drivning OMKA 10100075
Intermediate shaft
Rev. 01 Tab. 03.4

POS. Kod / Code POS. Kod / Code POS. Kod / Code

1 40210020 18 40410005 35
2 40220020 19 40200001 36
3 20040062 20 37
4 40050037 21 38
5 20280040 22 39
6 40050023 23 40
7 40190010 24 41
8 40010153 25 42
9 20290169 26 43
10 40060084 27 44
11 20160779 28 45
12 40050037 29 46
13 20040061 30 47
14 20390020 31 48
15 40220023 32 49
16 20470018 33 50
17 40220019 34 51
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 Hus PTO-huvud OMKA 10100075
Housing PTO-head
Rev. 01 Tab. 04.4

POS. Kod / Code POS. Kod / Code POS. Kod / Code

1 40160001 18 35
2 40220066 19 36
3 20010330 20 37
4 40160003 21 38
5 40160125 22 39
6 40160012 23 40
7 40200002 24 41
8 40220020 25 42
9 26 43
10 27 44
11 28 45
12 29 46
13 30 47
14 31 48
15 32 49
16 33 50
17 34 51

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 Axel drivning PTO-huvud OMKA 10100075
Intermediate shaft PTO-head
Rev. 01 Tab. 05.4

POS. Kod / Code POS. Kod / Code POS. Kod / Code

1 40050105 18 35
2 20280107 19 36
3 40010153 20 37
4 20290169 21 38
5 40060084 22 39
6 20160784 23 40
7 20290374 24 41
8 40050054 25 42
9 20390054 26 43
10 40220023 27 44
11 20470018 28 45
12 40210020 29 46
13 40220020 30 47
14 31 48
15 32 49
16 33 50
17 34 51

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 Axel drivning (utgång) PTO-huvud OMKA 10100075
Output driving shaft PTO-head
Rev. 01 Tab. 06.4

POS. Kod / Code POS. Kod / Code POS. Kod / Code

1 40050129 18 40440047 35
2 20030434 19 40060071 36
3 40210032 20 20150451 37
4 40440046 21 20160785 38
5 40060154 22 39
6 40060006 23 40
7 40260072 24 41
8 40060039 25 42
9 40260010 26 43
10 40260023 27 44
11 40010021 28 45
12 40010200 29 46
13 40060004 30 47
14 40050144 31 48
15 20120586 32 49
16 40050076 33 50
17 4060098 34 51

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 Axel drivning (utgång) för smörjoljepump OMKA 10100075
Output driving PTO-head with lubrication pump
Rev. 01 Tab. 07.4

POS. Kod / Code POS. Kod / Code POS. Kod / Code

1 40210006 18 20160785 36
2 40220020 19 37
3 20300426 20 38
4 40260072 22 39
5 40260010 23 40
6 40260023 24 41
7 40060039 25 42
8 40010021 26 43
9 40010200 27 44
10 40600004 28 45
11 40050144 29 46
12 20120586 30 47
13 40450076 31 48
14 40060098 32 49
15 40440047 33 50
16 40060071 34 51
17 20150451 35 52

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 Smörjoljesystem externt OMKA 10100075
Lubrication system external
Rev. 01 Tab. 08

POS. Kod / Code POS. Kod / Code POS. Kod / Code

1 40220006 18 40310024 35
2 40160024 19 40170068 36
3 40320007 20 40210065 37
4 40320003 21 40220018 38
5 40340091 22 40050045 39
6 40170061 23 20130019 40
7 40170051 24 40210024 41
8 20500023 25 40310024 42
9 40160055 26 43
10 40220099 27 44
11 40170086 28 45
12 40170078 29 46
13 40210367 30 47
14 40500002 31 48
15 40500006 32 49
16 20400008 33 50
17 40170090 34 51

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 21 KPTO
INSTALLATION
USE and
MAINTENANCE
MANUAL

Type : 21 KPTO

Specification number : 2490-E

Serial number :

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 21 KPTO - SPEC. 2490-E
SPECIAL FOR SANDVIK

TABLE Rev FILE DESCRIPTION

TF 6113 6 TF6113-gb.doc Features-use and maintenance
TF 6231 1 TF6231-gb .doc Procedures for conservation
TF 6093-A 2 TF6093-A.doc. Radial load (N / lb)
TF 6042 2 TF6042.doc Torsional vibration calculation data
TF 6114 1 TF6114.doc Arcusaflex technical data
TF 6115 TF6615.doc Recommended oil
TF 6014 2 TF6014.dwg Hydraulic scheme
TF 6007R TF6007 R.dwg Instruments
TE 3013 TE3013.dwg Spare parts junction boc
TE 6163 (1-3) 5 TE6163 1-3.doc Control panelElectric junction box
TE 6165 (1/3) TE6165 1/3.doc Logic diagram (control panel)
TE 6165 (2/3) TE6165 2/3.doc Electric interface (control panel)
TE 6165 (3/3) TE6165 3/3.doc Electric junction box
TF 5938-E 2 TF5938-ek.doc Filter
TF 6051 2 TF6051.doc Solenoid valve spares
TB 1066-C 2 TB1066-C.dwg KPT spares
TB 1070-B 3 TB1070-B.dwg KPT spares
TB 1071-A 4 TB1071-A.dwg KPT spares
TB 1072-B 8 TB1072-B.doc KPT spares description
TF 6119/1 4 TF6119/1-gb.dwg Trouble shooting
A 6560-E A6560-E.dwg KPT installation drawing
 WORKING AND MAINTENANCE TF 6113
INSTRUCTIONS FOR Rev. 6
KPTO/U FLUID COUPLING SERIES Sheet 1/3

FEATURES

1- KPT for internal conbustion engine (named KPTO or KPTU depending on radial output or in
line output) is a drain type fluid coupling. If drained out it works as a disconnected clutch.; if
progressively filled up it works as a soft starter.

2- KPT can be flanged to any internal combustion engine having a SAE housing and flywheel.

3 - KPT has a incorporated feed oil pump. This oil flow is used to fill up the fluid coupling, to
dissipate the heat generated during start up and steady running, to lubricate bearings.

4- KPT has some orifices, fitted on peripheral part, which continuously drain the oil supplied
by feed oil pump. Orifices have calculated diameter depending on application.
Because orifices are made in threaded plugs, they can be replaced to optimise
performances. Quick release valves, supplied as optional, drain oil in few seconds.

5- Through an electric valve (24V d.c. [standard] or: 12V d.c.; 110V a.c.; 220V a.c.) the pump
oil flow can be diverted to the oil tank. In such a way the fluid coupling is drained out (time
required depends by orifices diameter and input speed) while oil flow continues to assure
the tank cooling and bearings lubrication.

6- Oil is cleaned through a 25 micron filter with replaceable paper cartridge. Filter clogging
is indicated on pressure switchgauge dial (see TF6007-…) when is 1.7 bar over the rated
pressure (rated pressure is established during first start up as soon as oil temperature has
reached the working value). Pressure switch, already set during workshop test (becarefull to
check if setting was correct according to actual working condition like pipes length and oil
temperature) must be used as alarm signal for filter clogging.

7- Temperature switch (see TF6007-…), already set (see the test certificate), must be used as
alarm signal therefore should be connected to any device in respect of safety rules. Just as
suggestion, it could switch off electric valve or shut down the engine. When KPT is cooled
by engine jacket water, temperature switch setting could be max 95°C.

8- Cooler, either oil/water (see TF5999...) or oil/air (see relevant dwg.), is supplied according to
required working specifications and must be fitted in line between pump and filter (see
TF6014...; see relevant dwg.).

9- Overload and speed controller is a reading device of KPT output speed and also an alarm
device in case of unwished decreasing of speed (high slip). Connection of alarm switch
has the same target of temperature switch (see TF 5800-…).

TF6113-rev6-GB.doc 01-00
 WORKING AND MAINTENANCE TF 6113
INSTRUCTIONS FOR Rev. 6
KPTO/U FLUID COUPLING SERIES Sheet 2/3

INSTALLATION

- Check that flywheel be within SAE tolerances (see FIG.1 and also SAE J1033 rules).

- Mount elastic coupling driving ring on to the flywheel. Then mount KPT on to the flywheel
housing.

- First tight screws on flywheel housing then tight screws on support side flanges (both side
flanges must be fitted).

- Check (KPTO) that belts tension is within permissible value (see radial load table TF6093 in
this manual).

- Connect oil and water pipes (if any) in respect of pump pressure side diameter (suction and
pressure side diameters in case of separate pump).

- Supply correct water flow to the cooler (see final M-TECH technical quotation)

- Supply correct Voltage to electric motors, if any (check electric connections), electric valve and
devices (see test certificate).

START UP
IMPORTANT
- Check rotation direction of the pump. Once the pump is running, if no pressure is read on
filter pressure gauge, check again rotation (electric motor connections), pipes connection and
oil level (see maintenance for correct level).

- Check pressure be within correct value at steady running temperature (see test certificate).

a- Switch OFF electric valve.

b- Switch on the pump (whether electric motor pump is installed) and start engine.

c- Switch ON electric valve.

DISENGAGEMENT (STOP)

Switch OFF electric valve.

WITH ELECTRIC MOTOR PUMP

WHILE ENGINE IS “ON” AND LOAD STOPPED, FEED PUMP MUST BE ON AND VALVE
OFF. THIS TO ASSURE BEARINGS LUBRICATION.

TF6113-rev6-GB.doc 01-00
 WORKING AND MAINTENANCE TF 6113
INSTRUCTIONS FOR Rev. 6
KPTO/U FLUID COUPLING SERIES Sheet 3/3

MAINTENANCE & CHECKS

1- Change oil after first 100 working hours.Change oil every 4000 working hours unless evident
oil colour change. Correct oil level is the blue line on oil level indicators (first fill KPT, then run
the pump, electric valve OFF, to full fill heat exchanger, hence check level again, while engine
is stopped).
2- Change oil filter cartridge (25 micron) when pressure is 1.7 bar over rated value and/or
pressure switch is ON.
3- Change rotating seals (items 46 and 58 in TB1070-…) in case of considerable oil leakage.
Recommended spare parts are supplied from M-TECH or local distributor (see Sales
Network on back page of KPT catalogue).
4- Keep the cooler clean.Whether was a water cooler, see dedicated instruction pages in this
manual (TF6094). Whether was an air cooler, clean the radiator pack with air pressure or
wash carefully by hand. Do not use water pressure, it can damage the Aluminum pack.
5- Check periodically, possibly every 1000 hours, that pump chain be of correct length (hang 20
kg weight to stretch chain):

15 KPT Max length = 1265 mm

17-19 KPT Max length = 1362 mm
21-24 KPT Max lenght = 1556 mm
27 KPT Max length = 1914 mm

6- Check, periodically, elastic coupling condition.

7- Procedure in case of replacement of following parts (TB1070-… and TB1066-…):

elastic coupling hub (64) or input shaft (4) or washer (23).
It is necessary to shim the gap between washer and input shaft ; the gap must be within 0.05
mm and 0.15 mm. Be sure to seat hub tightly against bearing before measuring the shim gap
between the end of the input shaft and retainer washer clamping surface in the hub. Use
shims provided by M-TECH or equivalent (ask for table N2912).
Screws (24) must be refitted with Loctite and tightened at 50 Nm.

FIG.1

IMPORTANT

TF6113-rev6-GB.doc 01-00
 PROCEDURES FOR CONSERVATION
OF VARIABLE FILL FLUID COUPLING TF 6231
Rev. 1
KPT - KSL

FOLLOWING PROCEDURES ARE VALID FOR UNIT IN ITS ORIGINAL PACKAGING, STORED IN DRY,
CLEAN, DUST FREE INDOOR AMBIENT.

CHECK CONTROL

1 - INTERNAL PARTS

1.1 - SPRAY INSIDE HOUSING 0.25 Lt. OF OIL TECTYL 930 SAE 30.
3
1.2 - PUT INSIDE HOUSING SUITABLE AMOUNT OF DRYER PACKS (g/m ACCORDING TO PACKS
INSTRUCTIONS). ATTACH, EXTERNALLY, A WARNING SIGNAL LIKE “REMOVE BEFORE
OPERATION”.

1.3 - SEAL ALL OPENINGS AND PASSES BETWEEN HOUSING AND AMBIENT ( I.E. BREATHER,
INPUT/OUTPUT FOR COOLER).

2 - EXTERNAL PARTS

2.1 - WET WITH PROTECTIVE FLUID CRC 3.36 (OR EQUIVALENT) ALL STEEL PARTS NOT ALREADY
PAINTED OR PHOSPHATED.
IN CASE OF MARINE ENVIROMENT, USE PROTECTIVE FLUID CRC 6.66 MARINE (OR
EQUIVALENT) FOR 3 MONTHS PROTECTION, OR CRC PROTECTIVE MARINE FOR 6 MONTHS
PROTECTION.
AFTER THE 3 OR THE 6 MONTHS PERIOD, OPERATION MUST BE REPEATED FIRST
CLEANING CRC.
CRC IS CLEANABLE BY MEANS OF CRC MARIN ELMEC CLEAN DILUENT.

2.2 - ROTATING SEALS OR LABYRINTHS MUST BE PROTECTED WITH GREASE AGIP 33 FD OR

SHELL ALVANIA R3 OR EQUIVALENT.

2.3 - CHECK THAT CONNECTION WIRING BOX BE WELL SEALED.

2.4 - FOR MOTORS, PUMPS, INSTRUMENTS, PRESERVE THE ORIGINAL PACKAGING, IF ANY.

tf6231-gb.doc/4 02/02/05
 KPTO & KPTE TF 6093-A
PERMISSIBLE SIDE LOAD (N) Rev. 2
AND SUGGESTED PULLEY TRANSMISSION

- Calculated bearings life over 10.000 hours.

- Engine speed over the max listed below, needs approval by M-TECH.
- Pulley diameter is the minimum permissible. (Over 35 m/s, dynamic balancing is recommended).
- Belts nr. is maximum permissible.
- Timing belts must be approved by M-TECH.
- “X” distance is according to belts type & number.
- Side load includes 2.5 belt tensioning factor.

15
Up to Max “X” (mm) Max belts nr
kW/rpm Max load (N) Type - Min pulley ∅
200 / 2600 91 / 17.000 10 x 5V - 220 mm
17 - 19
Up to Max “X” (mm) Max belts nr
kW/rpm Max load (N) Type - Min pulley ∅
95 / 20.000 10 x 5V - 335 mm
250 / 1800 91 / 20.000 6 x 8V - 335 mm
95 / 20.000 7 x SPC - 335 mm
102 / 18.000 11 x 5V - 355 mm
300 / 2200 105 / 18.000 7 x 8V - 355 mm
107 / 18.000 8 x SPC - 355 mm

21
Up to Max “X” (mm) Max belts nr
kW/rpm Max load (N) Type - Min pulley ∅
150 / 31.000 10 x 8 V - 335 mm
400 / 1800
160 / 31.000 12 x SPC - 335 mm
165 / 29.000 11 x 8 V - 355 mm
470 / 2200
170 / 29.000 13 x SPC - 355 mm

24
Overlap Overlap
Up to
Max “X” (mm) Max belts nr
kW/rpm
Max load (N) Type - Min pulley ∅
88 / 40.000 12 x 8 V - 355 mm
545 / 1800
95 / 40.000 14 x SPC - 355 mm
117 / 35.000 14 x 8 V - 380 mm
620 / 2200
120 / 35.000 16 x SPC - 380 mm
Pulley must be installed overlapping bearing carrier by 89 mm.

27
Overlap Overlap
Up to
Max “X” (mm) Max belts nr
kW/rpm
Max load (N) Type - Min pulley ∅
800 / 1800 133 / 55.000 17 x 8V - 380 mm
Pulley must be installed overlapping bearing carrier by 115 mm.

ASK M-TECH FOR ANY APPLICATION DIFFERENT THAN ABOVE.

tf6093-a.doc 02-00
 RBD or AC ELASTIC COUPLING + KPT INPUT SIDE TF 6042
(for torsional vibration calculation) Rev.2

Dim.
TKN TKmax T
± KW
CT CTdyn ψ VR J1 JL rpm max
T (°C)
Size (10Hz) max
15/11S 860 2150 430 93 100 0.726 8.65 0.035 0.736 2600 120
15/11D 2060 6530 1030 461 691 0.726 8.65 0.082 0.782 2600 120
15/14S 1690 4220 845 206 309 0.726 8.65 0.180 0.836 2600 120

17/11D 2060 6530 1030 461 691 0.726 8.65 0.082 1.215 2600 120
17/14S 1690 4220 845 206 309 0.726 8.65 0.180 1.276 2600 120

19/11D 2060 6530 1030 461 691 0.726 8.65 0.082 1.773 2600 120
19/14S 1690 4220 845 206 309 0.726 8.65 0.180 1.833 2600 120
19/AC5-11 2500 7500 1250 13 1.25 5.03 0.065 1.832 2600 80
19/AC5-14 2500 7500 1250 13 1.25 5.03 0.179 1.830 2600 80

21/14D 3490 11040 1745 1010 1515 0.726 8.65 0.187 2.869 2200 120
21/AC6-14 4200 12600 2100 45 1.25 5.03 0.220 2.999 2600 80

24/14D 3490 11040 1745 1010 1515 0.726 8.65 0.187 5.332 2200 120
24/14D18 3490 11040 1745 1010 1515 0.726 8.65 0.870 5.332 2200 120
24/AC7-14 6300 18900 3100 100 1.25 5.03 0.312 5.742 2600 80
24/AC7-18 6300 18900 3100 100 1.25 5.03 0.519 5.742 2300 80

27/18D 5300 16720 2650 1885 2827 0.726 8.65 0.652 8.805 1800 120
27/AC8-18 7800 23400 3900 110 1.25 5.03 0.478 9.105 2300 80

TKN Nominal torque (Nm)

TKmax Max torque (Nm)

Continuous vibratory torque at 10 Hz
TKW (10Hz) For different fx frequencies TKW √(10/fx) is valid
CT Static stifness factor (Nm/rad)10³

CTdyn Dynamic stifness factor (Nm/rad)10³

ψ Relative damping

VR Resonance factor

J1 Elastic coupling driving part inertia

JL Elastic coupling driven part inertia + KPT input side

tf6042.doc date: 02-00

 ARCUSAFLEX TF 6114
TECHNICAL DATA Rev. 1

Max Torque Continuous Dynamic Max

ARCUSAFLEX Shore Nominal Torque Flange Size
Tk max Vibration Torque Stiffness Speed
Type / Size hardness TkN (Nm) * TkW 10 Hz (Nm) SAE J 620
(Nm) CTdyn. (Nm/rad) (rpm)
WN 200 500 100 1100
6.5
AC 2 NN 250 750 125 1700 4200
8
SN 330 1000 165 3300
WN 330 750 165 1100
6.5
AC 2,3 NN 360 900 180 1700 4200
8
SN 400 1000 200 2500
WN 500 1250 250 2100 8 4200
AC 2,6 NN 600 1800 300 3100 10 3600
SN 700 2100 350 4500 11.5 3500
WN 800 2000 400 3600
10 3600
AC 3 NN 900 2700 450 5000
11.5 3500
SN 1000 3000 500 7500
WN 1200 3000 600 8000
11.5 3500
AC 4 NN 1350 3600 650 10000
14 3000
SN 1550 4200 750 13500
WN 1800 4500 900 8500
AC 5 NN 2000 5400 1000 13000 14 3000
SN 2500 7500 1250 22000
WN 3100 7700 1500 16000
14 3000
AC 6 NN 3450 10000 1700 30000
18 2300
SN 4200 12600 2100 45000
WN 4600 10000 2300 35000
14 2600
AC 7 NN 5200 15600 2600 56000
18 2300
SN 6300 18900 3100 100000
WN 6200 14000 3100 38000
18 2300
AC 8 NN 7000 21000 3500 75000
21 2000
SN 7800 23400 3900 110000
WN 12400 28000 6200 76000
18 2300
AC 8 D NN 14000 42000 7000 150000
21 2000
SN 15600 46800 7800 220000
WN 8000 18000 4200 55000
18 2300
AC 9 NN 9000 27000 4800 100000
21 2000
SN 10000 30000 5500 190000
WN 16000 36000 8400 110000
AC 9 D NN 18000 54000 9600 200000 21 2000
SN 20000 60000 11000 380000

Shore hardness: WN = 50-55° Shore A

NN = 60-65° Shore A
SN = 70-75° Shore A

ƒ = 10 Hz, for other frequency ƒ x is valid TkW 10

* Continuous Vibration Torque ± TkW: at fx

Resonance factor VR and relative Damping Ψ

Shore hardness VR Ψ

WN 7.85 0.8
NN 5.46 1.15
SN 5.0 1.25

tf6114-rev.1.doc 02/2002
 RECOMMENDED OIL TF 6115
(ISO HM 32) REV. 0

AGIP OSO 32
ARAL VITAM GF 32
BP ENERGOL HLP 32
CASTROL HYSPIN AWS 32
CHEVRON RPM EP HYDRAULIC 32
ESSO NUTO H 32
MOBIL DTE 24
SHELL TELLUS 32
TEXACO RANDO HD 32
TOTAL AZOLLA ZS 32

tf6115.doc 17/03/97
 TF 5938...
OIL FILTER REV. 2

REFERNCE DIMENSION CARTRIDGE

TF 5938-O 1” ¼ 25 µm

X TF 5938-E ¾” 25 µm
TF 5938-K ¾” 10 µm

1
FILTER HEAD

2
BY-PASS

3
VITON SEAL

4
CARTRIDGE

TF5938-EK.doc / 14/09/01
M-TECH
 KPTO (U) TF 6119/1
TROUBLE SHOOTING REV. 4

UNIT FAILS TO OPERATE

1 - Check KPT output shaft turns freely with engine shutdown.

2 - Check solenoid valve (item 87 - TB1071-…) is operating.

3 - Check oil level. It must be at blue line on level indicator (item 37 - TB1070-…).

4 - Check oil pressure (item 109 - TB1071-…) (see test certificate).

5 - Remove cover plate (item 42 - TB1070-…) and check:

a) four orifice plugs (item 10 - TB1066-…) be tight
b) nuts (item 20 - TB1066-…) be tight.

6 - Check oil flow by inserting flow meter in feed line from pump to KPTO.

7 - Check (on KPTO with integral pump) condition of pump driving chain.

8 - Check temperature alarm switch (item 110 - TB1071-…) is set at correct level (see test
certificate).

UNIT OPERATES AT REDUCED OUTPUT SPEED

1 - Carry out checks from 1) to 7) as above.

2 - Check engine high idle speed with KPTO dis-engaged.

3 - Check driven machine condition.

OIL LOSS

1 - Check all pipe connections.

3 - Check seals (item 46 and 58 - TB1070-…).

3 - Check engine flywheel housing.

4 - Check engine coolant is not contaminated.

If vapor comes out from the breather, wait until oil temperature reaches more than 55-
60° C. If oil comes out from the breather, check orientation of oil keeper under cover
(item 42 - TB1070-B).

TOO MUCH OIL PRESSURE

1 - Check filter cartridge and replace if necessary (item 97 - TB1071-…).

2 - Check pressure gauge (item 109 - TB1071-…) be not defective.

3 - Check not obstruction inside oil tubes.

tf6119-1-gb.doc/4 05/03/01
 ELECTRIC VALVE TF5937-E TF 6051
DFE20/3A18ES.W201 - 24VDC - BSP
REV. 2

1
5
4
7
8

9
2

POS. CODE Q. DESCRIPTION

1 3CO2261320 1 Housing DFE/20/3-BSP

2 4SPI512040 3 Pin UNI6874 12x40
3 3CAS120341 1 Spool DFE20/3A
4 4GUA123526 2 O Ring 23.47x2.62
5 3MOL117310 1 Spring DF20 V.18ES
6 3TAP332200 1 Plug DFE20
7 4GUA130018 1 O Ring 29.87x1.78
8 4SOL519024 1 Solenoid 24VDC D19-46.79
9 4SOL519000 1 Pusher D19x4O

tf6051.doc/4 02/02/05
ONLY FOR 15 KPTO

ONLY FOR 27 KPTO

 M-TECH TRANSMISSIONS AB

ONLY FOR 15 KPTO

 KPTO - KPTU TB 1072-B
parts list
Rev. 8
(TB1066-C & TB1070-B & TB1071-A)

1 inner impeller 53 screw 105 drain tube

2 outer impeller 54 lock washer 106 plug
3 cover 55 SAE flange 107 copper packing
4 outer impeller shaft 56 roll bearing 108 panel
5 roll bearing 56a --- 109 pressure switch gauge
6 snap ring 57 bearing carrier 110 temperature switch gauge
7 screw 58 seal 111 pressure gauge pipe
8 lock washer 59 O-ring 112 ---
9 ring 60 screw 113 ---
10 orifice plug 61 lock washer 114 lubrication pipe
11 splined hub 62 screw 115 spacer
12 snap ring 63 lock washer 116 short end studs
13 coupling bearing carrier 64 splined hub 117 ---
14 ball bearing 65 flange (RBD) 118 suction flange
15 snap ring 66 rubber block (RBD) 119 straight union fitting
16 snap ring 67 driving ring (RBD) 120 suction pipe
17 screw 68 screw (RBD) 121 straight end fitting
18 ring 69 nut (RBD) 122 lock washer
19 short end stud / screw (for 27kpto) 70 lock washer (RBD) 123 chain drive
20 nut 71 key 124 cover
21 lock washer 72 feed pump 125 screw
22 O-ring 73 screw 126 lock washer
23 lock washer 74 lock washer 127 shim(s)
24 screw 75 hub 128 O-ring
25 --- 76 key 129 tab washer
26 --- 77 lock washer 130 tab washer
27 --- 78 screw 131 seal (not for 17/19)
28 --- 79 gear 132 flange
29 --- 80 screw 133 screw
30 --- 81 --- 134 lock washer
31 housing 82 --- 135 screw
32 baffle 83 --- 136 gasket
33 screw 84 --- 137 gasket
34 lock washer 85 straight end fitting 138 elastic coupling (AC)
35 screw 86 breather 139 driving ring (AC)
36 lock washer 87 solenoid valve 140 screw (AC)
37 oil level indicator 88 nut 142 lock washer (AC)
38 --- 89 lock washer 143 washer
39 --- 90 adapter 148 reducing fitting
40 magnetic plug 91 adapter 149 adapter
41 O-ring 92 reducing fitting 151 snap ring
42 cover 93 copper packing 152 nut (AC)
43 screw 94 “T” adapter 153 snap ring
44 lock washer 95 lubrication pipe 154 QD-bushing
45 bearing carrier 96 straight end fitting 155 hub for QD-bushing
46 seal 97 oil filter 156 screw
47 double roll bearing (KPTO) 98 adapter 157 key
47a ball bearing (KPTU) 99 copper packing 232 reducing fitting
48 snap ring 100 adapter 263 shim(s)
49 inner impeller shaft 101 copper packing
50 shim 102 feed tube
51 snap ring 103 adapter
52 O-ring 104 copper packing

tb1072b-gb.doc
SPARE PARTS AND MAINTENANCE
GUIDE

PART NUMBER : T0650C02

www.trackone.it

TRACK ONE SRL Phone : +39 059 468312

Via R. Carriera , N° 11 Mobile : +39 328 4818100 ISSUED : 13/02/06
41100 S.Damaso MO Fax : +39 059 467954
ITALY
 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

Cod. T0650C02 08/10/07 Rev.0 2 of 44

 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

Cod. T0650C02 08/10/07 Rev.0 3 of 44

 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

1. Safety and ranger instructions

To be observed

Warning signs
Warning:

Safety regulations and measures that protect the drive and other persons against injury and
ranger to life and limb

Caution :

Particular instructions to prevent damage to the vehicle. Failure to observe these instructions
can lead to warranty becoming void.

NB:

Particular instructions for better handling during operations , control and setting procedures
as well as maintenance work .

1.1. Foreword
These operating instructions are a part of the scope of delivery. They are to be kept close at
hand and are to remain with the machine if being sold again.

All details , data and illustration container in these operatine instructions are subject to
change as result of technical developments.

These operating instructions are not subject to any update service.

Information on la test developments can be obtained from :

TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY
Phone +39 059 468312
The illustrations in this manual are only diagrammatic and may differ from the actually
installed components of the respective undercarriage. In addition, it is possible that there
may also be other components on the undercarriage that are not described in this manual.
Conversely, there may also be components described in this manual that are missing on the
undercarriage.
All components and their functions are subject to technical change.
Cod. T0650C02 08/10/07 Rev.0 4 of 44
 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

1.2. In general

This undercarriage has been constructed to "state of the art" standards and is operationally
safe.
Nevertheless, machines can be the source of danger if they continue to be operated although
a fault is suspected or has already occurred or it has been repaired incorrectly.

Under these circumstances there is

• Danger to life and limb

• Danger to the machine and other facilities and equipment etc.

The machine must be shut down immediately if a fault is suspected or has already occurred
which could endanger the safety of the operator, other persons on site or surrounding
facilities and equipment etc.

All components have been carefully matched to each other. Fault-free operation and a long
service life are only possible if original spare parts are used.
.

1.3. Regulations for work safety

1.3.1 Personnel
Only properly trained and authorized personnel with appropriate specialist knowledge are to
be appointed with maintenance and repair work.

Appropriate measures must be taken before commencing any work on the undercarriage to
ensure that the equipment cannot start up unintentionally or be started up inadvertently by
others (e.g. blocks). All switching on and off procedures must be observed for this.

Protective equipment and clothing is mandatory for all work. Wear protective helmets, shoes
and gloves. Close fitting clothes help to avoid injuries.

If assistants are required to help in carrying out work, responsibilities must be clarified
beforehand so that there is no possibility of unclear competence occurring with regard to
safety aspects.

Cod. T0650C02 08/10/07 Rev.0 5 of 44

 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

1.3.2 Tools and equipment

Tools, lifting gear, fastening devices, jacks and other working equipment must be in a safe
operational and working condition.

All lifting and fastening devices on the crawler undercarriage are only designed for the
transportation of the undercarriage unless otherwise specified.

Metal splinters may break off and cause injuries when driving equipment bolts in or out. For
this reason, always wear safety goggles when driving bolts in or out.

Equipment or components which are being fitted or removed or where their installation
position is being changed must be secured against unintentional movement, slipping or
falling over using suitable lifting gear of suspension/support devices.

Systems and units (i.e. tensioning units) must be depressurized in an appropriate manner
before opening.

Damaged hydraulic or mechanical pre-tensioned spring elements must be exchanged as a

complete unit. Further information in this respect can be found in the respective component
descriptions and/or fitting and removal instructions.

2. Warranty
Applicable conditions of warranty are stipulated in the confirmation of order.

Warranty rights become void in the event of

• Damage as a result of malfunctions caused by incorrect use or incorrect operation.

• Repairs or alterations carried out by persons who are neither trained nor authorized to
do so.
• Damage being caused by accessories or spare parts being used for which no
approval has been provided by TRACK ONE SRL.

Safety instructions

3. Operating and Service Instructions

3.1. General Maintenance Instructions

3.1.1 Handling hydraulic substances and lubricants

The relevant applicable safety regulations for the respective products must be observed
when handling oil, grease or other chemical substances.
Cod. T0650C02 08/10/07 Rev.0 6 of 44
 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

Suitable safety measures must be taken to avoid scalding and burning when the machine
has warmed up (i.e. at operating temperature), as operating media are then at least the same
temperature.
Do not smoke if handling combustible fluids.
Caution with fire and naked flames. Not only fuel but also other operating media often have a
low flash point and ignite easily.
Lubricants that are not being reused must be disposed of in an environmentally friendly way.

3.1.2 Conversions or changes to the undercarriage

Unauthorized conversions or changes are not permitted for safety reasons. The rated
pressure of connected pressure relief valves and pressure tanks must not be altered.

Seals on units must not be removed.

3.1.3 Before starting up

Before starting up:
• Lubricate all lubrication points
• Check all oil levels and adjust if necessary
• Check function of all repaired components
• Carry out visual inspection of all components

3.1.4 Wear limits of undercarriage parts

Wear of the undercarriage is caused by movements, loads contact between parts of the
undercarriage and abrasive action of the ground.

This wear is increased by other factors including:

• Track resting on hard uneven rock bed during operation

• One-sided undercarriage load during turning
• Driving long distances in reverse
• Driving over obstructions recklessly
• A track which is not tensioned according to operating conditions
• A large degree of dirt on complete undercarriage

Undercarriage components must be replaced by new parts if they are worn to 100 %.
Otherwise, sudden machine failure is possible.

Careful and regular measurements are necessary in order to establish the extent of wear and
when replacements will be necessary.
Cod. T0650C02 08/10/07 Rev.0 7 of 44
 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

The parts involved and measuring parts must be cleaned thoroughly when carrying out
measurements. If possible, carry out measurements at several points. The degree of wear is
determined by the maximum value, not the average value.

3.1.5 Inspection intervals

COMPONENTS INTERVAL INPECTION EXTENT OF MAINTENANCE WORK

TRACK DAILY VISUAL EXTENT OF UNDERCARRIAGE DIRTINESS
UNDERCARRIAGE GENERAL CONDITION OF THE
UNDERCARRIAGE COMPONENTS
FASTENING ELEMENTS OF FRAME SECTIONS
AND UNDERCARRIAGE FASTENINGS
MONTHLY VISUAL FASTENING ELEMENTS OF FRAME SECTIONS
AND UNDERCARRIAGE FASTENINGS –
GROUSER SHOE FASTENING (SPOT-
CHECKS)
DRIVE –GEARBOX DAILY VISUAL SEAL OF GEAR-MOTOR UNIT AND POSSIBLE
HYDRAULIC CONNECTIONS
200 – 250 CHECK GEARBOX OIL LEVEL
WORKING
HOURS
300 – 2000 GEARBOX OIL CHANGE
WORKING
HOURS –
ONE YEAR
MAX
MONTHLY CHECK CONDITION AND WEAR ON SPROCKET
FRONT IDLER UNIT DAILY VISUAL GENERAL STATE OF SPRING AND TENSION
SYSTEM
WEEKLY SEAL OF THE FRONT IDLER AND
TENSIONING SYSTEM
RE-TENSIONING SPAN OF THE TRACK (MAX
POSSIBLE TENSIONING SPAN REACHED)
CHECK CONDITION OF AND WEAR ON FRONT IDLER
AMD SLIDING BRACKET
TRACK ROLLERS DAILY VISUAL CHECK FOR LEAKAGE
MONTHLY CHECK CONDITION OF AND WEAR ON TRACK
ROLLER
CARRIER ROLLER DAILY VISUAL CHECK FOR LEAKAGEi
OR WEARING MONTHLY CHECK CONDITION OF AND WEAR ON CARRIER
RAILS ROLLER
TRACK GROUP DAILY VISUAL CHECK FOR LEAKAGE (ONLY ON
LUBRICATED TRACK GROUP)
TRACK PRE-TENSIONING –TRACK SAG
MONTHLY CHECK CONDITION OF AND WEAR ON TRACK LINK
RUNNING SURFACES , BUSHINGS (OTHER
DIAMETER) ,AND STRETCHING OF
TRACK.CONDITION OF AND WEAR ON THE
GROUSER SHOES

Changes to intervals are possible depending on extent of use and operating conditions for
the machine.

Cod. T0650C02 08/10/07 Rev.0 8 of 44

 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

3.1.6 Tightening torque tables

These tables do not apply for fastening the shoes of the track.

FOR STANDARD BOLTS FOR EXPANSION BOLTS

Nm Nm
6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
M4 2,4 2,9 4,1 4,9 M4 1,3 1,6 2,2 2,7
M5 5,0 6,0 8,5 10,0 M5 2,8 3,3 4,6 5,5
M6 8,5 10,0 14,0 17,0 M6 4,7 5,5 8,0 9,5
M8 21,0 25,0 35,0 41,0 M8 12,0 14,0 20,0 24,0
M 10 41,0 49,0 69,0 83,0 M 10 25,0 29,0 41,0 50,0
M 12 72,0 86,0 120,0 145,0 M 12 44,0 52,0 74,0 88,0
M 14 115,0 135,0 190,0 230,0 M 14 71,0 84,0 120,0 140,0
M 16 180,0 210,0 295,0 355,0 M 16 115,0 135,0 190,0 225,0
M 18 245,0 290,0 405,0 485,0 M 18 155,0 180,0 255,0 305,0
M 20 345,0 410,0 580,0 690,0 M 20 225,0 265,0 375,0 450,0
M 22 465,0 550,0 780,0 930,0 M 22 310,0 365,0 520,0 620,0
M 24 600,0 710,0 1.000,0 1.200,0 M 24 390,0 460,0 650,0 780,0
M 27 890,0 1.050,0 1.500,0 1.800,0 M 27 600,0 700,0 990,0 1.200,0
M 30 1.200,0 1.450,0 2.000,0 2.400,0 M 30 800,0 950,0 1.350,0 1.600,0
M 36 2.480,0

FOR STANDARD BOLTS FINE THREAD FOR EXPANSION BOLTS WITH FINE THREAD

Nm Nm
6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
M 8x1 23,0 27,0 38,0 45,0 M 8x1 14,0 17,0 23,0 28,0
M10x1,25 44,0 52,0 73,0 88,0 M10x1,25 27,0 33,0 46,0 55,0
M12x1,25 80,0 95,0 135,0 160,0 M12x1,25 52,0 61,0 86,0 105,0
M 12x1,5 76,0 90,0 125,0 150,0 M 12x1,5 48,0 57,0 80,0 96,0
M 14x1,5 125,0 150,0 210,0 250,0 M 14x1,5 81,0 96,0 135,0 160,0
M 16x1,5 190,0 225,0 315,0 380,0 M 16x1,5 125,0 150,0 210,0 255,0
M 18x1,5 275,0 325,0 460,0 550,0 M 18x1,5 190,0 225,0 315,0 380,0
M 20x1,5 385,0 460,0 640,0 770,0 M 20x1,5 265,0 315,0 445,0 530,0
M 22x1,5 520,0 610,0 860,0 1.050,0 M 22x1,5 365,0 430,0 610,0 730,0
M 24x2 650,0 780,0 1.100,0 1.300,0 M 24x2 450,0 530,0 750,0 900,0
M 27x2 970,0 1.150,0 1.600,0 1.950,0 M 27x2 670,0 790,0 1.100,0 1.350,0
M 30x2 1.350,0 1.600,0 2.250,0 2.700,0 M 30x2 950,0 1.150,0 1.600,0 1.900,0

FOR STANDARD BOLTS FINE THREAD FOR UNFBOLTS WITH FINE THREAD

Nm Nm
M10x1 85,0 - 95,0 9/16"-20 110,0 - 120,0
M12x1 145,0 - 160,0 1/2"-20 165,0 - 185,0
M14x1,5 220,0 - 250,0 9/16"-18 240,0 - 270,0
M16x1,5 340,0 - 380,0 5/8"-18 330,0 - 370,0
M30x2 2.360,0 - 2.400,0 3/4"-14 575,0 - 650,0
7/8"-14 915,0 - 1.030,0
1“-14 1385,0 - 1560,0

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3.1.7 Serial number

All undercarriages or side frames have a serial number for identification.

The drawing part number and serial number are on TRACK ONE label located as shown on
figure 1 (except customer specific different request)

This serial number is always required when calling with inquiries or complaints.

Fig. 1

TRACK ONE LABEL

3.2. General assembly and disassembly instructions

3.2.1 Assembly instructions

The crawler undercarriages are supplied by TRACK ONE as a complete unit.
All necessary assembly work on components to be exchanged is described in the respective
individual chapters.

3.2.2 Disassembly instructions

Disassembling individual assemblies or components upon having reached their wear limits or
in the case of any failure occurrences is described separately for each component in the
individual chapters.
We recommend not carrying out any repair work on the building site, but exchanging the
component instead.
We recommend getting in contact with the TRACK ONE in the event of any major damage or
repeated failure of individual components.

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4. DRIVE
4.1. Technical features

Builder:TRASMITAL
Model: 713 C3B
Transmission ratio: 142
Motor capacity: 107 cc
Motor velocity: 1542 (1/min)
Output torque: 7351 daNm
Driving force: 17095 daN.

4.2. Drive – Function and operatine

4.2.1 General ranger instructions

Danger can occur in particular under the following circumstances:

• Product is handled insufficiently trained personnel

• Incorrect installation, operation and maintenance/repair
• The product is not being used for its designated purpose

Alterations to the product are not permitted unless approved beforehand.

The transmission is designed exclusively for use as drive transmission for an undercarriage.

4.2.2 Design of the drive

The design of the track undercarriage consists of a complete unit.
This unit consists of a fully encapsulated, multi-stage high-performance planetary gear and
the sprocket. The gear (2) is driven direct by hydraulic (1) or electric flange-mounted motors,

The sprocket (3) is available in standard, HD or special design with dirt pockets for packing
ground conditions.
Components adjoining the track are surface hardened to minimise wear. The connection to
the driving wheel and transmission is established with HF bolts (4). The necessary torque
levels for these are shown in the attached tables.

The drive traction is transmitted to the track via the motor, transmission and sprocket.

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1 - hydraulic motor
1
2 - gear
3 - sprocket
4 - bolt 4

2
3

4.2.3 Description of the transmission

The transmissions of the type series being used for the undercarriage have multi-stage
planetary gear depending on design.

A particular feature of the gear is its very compact and therefore space-saving design.

The gear can be fitted with an integrated multi-disc brake, which acts as parking brake. This
is activated by spring force and released hydraulically with pressure oil. The multi-disc brake
must be released without fail before switching on the drive hydraulic.

As a special design, the transmission can be supplied with a mechanical disengaging

mechanism enabling the transmission and hydraulic motor to be separated from each other,
e.g. if towing the machine following failure of the machine's hydraulic system.

4.2.4 Commissioning

• Prevent the transmission from getting dirty

• Avoid pollution. Make sure not to spill any lubricant when filling

The transmission is supplied ready for installation without oil filling. Starting up or using the
drive without any lubricant would lead to destruction of the transmission in next to no time.
See the chapter "Filling with transmission oil" for filling, topping-up or checking oil.

The transmission has been treated internally with a preservative agent that provides around
6 months protection against corrosion if stored under dry conditions. This internal
preservation does not have to be removed when starting up.
When fitting the hydraulic lines for parking brakes and hydraulic motor, make sure that no dirt
or other foreign bodies get into the transmission or hydraulic motor.
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4.3. Lubricants

4.3.1 Normal operating conditions (+ 10° to + 30° C)

We recommend only using lubricants that fulfil necessary viscosity requirements for
lubricating the transmission.

The viscosity rating on the rating plate on the transmission and the following requirements
must be observed!

Only the necessary viscosity ISO-VG 150 and ISO-VG 220 for normal operating conditions
from 10° to 30° C is stated on the rating plate.

4.3.2 Severe operating conditions (- 30° to + 50° C)

Under severe operating conditions, e.g. in an ambient temperature range between - 30° and
+50° C, we recommend using transmission oil with appropriate viscosity or a fully synthetic
lubricant.

For lower operating temperatures, use oil with a lower viscosity (SAE 80W - 90) and for
higher temperatures, us oil with higher viscosity (SAE 85W - 140).

4.4. Compact transmission with drive motor

Connecting the locating flange of the side frame as well as the sprocket is achieved using
adequately dimensioned bolt connections. Transmission of torque is achieved by frictional
locking.

Remove the protective caps when connecting the hydraulic hoses. Attention must be paid
that no dirt gets into the supply lines during the assembly process.

All prescribed parameters such as:

• Hydraulic pressure limits,

• maximum and minimum volume flow rates,
• allowance for oil leakage,
• brake air pressure monitoring,

must be observed when using the undercarriage hydraulic system. Please contact the
manufacturer where necessary for permitted values.

4.5. Parking brake

The multi-disc brake incorporated into the transmission is a parking brake that is kept
constantly closed by pressure springs. The maintenance-free brake is designed as a
separate compact unit and should only be removed from the transmission and exchanged as
a complete unit. This design protects all individual components such as discs, springs,
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sealing elements etc. against outside influences. Any repair work should only be carried out
by a specialist workshop.

Feeding hydraulic oil either direct or via the drive brake valve and a connecting line to the
brake connection of the compact unit opens the brake.

Pressure ranges within which the brakes can be vented must be observed. Only completely
vented brakes allow wear-free and fault free operation of the complete drive.

Use of a separate hydraulic circuit for supplying the brakes is recommended if operating
without parking brake valve.

4.5.1 Unlocking the parking brake

Undercarriages with drive units that are fitted with parking brakes cannot be moved when the
hydraulic system is not functioning. For this reason, it is possible to fit the undercarriage with
an unlocking mechanism.
With this mechanism, it is possible to tow the undercarriage even with the diesel or electric
motors switched off.

The unlocking device is located on the outside of the transmission and is held in its normal
position by bolts (1).

To unlock the parking brake, remove the bolts and screw in the claw clutch.

Attention must be paid that the unlocking device is returned to its original state when
returning to normal operation.

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4.6. Drive – Fitting and removal

Whenever working on the drive, always use suitable means to secure the device against
starting up by itself or being started by others.

An undercarriage that is not connected with the track by the sprocket is not secured against
movement by the transmission brake. This means that the undercarriage must be secured
separately when removing the drive.

Opening the track first is a precondition for fitting/removing the drive (see "Track" chapter).

• Notes on transmission oil must be observed

• All parts being fitted must be clean and free of grease

4.6.1 Connecting frame-transmission sprocket

2 3

The transmission [1] must be inserted carefully into the side frame so that there is no
damage to the flange surfaces. Check transmission seating for correct installation. Fasten
the transmission in place by inserting bolts [2] and washers [3] in the frame. Screw into place
by hand. Check again to ensure that transmission seating is correct.

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Pre-tighten all bolts by hand crosswise. See illustration below (example).

Tighten to torque level crosswise again according to size of bolt (torque level table).

4.6.2 Further instructions:

• Clean all locating/joining surfaces thoroughly.

• Lift the transmission carefully into the locating flange of the undercarriage using
appropriate hoisting gear.
• Fasten the transmission securely onto the undercarriage frame, before removing the
hoisting attachments.
• Make sure to avoid any axial forces when installing.
• Make sure to avoid any excessive force on the transmission housing.
• The transmission must not be tilted.
• Pay attention that no dirt or foreign particles get into the hydraulic system.
• The multi-disc parking brake is a transmission safety device. Make sure that no dirt or
foreign bodies get into the brake air connection.
• Make sure that the brake air connection is carefully sealed

4.6.3 Connecting sprocket - transmission

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Clean all locating/joining surfaces thoroughly. Hoist the sprocket with hoisting gear onto the
transmission and tighten onto the hub of the transmission without any heavy knocks.

Insert the bolts (1) and washers(2) for fastening the sprocket (3) into the holes and screw
into the thread in the transmission (4) by hand. Pre-tighten all bolts in the correct order and
then to correct tension using a torque wrench (see torque level table).

4.6.4 Removing sprocket

Slacken off track and undo track lock (see "Track" chapter).

Remove dirt from all parts and fastening elements. Use hoisting gear to secure the sprocket
against falling over. Undo the bolts on the driving wheel crosswise and remove completely.

Remove the driving wheel from transmission seat by tapping lightly with rubber hammer. If
provided, insert pull-off bolts into provided threaded holes and tighten evenly. Push the
sprocket off the transmission seat in this way and lift out using the hoisting gear.

4.6.5 Removing transmission

Remove dirt from all parts and fastening elements. Use hoisting gear to secure the
transmission against falling over. Undo the bolts on the frame crosswise and remove
completely.

Loosen the transmission from the frame seat by tapping lightly with rubber hammer, then lift
the transmission out of the frame carefully using the hoisting gear.

• Catch any dripping/leaking oil in suitable containers

• Only use approved transporting elements for transportation

4.7. Drive – Maintenance and inspection

4.7.1 General instructions

The complete drive unit consists of the following components:
• Motor
• Sprocket
• Transmission
• Integrated brake (only on request)
• Disengaging mechanism (only on request)

Always replace the complete component if it fails. Only use specialist workshops for repairs.

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4.7.2 Filling , topping-up and changing transmission oil

The transmission must be filled with fresh clean oil before starting up for the first time (see
details of lubricants for types of oil).

See the "Inspection intervals" table for intervals for oil checks or change.

Drive the machine onto a horizontal surface in a position where appropriate access to the
drive transmission is possible (see illustration).

4.7.3 Filling/Topping up with transmission oil:

Position the transmission so that the oil drain plug (2) is positioned vertically at its lowest
point (about 6 o'clock). The oil filler plug (1) should then be on the left or right outside of the
transmission middle (about 10 or 2 o'clock).

Fill up with oil until the level has reached the height of the filling hole. Insert filler plug with
new washer and tighten.

4.7.4 Draining off transmission oil:

Danger of scalds and burns from hot transmission oil. The transmission housing may also be
hot after running for longer periods. Always wear protective gloves and allow the
transmission to cool down first. Collect draining oil in appropriate containers and dispose of in
an environmentally safe manner.
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Place oil collection container underneath the transmission. Undo and remove oil filler plug (1)
and oil drain plug (2). Drain oil completely. Insert drain plug with new washer and tighten.

4.8. Motor
The motor is maintenance free and only has to be checked visually for leaks during
inspection.

4.8.1 Multi-disc parking brake

The multi-disc parking brake is integrated into the transmission on the motor side and is
lubricated by the transmission oil. Because of this design, the brake is maintenance free and
consequently only has to be checked for damage when carrying out a general overhaul of the
complete transmission.

The brake circuit must be vented (bled) after working on the brake or the hydraulic
connections.

4.8.2 Disengaging mechanism

The disengaging clutch is located on the rotor gear side (opposite the motor) and is not
subject to any special maintenance regulations.

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5. Front idler unit

5.1. Front idler unit – Function and description

Front idler units consist of the groups:

• 1) Front idler with brackets or sliding blocks

• 2) Yoke
• 3) Spring unit (pre-tensioned)
• 4) Grease tensioner

4
3
2
1

The front idler with sliding blocks (1) has a lifetime oil lubrication filling. The running surfaces
have been hardened to reduce wear. The yoke (2) acts as a transmission element between
the front idler and the following components. The spring unit (3) acts as protection for the
complete undercarriage against overloads from outer influences (e.g. dirt) and is therefore an
important component of the undercarriage.

SPRING UNIT IS PRE-TENSIONED THEREFORE IT IS DANGEROUS. BREAKS OR

TAMPERING MIGHT BE DANGEROUS FOR OPERATORS!

IMPORTANT! ANY KIND OF OPERATION ON THE PRE-TENSIONED SPRING UNIT

MUST BE DONE ONLY BY SKILLED OPERATORS AND INTO SPECIALIZED
WORKSHOPS WHERE SAFETY CAN BE ASSURED.
The track tensioner (4) is used for correct setting of track tension. The grease cylinder maybe
filled with/operated by grease or hydraulic oil.
The following applies for all spring units :
All spring units can either be bolted , inserted or fastened into the front idler yoke

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Type of idler units 3 4

2
Type 1 Standard 1
1) = Front idler with brackets
2) = Yoke
3) = Pre-tensioned spring unit
4) = Grease tensioner

1
Type 2 Integrated tensioning units
1) = Front idler
2) = Compact tensioning grease
tensioner inside of spring units

5.1.1 Front idler complete with sliding blocks and yoke

The front idler unit fulfills the following functions:

• Deflection with simultaneous guidance of the track.

• Positional adjustment via sliding blocks for setting track pre-tension and for guidance
during spring actions

3
1

2
1) = Front idler
2) = Sliding block
3) = Yoke
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The front idler (1) runs in the steel mount (2) with its sliding blocks and can move in a
longitudinal direction.

The friction surfaces of the front idler guidance in the frame are greased to minimise wear
(carried factory side during initial assembly).

Other components may be fastened on the front idler depending on the type of front
idler.

5.2. Spring unit

The function of the spring is to secure the complete undercarriage against overloads. An
overload can be caused by external influences (e.g. dirt accumulation) resulting in an
increase in track tension. Under these circumstances, the spring element action provides
relief for all components.
The spring can only operate perfectly as long as there is no significant dirt accumulation on
the spring.

5.2.1 Types of spring units

Various types of design can be used as spring element depending on the intended
application and load occurrence.
In a compressed state the spring element requires an opening in its counterpart (e.g. in the
cross-bar or panelling).

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5.3. Track Tensioner

The track is provided with the necessary pre-tension by the tensioning cylinder. In the event
of wear occurring to the undercarriage components or if there are changes in terrain
conditions, it will be necessary to adjust the tension of the track up or down (see chapter
Setting Track Pre-tension, Crawler Track).

The tensioning cylinder (1) is supplied in standard design as a grease-tensioning cylinder. To

tension or slacken off the track, grease is either applied through a special grease nipple (2)
on the tensioning cylinder or the grease filling can be drained off by unscrewing the grease
nipple halfway (illus. above).

Access to the grease tensioner is through hand holes (1) that are located at the sides in the
steel frame (1) (illus. below).

2
3

The hand holes may be closed by covering plates 2)with bolt (3).

Attention must be paid to the state of wear of the track in order to avoid damage to the track
tensioner.
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Re-tensioning is not permitted after reaching the wear limits for the track as this would cause
excess strain on the undercarriage components beyond the permitted limits and there would
no longer be any safety against forced breakage.

5.4. Fitting and removal

5.4.1 Fitting front idler unit – in general

Fitting and removing the front idler unit complete varies according to the design of the unit.
The various designs are described in the following chapters.

Under all circumstances, appropriate steps must be taken whenever working on the front
idler unit to ensure that the device cannot start up of its own accord or through intervention
by others. An undercarriage, which is not connected with the track by the sprocket, is not
prevented from moving by the gear brake. This means that the undercarriage must be
secured separately.
Furthermore, attention must be drawn to the dangers that can occur when working on or with
spring elements.
If a tension rod is damaged or broken, there is danger that a coil spring will not remain
in its pre-tensioned position but will force the front idler out of the frame through
sudden de-tensioning when the track is removed (see fig. 1., chap. Types of Spring
Elements Æ Coil spring).
This possible danger is detectable by the track remaining tensioned even after releasing the
pre-tension pressure out of the grease tensioner.
The spring elements that operate on a nitrogen or elastomer basis are high-pressure
containers that under no circumstances should be subjected to additional stress through
incorrect handling or external heat application.

If handling the track tensioners, make sure that any emerging oil or grease is collected and
disposed of in an environmentally correct manner.

The crawler track must be opened first before being able to fit or remove the front idler unit
(see Crawler Track chapter).

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Front idler unit – standard design

This design consists of:
1) = Front idler with bracket 3 4
2) = Yoke or cross-bar 2
3) = Spring unit
4) = Track grease tensioner 1

Push the piston of the track tensioner right

in as far as it will go. Screw the washer 1
2
and grease nipple into the hydraulic
Tensioner and tighten.

Insert the track tensioner from below into

the frame so that the grease nipple fits
through the appropriate hole in the
panelling. Set the tensioner in position
using the fastening bolts and then tighten.

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Place yoke on sliding blocks and fasten in

place with bolts.

Place spring unit on the yoke and tighten

in place with bolts.

Insert the assembled front idler unit

carefully into the greased guide rails of the
side sections using appropriate lifting gear.

Make sure that the front idler unit is

pushed in far enough without any collision
until the spring unit knocks against the
piston of the track tensioner.

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Front idler unit compact tensioning

unit
1) = Front idler with bracket
2) = Spring unit with integrated grease
tensione

Place yoke on sliding blocks and fasten in

place with bolts.

Screw the compact spring tensioning unit

onto the yoke.
If the unit is designed with an integrated
yoke, place the complete unit on the
sliding blocks and fasten in place using the
fastening elements.

Push the piston of the tensioning element

in as far as it will go.
Screw high pressure lubricating nipple with
washer into the track tensioner and
tighten.

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Insert the assembled front idler unit

carefully into the greased guide rails of the
side sections using appropriate lifting gear.

Make sure that the front idler unit is

pushed in far enough without any collision
until the spring unit knocks against the
partitioning panel of the frame and
remains there.

5.4.2 Removal
Removal is carried out analogue to the above in reverse order.

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6. Carrier rollers/support rails

6.1. Carrier rollers/support rails – Function and operation

6.1.1 In general
The carrier rollers/support rails are supplied as complete unit. The complete unit has to be
exchanged in the event of any damage, repairs or upon reaching wear limits.

6.1.2 Types of carrier rollers

Carrier rollers with one-sided bearing

Carrier rollers with two-sided bearing (in

this case the top roller is the same of the
lower roller)

Support rails are available in the designs:

• Wear-resistant steel
• Plastic support rails

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6.1.3 Function
The carrier rollers fulfill the following functions:

• Guiding the track in the upper strand

• Supporting the track in order to minimise track sag so as to prevent damage to
neighbouring components.

The running surface of the carrier rollers/support rails has been hardened (not in the case of
plastic support rails) to prevent wear. It is fitted with a "lifetime" seal (carrier rollers) in order
to prevent penetration by dirt and any loss of oil.
The carrier rollers are fitted as complete unit at the intended installation points above the
steel bearers and are ready for immediate use.

6.1.4 Carrier rollers/support rails – Fitting and removal

Undo the bolts of the faulty carrier roller,

remove and dispose.

Fit new roller using new bolts and re-join

track again as described in the following
chapter.

NOTE:
These fitting/removal instructions also apply analogue for two-sided bearing support rollers
and for the support rails

The only difference to the displayed fitting/removal of one-sided bearing carrier rollers is the
number and position of the bolts.
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7. Track rollers
7.1. Track rollers – Function and operation

7.1.1 In general
The track roller is supplied as complete unit. The complete unit has to be exchanged in the
event of any damage, repairs or upon reaching wear limits.

TRACK ROLLER

7.1.2 Types of track roller

Single flange track roller

Double flange track roller

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7.1.3 Function
The track rollers achieve the following functions:

• Guidance of the track so that the dynamic forces of the track are transmitted to the
ground
• Take-up loads coming from the machine

The surface of the roller has been hardened to reduce wear.

It is fitted with "lifetime" seals in order to prevent penetration by dirt and any loss of oil.

The track rollers are fitted as complete unit at the intended installation points under the rail
(see chapter "Track rollers – Fitting and removal) and are ready for immediate use.

7.1.4 Track rollers – Fitting and removal

If necessary, slacken off track and undo
track fastener (see "Track" chapter).

Raise the track undercarriage using a

lifting device and clean dirt off of all parts.

Undo the bolts of the faulty track roller,

remove and dispose.

If track guide is fitted, it will have to be

removed first at the appropriate points
before dismantling.

Fit new roller using new bolts and fasten in

place. Re-join track again as described in
the following chapter.

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8. Crawler track and grouser shoe

8.1. Crawler track and grouser shoe - Function and description

8.1.1 Design of the crawler track with grouser shoes

The grouser shoes are bolted onto the crawler track and forms a complete unit in accordance
with specification.

TRACK CHAIN
SHOE

8.1.2 Design of the crawler track

The crawler track, carrier of the grouser shoes, consists of the segments, which are divided
into left and right track links.
These track links together with the corresponding bushings and bolts are pressed together
and form a unit. This unit can be linked to any required length.

The individual elements of the crawler track have been induction hardened making them
extremely wear resistant.

8.2. Grouser shoes – General description

The grouser shoes are supplied in forms and widths depending on requirements and
demands.

1
2

Tipologia base
• 1- single grouser shoe
• 2- double grouser shoe
• 3- triple grouser shoe
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8.2.1 Function
The following functions are fulfilled by crawler tracks with grouser shoes:

• Taking-up loads coming from the machine

• Transmission of drive output into drive movement

The running surface of the crawler track has been hardened to reduce wear.

8.3. Crawler track and grouser shoes – Fitting and removal

8.3.1 In general

These instructions describe the correct method of fastening the shoes onto the track.
Incorrect assembly is the most common cause for failure of the connection between grouser
shoe and crawler track.

• Remove all forms of foreign bodies/materials from the contact surfaces of the
links, which could get into the connection with the shoes and the bolts (e.g.
paint, primer, rust, dirt etc.). Brushing or grinding lightly can achieve this.
• Clean the contact surfaces and the nut seats of the track links
• Coat the thread and contact surfaces underneath the bolt heads with a thin
layer of oil (preferably) or grease

• Driving hardened end bolts in or out by hammer involves considerable danger

for personnel as a result of material shearing off. Take appropriate protective
measures to prevent injuries (e.g. by wearing goggles).

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Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

8.3.2 Fitting grouser shoes

It is often underestimated how important it
is to observe the correct procedure when
fitting grouser shoes.
Work that is carried out incorrectly can
result in the bolts being over-stretched and
in the worst case even lead to damage to
the track links.
We urgently recommend always using PIN LINK SIDE
NEW bolts and nuts for fitting grouser (PIN BOSS)
shoes. Used bolts can already be
deformed and no longer guarantee
optimum clamping force.

Grouser shoes

Remove all forms of foreign body/material

from the contact surfaces of the shoes that
could get into the connection with the track
links and the bolts (e.g. paint, primer, rust,
dirt etc.). Brushing or grinding lightly can
achieve this.
FRONT SHOES EDGE (A)

Also clean the contact surfaces and the

nut seats of the track links.

Place the grouser shoes with the front

edge (A) in correspondence of the pin link
side over the bolthole of the track links.

Coat the thread and contact surfaces

underneath the bolt heads with a thin layer
of oil (preferably) or grease.

Insert the bolts in the holes and screw into

the nuts by a few turns.

Make sure that the flatter side of the nuts

is resting against the nut seat in the track
link (the rounded side of the nut must be
facing the running surface of the track
link).

Tighten all bolts fully without applying any

particular force.

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41100 S.Damaso MO
ITALY

Select a tightening procedure (see

"Tightening procedures" on the following 1
page) and establish the necessary torque
according to the table at the end of these 3
instructions.

Tighten the bolts crosswise according to

the selected tightening procedure as
shown in the diagram.
Caution!
Do not over-tighten the bolts!
2

8.3.3 Torque check / Re-tightening

Due to normal settling occurrences, all bolts should be re-tightened after about 50 operating
hours. A torque system must be used for this without undoing the bolts beforehand.

Further checks must be made at regular intervals based on the experience of the machine
owner/operator and/or the recommendation of the machine manufacturer. If the bolts can be
turned on by more than 90° at required torque setting during an inspection, have the
complete grouser shoe fitted again new as described above.

8.4. Tightening procedure for track bolts

The necessary torque for each individual bolt is intended for two different tightening
procedures: the torque procedure and the turning angle method.

The turning angle method is used in order to exclude the influence of the friction factor as far
as possible. That is why it should be given preference over the torque procedure.

The torque levels are for specified for ISO strength classes 11.9, 12.9 and special bolts 13.9.

8.4.1 Torque procedure

Tighten the bolts to the appropriate torque level in the above stated order. The torque level is
to be achieved using a torque wrench whereby attention must be paid to an even turning
movement. Sudden jerking movements result in torque peaks and lead to incorrect results.
Stop tightening as soon as the prescribed torque level has been reached.

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Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

8.4.2 Turning angle procedure (to be given preference under site conditions)
With this process, the bolts are first tightened crosswise as described to a pre-set torque
according to the table.After this, ideal pre-stressing of the bolts is achieved by subsequent
turn through 120° (1/3 of a turn).A defined plastic deformation of the bolts can occur with this
procedure so that maximum pre-stressing is achieved for the individual bolts.

In both cases, tightening the bolts in excess of specifications leads to stress on the bolts
beyond the yield point combined with non-permitted plastic deformation and the danger of a
premature failure of the bolt connection.

8.4.3 Tightening torque for track bolts [Nm]

Streght class Streght class Streght class
[Nm] 11.9 12.9 13.9
Torque Turning angle Torque Turning angle Torque Turning angle
Bolt procedure procedure procedure procedure procedure procedure
M10 x 1 90 ± 5 30 ± 2 100 ± 5 32 ± 2
105 ± 5 35 ± 2
M12 x 1 160 ± 10 50 ± 3 170 ± 10 55 ± 3
180 ± 10 60 ± 3
M14 x 1.5 240 ± 15 80 ± 5 260 ± 15 85 ± 5
270 ± 15 90 ± 5
M16 x 1.5 370 ± 20 180 ± 10 390 ± 20 190 ± 10
410 ± 20 200 ± 10
M18 x 1.5 540 ± 30 260 ± 15 570 ± 30 280 ± 15
600 ± 30 290 ± 15
M19 x 1.5 650 ± 35 320 ± 15 690 ± 35 340 ± 15
720 ± 35 360 ± 20
M20 x 1.5 750 ± 35 340 ± 15 800 ± 40 360 ± 20
830 ± 40 380 ± 20
M22 x 1.5 1000 ± 50 380 ± 20 1070 ± 50 400 ± 20
1120 ± 55 420 ± 20
M22 x 2 1080 ± 50
M24 x 1.5 1320 ± 65 440 ± 20 1410 ± 70 470 ± 20 1470 ± 70 490 ± 25
M27 x 1.5 1920 ± 95 630 ± 30 2050 ± 100 670 ± 30 2140 ± 100 700 ± 35
M30 x 2 2580 ± 130 850 ± 40 2760 ± 140 910 ± 50 2870 ± 140 950 ± 50
M32 X 2 3100 ± 150 1000 ± 50 3310 ± 165 1070 ± 50 3450 ± 170 1110 ± 55
M36 X 2 4550 ± 230 2270 ± 110 4860 ± 245 2430 ± 120 5070 ± 250 2530 ± 125
Streght class Streght class Streght class
[Nm] 11.9 12.9 13.9
Torque Turning angle Torque Turning angle Torque Turning angle
Bolt procedure procedure procedure procedure procedure procedure
7/16 - 20 UNF 115 ± 5 40 ± 2 125 ± 5 43 ± 2 130 ± 5 45 ± 2
½ - 20 UNF 180 ± 10 60 ± 3 190 ± 10 65 ± 3 200 ± 10 70 ± 3
9/16 - 18 UNF 260 ± 15 90 ± 5 275 ± 15 95 ± 5 290 ± 15 100 ± 5
5/8 - 18 UNF 360 ± 20 180 ± 10 385 ± 20 190 ± 10 400 ± 20 200 ± 10
¾ - 16 UNF 630 ± 30 320 ± 15 675 ± 35 340 ± 15 700 ± 35 360 ± 20
7/8 - 14 UNF 1010 ± 50 350 ± 15 1080 ± 55 370 ± 20 1130 ± 55 390 ± 20
1 - 14 UNS 1540 ± 80 520 ± 30 1650 ± 80 560 ± 30 1720 ± 85 580 ± 30
1 1/8 - 12 UNF 2250 ± 110 760 ± 40 2400 ± 120 810 ± 40 2500 ± 125 850 ± 40

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Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

8.5. Fitting the crawler track

When laying out the track, pay attention to
straightness and possibly track
dimensions.

P Place a wooden block under the end

position of the track (front idler side,
bushing side of the free track upwards).

Pay attention to the correct position and

direction of the track segments and
grouser shoes.
Place the complete pre-assembled side
section on the track.
Important! If running gears (left and right
side) have to be positioned to each other,
carry out an intermediate check and align
appropriately.

If the trackside is standing correctly in line,

pull the track over the drive unit in the
direction of the front idler over the side
section.
Make sure that the bushings of the track
grip into the gaps between the teeth of the
sprocket.

End position of the track ends is the upper

section of the front idler.

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Via R. Carriera , N° 11
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ITALY

Grease two spacers and insert in the

counter bores of the track links (use seal
washers as well if necessary).

Align track segments to each other.

Grease the tips of the master pin and
insert in the hole. Drive in with a heavy
hammer if using small track sizes.
Observe safety instructions. Driving
master pin in and out with a hammer can
cause danger from material chipping off.
Wear protective goggles.

If using larger tracks, drive the master pin

in using a hydraulic pin-driving tool.

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Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

ightening the track (all models)

Tightening the track.
Attention must be paid that all components
of the track are in the correct position.

A grease gun is required for tightening.

Push the connector on the end of the hose
over the grease nipple of the grease-
tensioning valve. Activate the grease gun
for as long as necessary until the track
tension is correct (see notes on tensioning
element in the Front idler unit chapter).

Important!
There must be sag of 2-3 cm over a length
(L) of 1-1.5 m. This applies linear for the
free length (L) smaller or greater than 1-
1.5 m (at least 4 track elements).

Measure the extent of sag using a ruler.

This is achieved by measuring the
distance f from the edge of the grouser
shoe to the ruler (in the middle of the sag).
RULER

Remove the connector upon completion of the tensioning process. The undercarriage should
now be moved back and forth by about 1 turn of the sprocket. Check position of the tracks on
front idler and sprocket.

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 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

Tracks that are too loose can slip out of the flanges of the rollers, sprocket and front idler and
increase wear.

Tracks that are too tight increase the wear on the front idler and drive bearings as well as the
wear on track pins and bushings.
It also requires greater motor output for driving and consequently a higher consumption of
fuel.

Depending on the design, it is possible that there is no sag in the upper strand on some
models. In this case, the track tension can be set by pressure measurement in the tensioning
element or by lifting the undercarriage (measurement of the sag in the upper strand – the
above rules for the distances L and f also apply in this case).

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 TRACK ONE SRL
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41100 S.Damaso MO
ITALY

9. Other/Special components
9.1. Track guide – Function and operation

9.1.1 In general
Track guides are used wherever track sag occurs on undercarriages while travelling over
obstructions. The result is that the track can run outside the flanges of the track rollers.

There are various types of track guides. Differentiation is made between welded and bolted
designs. There are also designs that cover the complete length of the undercarriage and
others that are fitted in sections.

9.1.2 Types of track guide

Track guide, welded design as segment

(With this design, the undercarriage has to
be raised for fitting or removal).

Track guide, bolted design as segment

(With this design, the undercarriage does
not have to be raised for fitting or
removal).

Version without cross-link possible Æ

"lightweight design“

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ITALY

Track guide, bolted design over complete

length of the side frame
(With this design, the undercarriage does
not have to be raised for fitting or
removal).

9.1.3 Function
Track guide acts as a "threading aid" for the track. If sagging occurs in the track, it comes
away from the track rollers. As the sag recedes, the track guide ensures that the track and
the track roller are properly aligned again.

9.1.4 Track guide – Fitting and removal

There are two fundamental designs of track guide.

In the case of the welded design, the undercarriage has to be raised in order to be able to fit
the track guide because there is no possibility of fitting the chain guide from the side. After
raising the undercarriage, the track guide is mounted onto the undercarriage with bolts.
Removal is analogue in reverse order.

In the case of bolted designs, they can be fitted without raising the undercarriage because
the track guide is in several parts. In this case, one side of the track guide is bolted onto the
undercarriage. The cross link is then connected to the first side of the track guide. The
second side of the track guide is then bolted onto the cross-link. The second side is then
bolted onto the undercarriage. Removal is analogue in reverse order.

Attention must be paid that there is no contact between the track guide and the track roller
body and that there is adequate play between the track guide and the track (pin boss of the
track).

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41100 S.Damaso MO
ITALY

9.2. Covers

9.2.1 In general
Covers are shown in the following illustration, they occur on all standard undercarriages (not
all covers are present on all undercarriages).

It is also possible that additional covers are present on the undercarriage that are not shown
in the illustration. Typical covers are for the hydraulic motor or for the hand hole for access to
the lubrication nipple of the tensioning element.

Take care when handling the plates as they can be very heavy depending on size and can
therefore cause injuries.

9.2.2 Function
Covers made of sheet metal are used on an undercarriage. They are used for:
• Covering units and hydraulic lines
• Protection against dirt and contamination
• Protecting people against injury

Cod. T0650C02 08/10/07 Rev.0 44 of 44

SPARE PARTS AND MAINTENANCE
GUIDE

PART NUMBER : T0650C03

www.trackone.it

TRACK ONE SRL Phone : +39 059 468312

Via R. Carriera , N° 11 Mobile : +39 328 4818100 ISSUED : 13/02/06
41100 S.Damaso MO Fax : +39 059 467954
ITALY
 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

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 TRACK ONE SRL
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41100 S.Damaso MO
ITALY

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 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

1. Safety and ranger instructions

To be observed

Warning signs
Warning:

Safety regulations and measures that protect the drive and other persons against injury and
ranger to life and limb

Caution :

Particular instructions to prevent damage to the vehicle. Failure to observe these instructions
can lead to warranty becoming void.

NB:

Particular instructions for better handling during operations , control and setting procedures
as well as maintenance work .

1.1. Foreword
These operating instructions are a part of the scope of delivery. They are to be kept close at
hand and are to remain with the machine if being sold again.

All details , data and illustration container in these operatine instructions are subject to
change as result of technical developments.

These operating instructions are not subject to any update service.

Information on la test developments can be obtained from :

TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY
Phone +39 059 468312
The illustrations in this manual are only diagrammatic and may differ from the actually
installed components of the respective undercarriage. In addition, it is possible that there
may also be other components on the undercarriage that are not described in this manual.
Conversely, there may also be components described in this manual that are missing on the
undercarriage.
All components and their functions are subject to technical change.

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ITALY

1.2. In general

This undercarriage has been constructed to "state of the art" standards and is operationally
safe.
Nevertheless, machines can be the source of danger if they continue to be operated although
a fault is suspected or has already occurred or it has been repaired incorrectly.

Under these circumstances there is

• Danger to life and limb

• Danger to the machine and other facilities and equipment etc.

The machine must be shut down immediately if a fault is suspected or has already occurred
which could endanger the safety of the operator, other persons on site or surrounding
facilities and equipment etc.

All components have been carefully matched to each other. Fault-free operation and a long
service life are only possible if original spare parts are used.
.

1.3. Regulations for work safety

1.3.1 Personnel
Only properly trained and authorized personnel with appropriate specialist knowledge are to
be appointed with maintenance and repair work.

Appropriate measures must be taken before commencing any work on the undercarriage to
ensure that the equipment cannot start up unintentionally or be started up inadvertently by
others (e.g. blocks). All switching on and off procedures must be observed for this.

Protective equipment and clothing is mandatory for all work. Wear protective helmets, shoes
and gloves. Close fitting clothes help to avoid injuries.

If assistants are required to help in carrying out work, responsibilities must be clarified
beforehand so that there is no possibility of unclear competence occurring with regard to
safety aspects.

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Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

1.3.2 Tools and equipment

Tools, lifting gear, fastening devices, jacks and other working equipment must be in a safe
operational and working condition.

All lifting and fastening devices on the crawler undercarriage are only designed for the
transportation of the undercarriage unless otherwise specified.

Metal splinters may break off and cause injuries when driving equipment bolts in or out. For
this reason, always wear safety goggles when driving bolts in or out.

Equipment or components which are being fitted or removed or where their installation
position is being changed must be secured against unintentional movement, slipping or
falling over using suitable lifting gear of suspension/support devices.

Systems and units (i.e. tensioning units) must be depressurized in an appropriate manner
before opening.

Damaged hydraulic or mechanical pre-tensioned spring elements must be exchanged as a

complete unit. Further information in this respect can be found in the respective component
descriptions and/or fitting and removal instructions.

2. Warranty
Applicable conditions of warranty are stipulated in the confirmation of order.

Warranty rights become void in the event of

• Damage as a result of malfunctions caused by incorrect use or incorrect operation.

• Repairs or alterations carried out by persons who are neither trained nor authorized to
do so.
• Damage being caused by accessories or spare parts being used for which no
approval has been provided by TRACK ONE SRL.

Safety instructions

3. Operating and Service Instructions

3.1. General Maintenance Instructions

3.1.1 Handling hydraulic substances and lubricants

The relevant applicable safety regulations for the respective products must be observed
when handling oil, grease or other chemical substances.
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41100 S.Damaso MO
ITALY

Suitable safety measures must be taken to avoid scalding and burning when the machine
has warmed up (i.e. at operating temperature), as operating media are then at least the same
temperature.
Do not smoke if handling combustible fluids.
Caution with fire and naked flames. Not only fuel but also other operating media often have a
low flash point and ignite easily.
Lubricants that are not being reused must be disposed of in an environmentally friendly way.

3.1.2 Conversions or changes to the undercarriage

Unauthorized conversions or changes are not permitted for safety reasons. The rated
pressure of connected pressure relief valves and pressure tanks must not be altered.

Seals on units must not be removed.

3.1.3 Before starting up

Before starting up:
• Lubricate all lubrication points
• Check all oil levels and adjust if necessary
• Check function of all repaired components
• Carry out visual inspection of all components

3.1.4 Wear limits of undercarriage parts

Wear of the undercarriage is caused by movements, loads contact between parts of the
undercarriage and abrasive action of the ground.

This wear is increased by other factors including:

• Track resting on hard uneven rock bed during operation

• One-sided undercarriage load during turning
• Driving long distances in reverse
• Driving over obstructions recklessly
• A track which is not tensioned according to operating conditions
• A large degree of dirt on complete undercarriage

Undercarriage components must be replaced by new parts if they are worn to 100 %.
Otherwise, sudden machine failure is possible.

Careful and regular measurements are necessary in order to establish the extent of wear and
when replacements will be necessary.
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41100 S.Damaso MO
ITALY

The parts involved and measuring parts must be cleaned thoroughly when carrying out
measurements. If possible, carry out measurements at several points. The degree of wear is
determined by the maximum value, not the average value.

3.1.5 Inspection intervals

COMPONENTS INTERVAL INPECTION EXTENT OF MAINTENANCE WORK

TRACK DAILY VISUAL EXTENT OF UNDERCARRIAGE DIRTINESS
UNDERCARRIAGE GENERAL CONDITION OF THE
UNDERCARRIAGE COMPONENTS
FASTENING ELEMENTS OF FRAME SECTIONS
AND UNDERCARRIAGE FASTENINGS
MONTHLY VISUAL FASTENING ELEMENTS OF FRAME SECTIONS
AND UNDERCARRIAGE FASTENINGS –
GROUSER SHOE FASTENING (SPOT-
CHECKS)
DRIVE –GEARBOX DAILY VISUAL SEAL OF GEAR-MOTOR UNIT AND POSSIBLE
HYDRAULIC CONNECTIONS
200 – 250 CHECK GEARBOX OIL LEVEL
WORKING
HOURS
300 – 2000 GEARBOX OIL CHANGE
WORKING
HOURS –
ONE YEAR
MAX
MONTHLY CHECK CONDITION AND WEAR ON SPROCKET
FRONT IDLER UNIT DAILY VISUAL GENERAL STATE OF SPRING AND TENSION
SYSTEM
WEEKLY SEAL OF THE FRONT IDLER AND
TENSIONING SYSTEM
RE-TENSIONING SPAN OF THE TRACK (MAX
POSSIBLE TENSIONING SPAN REACHED)
CHECK CONDITION OF AND WEAR ON FRONT IDLER
AMD SLIDING BRACKET
TRACK ROLLERS DAILY VISUAL CHECK FOR LEAKAGE
MONTHLY CHECK CONDITION OF AND WEAR ON TRACK
ROLLER
CARRIER ROLLER DAILY VISUAL CHECK FOR LEAKAGEi
OR WEARING MONTHLY CHECK CONDITION OF AND WEAR ON CARRIER
RAILS ROLLER
TRACK GROUP DAILY VISUAL CHECK FOR LEAKAGE (ONLY ON
LUBRICATED TRACK GROUP)
TRACK PRE-TENSIONING –TRACK SAG
MONTHLY CHECK CONDITION OF AND WEAR ON TRACK LINK
RUNNING SURFACES , BUSHINGS (OTHER
DIAMETER) ,AND STRETCHING OF
TRACK.CONDITION OF AND WEAR ON THE
GROUSER SHOES

Changes to intervals are possible depending on extent of use and operating conditions for
the machine.

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ITALY

3.1.6 Tightening torque tables

These tables do not apply for fastening the shoes of the track.

FOR STANDARD BOLTS FOR EXPANSION BOLTS

Nm Nm
6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
M4 2,4 2,9 4,1 4,9 M4 1,3 1,6 2,2 2,7
M5 5,0 6,0 8,5 10,0 M5 2,8 3,3 4,6 5,5
M6 8,5 10,0 14,0 17,0 M6 4,7 5,5 8,0 9,5
M8 21,0 25,0 35,0 41,0 M8 12,0 14,0 20,0 24,0
M 10 41,0 49,0 69,0 83,0 M 10 25,0 29,0 41,0 50,0
M 12 72,0 86,0 120,0 145,0 M 12 44,0 52,0 74,0 88,0
M 14 115,0 135,0 190,0 230,0 M 14 71,0 84,0 120,0 140,0
M 16 180,0 210,0 295,0 355,0 M 16 115,0 135,0 190,0 225,0
M 18 245,0 290,0 405,0 485,0 M 18 155,0 180,0 255,0 305,0
M 20 345,0 410,0 580,0 690,0 M 20 225,0 265,0 375,0 450,0
M 22 465,0 550,0 780,0 930,0 M 22 310,0 365,0 520,0 620,0
M 24 600,0 710,0 1.000,0 1.200,0 M 24 390,0 460,0 650,0 780,0
M 27 890,0 1.050,0 1.500,0 1.800,0 M 27 600,0 700,0 990,0 1.200,0
M 30 1.200,0 1.450,0 2.000,0 2.400,0 M 30 800,0 950,0 1.350,0 1.600,0
M 36 2.480,0

FOR STANDARD BOLTS FINE THREAD FOR EXPANSION BOLTS WITH FINE THREAD

Nm Nm
6.9 8.8 10.9 12.9 6.9 8.8 10.9 12.9
M 8x1 23,0 27,0 38,0 45,0 M 8x1 14,0 17,0 23,0 28,0
M10x1,25 44,0 52,0 73,0 88,0 M10x1,25 27,0 33,0 46,0 55,0
M12x1,25 80,0 95,0 135,0 160,0 M12x1,25 52,0 61,0 86,0 105,0
M 12x1,5 76,0 90,0 125,0 150,0 M 12x1,5 48,0 57,0 80,0 96,0
M 14x1,5 125,0 150,0 210,0 250,0 M 14x1,5 81,0 96,0 135,0 160,0
M 16x1,5 190,0 225,0 315,0 380,0 M 16x1,5 125,0 150,0 210,0 255,0
M 18x1,5 275,0 325,0 460,0 550,0 M 18x1,5 190,0 225,0 315,0 380,0
M 20x1,5 385,0 460,0 640,0 770,0 M 20x1,5 265,0 315,0 445,0 530,0
M 22x1,5 520,0 610,0 860,0 1.050,0 M 22x1,5 365,0 430,0 610,0 730,0
M 24x2 650,0 780,0 1.100,0 1.300,0 M 24x2 450,0 530,0 750,0 900,0
M 27x2 970,0 1.150,0 1.600,0 1.950,0 M 27x2 670,0 790,0 1.100,0 1.350,0
M 30x2 1.350,0 1.600,0 2.250,0 2.700,0 M 30x2 950,0 1.150,0 1.600,0 1.900,0

FOR STANDARD BOLTS FINE THREAD FOR UNFBOLTS WITH FINE THREAD

Nm Nm
M10x1 85,0 - 95,0 9/16"-20 110,0 - 120,0
M12x1 145,0 - 160,0 1/2"-20 165,0 - 185,0
M14x1,5 220,0 - 250,0 9/16"-18 240,0 - 270,0
M16x1,5 340,0 - 380,0 5/8"-18 330,0 - 370,0
M30x2 2.360,0 - 2.400,0 3/4"-14 575,0 - 650,0
7/8"-14 915,0 - 1.030,0
1“-14 1385,0 - 1560,0

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Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

3.1.7 Serial number

All undercarriages or side frames have a serial number for identification.

The drawing part number and serial number are on TRACK ONE label located as shown on
figure 1 (except customer specific different request)

This serial number is always required when calling with inquiries or complaints.

Fig. 1

TRACK ONE LABEL

3.2. General assembly and disassembly instructions

3.2.1 Assembly instructions

The crawler undercarriages are supplied by TRACK ONE as a complete unit.
All necessary assembly work on components to be exchanged is described in the respective
individual chapters.

3.2.2 Disassembly instructions

Disassembling individual assemblies or components upon having reached their wear limits or
in the case of any failure occurrences is described separately for each component in the
individual chapters.
We recommend not carrying out any repair work on the building site, but exchanging the
component instead.
We recommend getting in contact with the TRACK ONE in the event of any major damage or
repeated failure of individual components.

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Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

4. DRIVE
4.1. Technical features

Builder:TRASMITAL
Model: 713 C3B
Transmission ratio: 142
Motor capacity: 107 cc
Motor velocity: 1542 (1/min)
Output torque: 7351 daNm
Driving force: 17095 daN.

4.2. Drive – Function and operatine

4.2.1 General ranger instructions

Danger can occur in particular under the following circumstances:

• Product is handled insufficiently trained personnel

• Incorrect installation, operation and maintenance/repair
• The product is not being used for its designated purpose

Alterations to the product are not permitted unless approved beforehand.

The transmission is designed exclusively for use as drive transmission for an undercarriage.

4.2.2 Design of the drive

The design of the track undercarriage consists of a complete unit.
This unit consists of a fully encapsulated, multi-stage high-performance planetary gear and
the sprocket. The gear (2) is driven direct by hydraulic (1) or electric flange-mounted motors,

The sprocket (3) is available in standard, HD or special design with dirt pockets for packing
ground conditions.
Components adjoining the track are surface hardened to minimise wear. The connection to
the driving wheel and transmission is established with HF bolts (4). The necessary torque
levels for these are shown in the attached tables.

The drive traction is transmitted to the track via the motor, transmission and sprocket.

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1 - hydraulic motor
1
2 - gear
3 - sprocket
4 - bolt 4

2
3

4.2.3 Description of the transmission

The transmissions of the type series being used for the undercarriage have multi-stage
planetary gear depending on design.

A particular feature of the gear is its very compact and therefore space-saving design.

The gear can be fitted with an integrated multi-disc brake, which acts as parking brake. This
is activated by spring force and released hydraulically with pressure oil. The multi-disc brake
must be released without fail before switching on the drive hydraulic.

As a special design, the transmission can be supplied with a mechanical disengaging

mechanism enabling the transmission and hydraulic motor to be separated from each other,
e.g. if towing the machine following failure of the machine's hydraulic system.

4.2.4 Commissioning

• Prevent the transmission from getting dirty

• Avoid pollution. Make sure not to spill any lubricant when filling

The transmission is supplied ready for installation without oil filling. Starting up or using the
drive without any lubricant would lead to destruction of the transmission in next to no time.
See the chapter "Filling with transmission oil" for filling, topping-up or checking oil.

The transmission has been treated internally with a preservative agent that provides around
6 months protection against corrosion if stored under dry conditions. This internal
preservation does not have to be removed when starting up.
When fitting the hydraulic lines for parking brakes and hydraulic motor, make sure that no dirt
or other foreign bodies get into the transmission or hydraulic motor.

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4.3. Lubricants

4.3.1 Normal operating conditions (+ 10° to + 30° C)

We recommend only using lubricants that fulfil necessary viscosity requirements for
lubricating the transmission.

The viscosity rating on the rating plate on the transmission and the following requirements
must be observed!

Only the necessary viscosity ISO-VG 150 and ISO-VG 220 for normal operating conditions
from 10° to 30° C is stated on the rating plate.

4.3.2 Severe operating conditions (- 30° to + 50° C)

Under severe operating conditions, e.g. in an ambient temperature range between - 30° and
+50° C, we recommend using transmission oil with appropriate viscosity or a fully synthetic
lubricant.

For lower operating temperatures, use oil with a lower viscosity (SAE 80W - 90) and for
higher temperatures, us oil with higher viscosity (SAE 85W - 140).

4.4. Compact transmission with drive motor

Connecting the locating flange of the side frame as well as the sprocket is achieved using
adequately dimensioned bolt connections. Transmission of torque is achieved by frictional
locking.

Remove the protective caps when connecting the hydraulic hoses. Attention must be paid
that no dirt gets into the supply lines during the assembly process.

All prescribed parameters such as:

• Hydraulic pressure limits,

• maximum and minimum volume flow rates,
• allowance for oil leakage,
• brake air pressure monitoring,

must be observed when using the undercarriage hydraulic system. Please contact the
manufacturer where necessary for permitted values.

4.5. Parking brake

The multi-disc brake incorporated into the transmission is a parking brake that is kept
constantly closed by pressure springs. The maintenance-free brake is designed as a
separate compact unit and should only be removed from the transmission and exchanged as
a complete unit. This design protects all individual components such as discs, springs,
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sealing elements etc. against outside influences. Any repair work should only be carried out
by a specialist workshop.

Feeding hydraulic oil either direct or via the drive brake valve and a connecting line to the
brake connection of the compact unit opens the brake.

Pressure ranges within which the brakes can be vented must be observed. Only completely
vented brakes allow wear-free and fault free operation of the complete drive.

Use of a separate hydraulic circuit for supplying the brakes is recommended if operating
without parking brake valve.

4.5.1 Unlocking the parking brake

Undercarriages with drive units that are fitted with parking brakes cannot be moved when the
hydraulic system is not functioning. For this reason, it is possible to fit the undercarriage with
an unlocking mechanism.
With this mechanism, it is possible to tow the undercarriage even with the diesel or electric
motors switched off.

The unlocking device is located on the outside of the transmission and is held in its normal
position by bolts (1).

To unlock the parking brake, remove the bolts and screw in the claw clutch.

Attention must be paid that the unlocking device is returned to its original state when
returning to normal operation.

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4.6. Drive – Fitting and removal

Whenever working on the drive, always use suitable means to secure the device against
starting up by itself or being started by others.

An undercarriage that is not connected with the track by the sprocket is not secured against
movement by the transmission brake. This means that the undercarriage must be secured
separately when removing the drive.

Opening the track first is a precondition for fitting/removing the drive (see "Track" chapter).

• Notes on transmission oil must be observed

• All parts being fitted must be clean and free of grease

4.6.1 Connecting frame-transmission sprocket

2 3

The transmission [1] must be inserted carefully into the side frame so that there is no
damage to the flange surfaces. Check transmission seating for correct installation. Fasten
the transmission in place by inserting bolts [2] and washers [3] in the frame. Screw into place
by hand. Check again to ensure that transmission seating is correct.

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Pre-tighten all bolts by hand crosswise. See illustration below (example).

Tighten to torque level crosswise again according to size of bolt (torque level table).

4.6.2 Further instructions:

• Clean all locating/joining surfaces thoroughly.

• Lift the transmission carefully into the locating flange of the undercarriage using
appropriate hoisting gear.
• Fasten the transmission securely onto the undercarriage frame, before removing the
hoisting attachments.
• Make sure to avoid any axial forces when installing.
• Make sure to avoid any excessive force on the transmission housing.
• The transmission must not be tilted.
• Pay attention that no dirt or foreign particles get into the hydraulic system.
• The multi-disc parking brake is a transmission safety device. Make sure that no dirt or
foreign bodies get into the brake air connection.
• Make sure that the brake air connection is carefully sealed

4.6.3 Connecting sprocket - transmission

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Clean all locating/joining surfaces thoroughly. Hoist the sprocket with hoisting gear onto the
transmission and tighten onto the hub of the transmission without any heavy knocks.

Insert the bolts (1) and washers(2) for fastening the sprocket (3) into the holes and screw
into the thread in the transmission (4) by hand. Pre-tighten all bolts in the correct order and
then to correct tension using a torque wrench (see torque level table).

4.6.4 Removing sprocket

Slacken off track and undo track lock (see "Track" chapter).

Remove dirt from all parts and fastening elements. Use hoisting gear to secure the sprocket
against falling over. Undo the bolts on the driving wheel crosswise and remove completely.

Remove the driving wheel from transmission seat by tapping lightly with rubber hammer. If
provided, insert pull-off bolts into provided threaded holes and tighten evenly. Push the
sprocket off the transmission seat in this way and lift out using the hoisting gear.

4.6.5 Removing transmission

Remove dirt from all parts and fastening elements. Use hoisting gear to secure the
transmission against falling over. Undo the bolts on the frame crosswise and remove
completely.

Loosen the transmission from the frame seat by tapping lightly with rubber hammer, then lift
the transmission out of the frame carefully using the hoisting gear.

• Catch any dripping/leaking oil in suitable containers

• Only use approved transporting elements for transportation

4.7. Drive – Maintenance and inspection

4.7.1 General instructions

The complete drive unit consists of the following components:
• Motor
• Sprocket
• Transmission
• Integrated brake (only on request)
• Disengaging mechanism (only on request)

Always replace the complete component if it fails. Only use specialist workshops for repairs.

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4.7.2 Filling , topping-up and changing transmission oil

The transmission must be filled with fresh clean oil before starting up for the first time (see
details of lubricants for types of oil).

See the "Inspection intervals" table for intervals for oil checks or change.

Drive the machine onto a horizontal surface in a position where appropriate access to the
drive transmission is possible (see illustration).

4.7.3 Filling/Topping up with transmission oil:

Position the transmission so that the oil drain plug (2) is positioned vertically at its lowest
point (about 6 o'clock). The oil filler plug (1) should then be on the left or right outside of the
transmission middle (about 10 or 2 o'clock).

Fill up with oil until the level has reached the height of the filling hole. Insert filler plug with
new washer and tighten.

4.7.4 Draining off transmission oil:

Danger of scalds and burns from hot transmission oil. The transmission housing may also be
hot after running for longer periods. Always wear protective gloves and allow the
transmission to cool down first. Collect draining oil in appropriate containers and dispose of in
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an environmentally safe manner.

Place oil collection container underneath the transmission. Undo and remove oil filler plug (1)
and oil drain plug (2). Drain oil completely. Insert drain plug with new washer and tighten.

4.8. Motor
The motor is maintenance free and only has to be checked visually for leaks during
inspection.

4.8.1 Multi-disc parking brake

The multi-disc parking brake is integrated into the transmission on the motor side and is
lubricated by the transmission oil. Because of this design, the brake is maintenance free and
consequently only has to be checked for damage when carrying out a general overhaul of the
complete transmission.

The brake circuit must be vented (bled) after working on the brake or the hydraulic
connections.

4.8.2 Disengaging mechanism

The disengaging clutch is located on the rotor gear side (opposite the motor) and is not
subject to any special maintenance regulations.

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5. Front idler unit

5.1. Front idler unit – Function and description

Front idler units consist of the groups:

• 1) Front idler with brackets or sliding blocks

• 2) Yoke
• 3) Spring unit (pre-tensioned)
• 4) Grease tensioner

4
3
2
1

The front idler with sliding blocks (1) has a lifetime oil lubrication filling. The running surfaces
have been hardened to reduce wear. The yoke (2) acts as a transmission element between
the front idler and the following components. The spring unit (3) acts as protection for the
complete undercarriage against overloads from outer influences (e.g. dirt) and is therefore an
important component of the undercarriage.

SPRING UNIT IS PRE-TENSIONED THEREFORE IT IS DANGEROUS. BREAKS OR

TAMPERING MIGHT BE DANGEROUS FOR OPERATORS!

IMPORTANT! ANY KIND OF OPERATION ON THE PRE-TENSIONED SPRING UNIT

MUST BE DONE ONLY BY SKILLED OPERATORS AND INTO SPECIALIZED
WORKSHOPS WHERE SAFETY CAN BE ASSURED.
The track tensioner (4) is used for correct setting of track tension. The grease cylinder maybe
filled with/operated by grease or hydraulic oil.
The following applies for all spring units :
All spring units can either be bolted , inserted or fastened into the front idler yoke

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Type of idler units 3 4

2
Type 1 Standard 1
1) = Front idler with brackets
2) = Yoke
3) = Pre-tensioned spring unit
4) = Grease tensioner

1
Type 2 Integrated tensioning units
1) = Front idler
2) = Compact tensioning grease
tensioner inside of spring units

5.1.1 Front idler complete with sliding blocks and yoke

The front idler unit fulfills the following functions:

• Deflection with simultaneous guidance of the track.

• Positional adjustment via sliding blocks for setting track pre-tension and for guidance
during spring actions

3
1

2
1) = Front idler
2) = Sliding block
3) = Yoke

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The front idler (1) runs in the steel mount (2) with its sliding blocks and can move in a
longitudinal direction.

The friction surfaces of the front idler guidance in the frame are greased to minimise wear
(carried factory side during initial assembly).

Other components may be fastened on the front idler depending on the type of front
idler.

5.2. Spring unit

The function of the spring is to secure the complete undercarriage against overloads. An
overload can be caused by external influences (e.g. dirt accumulation) resulting in an
increase in track tension. Under these circumstances, the spring element action provides
relief for all components.
The spring can only operate perfectly as long as there is no significant dirt accumulation on
the spring.

5.2.1 Types of spring units

Various types of design can be used as spring element depending on the intended
application and load occurrence.
In a compressed state the spring element requires an opening in its counterpart (e.g. in the
cross-bar or panelling).

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5.3. Track Tensioner

The track is provided with the necessary pre-tension by the tensioning cylinder. In the event
of wear occurring to the undercarriage components or if there are changes in terrain
conditions, it will be necessary to adjust the tension of the track up or down (see chapter
Setting Track Pre-tension, Crawler Track).

The tensioning cylinder (1) is supplied in standard design as a grease-tensioning cylinder. To

tension or slacken off the track, grease is either applied through a special grease nipple (2)
on the tensioning cylinder or the grease filling can be drained off by unscrewing the grease
nipple halfway (illus. above).

Access to the grease tensioner is through hand holes (1) that are located at the sides in the
steel frame (1) (illus. below).

2
3

The hand holes may be closed by covering plates 2)with bolt (3).

Attention must be paid to the state of wear of the track in order to avoid damage to the track
tensioner.
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Re-tensioning is not permitted after reaching the wear limits for the track as this would cause
excess strain on the undercarriage components beyond the permitted limits and there would
no longer be any safety against forced breakage.

5.4. Fitting and removal

5.4.1 Fitting front idler unit – in general

Fitting and removing the front idler unit complete varies according to the design of the unit.
The various designs are described in the following chapters.

Under all circumstances, appropriate steps must be taken whenever working on the front
idler unit to ensure that the device cannot start up of its own accord or through intervention
by others. An undercarriage, which is not connected with the track by the sprocket, is not
prevented from moving by the gear brake. This means that the undercarriage must be
secured separately.
Furthermore, attention must be drawn to the dangers that can occur when working on or with
spring elements.
If a tension rod is damaged or broken, there is danger that a coil spring will not remain
in its pre-tensioned position but will force the front idler out of the frame through
sudden de-tensioning when the track is removed (see fig. 1., chap. Types of Spring
Elements Æ Coil spring).
This possible danger is detectable by the track remaining tensioned even after releasing the
pre-tension pressure out of the grease tensioner.
The spring elements that operate on a nitrogen or elastomer basis are high-pressure
containers that under no circumstances should be subjected to additional stress through
incorrect handling or external heat application.

If handling the track tensioners, make sure that any emerging oil or grease is collected and
disposed of in an environmentally correct manner.

The crawler track must be opened first before being able to fit or remove the front idler unit
(see Crawler Track chapter).

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Front idler unit – standard design

This design consists of:
1) = Front idler with bracket 3 4
2) = Yoke or cross-bar 2
3) = Spring unit
4) = Track grease tensioner 1

Push the piston of the track tensioner right

in as far as it will go. Screw the washer 1
2
and grease nipple into the hydraulic
Tensioner and tighten.

Insert the track tensioner from below into

the frame so that the grease nipple fits
through the appropriate hole in the
panelling. Set the tensioner in position
using the fastening bolts and then tighten.

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Place yoke on sliding blocks and fasten in

place with bolts.

Place spring unit on the yoke and tighten

in place with bolts.

Insert the assembled front idler unit

carefully into the greased guide rails of the
side sections using appropriate lifting gear.

Make sure that the front idler unit is

pushed in far enough without any collision
until the spring unit knocks against the
piston of the track tensioner.

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Front idler unit compact tensioning

unit
1) = Front idler with bracket
2) = Spring unit with integrated grease
tensione

Place yoke on sliding blocks and fasten in

place with bolts.

Screw the compact spring tensioning unit

onto the yoke.
If the unit is designed with an integrated
yoke, place the complete unit on the
sliding blocks and fasten in place using the
fastening elements.

Push the piston of the tensioning element

in as far as it will go.
Screw high pressure lubricating nipple with
washer into the track tensioner and
tighten.

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Insert the assembled front idler unit

carefully into the greased guide rails of the
side sections using appropriate lifting gear.

Make sure that the front idler unit is

pushed in far enough without any collision
until the spring unit knocks against the
partitioning panel of the frame and
remains there.

5.4.2 Removal
Removal is carried out analogue to the above in reverse order.

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6. Carrier rollers/support rails

6.1. Carrier rollers/support rails – Function and operation

6.1.1 In general
The carrier rollers/support rails are supplied as complete unit. The complete unit has to be
exchanged in the event of any damage, repairs or upon reaching wear limits.

6.1.2 Types of carrier rollers

Carrier rollers with one-sided bearing

Carrier rollers with two-sided bearing (in

this case the top roller is the same of the
lower roller)

Support rails are available in the designs:

• Wear-resistant steel
• Plastic support rails

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6.1.3 Function
The carrier rollers fulfill the following functions:

• Guiding the track in the upper strand

• Supporting the track in order to minimise track sag so as to prevent damage to
neighbouring components.

The running surface of the carrier rollers/support rails has been hardened (not in the case of
plastic support rails) to prevent wear. It is fitted with a "lifetime" seal (carrier rollers) in order
to prevent penetration by dirt and any loss of oil.
The carrier rollers are fitted as complete unit at the intended installation points above the
steel bearers and are ready for immediate use.

6.1.4 Carrier rollers/support rails – Fitting and removal

Undo the bolts of the faulty carrier roller,

remove and dispose.

Fit new roller using new bolts and re-join

track again as described in the following
chapter.

NOTE:
These fitting/removal instructions also apply analogue for two-sided bearing support rollers
and for the support rails

The only difference to the displayed fitting/removal of one-sided bearing carrier rollers is the
number and position of the bolts.
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7. Track rollers
7.1. Track rollers – Function and operation

7.1.1 In general
The track roller is supplied as complete unit. The complete unit has to be exchanged in the
event of any damage, repairs or upon reaching wear limits.

TRACK ROLLER

7.1.2 Types of track roller

Single flange track roller

Double flange track roller

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7.1.3 Function
The track rollers achieve the following functions:

• Guidance of the track so that the dynamic forces of the track are transmitted to the
ground
• Take-up loads coming from the machine

The surface of the roller has been hardened to reduce wear.

It is fitted with "lifetime" seals in order to prevent penetration by dirt and any loss of oil.

The track rollers are fitted as complete unit at the intended installation points under the rail
(see chapter "Track rollers – Fitting and removal) and are ready for immediate use.

7.1.4 Track rollers – Fitting and removal

If necessary, slacken off track and undo
track fastener (see "Track" chapter).

Raise the track undercarriage using a

lifting device and clean dirt off of all parts.

Undo the bolts of the faulty track roller,

remove and dispose.

If track guide is fitted, it will have to be

removed first at the appropriate points
before dismantling.

Fit new roller using new bolts and fasten in

place. Re-join track again as described in
the following chapter.

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8. Crawler track and grouser shoe

8.1. Crawler track and grouser shoe - Function and description

8.1.1 Design of the crawler track with grouser shoes

The grouser shoes are bolted onto the crawler track and forms a complete unit in accordance
with specification.

TRACK CHAIN
SHOE

8.1.2 Design of the crawler track

The crawler track, carrier of the grouser shoes, consists of the segments, which are divided
into left and right track links.
These track links together with the corresponding bushings and bolts are pressed together
and form a unit. This unit can be linked to any required length.

The individual elements of the crawler track have been induction hardened making them
extremely wear resistant.

8.2. Grouser shoes – General description

The grouser shoes are supplied in forms and widths depending on requirements and
demands.

1
2

Tipologia base
• 1- single grouser shoe
• 2- double grouser shoe
• 3- triple grouser shoe
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8.2.1 Function
The following functions are fulfilled by crawler tracks with grouser shoes:

• Taking-up loads coming from the machine

• Transmission of drive output into drive movement

The running surface of the crawler track has been hardened to reduce wear.

8.3. Crawler track and grouser shoes – Fitting and removal

8.3.1 In general

These instructions describe the correct method of fastening the shoes onto the track.
Incorrect assembly is the most common cause for failure of the connection between grouser
shoe and crawler track.

• Remove all forms of foreign bodies/materials from the contact surfaces of the
links, which could get into the connection with the shoes and the bolts (e.g.
paint, primer, rust, dirt etc.). Brushing or grinding lightly can achieve this.
• Clean the contact surfaces and the nut seats of the track links
• Coat the thread and contact surfaces underneath the bolt heads with a thin
layer of oil (preferably) or grease

• Driving hardened end bolts in or out by hammer involves considerable danger

for personnel as a result of material shearing off. Take appropriate protective
measures to prevent injuries (e.g. by wearing goggles).

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8.3.2 Fitting grouser shoes

It is often underestimated how important it
is to observe the correct procedure when
fitting grouser shoes.
Work that is carried out incorrectly can
result in the bolts being over-stretched and
in the worst case even lead to damage to
the track links.
We urgently recommend always using PIN LINK SIDE
NEW bolts and nuts for fitting grouser (PIN BOSS)
shoes. Used bolts can already be
deformed and no longer guarantee
optimum clamping force.

Grouser shoes

Remove all forms of foreign body/material

from the contact surfaces of the shoes that
could get into the connection with the track
links and the bolts (e.g. paint, primer, rust,
dirt etc.). Brushing or grinding lightly can
achieve this.
FRONT SHOES EDGE (A)

Also clean the contact surfaces and the

nut seats of the track links.

Place the grouser shoes with the front

edge (A) in correspondence of the pin link
side over the bolthole of the track links.

Coat the thread and contact surfaces

underneath the bolt heads with a thin layer
of oil (preferably) or grease.

Insert the bolts in the holes and screw into

the nuts by a few turns.

Make sure that the flatter side of the nuts

is resting against the nut seat in the track
link (the rounded side of the nut must be
facing the running surface of the track
link).

Tighten all bolts fully without applying any

particular force.

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Select a tightening procedure (see

"Tightening procedures" on the following 1
page) and establish the necessary torque
according to the table at the end of these 3
instructions.

Tighten the bolts crosswise according to

the selected tightening procedure as
shown in the diagram.
Caution!
Do not over-tighten the bolts!
2

8.3.3 Torque check / Re-tightening

Due to normal settling occurrences, all bolts should be re-tightened after about 50 operating
hours. A torque system must be used for this without undoing the bolts beforehand.

Further checks must be made at regular intervals based on the experience of the machine
owner/operator and/or the recommendation of the machine manufacturer. If the bolts can be
turned on by more than 90° at required torque setting during an inspection, have the
complete grouser shoe fitted again new as described above.

8.4. Tightening procedure for track bolts

The necessary torque for each individual bolt is intended for two different tightening
procedures: the torque procedure and the turning angle method.

The turning angle method is used in order to exclude the influence of the friction factor as far
as possible. That is why it should be given preference over the torque procedure.

The torque levels are for specified for ISO strength classes 11.9, 12.9 and special bolts 13.9.

8.4.1 Torque procedure

Tighten the bolts to the appropriate torque level in the above stated order. The torque level is
to be achieved using a torque wrench whereby attention must be paid to an even turning
movement. Sudden jerking movements result in torque peaks and lead to incorrect results.
Stop tightening as soon as the prescribed torque level has been reached.

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 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

8.4.2 Turning angle procedure (to be given preference under site conditions)
With this process, the bolts are first tightened crosswise as described to a pre-set torque
according to the table.After this, ideal pre-stressing of the bolts is achieved by subsequent
turn through 120° (1/3 of a turn).A defined plastic deformation of the bolts can occur with this
procedure so that maximum pre-stressing is achieved for the individual bolts.

In both cases, tightening the bolts in excess of specifications leads to stress on the bolts
beyond the yield point combined with non-permitted plastic deformation and the danger of a
premature failure of the bolt connection.

8.4.3 Tightening torque for track bolts [Nm]

Streght class Streght class Streght class
[Nm] 11.9 12.9 13.9
Torque Turning angle Torque Turning angle Torque Turning angle
Bolt procedure procedure procedure procedure procedure procedure
M10 x 1 90 ± 5 30 ± 2 100 ± 5 32 ± 2
105 ± 5 35 ± 2
M12 x 1 160 ± 10 50 ± 3 170 ± 10 55 ± 3
180 ± 10 60 ± 3
M14 x 1.5 240 ± 15 80 ± 5 260 ± 15 85 ± 5
270 ± 15 90 ± 5
M16 x 1.5 370 ± 20 180 ± 10 390 ± 20 190 ± 10
410 ± 20 200 ± 10
M18 x 1.5 540 ± 30 260 ± 15 570 ± 30 280 ± 15
600 ± 30 290 ± 15
M19 x 1.5 650 ± 35 320 ± 15 690 ± 35 340 ± 15
720 ± 35 360 ± 20
M20 x 1.5 750 ± 35 340 ± 15 800 ± 40 360 ± 20
830 ± 40 380 ± 20
M22 x 1.5 1000 ± 50 380 ± 20 1070 ± 50 400 ± 20
1120 ± 55 420 ± 20
M22 x 2 1080 ± 50
M24 x 1.5 1320 ± 65 440 ± 20 1410 ± 70 470 ± 20 1470 ± 70 490 ± 25
M27 x 1.5 1920 ± 95 630 ± 30 2050 ± 100 670 ± 30 2140 ± 100 700 ± 35
M30 x 2 2580 ± 130 850 ± 40 2760 ± 140 910 ± 50 2870 ± 140 950 ± 50
M32 X 2 3100 ± 150 1000 ± 50 3310 ± 165 1070 ± 50 3450 ± 170 1110 ± 55
M36 X 2 4550 ± 230 2270 ± 110 4860 ± 245 2430 ± 120 5070 ± 250 2530 ± 125
Streght class Streght class Streght class
[Nm] 11.9 12.9 13.9
Torque Turning angle Torque Turning angle Torque Turning angle
Bolt procedure procedure procedure procedure procedure procedure
7/16 - 20 UNF 115 ± 5 40 ± 2 125 ± 5 43 ± 2 130 ± 5 45 ± 2
½ - 20 UNF 180 ± 10 60 ± 3 190 ± 10 65 ± 3 200 ± 10 70 ± 3
9/16 - 18 UNF 260 ± 15 90 ± 5 275 ± 15 95 ± 5 290 ± 15 100 ± 5
5/8 - 18 UNF 360 ± 20 180 ± 10 385 ± 20 190 ± 10 400 ± 20 200 ± 10
¾ - 16 UNF 630 ± 30 320 ± 15 675 ± 35 340 ± 15 700 ± 35 360 ± 20
7/8 - 14 UNF 1010 ± 50 350 ± 15 1080 ± 55 370 ± 20 1130 ± 55 390 ± 20
1 - 14 UNS 1540 ± 80 520 ± 30 1650 ± 80 560 ± 30 1720 ± 85 580 ± 30
1 1/8 - 12 UNF 2250 ± 110 760 ± 40 2400 ± 120 810 ± 40 2500 ± 125 850 ± 40

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 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

8.5. Fitting the crawler track

When laying out the track, pay attention to
straightness and possibly track
dimensions.

P Place a wooden block under the end

position of the track (front idler side,
bushing side of the free track upwards).

Pay attention to the correct position and

direction of the track segments and
grouser shoes.
Place the complete pre-assembled side
section on the track.
Important! If running gears (left and right
side) have to be positioned to each other,
carry out an intermediate check and align
appropriately.

If the trackside is standing correctly in line,

pull the track over the drive unit in the
direction of the front idler over the side
section.
Make sure that the bushings of the track
grip into the gaps between the teeth of the
sprocket.

End position of the track ends is the upper

section of the front idler.

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 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

Grease two spacers and insert in the

counter bores of the track links (use seal
washers as well if necessary).

Align track segments to each other.

Grease the tips of the master pin and
insert in the hole. Drive in with a heavy
hammer if using small track sizes.
Observe safety instructions. Driving
master pin in and out with a hammer can
cause danger from material chipping off.
Wear protective goggles.

If using larger tracks, drive the master pin

in using a hydraulic pin-driving tool.

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 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

ightening the track (all models)

Tightening the track.
Attention must be paid that all components
of the track are in the correct position.

A grease gun is required for tightening.

Push the connector on the end of the hose
over the grease nipple of the grease-
tensioning valve. Activate the grease gun
for as long as necessary until the track
tension is correct (see notes on tensioning
element in the Front idler unit chapter).

Important!
There must be sag of 2-3 cm over a length
(L) of 1-1.5 m. This applies linear for the
free length (L) smaller or greater than 1-
1.5 m (at least 4 track elements).

Measure the extent of sag using a ruler.

This is achieved by measuring the
distance f from the edge of the grouser
shoe to the ruler (in the middle of the sag).
RULER

Remove the connector upon completion of the tensioning process. The undercarriage should
now be moved back and forth by about 1 turn of the sprocket. Check position of the tracks on
front idler and sprocket.

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 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

Tracks that are too loose can slip out of the flanges of the rollers, sprocket and front idler and
increase wear.

Tracks that are too tight increase the wear on the front idler and drive bearings as well as the
wear on track pins and bushings.
It also requires greater motor output for driving and consequently a higher consumption of
fuel.

Depending on the design, it is possible that there is no sag in the upper strand on some
models. In this case, the track tension can be set by pressure measurement in the tensioning
element or by lifting the undercarriage (measurement of the sag in the upper strand – the
above rules for the distances L and f also apply in this case).

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 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

9. Other/Special components
9.1. Track guide – Function and operation

9.1.1 In general
Track guides are used wherever track sag occurs on undercarriages while travelling over
obstructions. The result is that the track can run outside the flanges of the track rollers.

There are various types of track guides. Differentiation is made between welded and bolted
designs. There are also designs that cover the complete length of the undercarriage and
others that are fitted in sections.

9.1.2 Types of track guide

Track guide, welded design as segment

(With this design, the undercarriage has to
be raised for fitting or removal).

Track guide, bolted design as segment

(With this design, the undercarriage does
not have to be raised for fitting or
removal).

Version without cross-link possible Æ

"lightweight design“

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 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

Track guide, bolted design over complete

length of the side frame
(With this design, the undercarriage does
not have to be raised for fitting or
removal).

9.1.3 Function
Track guide acts as a "threading aid" for the track. If sagging occurs in the track, it comes
away from the track rollers. As the sag recedes, the track guide ensures that the track and
the track roller are properly aligned again.

9.1.4 Track guide – Fitting and removal

There are two fundamental designs of track guide.

In the case of the welded design, the undercarriage has to be raised in order to be able to fit
the track guide because there is no possibility of fitting the chain guide from the side. After
raising the undercarriage, the track guide is mounted onto the undercarriage with bolts.
Removal is analogue in reverse order.

In the case of bolted designs, they can be fitted without raising the undercarriage because
the track guide is in several parts. In this case, one side of the track guide is bolted onto the
undercarriage. The cross link is then connected to the first side of the track guide. The
second side of the track guide is then bolted onto the cross-link. The second side is then
bolted onto the undercarriage. Removal is analogue in reverse order.

Attention must be paid that there is no contact between the track guide and the track roller
body and that there is adequate play between the track guide and the track (pin boss of the
track).

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 TRACK ONE SRL
Via R. Carriera , N° 11
41100 S.Damaso MO
ITALY

9.2. Covers

9.2.1 In general
Covers are shown in the following illustration, they occur on all standard undercarriages (not
all covers are present on all undercarriages).

It is also possible that additional covers are present on the undercarriage that are not shown
in the illustration. Typical covers are for the hydraulic motor or for the hand hole for access to
the lubrication nipple of the tensioning element.

Take care when handling the plates as they can be very heavy depending on size and can
therefore cause injuries.

9.2.2 Function
Covers made of sheet metal are used on an undercarriage. They are used for:
• Covering units and hydraulic lines
• Protection against dirt and contamination
• Protecting people against injury

Cod. T0650C03 08/10/07 Rev.0 44 of 44

 INTERNATIONAL LTD.

D6C
CRAWLER TRACK SERIES.
Covering Track Models:
VZ2175

OPERATION, MAINTENANCE
& PARTS MANUAL
TRACKLINE INTERNATIONAL Ltd.
9 Spencer Parade, Northampton,
England NN1 5AQ
Tel: 01604 232828
Fax: 01604 232324
Email: sales@trackline-international.com
Web: www.trackline-international.com
 QM
S
QMS Quality Management Systems.

Registration Certificate
This document certifies that the quality administration systems of

TRACKLINE INTERNATIONAL LIMITED

have been assessed and approved by QMS Quality Management Systems to the
following quality administration systems, standards and guidelines:

BS EN ISO 9001 - 2000

The approved quality administration systems apply to the following:

THE DESIGN, MANUFACTURE AND SALES OF TRACK LAYING MOBILITY
SOLUTIONS FOR CONSTRUCTION, QUARRYING, INDUSTRIAL
AND RELATED EQUIPMENT.

Original Approval: 17th September 2002 QM

Current Certificate: 17th September 2002 S

Certificate Expiry: 16th September 2012

ISO 9001
Certificate Number: GB 10457 REGISTERED FIRM

QMS
Quality Management Systems
Track Model:
Serial Numbers:
Date of Manufacture:
Weight (per pair) Kg:
Inspected by:

Manual Issue No. D6C - Z2175 - 01

Manual Issue Date: 13/10/04
NOTES ON TERMS USED IN THIS MANUAL:
The following terms have been used in this manual in order to differentiate the parties to which this manual
applies:

Track Set: This is the pair of tracks which go together to make up a set for which this manual refers.
Host Machine: This refers to the machine to which the Track set are fitted.
Host Client: This is the manufacturer of the Host machine who has directly purchased the Track set
from Trackline International.
End user: This refers to whoever operates the Host machine, whether it be the owner of the Host
machine, their employees or the Host Client themselves.

FOREWORD/RESERVATION OF RIGHTS:

This manual has been produced to enable safe, correct and efficient fitting, operation and maintenance of the
Track Sets during their operating life time. By following these instructions you will help to reduce the risk of
accidents, keep repair costs to a minimum and increase reliability of the Track Set.

We strongly insist that the Host Client & their staff and the End User & their staff must read and understand
all aspects of this manual and pay particular attention to the safety and maintenance sections. Keep a copy
of this manual at the operational site at all times.

This manual refers to the FL4 Track series which includes the following Track Models:

VZ2175

While all attempts have been made to ensure that the information contained in this manual is correct, some
variations do exist between Track models and Host Client specifications. Therefore, some incorrect
information may be contained. However, all information, illustrations and specifications in this manual are
based on the latest information available at the time of publication.

Future updated issues of this manual or manuals belonging to similar Track models, may not be specific to all
Track Sets. Trackline International reserve the right to change specification of the Track models and
therefore reserve the right to alter any information, contained in this manual, without prior notice.

Tel: 0044 1604 232828 Fax: 0044 1604 232324 Page 1

COPYRIGHT:

No copies or reproductions may be made from this manual without prior consent of TRACKLINE
INTERNATIONAL Ltd. This manual, complete or in part, must not be loaned to a third party.

WARRANTY:

All parts and components supplied by Trackline International Ltd. in connection with any products or services,
are supplied in accordance with the terms set out in the standard terms and conditions of sale. The Company
shall endeavour to ensure that all products are manufactured to the highest standards of the industry and
carry a 15 month warranty from the date of invoice or (12 months or 1000 hours from the Host Machine
commissioning date), whichever is sooner.

The Company shall in no circumstances be liable for damages of any kind whether direct or consequential
(including but not limited to loss of profit, expenditure incurred, or delay in the execution of any work being
carried out by or for the customer), arising out of, or in connection with the manufacture, or servicing, or
failure to perform the servicing, or failure to return the equipment, or any act done in connection therewith,
except:-
Nothing in this clause shall limit the Company's liability for death or personal injury arising out of negligence
within the United Kingdom.

SPECIFICATION ALTERATIONS:

Trackline Tracks are supplied a as set, to be fitted as a set, to a specific Host Machine. They should not be
operated in a free standing position or be fitted separately to two different Host machines.

At the time of initial design Trackline engineers will have determined the correct specification of the Tracks to
be used on each Host machine. This specification will have been determined through consultation with a
representative of the Host Client, where parameters such as Host machine type, weight, working
environment, correct method of connecting the Track Set to the Host machine and Track Set alterations etc.
will have been determined. Therefore, if at any point in the future the Host client, End User or any other
person wishes to change these parameters, on any one or all Track Sets, they must first consult Trackline
International Ltd. and receive written authorisation prior to the changes taking place.

Where any unauthorised alterations by the Host Client, End User or any other person take place, such as
those listed below, warranty will automatically be invalidated. Trackline International will not be held
responsible for any direct or indirect damage, accident, injury or loss etc. arising from such unauthorised
alterations.

UNAUTHORISED SPECIFICATION ALTERATIONS:

Where the Track Set has been fitted to a different Host Machine (type or model) than that stated.
Where the overall weight of the Host machine has changed.
Where the working environment of the Host machine has changed.
Where the method of connecting the Track Set to the Host machine has changed.
Where new alterations to the Track Set are required.
Where additional items/structures have to be welded/fitted to the Track Set.
Where hydraulic pressures and/or flow rates required to drive the Tracks have changed.
Where the Track Set has been removed from the original Host Machine and re-fitted to another Machine.
Where non-genuine spare parts or spare parts not supplied by Trackline International are fitted to the Track
Set.
Where any other changes to the Host machine take place that will affect the original or authorised amended
specifications, previously agreed between Trackline International and the Host Client or their representative.

Tel: 0044 1604 232828 Fax: 0044 1604 232324 Page 2

 CONTENTS
PAGE No.
SECTION 1.0 FAMILIARIZATION. 4

1.1 Track Familiarization. 4

1.2 Track illustration. 5
1.3 General Description. 6
1.4 Notes. 7

SECTION 2.0 SAFETY. 8

2.1 Safety Introduction. 8

2.2 Safety Signs in this Manual. 9
2.3 Safety before and during Transportation. 10
2.4 Safety before and during Fitting Tracks to Host Machinery. 10
2.5 Safety before and during Maintenance. 10

SECTION 3.0 TRANSPORTATION. 11

3.1 Safety before and during Transportation. 11

3.2 Transportation of Tracks. 12

SECTION 4.0 FITTING TRACKS TO HOST MACHINERY. 13

4.1 Safety before and during Fitting Tracks to Host Machinery. 13

4.2 Fitting Tracks to a Host Machine. 14
4.2.1 Track Mountings. 14
4.2.2 Track Direction. 14
4.2.3 Track Alignment. 14
4.2.4 Levelling the Track Group. 14
4.3 Connecting the Hydraulics. 15
4.3.1 Notes. 16
4.4 Gearbox Oil. 17
4.5 Pre-operation Checks. 17

SECTION 5.0 MAINTENANCE. 18

5.1 Safety before and during Maintenance. 18

5.2 Maintenance Introduction. 19
5.3 Initial Maintenance Schedule. 19
5.4 Daily/Weekly Maintenance Schedule. 19
5.5 Monthly Maintenance Schedule. 19
5.6 Lubrication. 19
5.7 Wear Limits. 20
5.7.1 Track Shoe Wear Limits. 20
5.7.2 Track Link Wear Limits. 21
5.7.3 Internal Pins and Bushings Wear Limits. 22
5.7.4 Sprocket Wear Limits. 22
5.7.5 External Bushings Wear Limits. 23
5.7.6 Track Rollers Wear Limits. 24
5.7.7 Idler Wear Limits. 25

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 CONTENTS CONTINUED:

PAGE No.
SECTION 5.0 MAINTENANCE CONTINUED.

5.8 Track Adjustment. 26

5.8.1 Track Adjustment Settings. 26
5.8.2 Increasing the Track Tension. 26
5.8.3 Releasing the Track Tension. 26
5.9 Gearbox Oil Level. 27
5.9.1 Checking and Filling Gearbox Oil. 27
5.9.2 Draining Gearbox Oil. 27
5.10 Bolt Torque Settings. 27
5.11 Replacing the Track Shoes. 28
5.11.1 Removing a Track Shoe. 28
5.11.2 Fitting a Track Shoe. 28
5.12 Replacing the Sprocket. 28
5.13 Removing the Track Group. 29
5.14 Fitting the Track Group. 30
5.15 Replacing the Gearbox. 31
5.15.1 Removing the Gearbox. 31
5.15.2 Fitting the Gearbox. 32
5.16 Replacing the Motor. 33
5.16.1 Removing the Motor. 33
5.16.2 Fitting the Motor. 33
5.17 Replacing the Motion Control Block. 34
5.17.1 Removing the Motion Control Block. 34
5.17.2 Fitting the Motion Control Block. 34
5.18 Replacing the Hose Kit. 35
5.18.1 Replacing the Brake Hose. 35
5.18.2 Replacing the Drain Hose. 35
5.19 Replacing a Track Roller. 36
5.20 Replacing the Idler Group. 37
5.20.1 Removing the Idler Group. 37
5.20.2 Fitting the Idler Group. 37
5.21 Removing the Idler from the Spring Tension Unit. 38
5.22 Replacing the Tension Cylinder. 39
5.22.1 Removing the Tension Cylinder. 39
5.22.2 Fitting the Tension Cylinder. 39
5.23 Fitting a Track Link Repair Kit. 40
5.23.1 Removing the Damaged Link. 40
5.23.2 Fitting the Repair Link. 41

SECTION 6.0 FAULT FINDING. 42

6.1 Fault Finding Introduction. 42

6.2 Possible Faults. 43 - 44

SECTION 7.0 SPARE PARTS. 45

7.1 Spare Part Ordering Information. 45

7.2 Locating the Track Serial and Model numbers. 45
7.3 Parts illustration. 46
7.4 Parts List. 47 - 53

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 SECTION 1.0

FAMILIARIZATION

! CAUTION Ensure that all personnel are familiar with all

aspects of the Tracks.

1.1 TRACK FAMILIARIZATION.

The terms and descriptions given for the parts and assemblies, shown in section 1.2, are used throughout this
manual. In the interests of safety, efficiency and better communications please ensure that all persons
involved at any stage with Trackline Tracks become familiar with all part names and descriptions used.

Fitters, operators and maintenance staff should become familiar with the location of each part on the Tracks,
know how they are assembled and become aware of the associated hazards.

Tel: 0044 1604 232828 Fax: 0044 1604 232324 Page 4

1.2 TRACK ILLUSTRATION.

1A ITEM DESCRIPTION:
4 1 Track Group Complete.
1A Track Shoe.
1B Link Assembly.
2 Track Frame.
1B 3 Inspection Plate.
1 2 3
4 Hydraulic Motor.
5 -
6 -
7 -
8 -
9 -
10 Idler Group.
10A Idler
10B Spring Tensioning Unit.
10C Track Tensioner.
11 10D Track Adjuster Grease Valve.
10E Grease Gun Connector.
11 Track Guide.
10 12 Track Roller.
13 Serial Plate.
12 14 Sprocket.
15 Gearbox.
16 Master Pin.
13 14 15 17 Gearbox Oil Filler Plug.
18 Gearbox Oil Drain Plug.
16
10E
17
10A
18
10B 10C
10D

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1.3 GENERAL DESCRIPTION.
The Tracks will normally be delivered in a set of two, known as a Track Set. The Tracks in a Track Set will be
opposites, 1 Left Hand Side and 1 Right Hand Side. Each track consists of six main assemblies: Track
Frame, Track Group, Drive Assembly, Motion Control, Idler Group and Track Rollers.

(i). Track Frame:

The Track Frame, (2), is the main structure of the track onto which all the other assemblies are mounted,
including the Host Machine. The weight of the Host Machine must be distributed along the length of the
Track Frames.

(ii). Track Group:

The Track Group, (1), comprises of a sectional chain link assembly, (1B), with triple bar grouser shoes, (1A),
bolted to it.

(iii). Drive Assembly:

The Drive Assembly, which is located at the rear end of the track, consists of a Planetary Gearbox, (15),
which is driven by a hydraulic motor, (4). Within the Gearbox is a safety negative multidisc brake which is
hydraulically driven. A small pressure is required to release the brakes. The brakes are for static (park)
braking only and are not capable of providing dynamic braking.

(iv). Idler Group:

The Idler Group, (10), which is located at the opposite end of the Track to the Drive Assembly, acts as an
Idler Wheel, Track Tensioner and as a Suspension unit. In the event of an excessive load being placed on
the track when it is moving, the recoil spring will allow the idler to move backwards. Track tensioning works
by pumping grease through the Track Adjuster Grease Valve, (10D) and into the Track Tensioner, (10C). The
Tensioner then pushes the Spring Tension Unit, (10B) and the Idler, (10A) forward, thus, tightening the
tension on the track.

(v). Track Rollers:

The Track Rollers, (12), are located on the underside of the Track Frame. These rollers align the Track
Group and carry the entire weight of the Host Machine.

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1.4 NOTES.

Tel: 0044 1604 232828 Fax: 0044 1604 232324 Page 7

 SECTION 2.0

SAFETY

2.1 SAFETY INTRODUCTION.

All personnel who fit, maintain, repair or carry out work near or on Trackline Tracks, including personnel who
operate the Host Machinery, must be properly trained in correct and safe procedures for operation,
maintenance and repair etc.

This section in no way replaces any laws or other binding accident prevention and environmental protection
regulations.

The Track Set and the Host Machine must be used as they were intended.

Before fitting, operating, maintaining or repairing Trackline Tracks all personnel must:

(i). Have read and understood all aspects of this manual.

(ii). Be aware of all the hazards associated with the Tracks.

(iii). Have received specific and adequate training for any particular task to be carried out.

(iv). Be completely familiar will all parts of the Track Set, see section 1.2.

(v). Be aware of all moving parts on the Tracks.

(vi). Have read and understood the Host Machine's "Operation and Safety" manual.

(vii). Be aware of the limits of performance on the Host Machine.

We recommend that the minimum personal protection worn by personnel carrying any type of work on the
Tracks should be as follows:

Safety Goggles, Safety Boots, Overalls, Safety Helmet, Gloves, High Visibility Vest.
Note: all protective clothing should be EN/ANSI approved.

This is only a recommendation, it remains the responsibility of the Host Client and End user to ensure that
adequate safety procedures and equipment are in place before work is carried out on Trackline Tracks.

Tel: 0044 1604 232828 Fax: 0044 1604 232324 Page 8

2.2 SAFETY SIGNS IN THIS MANUAL.

The following safety signs are seen throughout this manual to highlight areas of potential hazards.
Ensure that you make yourself familiar with each sign and their corresponding level of hazard warning.

(i). The CAUTION sign below indicates a minor or moderate hazard potential. In this situation care
should be taken to avoid the risk otherwise injury to personnel may occur.

! CAUTION
(ii). The WARNING sign below indicates a high hazard potential. In this situation extra care should be
taken to avoid the risk otherwise severe injury or death to personnel could occur.

! WARNING
(iii). The DANGER sign below indicates the highest level of hazard potential. In this situation extreme
care should be taken to avoid the risk otherwise severe injury or death to personnel will occur.

! DANGER

Tel: 0044 1604 232828 Fax: 0044 1604 232324 Page 9

 Before carrying out any work on Trackline Tracks

! CAUTION you Must read and understand the Safety

instructions for each section of this manual.

2.3 SAFETY BEFORE AND DURING TRANSPORTATION.

(i). Trackline Tracks will usually be delivered to the Host client on a trailer. Before unloading the Tracks from
the trailer ensure that you have a suitable lifting device. We strongly recommend that you use a forklift to lift
and/or transport the Tracks. Whatever lifting device is used it must have a lifting capacity equal to or above
the weight of each individual track. (The weight of each Track is shown on the Serial plate)

(ii). Ensure that only trained staff are allowed to unload or transport the tracks.

(iii). Only lift and/or transport one Track at a time.

(iv). Ensure that the Tracks are unloaded and/or transported in accordance with the procedures given in
section 3.2.

(v). Ensure that the tracks are stored correctly as shown in section 3.2.

2.4 SAFETY BEFORE AND DURING FITTING TRACKS TO HOST MACHINERY.

(i). Ensure that adequate instruction and training has been provided to the personnel who are fitting the
tracks to the Host machine.

(ii). Ensure that lifting equipment of adequate capacity is used to fit the tracks.

(iii). Ensure that the Host machine is stable and is supported well enough to take the weight of both itself
and the weight of the Tracks when they are fitted.

(iv). Ensure that the correct equipment, tools, safety devices and personal protection are used.

(v). Ensure that there is adequate space around the Host Machine to manoeuvre the Tracks into
place.

2.5 SAFETY BEFORE AND DURING MAINTENANCE.

(i). Ensure that adequate instruction and training has been provided to the personnel who are carrying out
any work on the Tracks.

(ii). Ensure that the personnel carrying out the work know, understand, and follow the relevant procedures
shown in this manual.

(iii). Ensure that all personnel have read and understood the safety procedures shown in the Host
Machine's Operation and Safety Manual.

(iv). Ensure that the correct equipment, tools, safety devices and personal protection are used.

(v). When personnel are working with lubricants, especially Hydraulic oil, extra care must be taken. Use
proper protective gloves and eye goggles. Hydraulic oil under pressure can penetrate skin. Always relieve
pressure on Hydraulic systems before unscrewing Hydraulic fittings. If even a small amount of oil
penetrates the skin seek medical help immediately.

(vi). Ensure that there is adequate space around the Host Machine to carry out the relevant maintenance or
repair.

(vii). Ensure that the Host Machine is "Locked Out" as per the Host Machine's instruction manual.

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 SECTION 3.0

TRANSPORTATION

Serious Nip and Crush Hazards exist when

! WARNING Transporting Tracks. Always use lifting

equipment with adequate lifting capacity.

3.1 SAFETY BEFORE AND DURING TRANSPORTATION.

(i). Trackline Tracks will usually be delivered to the Host client on a trailer. Before unloading the Tracks from
the trailer ensure that you have a suitable lifting device. We strongly recommend that you use a forklift truck
to lift and/or transport the Tracks. Whatever lifting device is used it must have a lifting capacity equal to or
above the weight of each individual track. (The weight of each Track is shown on the Serial plate)

(ii). Ensure that only trained staff are allowed to unload or transport the tracks.

(iii). Only lift and/or transport one Track at a time.

(iv). Ensure that the Tracks are unloaded and/or transported in accordance with the procedures given in
section 3.2.

(v). Ensure that the tracks are stored correctly as shown in section 3.2.

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 Before transporting Trackline tracks you Must

! DANGER fully understand and carry out the following

procedures.

3.2 TRANSPORTATION OF TRACKS. (A)

(i). Track Sets will normally be delivered on a trailer. To

remove the Tracks from the trailer and when transporting on
site, we strongly recommend that you use a forklift truck.

(ii). The forklift truck that you use should have a lifting
capacity equal to or more than the weight of any individual
track. To find the weight of each track refer to the serial plate
located on the side of each track frame.
(B)
(iii). Only allow trained forklift operators to transport tracks.

(iv). Only lift one track at a time.

(v). To lift the Track place the forklift toes between the bottom
Track Rollers on the underside of the Track Frame, as shown in
(B) and (C). The toes should lift against the flat underside
edge of the Track Frame.

(vi). To provide stability ensure that the forklift is in the centre

of the Track and that the forklift toes are as wide as possible. (C)

(vii). When lifting the Track ensure that the end of the toes are
at least six inches past the Track Frame. Tilt the toes up
slightly to avoid the Track sliding off. In wet conditions extra
care should be taken as the wet increases the chances of
Tracks sliding off the toes.

(viii). Do not lift the tracks at any other point especially

underneath the Track Group. This can cause great stress on
the Idler, Spring Tension Unit and Sprocket.
(D)
(ix). Care must be taken when inserting forklift toes between
the Track Rollers. Forklift toes impacting on these rollers can
cause misalignment and/or internal seal damage.

(x). Care must be taken when moving or storing the Tracks.

Heavy impacts on any part of the Track can cause
misalignment or internal damage. The Gearbox and Motion
Control Blocks are especially vulnerable to impact damage.

(xi). The Tracks should only be stored in the upright position,

as shown in (D). Tracks should not be stored on top of each
other. We strongly recommend that the Tracks should never
be turned on their side. However, in cases where this has to be
done we would recommend that two forklifts are used and that
extra care is taken to avoid any form of impact. Tracks should
only remain on their side for as short a period of time as
possible.

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 SECTION 4.0

FITTING TRACKS TO
HOST MACHINERY

! WARNING Serious Nip and Crush Hazards exist when fitting

Tracks onto Host Machinery.

4.1 SAFETY BEFORE AND DURING FITTING TRACKS TO HOST MACHINERY.

(i). Ensure that adequate instruction and training has been provided to the personnel who are fitting the
tracks to the Host machine.

(ii). Ensure that lifting equipment of adequate capacity is used to fit the tracks.

(iii). Ensure that the Host machine is stable and is supported well enough to take the weight of not only
itself but also the weight of both Tracks when they are fitted.

(iv). Ensure that the correct equipment, tools, safety devices and personal protection are used.

(v). Ensure that there is adequate space around the Host machine to manoeuvre the Tracks into
place.

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4.2 FITTING TRACKS TO A HOST MACHINE.

In order to ensure that the Tracks operate correctly for a long life time, (A).
it is imperative that each Track Set is fitted correctly to each Host
Machine.
A suitable design for mounting the Tracks to the Host Machine should
have been discussed with Trackline engineers, at the time of initial
purchase. Therefore, the agreed mounting design should be used on
each and every Host Machine of that type.
Where the Host Client wishes to fit similar Tracks to different Host
Machines they should not assume that the same mounting design will
be acceptable. Always consult Trackline before fitting Tracks to
(B)
different Host Machines.

IMPORTANT:
No alterations, additions or changes should be made to the Tracks or
the mounting design during fitting or at any other time without
Trackline authorisation. Where changes are made to the Host (C)
Machine, which alter it's weight, Trackline should also be notified.

4.2.1 TRACK MOUNTINGS.

While the Track mountings will vary between different Host Machines
some important aspects will remain the same throughout. The Host
Client should ensure that the mounting brackets are fitted correctly and
are of a suitable strength to carry the weight of the Host machine.
Trackline takes no responsibility for Track mounts which are fitted by (D)
the Host Client.

4.2.2 TRACK DIRECTION.

The Tracks should be fitted so that the Drive end of the Track i.e. the
(E).
Gearbox and Motor, is located at the rear end of the Host Machine
when it is being tracked forward, as shown at (E). Forward

4.2.3 TRACK ALIGNMENT.

The Tracks should be fitted exactly parallel to each other, as shown at Reverse
(A), and square to each other, as shown at (B). If the Tracks are not
fitted perfectly parallel and square, as shown at (C) and (D), excessive
wear may occur to the Track components. It is also likely that the Host Hydraulic Motor
Machine will track in a circular motion when moving. The Host & Gearbox
Machine should be also mounted parallel and central to the Tracks.

4.2.4 LEVELLING THE TRACK GROUP. (F).

Once the Host Machine has been fitted the Track Groups should be
checked to ensure they are level and straight. Check the levelness
above the Sprocket and Idler, as shown in (F) and (G). To visually
check the straightness of the Track Group stand at one end of the
Track and look along its length. The edge of the Track Shoes should
be running perfectly straight. (G)

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 Beware of Hydraulic oil. Always use suitable

! CAUTION gloves and barrier cream when working with

Hydraulic oil.

4.3 CONNECTING THE HYDRAULICS.

(i). Cleanliness is essential when fitting the hydraulic hoses to Drain

the Motors. Contamination in the Ports will cause operating (A). Connection.
problems later on. Ensure that all hoses have been M1
thoroughly cleaned before fitting. Before removing the caps
on the Motors ensure that the surrounding work area is clean
and free from dust and dirt etc. Do not remove caps until
you are ready to fit hoses.

(ii). Before connecting the hydraulics you should become

completely familiar with the operation and function of the M2
Motors.

(iii). In order to drive the Tracks a hydraulic oil supply is

required. The oil pressures and flow-rates required to drive Brake
the Tracks will vary between different Host machines. Connection.
Contact Trackline to determine flow-rate and pressure
requirement.
The oil supply to each Track should be supplied from
separate Directional Control Valves. These valves should
typically be "3 position / 4 way" valves and when switched
should provide forward / reverse and stop functions.

(iv). High pressure hydraulic hose should be used to connect

the supplies from the Directional Control Valves to the
Motors. The Hoses should be fitted directly from the
Directional Control Valves to Ports M1 & M2 on the Motors.

(v). In order to release the brakes the system requires a

small supply pressure line fitted to the Gearbox, as shown at
(A). The pressure supply to the brakes must be limited to
not more than 45 bar, which is just sufficient to release the
brakes.

(vi). The system also requires a Drain line to be fitted to the

"Drain Connection", as shown at (A). It is recommended that
to prevent any significant back pressure affecting the brakes,
the Drain line should be fitted directly to the top of the
hydraulic tank. Back pressure in the drain line has the
potential to prevent the brakes from operating correctly
and/or damaging the Brake Pressure Regulator.

(vii). It is strongly recommended that Pressure Relief valves

are fitted between the Pump and the Directional Control
Valves.

(viii). Ensure that suitable dowty seals are used on the hose
connection fittings to prevent leaks.

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4.3.1 NOTES.

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4.4 GEARBOX OIL.

When the Tracks are delivered to the Host Client the gearboxes will not contain oil. Before operating the
Tracks the Gearboxes must be filled with oil. It is essential that the correct grade of oil is used. Refer to
section 5.6 for the correct oil type and procedures on how to fill the Gearbox with oil.

4.5 PRE-OPERATION CHECKS.

Before operating the Tracks for the first time carry out the following checks:

(i). Check alignment of the Tracks.

(ii). Check alignment and levelness of the Track Groups.
(iii). Check that the Hydraulics are fitted correctly.
(iv). Check for Hydraulic oil leaks.
(v). Check that the Gearbox has been filled with oil.
(vi). Check the Track adjustment, see section 5.8.

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 SECTION 5.0

MAINTENANCE

! WARNING Serious Nip and Crush Hazards exist when

carrying out work on the Tracks.

5.1 SAFETY BEFORE AND DURING MAINTENANCE.

(i). Ensure that adequate instruction and training has been provided to the personnel who are carrying out
any work on the Tracks.

(ii). Ensure that the personnel carrying out the work know, understand and follow the relevant procedures
shown in this manual.

(iii). Ensure that all personnel have read and understood the safety procedures shown in the Host
Machine's Operation and Safety Manual.

(iv). Ensure that the correct equipment, tools, safety devices and personal protection are used.

(v). When personnel are working with lubricants, especially Hydraulic oil, extra care must be taken. Use
proper protective gloves and eye goggles. Hydraulic oil under pressure can penetrate skin. Always relieve
pressure on Hydraulic systems before unscrewing Hydraulic fittings. If even a small amount of oil
penetrates the skin seek medical help immediately.

(vi). Ensure that there is adequate space around the Host Machine to carry out the relevant maintenance or
repair.

(vii). Ensure that the Host Machine is "Locked Out" as per the Host Machine's instruction manual.

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5.2 MAINTENANCE INTRODUCTION.

The maintenance of the Tracks is the responsibility of the Owner/User of the Host Machine. In the interests of
safety and continued plant reliability, the Tracks should be properly maintained using the following procedures
and recommendations.

5.3 INITIAL MAINTENANCE SCHEDULE.

(i). Re-torque all bolts after the first 50 hours of operation, followed at 250 hours of operation and then as per
the monthly schedule, see section 5.10 for bolt torque settings.
(ii). The wear limits should be checked after the first 1000 hours of operation, in addition to the monthly
checks, see section 5.7 for wear limits.
(iii). The oil in the Gearbox should be replaced after the first 200 hours of operation and every 2000 hours
thereafter or at least once per year. See section 5.9 for details on replacing the oil in the gearbox.

5.4 DAILY/WEEKLY MAINTENANCE CHECKS.

The following checks should be on a daily/weekly basis:

(i). Clear all material, especially stones and rocks, from around the Sprocket, Idler and Track Group.
(ii). Check the tension of the Track, see section 5.8 for details on Track tensioning.
(iii). Check for loose bolts all round the Tracks, especially around the Drive Assembly. Tighten loose bolts
immediately, see section 5.10 for bolt torque settings.
(iv). Check for oil leaks around the Hydraulic Motor. Investigate and repair any leaks immediately.
(v). Check for grease leaks in and around the Track Tensioning Unit. Open the inspection plate on the side of
the Track Frame to inspect the Track adjuster valve. Investigate and repair any leaks immediately.
(vi). Check all the Track Rollers for oil leaks, alignment and loose bolts.
Note: The Track Rollers are "Lubricated for Life". No servicing is therefore required. If however an oil leak is
discovered a complete replacement roller should be fitted immediately.
Important: Removal of the sealed filler plug on a Track Roller invalidates warranty.
(vii). Check for external damage on all parts of the Tracks but particularly the Track Group.

5.5 MONTHLY MAINTENANCE CHECKS.

In addition to the above daily/weekly checks, the following checks should be carried out on a monthly basis:
(i). Re-torque all bolts, especially the Sprocket bolts, see section 5.10 for bolt torque settings.
(ii). Check all wear limits, see section 5.7 for wear limits.
(iii). Check Track Group alignment and levelness, see section 4.2 for details on Track Group alignment and
levelness.
(iv). Check the Gearbox oil level and add if necessary, see section 5.9 for details on checking the oil level.

5.6 LUBRICATION.

(i). Gearbox Lubrication:

Please note the Gearboxes are shipped from Trackline WITHOUT oil. The oil required should conform to the
following specification:
MIL-L-2105 or API GL5 Grade 80W/90
Examples of such oils are: Texaco Geartex EP-B 80W/90 Century Oils BOA 80W/90
All leading oil suppliers will offer equivalents.

(ii). Track Adjustment:

The Track adjustment system requires a good quality all purpose grease such as:
Texaco EP2 All Purpose Grease.
All leading oil suppliers will offer equivalents.

No lubrication is required on any other parts of the tracks.

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5.7 WEAR LIMITS.

During the lifetime of a Track Set wear on some parts is inevitable. To ensure that damage and repair costs
due to wear are kept to a minimum it is imperative that the amount of wear on certain parts is measured
regularly. See section 5.3 for maintenance schedule. To show the maximum amount of wear that can take
place on each part we have listed the wear limits for these parts. The percentage increments of the different
stages of wear is also shown. For example, 25% wear is the initial wear taking place, 100% wear is the
maximum wear that can take place before damage is caused. Note: When 75% wear is detected operators
should schedule an overhaul and replacement of parts.
Areas where excessive wear is likely to occur is shown in red on the following illustrations.

We have also shown what we consider is the most practical way to measure wear on each part. In order to
measure for wear you will require the following tools: an outside calliper, a depth gauge and a tape measure.

5.7.1 TRACK SHOE WEAR LIMITS.

(A).
The most common part to wear and the most important to
check is the Track Shoe, as shown at (B).

A depth gauge should be used to measure from the top of x.

the grouser to the Shoe plate, as shown at (A). Schedule a
replacement service if at 75% wear. Replace immediately if
at 100% wear.

Wear Limit - Dimension x. Note: Dimensions in mm

Component. New 25% 50% 75% 100%

(B)
Track Shoe 18 15 12 8 4

Other types of wear can occur on the Track Shoe which is not
regarded as normal and should be investigated immediately.

Wear on the overlapping surfaces, as shown at (C). This is

normally caused by a snaking chain. Check the Track group
alignment. (C)

Enlarged bolt holes, as shown at (D). This is caused when

the bolts holding the Track Shoes to the Track Links are not
tight enough and movement of the Shoe occurs. Replace
damaged Shoes and tighten all bolts to correct torque, see
section 5.10 for bolt torque settings.

(D)

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5.7.2 TRACK LINK WEAR LIMITS.

The most common area to wear on the Track Link is the (A).
running surface, as shown at (B).
x.
A depth gauge should be used to measure from the top of
the Link running surface to the Track Shoe, as shown at (A).
Schedule a replacement service if at 75% wear. Replace
immediately if at 100% wear.
(B)
Wear Limit - Dimension x. Note: Dimensions in mm

Component. New 25% 50% 75% 100%

Track Link 70 69.2 68 66.7 65

Other types of wear can occur on the Track Link which is not
regarded as normal and should be investigated immediately. (C)

Excessive side rail wear, as shown at (C). This may be

caused by a snaking chain, misalignment or extreme
operating conditions such as steep ground or sudden turns
etc. Check the tension of the Track Group and the alignment
of the Sprocket, Idler and Track Rollers.

Excessive Pin boss side wear, as shown at (D). This is (D)

caused when the top flange of the Track Rollers rub against
the boss. Check the wear on the running surface of the Track
Link and the tread wear on the Track Rollers.

Excessive Pin boss face wear, as shown at (E). This is the

result of excessive snaking of the chain due to Sprocket and
Track Roller misalignment or uneven Track Roller tread wear.
Check for Sprocket misalignment and rotate Track Rollers (E).
where necessary.

Gouges on inside edge of rail, as shown at (F). This is

caused by the Sprocket teeth catching on the inside of the rail
due to a twisted chain or a misaligned Sprocket. Check Chain
and Sprocket alignment.

Gouges on both sides of rail, as shown at (G). This is (F).

caused when the Tracks are subjected to excessive shock
loads. This effect can be exaggerated if the Track Tension is
to tight. This will only have a detrimental effect on the link if
more than 30% of the rail is damaged. Check Track Tension
and reduce shock loads where possible.

(G).

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5.7.3 INTERNAL PINS AND BUSHINGS WEAR LIMITS.

Wear occurs on the internal pins and bushings due to the (A).
circular motion of the Tracks and will normally occur as
shown at (B). When wear occurs the Track chain tends to
elongate. Therefore, to measure the extent of the wear an x.
average must be taken over a section of the chain
containing no less than four links (five pins). Do not include
the master pin in the section to be measured and ensure that
the section is on the top side of the Track. The Track should (B)
also be well tensioned.

Using a tape measure or similar adequate measuring device,

measure from the centre of the first pin to the centre of the
fifth pin, as shown at (A). Schedule a replacement service if
wear is at 75%. Replace immediately if at 100% wear.

Wear Limit - Dimension x. Note: Dimensions in mm

Component. New 25% 50% 75% 100%

Internal
560 563 566 569 573
Pin & Bush

Other problems can occur with the internal pins which are not regarded as normal and should be investigated
immediately.

Worn pin end. Can be caused if the Host Machine is operating on uneven ground, has incorrect chain
tension or Track Roller wear. Check chain tension and rotate Track Rollers where necessary.

Loose pins. This may be caused by damaged or loose Track Shoes, damaged chain links or by excessive
operation of the Host Machine.

Broken pins. This is mainly caused by excessive shock loads on the Tracks or by rocks or material jamming
between the Sprocket and the Chain Link. Ensure that material cannot get jammed between the Sprocket and
the Chains Links.

5.7.4 SPROCKET WEAR LIMITS.

(C) x. z.
Wear occurs on the Sprocket due to the circular motion of y.
the Tracks and will normally occur as shown at (D). It is very
difficult to measure the extent of wear as no trace of the
original teeth remain. It is therefore impossible to provide
data to measure against. However, it is recommended that
the wear be evaluated against an unused Sprocket of the
same type. (D)

Generally when the Sprocket has worn to the extent that it

matches any or all of the points on Figure (C), then is should
be replaced.

Point x. - Reverse drive side wear.

Point y. - Radial wear.
Point z. - Forward drive side wear.

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5.7.5 EXTERNAL BUSHINGS WEAR LIMITS.
(A). Forward Direction Wear
Wear occurs on the external bushings due to the contact
between the Sprocket Tooth and the Bushing, as shown at Radial Wear
(C). Wear occurs on three points on the bushing as shown
at (A). On the top edge due the forward motion of the Track,
the bottom edge due the reverse motion of the Track and the
radius due to contact with the Sprocket tooth and the
Bushing.

Use an outside calliper to measure the wear, as shown at Reverse Direction Wear
(B). Schedule a replacement service if wear is at 75%.
Replace immediately if at 100% wear. (B)
Note: The Link will have to be replaced as the bushing
cannot be removed.
Wear Limit - Dimension x. Note: Dimensions in mm

Component. New 25% 50% 75% 100% x.

External
37 36.5 35.9 35.2 34.3
Bushing

Other problems can occur with the bushings which are not
regarded as normal and should be investigated immediately.
(C)
Collapse of the bushing wall. Mainly due to excessive
internal or external wear. Excessive shock loads or material
jamming between the Sprocket and the Track Link may also
cause this problem. Adjust Chain tension and ensure regular
bushing wear checks and replace immediately if 100% wear
is reached.

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5.7.6 TRACK ROLLERS WEAR LIMITS.
(A) x.
Wear occurs mostly on the inside diameter of the Track
Roller which is known as tread wear, as shown at (B). To
measure the tread wear use an outside calliper and measure
across the diameter on both treads of the roller, as shown at
(A). The smallest diameter will therefore have the highest
wear.

It is normally sufficient to measure only the rollers closest to

the Sprocket and Idler as these will have the highest rates of
(B)
wear.

Schedule a replacement service if wear is at 75%. Replace

immediately if at 100% wear.

Wear Limit - Dimension x. Note: Dimensions in mm

Component. New 25% 50% 75% 100%

Track Roller 162 160 157.5 154.5 150

Other wear can occur on the Track Rollers which is not

(C)
regarded as normal and should be investigated immediately.

Excessive side flange wear, as shown at (C). This is

usually caused by roller misalignment or the chain becoming
very slack. If rollers are within their wear limit then realign
the rollers and/or adjust the Track tension.

Top flange wear, as shown at (D). This is due to the top

flange contacting against the Link pin boss or excessive
snaking of the chain. Check the tread wear on the Track
Roller and the wear on the chain links. If wear is not at
100% then adjust the Track tension. (D)

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5.7.7 IDLER WEAR LIMITS.
(A)
Wear occurs mostly on the radial tread of the Idler, as shown
x.
at (B). To determine the tread wear measure from the top
flange to the treads, as shown at (A). Firstly, however, it
must be confirmed that the top flange is not worn. This can
normally be done by visual inspection.

Schedule a replacement service if wear is at 75%. Replace

immediately if at 100% wear.
Wear Limit - Dimension x. Note: Dimensions in mm (B)
Component. New 25% 50% 75% 100%

Idler 15 15.7 16.6 17.8 19

Other wear can occur on the Idler which is not regarded as

normal and should be investigated immediately.

Excessive side flange wear, as shown at (C). This is

usually caused by either operating conditions, track tension,
roller misalignment or poor Idler tread conditions. Ensure
that the Track is tensioned correctly. Also ensure that the (C)
Idler and Track rollers are correctly aligned.

Top flange wear, as shown at (D). This is normally caused

by poor Idler tread conditions or by material packing between
the Idler and the chain. Ensure that the Track is correctly
tensioned and that material is removed from around the
Idler.

Note: Excessive Idler tread wear may cause cracking or

collapse of the Idler.

(D)

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 Grease under pressure can cause serious injury.

! WARNING Never unscrew a Track Adjuster Valve by more

than a 1/2 turn, when the Track is under tension.

5.8 TRACK ADJUSTMENT.

After maintenance or over time the Track will become slack
and will have to be adjusted. The adjustment of the tracks
operates through a Tensioning Cylinder, (C). When the
Cylinder is filled with grease it extends and pushes the
Spring Tension unit, (B), and the Idler, (A), forward. The
grease is filled through the Track Adjuster Grease Valve,
(D). (A)
(B)
5.8.1 TRACK ADJUSTMENT SETTINGS. (C)
In order to establish if the track requires tensioning move the
Host machine a few metres forwards and backwards on level
(D)
ground. This allows the tracks to adopt their natural degree
of tension.
Note: Do not slew the machine.
(E). 35mm
Using a straight edge and a measuring tape measure the
droop of the Track Group, as shown at (E). For this
particular Track Set the droop should not exceed 35mm.
Note: It is also important that the Track is not tensioned too
tightly as this places excessive loads on the Gearbox and
Idler bearings. It will also lead to accelerated wear and
premature failures.

5.8.2 INCREASING THE TRACK TENSION.

To increase the tension of the Track: (F).
(i). Remove the inspection cover on the side of the Track
Frame, as shown at (F).
(ii). Ensure that the Track Adjuster Valve, (H), is tight.
(iii). Attach the special grease gun connector, (G), to a (G).
grease gun and fit it onto the Track Adjuster Valve, (H).
(iv). Pump grease into the valve until the droop of the Track
is correct.
(v). Move the Host machine backwards and forwards a few
times more and then re-check the droop. Add more grease
if required.
(vi). Check for any escaping grease around the Tensioning
unit and finally close the inspection cover when finished.
Important: Ensure that the correct grease is used, see (H).
section 5.6 for correct grease type.

5.8.3 RELEASING THE TRACK TENSION.

To the release the tension on the Tracks:
(i). Remove the inspection cover on the side of the Track
Frame, as shown at (F).
(ii). Loosen the Track adjuster valve, (H), by turning it one
half turn anticlockwise.
(iii). Grease should now escape slowly from the Track
Tensioning Cylinder and the Track should slacken.
(iv). If the Track fails to loosen apply a little pressure to the
Idler end of the Track to push the Idler group in.
(v). Replace the inspection cover when completed.

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5.9 GEARBOX OIL LEVEL.

The Gearbox on the Tracks will be delivered to the Host Client (A)
without oil. It is therefore vital that oil is added before
operation. For details on the correct oil to be used see section
Oil Fill
5.6. For details on the oil maintenance schedule see section
Hole
5.3.

Important: Cleanliness is essential when checking, filling or Oil Drain

replacing oil in the gearbox. Gearbox operating life will be Hole
dramatically shortened if the oil becomes contaminated. Only
use new clean oil in clean containers and fillers.

5.9.1 CHECKING AND FILLING GEARBOX OIL.

(B)
(i). Move the Host Machine to a level surface and bring the oil
fill and oil drain holes to the position shown at (A). Oil Fill
(ii). Thoroughly clean around both plugs removing all potential Hole
contaminants.
(iii). Remove both plugs. Oil Drain
(iv). Fill the oil through the upper hole until it runs out of the Hole
lower hole.
(v). Wait a few moments until any trapped air has escaped
and then re-check the level. Add more oil if necessary.
Note: The gearbox should hold approximately 5 litres of oil.

5.9.2 DRAINING GEARBOX OIL.

(i). Move the Host Machine to a level surface and bring the oil fill and oil drain Holes to the position shown
at (B).
(ii). Thoroughly clean around both plugs removing all potential contaminants.
(iii). Remove both plugs and allow the oil to drain. The oil will drain quickly if it is hot, however, care
should be taken to avoid burns to the operator.
Note: Dispose of used oil safely and in a environmentally friendly manner.
(iv). Move the machine to bring the plugs to the fill position, as shown at (A).
Important: Do not move the machine any further until the oil has been replaced into the gearbox.
(iv). Re-fill the oil as per the procedure in section 5.9.1.

5.10 BOLT TORQUE SETTINGS.

Tightening Torque M (Nm)
Tread Size 4.6 4.8 5.6 8.8 10.9 12.9
M6 3.7 4.6 10.5 15 18
M8 8.9 11 26 36 43
M10 18 22 51 72 87
M12 31 39 89 125 150
M14 50 62 141 198 240
M16 76 95 215 305 365
M18 105 130 295 420 500
M20 146 184 420 590 710
M22 198 250 570 800 960
M24 251 315 725 1020 1220
M27 376 470 1070 1510 1810
M30 604 635 1450 2050 2450
5/8" UNF 170
3/4" UNC 422

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 Serious nip and Crush hazards exist when

! WARNING Replacing Parts on the Tracks. Read all Safety

procedures before carrying out work on Tracks.

5.11 REPLACING THE TRACK SHOES.

(A).
In some situations it may be necessary to remove or replace
one or more of the Track Shoes. If this is necessary then the
following procedures should be carried out.

Important: "Lock Out" the Host machine as per the instructions

in the Host Machine operation manual. This will ensure that the
Host machine cannot be moved while this procedure is being
carried out. (B)

5.11.1 REMOVING A TRACK SHOE.

(i). Track the Host machine so that the Shoe to be removed is at

the top of the Track Group, as shown at (A).
(ii). Unscrew the Track Shoe mounting bolts, as shown at (B).
Note: The nuts on these bolts, shown at (C), are self tightening
and therefore should not need a spanner to hold them.
(iii). Lift off the Track Shoe.

5.11.2 FITTING A TRACK SHOE.

(i). Set the Track Shoe onto the Track Link, align the bolt holes
(C)
and insert the mounting bolts, (4off, 5/8" UNF), as shown at (B).
Note: Grease the bolt and Nut with a multi-purpose grease
before fitting.
(ii). Tighten the Track Shoe mounting bolts to a 170 Nm + 1/3
Turn torque setting.

5.12 REPLACING THE SPROCKET.

(i). In order for the Sprocket to be replaced the Track Group

must be removed and the Host machine must be raised. See
section 5.13 for details on removing the Track Group.
(ii). Remove the Sprocket by unscrewing the mounting bolts
shown at (D). (D)
(iii). To re-fit the Sprocket onto the Gearbox ensure that the
mating faces on the Sprocket and Gearbox are completely
clean. It is imperative that the Sprocket is located square to the
Track Frame. Any misalignment will cause excessive wear.
(iv). Insert the Sprocket mounting bolts, (18off, M16x50mm, 8.8
bolts), as shown at (D).
(v). Tighten the Sprocket mounting bolts to a 215 Nm torque
setting.
(vi). Re-fit the Track Group and lower the Host machine as per
the procedures shown in section 5.14.

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 ! DANGER Serious nip and Crush hazards exist when
removing and/or replacing the Track Groups.

5.13 REMOVING THE TRACK GROUP.

(A).
(i). Move the Host machine so that the Master pin is
located over the top of the Sprocket, as shown at (A).
Note: The master pin is distinctive in that it has a
machined indentation on each end.
(ii). "Lock Out" the Host machine as per the instructions in
the Host Machine operation manual. This will ensure that
the Host machine cannot be moved while this procedure is
being carried out.
(iii). Release the tension on the Track as per the
procedure shown in section 5.8.3.
(iv). Insert supports at the short end of the Track Group
and between the Track Frame and the Track Group, as
shown at (B). This will prevent the Track Group from Remove Shoe above Master Pin.
falling when the Master pin is removed. Wooden or
concrete blocks should be adequate.
(v). Remove the Track shoe directly above the Master pin, (B)
as shown at (C), by following the procedure given in
section 5.11. Remove
(vi). Remove the Master pin. If possible it should be Master Pin.
knocked out away from the Host Machine. Apply some
heat if necessary.
(vii). To fold out the Track Group you will require a lifting
device with a S.W.L. of not less than 2 Tonnes. It must
also be able to extend to a height of 4 metres above the
Tracks. We recommend the use of a mobile crane to
carry out this procedure.
(viii). Attach a shackle to the link on the short end of the
Track Group. Then attach the lifting device to the shackle, Wooden Supports.
remove the support and lower the Track group to the
ground, as shown at (C).
(ix). Attach the shackle to the link on the long end of the (C) Long
Track Group. Then attach the lifting device to the shackle End
and lift the Track Group up and back folding it over onto
the ground.
(x). The Host machine will now have to be raised so that
the Track Group can be removed from underneath the
Track Frame. Contact the Host Machine manufacturer to Short
obtain instructions on how to safely raise the Host End
Machine.
(xi). Once the Machine is raised high enough for the
Sprocket to clear the Track Group, remove the Track
Group from underneath the Track Frame.

Remove Support. Attach lifting

Shackle to Links.

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 ! DANGER Serious nip and Crush hazards exist when
fitting/re-fitting the Track Groups.

5.14 FITTING THE TRACK GROUP.

(A). Open Ended
(i). A new Track Group supplied by Trackline International will be Link.
delivered rolled up.
(ii). Roll the Track Group out flat adjacent to the Host machine.
We recommend the use of a forklift or crane to carry out this
operation.
(iii). With the Host machine adequately raised so that the
Sprocket clears the Track Group, slide the Track Group 5 Links.
underneath the Track Frame.
Note: To ensure that the Track Group is fitted in the correct (B) Long
direction always have the open ended link at the short end End
closest to the Sprocket, as shown at (A).
(iv). In order to ensure that the Master pin ends up above the
Sprocket bring the short end of the Track Group approximately 5 Short
Links past the centre of the Sprocket, as shown at (A). End
(v). Lower the Host Machine down slowly ensuring that the
Sprocket and Track Rollers line up with the centre of the Links
on the Track Group.
(vi). To fold the Track Group onto the Track Frame you will
require a lifting device with a S.W.L. of not less than 2 Tonnes.
It must also be able to extend to a height of 4 metres above the
tracks. We recommend the use of a mobile crane to carry out
this procedure.
(vii). Place some support blocks along the top of the Track Insert Support Insert Washers
Frame to support the long end of the Track Group. Block. before joining Links.
(viii). Attach a lifting shackle to the last Link on the long end of
the Track Group. (C)
(ix). Using the lifting device lift and fold the Track Group onto
the Track Frame ensuring that is rests correctly onto the Idler
and Sprocket.
(x). Attach a shackle to the last Link on the short end of the
Track Group and raise it up to connect with the other Link, as
shown at (B). Insert a support block to hold the Track Group in
place.
(xi). Before connecting the Links, washers need to fitted into to
the open ended Link, as shown at (C). We strongly recommend
that when re-fitting the Track Group you fit a new Master pin and (D)
washers.
(xii). When the washers are in place line up the two Links and fit
the Master Pin. The Master Pin should be inserted fully so that
the two ends are flush with the edge of the bushing. For easier
fitting ensure that the Master Pin and bores are well greased.
(xiii). Fit the Track Shoe above the Master Pin ensuring that the
bolts are tightened to the correct torque. See section 5.11 for
details on fitting the Track Shoe.
(xiv). To Tension the Track follow the procedures given in
section 5.8.
(xv). Finally check the levelness of the Track Group above the
Sprocket and Idler, as shown in (E) and (F). To visually check (E) (F).
the straightness of the Track Group stand at one end and look
along the length of the Track. The edge of the Track Shoes
should be running perfectly straight.

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 Serious nip and Crush hazards exist when

! WARNING Replacing Parts on the Tracks. Read Safety

procedures before carrying out work on Tracks.

5.15 REPLACING THE GEARBOX.

(A).
In the unlikely event of a problem occurring with the Gearbox it
is often more economical to replace the entire gearbox than try
to repair it on-site. On-site repairs often involve costly downtime
of the Host machine, requires highly trained service personnel
and it has the potential for contamination which could cause
further problems.

During the replacement of the Gearbox cleanliness is vital. We

recommend that prior to removing the Gearbox a power washer
is used to thoroughly wash around the entire drive system.

Important: "Lock Out" the Host machine as per the instructions

in the Host Machine's operation manual. This will ensure that
the Host machine cannot be moved while this procedure is being (C)
carried out.
(B)
5.15.1 REMOVING THE GEARBOX.

(i). In order to remove the Gearbox the Host Machine must be

raised and the Track Group removed first. See section 5.13 for
details on removing the Track Group. (D)
(ii). Once the Track Group has been removed unbolt the cover
plate on the inside of the Track, as shown at (B).
(iii). Once the pressure in the Hydraulic system has been
relieved unscrew the Brake hose. Place a bung in the end of the
Brake hose and a cap on the Brake fitting.
Note. There is no need to remove the main supply hoses which (F).
are connected to the Motor.
(iv). Unscrew the two bolts holding the motor, as shown at (C),
then slide the motor out.
Note: There is a splined shaft on the motor which inserts into the (G)
gearbox. There is also a seal between the Motor and the
Gearbox.
(v). Remove the Sprocket by unscrewing the mounting bolts
shown at (G).
Note: To lift the Gearbox out you will require a lifting device with
a S.W.L. of no less than 250kg. We recommend the use of a
lifting strap placed around the main body of the Gearbox.
(vi). Before unscrewing the Gearbox mounting bolts place the
lifting strap onto the Gearbox and attach the lifting device. Allow
Use a Lifting Strap
the lifting device to take the strain.
around the main
(vii). Unscrew the Gearbox mounting bolts, as shown at (D),
body of Gearbox.
then lift the Gearbox back and out.

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 Serious nip and Crush hazards exist when

! WARNING Replacing Parts on the Tracks. Read Safety

procedures before carrying out work on Tracks.

5.15.2 FITTING THE GEARBOX.

(A).
(i). In order to re-fit the Gearbox a lifting device with a S.W.L. of
not less than 250 kg and a lifting strap will be required.
(ii). To lift the Gearbox into place attach the lifting strap around
the main body of the Gearbox.
(iii). Ensure that the Gearbox and Track Frame mounting faces
are perfectly clean. Remove all coverings and packaging
material from the Gearbox.
(iv). Lift the Gearbox into the Track Frame and insert the
mounting bolts, (18off, M16x60mm, 8.8 bolts plus M16 heavy
duty spring washers), as shown at (B).
(v). Tighten the Gearbox mounting bolts to a 215 Nm torque
setting. (C)
(vi). Fit the Motor onto the Gearbox ensuring that the splined
shaft and seal are properly located. Always fit a new seal when (B)
fitting the Motor.
(vii). Insert the two mounting bolts, (2off, M16x40mm, 8.8 bolts),
as shown at (C), then tighten to a 215 Nm torque setting.
Ensure that Loctite 603 or similar stud lock is applied to the bolts
before fitting.
(vii). Connect a 1/4" BSP Male-Male adapter and 1/4" Dowty
seal into the braking port on the hub flange. Then connect the
braking hose.
(viii). Fit the Sprocket onto the Gearbox. Ensure that the
mating faces on the Sprocket and Gearbox are completely
clean. It is imperative that the Sprocket is located square to the (E).
Track Frame. Any misalignment will cause excessive wear.
(ix). Insert the Sprocket mounting bolts, (18off, M16x50mm 8.8
bolts plus M16 heavy duty spring washers), as shown at (E).
(x). Tighten the Sprocket mounting bolts to a 215 Nm torque
setting.
(xi). Replace the cover plate on the inside of the Track Frame.
(xii). Re-fit the Track Group as per the procedures shown in
section 5.14.

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 Beware of Hydraulic oil. Always use suitable

! CAUTION gloves and barrier cream when working with

Hydraulic oil.

5.16 REPLACING THE MOTOR.

(B)
During replacement of the Motor cleanliness is vital. We (A).
recommend that prior to removing the Motor a power washer is
used to thoroughly wash around the entire drive system.

Important: "Lock Out" the Host machine as per the instructions

in the Host machine's operation manual. This will ensure that the
Host machine cannot be moved while this procedure is being
carried out.

Warning: A Motor may weigh as much as 20 kg therefore care

should be taken to avoid crushed or nipped fingers or toes.

5.16.1 REMOVING THE MOTOR.

(i). Remove the cover plate from the inside of the Track.
(ii). Ensure that the pressure from the Host machine's hydraulic
system has been relieved.
(iii). Remove the main supply Hoses and fit caps on the Hoses
and in the Motor Ports.
(iv). Disconnect the Drain hose from the side of the motor. Fit a
cap on this hose to prevent contamination.
(v). To remove the Motor unscrew the two mounting bolts, as
shown at (B). Then slide the motor out.
Note: There is a splined shaft on the motor which inserts into the
gearbox. There is also a seal between the Motor and the
Gearbox.
(vi). Cover the Gearbox hub with a clean cloth to prevent
contamination.

5.16.2 FITTING THE MOTOR.

(i). Remove any packaging from the Motor and ensure that the
mating faces of the Motor and the Gearbox hub are completely
clean.
(ii). Align the mounting holes taking care to properly locate the
shaft of the Motor and avoid damaging the seal. Always fit a
new seal when replacing the Motor.
(iii). Insert the two mounting bolts, (2off, M16x40mm, 8.8 bolts),
as shown at (B) and tighten to a 215 Nm torque setting. Note:
Ensure that Loctite 603 or similar stud lock is applied to the bolts
before fitting.
(iv). Connect a 1/4" BSP Male-Male adapter and 1/4" Dowty seal
into the Drain port on the side of the Motor. Then connect the
Drain hose, as shown at (A).
(v). Re-connect the main supply Hoses correctly.
(vi). Replace the cover plate on the inside of the Track Frame.
(vii). After moving the machine a few metres check for leaks.

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 Beware of Hydraulic oil. Always use suitable

! CAUTION gloves and barrier cream when working with

Hydraulic oil.

5.17 REPLACING THE MOTION CONTROL BLOCK, (if fitted).

(A).
During the replacement of the Motion Control Block cleanliness is
vital. We recommend that prior to removing the Motion Control
Block a power washer is used to thoroughly wash around the BR DR
entire drive system.

Important: "Lock Out" the Host machine as per the instructions in

the Host Machine's operation manual. This will ensure that the
Machine cannot be moved while this procedure is being carried
out.
Brake Drain
5.17.1 REMOVING THE MOTION CONTROL BLOCK. Hose Hose

(i). Remove the cover plate from the inside of the Track.
(B)
(ii). Ensure that the pressure from the Host machine's hydraulic
system has been relieved.
(iii). Disconnect the main supply hoses from ports V1 and V2 of
the Motion Control Block. Place a marker on each hose to
identify which is fitted to V1 and V2. Fit bungs in these hoses to
prevent contamination.
(iv). Disconnect the Brake and Drain hoses from ports BR and DR
of the Motion Control Block. Fit caps on these hoses to prevent
contamination.
(v). To remove the Motion Control Block unscrew the six
mounting bolts, as shown at (B).
Note: There are standard Nitrile O-ring seals between the Motion
(C)
Control Block and the Motor, as shown at (C).
(vi). Cover the Motor with a clean cloth to prevent contamination.

5.17.2 FITTING THE MOTION CONTROL BLOCK.

(i). Remove any packaging from the new Motion Control Block
and ensure that the mating faces of the Block and the Motor are
completely clean.
(ii). Align the holes on the Motion Control Block with the holes on
the motor. Take care not to lose or damage the seals on the
Block.
(iii). Insert the six mounting bolts, (6off, M8 X 120 Cap Heads), as
shown at (B).
(v). Tighten the mounting bolts to a 23 Nm torque setting.
(vi). Fit the Brake hose and the Drain hose, as shown at (A).
Brake Hose - BR
Drain Hose - DR
Note: 1/4" Dowty seals should be fitted between the hoses and
the Motion Control Block.
(vii). Fit the Supply hoses from the Host machine's hydraulic
system to ports V1 & V2 in the same position as they were
removed.
(viii). Replace the cover plate on the inside of the Track Frame.
(ix). After moving the machine a few metres check for leaks.

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 Beware of Hydraulic oil. Always use suitable

! CAUTION gloves and barrier cream when working with

Hydraulic oil.

5.18 REPLACING THE HOSE KIT (if fitted).

Host Machine Drain
During the replacement of the Drain and Brake hoses
Hose connection
cleanliness is vital. We recommend that prior to removing the
hoses a power washer is used to thoroughly wash around the (A).
entire drive system.

Important: "Lock Out" the Host Machine as per the instructions BR DR

in the Host machine's operation manual. This will ensure that

the Host machine cannot be moved while this procedure is being
carried out.

5.18.1 REPLACING THE BRAKE HOSE.

Brake Drain
(i). Remove the cover plate from the inside of the Track. Hose Hose
(ii). Ensure that the pressure from the Host machine's hydraulic
system has been relieved.
(iii). The Hydraulic Brake hose is connected to the Gear Hub, as
shown at (A). A 1/4" BSP Male-Male adapter and 1/4" Dowty
seal are fitted directly to the Gearbox Hub onto which the Brake
Hose is fitted.
(iv). The other end of the Brake hose is connected directly to
Port BR on the Motion Control Block, as shown at (A). A 1/4"
dowty seal is fitted between the Hose and the Motion Control
Valve.
(v). Only replace this hose with proper wire braided reinforced
hoses equivalent to SAE 100R1AT DIN EN 853-1SN.

5.18.2 REPLACING THE DRAIN HOSE.

(i). Remove the cover plate from the inside of the Track.
(ii). Ensure that the pressure from the Host Machine's hydraulic
system has been relieved.
(iii). The Hydraulic Drain hose is connected from the Motion
Control Block to the Motor and then to the Host Machine Drain
hose, as shown at (A). A 1/4" BSP Male-Male adapter and 1/4"
Dowty seal is fitted directly to the Motor.
(iv). The Brake hose is connected directly to Port DR on the
Motion Control Block, as shown at (A). A 1/4" dowty seal is
fitted between the Hose and the Motion Control Valve.
(v). Only replace this hose with proper wire braided reinforced
hoses equivalent to SAE 100R1AT DIN EN 853-1SN.

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 Serious nip and Crush hazards exist when

! WARNING Replacing Parts on the Tracks. Read Safety

procedures before carrying out work on Tracks.

5.19 REPLACING A TRACK ROLLER.

Important: "Lock Out" the Host Machine as per the instructions

in the Host machine's operation manual. This will ensure that
the Host machine cannot be moved while this procedure is being
(A).
carried out.

Note: A Track Roller may weigh as much as 20 kg therefore

care should be taken to avoid crushed or nipped fingers or toes.

(i). Release the Track Tension as per the procedures set out in
section 5.8.3.
(ii). In order for the Track Group to clear the Roller the Host
machine will have to be raised up. Contact the Host Machine
manufacturer to obtain instructions on how to safely raise the
Host Machine.
(iii). Once raised the Track Group should hang well below the
Track Rollers and provide enough space to remove the Roller, (B)
as shown at (A).
(iv). Unscrew the four mounting bolts holding the Track Roller, (C)
as shown at (B).
(v). To fit a new roller align the holes in the roller with the holes
in the Track Frame.
(vi). Insert the four mounting bolts, (4off, M12x50mm 8.8 bolts
plus M12 Heavy Duty Spring Washers), as shown at (B).
(vii). Ensure that the Roller is fitted in line with the other Rollers.
Misalignment can cause excessive wear of the Roller and Chain
Links.
(viii). Tighten the mounting bolts to a 90 Nm torque setting.
(ix). Lower the Host Machine down ensuring that the Track
Group locates correctly into the Track Rollers.
(x). Re-tension the Tracks as per the instructions given in
section 5.8.2.
Note: The Track Rollers are "Lubricated for Life". No servicing
is therefore required. If, however, an oil leak is discovered a
complete replacement roller should be fitted immediately.
Removal of the sealed filler plug on a Track Roller invalidates
warranty.

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 Serious nip and Crush hazards exist when

! DANGER Replacing Parts on the Tracks. Read Safety

procedures before carrying out work on Tracks.

5.20 REPLACING THE IDLER GROUP. (A).

As material is likely to have built around the Idler Group, it is

suggested that a power washer is used to wash around the Idler
Group and slide rails.
Grease can be applied to the slide rails to allow the Idler Group
to slide more easily if required.

5.20.1 REMOVING THE IDLER GROUP.

(i). Remove the Track Group and raise the Host Machine as per
the instructions given in section 5.13.
(ii). Once the Track Group has been removed slide the Idler
Group out as far it can go without it falling out of the slide rails.
Note: The Idler is not bolted into the Track Frame, therefore, it
should slide out as soon as the Track Group has been removed. Slide Rails
(iii). To lift the Idler Group out of the Track Frame you will
require a lifting device with a S.W.L. of no less than 100 kg. We
recommend the use of a mobile crane for this operation. (B)
(iii). Attach a lifting strap between the Idler and the Spring
Tension unit, as shown at (B). Allow the crane to take the strain.
(iv). Slide the Idler Group out further until it is clear of the Track
Frame and lift it away from the Track.

5.20.2 FITTING THE IDLER GROUP.

(i). Before fitting the Idler Group ensure that the Tension
Cylinder is fitted correctly, see section 5.22.
Attach lifting strap
(ii). To lift the Idler Group into the Track Frame you will require a
at this point.
lifting device with a S.W.L. of no less than 100 kg. We
recommend the use of a mobile crane for this operation.
(iii). Attach a lifting strap between the Idler and the Spring View of the underside
Tension unit, as shown at (B). of the Track Frame
(iv). Lift the Idler Group into the slide rails with the Spring
Tension Unit entering the Track Frame first, as shown at (A). (C)
(v). Push the Idler Group back against the Tension Cylinder, as
shown at (C).
(vi). Re-fit the Track Group as per the instructions given in Idler
section 5.14.

Spring
Tension Unit
Tension
Cylinder
Track Adjuster
Grease Valve

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 Unscrewing the wrong bolts on the Spring

! DANGER Tension Unit will release the Spring which could

cause severe injury, damage or death.

5.21 REMOVING THE IDLER FROM THE SPRING TENSION (A).

UNIT.

In the unlikely event of damage occurring to the Idler or Spring

Tension Unit they can be separated and replaced individually, as
shown at (A).

However, special care must be taken to avoid unscrewing the

wrong bolts on the Spring Tension Unit. As the spring is under
great tension if it is released it could cause severe injury,
damage or even death.
Idler Spring Tension
(i). The Idler group must be removed from the Track Frame as
Unit
per the instructions given in section 5.20.1

(ii). To remove the Idler from the Spring Tension Unit unscrew
the four mounting bolts, as shown at (B).

(iii). The bolts on the Spring Tension Unit which must not be
removed are shown at (C).

(iv). To re-fit the Idler, simply align the mounting holes and
replace the four bolts. Ensure that the bolts are tightened to the
(B)
correct torque setting, see section 5.10 for bolt torque settings.

(v). Replace the Idler Group into the Track Frame as per the
instructions given in section 5.20.2.

Idler Mounting
Bolts.

(C)

DO NOT
remove these bolts

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 Serious nip and Crush hazards exist when

! WARNING Replacing Parts on the Tracks. Read Safety

procedures before carrying out work on Tracks.

5.22 REPLACING THE TENSION CYLINDER. (A)

If a problem occurs with the Tension Cylinder we would recommend

that the complete Tension Cylinder is replaced rather than trying to
repair it.
As material is likely to have built around the Idler Group use a power
washer to wash around the Tension Cylinder, Idler Group and slide
rails.

Note: A tension cylinder may weigh as much as 15 kg, therefore, care

should be taken to avoid crushed or nipped fingers, or toes.
View of the underside
5.22.1 REMOVING THE TENSION CYLINDER. of the Track Frame

(i). Remove the Track Group as per the instructions given in section
(B)
5.13.
(ii). Once the Track Group has been removed slide the Idler Group
forward away from the Tension Cylinder. Do not slide the Idler Group
completely out, only a short space between the Tension Cylinder and
the Spring Tension Unit is required. To ensure safety insert a wedge
to prevent the Idler Group from moving while the Tension Cylinder is Remove
being removed. Track Roller
Note: The Idler is not bolted into the Track Frame nor is it attached to
the Tension Cylinder, therefore, it should slide out easily once the
Track Group has been removed. Spring
(iii). Open the inspection plate on the side of the Track Frame and Tension Unit
remove the Track Adjuster Grease Valve, as shown at (D).
Important: Never remove the Track Adjuster Grease Valve unless Tension
the tension has been released off the Tracks. Cylinder
(iii). Remove the Track Roller directly below the Tension Cylinder, as
shown at (B).
Track Adjuster
(iv). Unscrew the two mounting bolts holding the Tension Cylinder in
Grease Valve
place. Access to these two bolts is through the inspection hole on the
side of the Track Frame. Tension Cylinder
(v). Once the mounting bolts are removed the Tension Cylinder mounting Face
should drop down out of the Track Frame.
(C)
5.22.2 FITTING THE TENSION CYLINDER.

(i). Ensure that the Idler Group is moved forward and wedged allowing
enough space for the Tension Cylinder to be fitted.
(ii). Fit the Tension Cylinder up from underneath the Track Frame.
(iii). Insert the mounting bolts, (M12x45, Class 8.8 plus M12 heavy
duty spring washers ).
Slide Rails
(iv). Tighten the mounting bolts to a 90 Nm torque setting.
(v). Remove the wedge and push the Idler Group back against the (D)
Tension Cylinder, as shown at (B).
(vi). Fit the Track Roller as per the instructions given in section 5.19.
(vii). Fit the Track Adjuster Grease Valve and Gasket.
(viii). Fit the Track Group and lower the Host machine as per the
instructions given in section 5.14.

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 ! WARNING If burning gear is used to cut Links, ensure that
proper personal protective equipment is used.

5.23 FITTING A TRACK LINK REPAIR KIT. (A).

If a Track link becomes excessively worn or damaged it

needs to be replaced immediately. To do this a Link
Repair Kit is required, as shown at (A).

As material is likely to have built uparound the Track

Links use a power washer to wash around the defective
link.

5.23.1 REMOVING THE DAMAGED LINK.

(i). Move the Host machine so that the damaged Link is (B)
located over the top of the Sprocket.
(ii). Place some support blocks along the top of the Track
Frame and at the Sprocket end to support the Track
Group, as shown at (B).
(iii). Release the Track Tension by following the
instructions given in section 5.8.3.
(iv). Remove the Track Shoes above and either side of
the damaged Link, as shown at (C).
(v). To remove Pins 1 & 2 apply heat to points (X1), (X2),
(Y1) & (Y2) and knock the pins out. Be careful not to
apply excessive heat to the Links 1 & 3.
(vi). If the pins cannot be removed from the link using
heat they will have to be cut. Pin 1. Damaged Pin 2.
(vii). To remove Pin 1 cut through the Pin and Bushings Link
X1. Y1.
at points (W1) & (W2) on the damaged Link, as shown at
(D). This should allow Link 1 to disconnect from the (C)
damaged Link.
(viii). The reminder of Pin 1 should now be able to be
knocked out of the bushing on Link 1.
Note: When cutting the damaged Link be careful not to
cut into Link 1 & 3 as they must remain serviceable.
(ix). To remove Pin 2 cut through the Pin and Bushing at
point (Z) on the damaged Link, as shown at (D).
Note: Two cuts should be made through the Pin and
Bushing at point (Z) so that a section of approximately 1" X2. Y2.
can be removed.
(x). Each end of Pin 2 should now be able to be knocked W1. Z.
inwards.
(xi). File down any burrs on Links 1 & 3 before attempting (D)
to fit the Repair Link.

Link 1. W2. Damaged Link 3.

Link

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 Serious nip and Crush hazards exist when

! WARNING Replacing Parts on the Tracks. Read Safety

procedures before carrying out work on Tracks.

5.23.2 FITTING THE REPAIR LINK. Repair Link Link 3.

(A).
(i). Fit the open end of the Repair Link to Link 1 first.

(ii). If possible spring the Repair Link open so that it

easily fits over the top of the protruding bush on Link 1.
Fit
Spacers
(iii). If this is not possible then trim the ends of the Bush
on Link 1 until the Repair Link fits over it.

(iv). Ensure there are no burrs on either Link.

(v). If the Bush has to be trimmed then spacers will have

to fitted to the inside of the Repair Link, as shown at (A).

(vi). Carefully grease the bores and pin using a multi-

purpose grease. Link 1. Fit Spacers

(vii). Align the bores and insert Pin 1 through the Links
until the edges are flush, as shown at (B).
Pin 1. Pin 2.
(viii). Follow the steps listed above to fit the other end of
the Repair Link into Link 3. (B)

(ix). Fit the Track Shoe.

Note: If the original Track Shoe is damaged fit a new
Shoe.

(x). Ensure that all the Track Shoe mounting bolts are
tightened to a torque setting of 258 Nm. Repair
Link
(xi). Tension the Track as per the instructions given in
section 5.8.2.

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 SECTION 6.0

FAULT FINDING.

6.1 FAULT FINDING INTRODUCTION.

To help find and remedy faults quickly we have listed several general faults that may occur during the
operating life of the Tracks.
It is of course impossible to foresee every problem that could occur, therefore, only a general fault finding
approach is provided.

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6.2 POSSIBLE FAULTS.

(i). One Track not operating or operating slower than the other?

- Check that the same size of Motors have been fitted to both Tracks.

- Check if the brake is releasing.

Fit a pressure clock to the Brake Hose. A pressure of at least 285 PSI / 20 bar is required to release the
brakes.
If the correct pressure is not going to the Brake hose it is likely to be a problem with the Motion Control Block,
possibly contamination. If a Load Control Valve should jam due to oil-entrained debris then the likelihood is
that it will not open and will not allow the motor to turn in one direction. This will cause the Host Machine to
‘crab’in one direction. Swapping the valves over from one Track to the other will usually transfer the problem
to the opposite direction.
Similarly, if the Brake Pressure Regulator Valve is jammed due to debris the motor will stop turning on one
side. Swap the Pressure Regulator from the opposite block to see if the problem is in the Brake Valve.

Try removing the Valves and cleaning them thoroughly taking care not to damage the external cavity seals.
Also check the ports in the Block for dirt etc. If this does not work replace the valves with new ones. Always
cross-reference the part numbers on the new valves with the old valve, before fitting. It is critical that the
correct Valves are fitted. Valves should never be dismantled as no internal seals or parts are available.

If the valves continue to jam then the oil in the hydraulic system is not being filtered to the required level of
cleanliness.

- If the correct pressure is going to the Brake Hose then the Motor, Brake or Brake Piston Seals may be
damaged.

- To check for a Motor fault swap over the Motors on the two Tracks. If the fault is in the Motor, replace with a
new Motor.

- To check for a faulty Brake remove the Motor and look into the Gearbox for heat discolouration and/or
fragments of Brake disc. If the fault is in the Brakes the complete Gearbox will have to be replaced.

-To check for faulty Brake Piston seals remove the Motor. If there is Hydraulic oil in the Gearbox entrance
then the seals are damaged. While it may be possible to replace these seals on-site we strongly
recommended that a replacement Gearbox is fitted and an overhaul of the damaged Gearbox be carried out
off-site.

(ii). Excessive oil leaking around Drive Assembly?

- Seals damaged between Motion Control Block and Motor.

Remove Motion Control Block and replace seals.

Note: Seal damage may be caused by excessive oil temperatures. Check oil operating temperature and
environmental conditions.

- Seal damaged between Motor and Gearbox.

Remove Motor and replace seal.

Note: Seal damage may be caused by excessive oil temperatures. Check oil operating temperature and
environmental conditions.

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6.2 POSSIBLE FAULTS CONTINUED.

(iii). Track will not stay tensioned?

- Grease escaping.

Check that the Track Adjuster Grease Valve is tight, has a properly fitted seal and that there is no grease
leaking past it.

Check around the Tensioning Cylinder for escaping grease. This will indicate that the seals are damaged in
the Tensioning Cylinder. Replace with a new Cylinder immediately.

(iv). Track Group running off Sprocket and/or Idler?

- Track Group too loose. Check Track tension, see section 5.8.
- Excessive misalignment. Check alignment of Sprocket, Idler and Track Rollers.
- Excessive component wear. Check wear limits, see section 5.7.
- Twisted Track Frame. Check Track Frame.

(v). Excessive Component Wear rate?

- See section 5.7 for excessive wear problems.

(vi). Track Roller leaking oil?

- Damaged or worn seals. Replace with a new Track Roller.

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 SECTION 7.0

SPARE PARTS.

7.1 SPARE PART ORDERING INFORMATION.

To ensure that you receive the parts you require without delay we will require the following information at the
time of order:

Your company name and delivery address.

Your contact name and number.
The track serial number (see below for details).
The track model number (see below for details).
The part number.
The part description.
The quantity required.

Note: Ensure that you order all the required parts such as Bolts and Washers etc. Do not assume that such
items will automatically be sent with main components.

7.2 LOCATING THE TRACK SERIAL AND MODEL NUMBERS.

Each Track will have a serial plate located on the Frame as shown below. From this plate you will find the
serial number and model number as shown.

Serial
Plate

On the following pages the parts numbers for several models of Tracks are listed. Only choose the part
numbers relating to your particular model of Tracks. Quantities shown are per Track Set. When ordering
parts for only one Track the quantities should be halved.

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7.3 PARTS ILLUSTRATION.
3A 3B 3C 4 5

1 2 3

12 6

7*
12A 15
8*
12B 11
9*
13 10*

14 * Optional part

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7.4 PARTS LIST. Note: Quantities shown are per Track set. When requiring parts for only one Track quantities should be halved.

Item No. Model No. Part No. Description. Qty. Photo.

1 Z2175 Z2174LH Track Frame (Left Hand Side) 1

2 Z2175 Z2175RH Track Frame (Right Hand Side) 1

3 Z2175 VSI86/47/400 Track Group Complete (400mm Wide Shoes) 2

3 Z2175 VSI86/47/500 Track Group Complete (500mm Wide Shoes) 2

3A Z2175 VOK520/47 Link Assembly 2

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7.4 PARTS LIST CONTINUED: Note: Quantities shown are per Track Set. When requiring parts for only one Track quantities should be halved.

Item No. Model No. Part No. Description. Qty. Photo.

3B Z2175 VOK428A Master Pin 2

3C Z2175 VOK237/400 Track Shoe (400mm Wide Shoe) 94

3C Z2175 VOK237/500 Track Shoe (500mm Wide Shoe) 94

3D Z2175 VCR1105 & VCR1967 Track Shoe Bolt Set 376

(Part No. includes Bolt & Nut)

3E Z2175 OK520/1LRK/I Track Link Repair Kit -

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7.4 PARTS LIST CONTINUED: Note: Quantities shown are per Track Set. When requiring parts for only one Track quantities should be halved.

Item No. Model No. Part No. Description. Qty. Photo.

4 Z2175 Z1874 Sprocket 2

4A Z2175 M2060HTB & M20NORDLOCK Sprocket Bolt Set 48

(Part No. includes Bolt & Spring Washer)

5 Z2175 M1482/G Gearbox 2

5A Z2175 710317009 Gearbox Gasket 2

No Photo

5B Z2175 M2080HTB & M20NORDLOCK Gearbox Bolt Set 48

(Part No. includes Bolt & Spring Washer)

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7.4 PARTS LIST CONTINUED: Note: Quantities shown are per Track Set. When requiring parts for only one Track quantities should be halved.

Item No. Model No. Part No. Description. Qty. Photo.

6 Z2175 M1482/M Motor 2

6A Z2175 715303449 Motor Mounting Seal Kit 2

No Photo

6B Z2175 711360004 Motor Mounting Bolts 4

7 Z2175 Motion Control Block ( *optional) 2

(not complete with Load Control or Pressure
Regulator valves)

7A Z2175 Motion Control Block Seal Kit ( *optional) 2

No Photo

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7.4 PARTS LIST CONTINUED: Note: Quantities shown are per Track Set. When requiring parts for only one Track quantities should be halved.

Item No. Model No. Part No. Description. Qty. Photo.

7B Motion Control Block Bolt Set ( *optional) 12

(Part No. includes Bolt & Spring Washer)

8 Load Control Valve ( *optional) 4

(Note: Some valves may vary for different Host
Clients, always cross reference part no. on existing
valve with new one)

9 Pressure Regulator Set 30 Bar ( *optional) 2

(Note: Some Regulators may vary for different Host
Clients, always cross reference part no. on existing
regulator with new one)

10 Hose Kit ( *optional) 2

11 Z2175 VPC395 Track Roller 18

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7.4 PARTS LIST CONTINUED: Note: Quantities shown are per Track Set. When requiring parts for only one Track quantities should be halved.

Item No. Model No. Part No. Description. Qty. Photo.

11A Z2175 M3/4UNCHTB & M3/4HDSW Track Roller Bolt Set 72

(Part No. includes Bolt & Spring Washer)

12 Z2175 VFT2764M/HD Idler Group Complete 2

12A Z2175 VFT2763M/HD Idler 2

12B Z2175 VSI302M/HD Spring Tension Unit 2

13 Z2175 VSI380 Track Tensioner 2

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7.4 PARTS LIST CONTINUED: Note: Quantities shown are per Track Set. When requiring parts for only one Track quantities should be halved.

Item No. Model No. Part No. Description. Qty. Photo.

13A M1645HTB & M16HDSW Track Tensioner Bolt Set 4

(Part No. includes Bolt & Spring Washer)

14 VAT34/35 Track Adjuster Valve 2

(Part No. includes Valve & Seal)

15 M1442-2 Track Adjuster Grease Gun Fitting 1

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 Replacing the crusher
drive belts
UH440i / US440i uses pre-tensioned V-belts1 (SPC,
22 x 18) for the crusher belt drive. The belts are only tensioned twice, and
that is during the installation and after 10 hours running time. Using pre-
tensioned belts makes it possible to replace a single belt in case of damage.
The tensioning is done by adjusting the complete power unit’s position. The
position is changed using the two tension screws (1), one on each side of the
machine, below the engine.

1. Currently VECO 200® “label DYNAM”, SPC = 22 x 18

UH440i / US440i © Sandvik SRP AB – Doc. no. S 281.841 en Ver. 1 1

Replacing the crusher drive belts

Removing the old V-belts

Turn off all equipment before you begin!
Make sure that the engine and all other equipment is turned off
before you begin to work with the crusher drive belts.
WARNING!
NOTE! In case of damage, a single belt can be replaced.

a) Remove the belt guards, protecting the crusher drive belts.

b) Remove the inspection covers below the belt guard to get access to
tension screw and crusher pulley.
c) Loosen the two bolts (1) on each of the four legs of the power unit.
3 2
A

1 4

d) Fill the lubrication points (2) with grease.

e) Clean the screw threads (3) of the two tensioning screws.
f) Loosen the inner lock nuts (4) and move them in direction A.
NOTE! Use a 65 mm Combination wrench.
g) Turn the head (5) of the two tensioning screws clockwise to move the
complete power unit and thereby slacken the belts.

Work in parallel!
Work in parallel with the two tensioning screws. Don’t move them
more than 5 mm at a time or you might end up with two non parallel
WARNING! shafts and/or misaligned pulleys.

h) Lift off the V-belts when they have slackened enough.

2 © Sandvik SRP AB – Doc. no. S 281.841 en Ver. 1 UH440i / US440i

 Replacing the crusher drive belts

Attaching and tensioning new V-belts

a) Install the new V-belts on the drive by attaching them to the two pulleys.

Do not force!
Do not force when installing the belt in the grooves of the pulleys.
Any kind of excessive effort can damage the tensile cord.
WARNING!
b) If necessary, loosen the inner lock nuts (1) and move them in
direction A.
c) Turn the head (2) of the two tensioning screws anti-clockwise to move
them in direction B.
A B

3 1

Work in parallel!
Work in parallel with the two tensioning screws. Don’t move them
more than 5 mm at a time or you might end up with two non parallel
WARNING! shafts and/or misaligned pulleys.

Max difference between the two shafts = 0,5°

Max misalignment = 8 mm per meter of distance between shafts

d) Turn the inner lock nuts (1) to move them in the same direction (B). This
will move the complete power unit and thereby progressively stretch the
belts.

UH440i / US440i © Sandvik SRP AB – Doc. no. S 281.841 en Ver. 1 3

Replacing the crusher drive belts

e) Check the tension by looking at the gauge marks on the innermost and
outermost belts. Measure the distance accurately between the outside of
the two marks.

The gauge marks and text looks like this:

I < Tension of the installation / Init tension = nnn mm > I

f) When length between marks is reached, re-tighten the two bolts (3) on
each of the four legs of the power unit.
g) Re-attach all belt guards and inspection covers.
h) Run the crusher empty for a few minutes to settle the belts into the
grooves.
i) Re-check the distance between the marks.
j) If necessary, re-tension the belts so that the distance between marks is
reached again.
NOTE! After 10 hours running time, re-tension the belts.

Re-tensioning the new belts

The new belts must be re-tensioned after about 10 hours running time with a
tension tester:
Article number. 879.0662-00
a) Open the rightmost inspection hatch (towards the hinges) on the belt
guard.
b) Press each belt 22 mm. The force needed should be 5.2 kg on each belt.

c) Close the inspection hatch.

NOTE! There is no need to re-tension the belts after the first re-tensioning. Instead,
belts are replaced when they become too slack, damaged or worn out.

4 © Sandvik SRP AB – Doc. no. S 281.841 en Ver. 1 UH440i / US440i

OPERATION AND MAINTENANCE INSTRUCTIONS

BELT FEEDER RRA 4811

 1 TRANSPORT & COMMISSIONING MANUAL

BELT FEEDER RRA4811 2 OPERATOR’S MANUAL

OPERATION AND
MAINTENANCE
INSTRUCTIONS
3 ELECTRICAL DOCUMENTATION
Rev. 05, 09082007

4 PRODUCT DOCUMENTATION

5 WEAR PARTS CATALOQUE

6 SPARE PARTS CATALOQUE

7 MAINTENANCE MANUAL

10
 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007

1 TRANSPORT & COMMISSIONING MANUAL

ROX 11-01-01 GENERAL REGULATIONS AND INSTRUCTIONS

ROX 11-01-07 SAFETY INSTRUCTIONS FOR CONVEYORS AND MATERIAL

HANDLING EQUIPMENT

INSTRUCTION DUST

INSTRUCTION DANGER

INSTRUCTION LOCKOUT PROCEDURE

ROX 11-02-05 COMMISSIONING

INSTRUCTION MOBILE FEEDER

RRA4811-J2 TRANSPORT/OPERATING POSITION

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\RRA4811 Interleafs_rev0.doc

 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION ROX 11-01-01

GENERAL REGULATIONS AND INSTRUCTIONS

1. INTRODUCTION

This maintenance and operation manual is intented for the operating,

inspection and maintenance personnel.

This manual has to be read through carefully, and it has to be always at the
disposal of the personnel.

The instructions and descriptions of this manual are necessary when the
equipment is inspected, regulated, started, operated and serviced.

A new operator obtains from this manual the basic information about the
equipment and its operation. The skill to operate the equipment develops with
experience.

Sandvik Hollola has a principle of continuous development of machines and

equipment. That is way why your equipment and the data presented in this
manual may differ somewhat from each other.

There may be several versions and delivery alternatives of the machines and
equipment, and therefore in these general instructions may be described
equipment and functions which are not included in the delivery in your case.

The maintenance and operation manual is continually modified and improved

in order that its content would be up-to-date.

Sandvik Hollola reserves the right to alterations in machines and equipment

without prior notice in maintenance and operation instructions and other
corresponding documents.

If you have any questions concerning this manual or the equipment, machines
or systems delivered by Sandvik Hollola, please contact Sandvik Hollola.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION ROX 11-01-01

2. OBLIGATIONS OF THE OWNER

The owner is obliged to see to that:

- The safety, operation, maintenance and inspection instructions in force are

observed in the operation of the machines and equipment. These
instructions have to be at the disposal of those who need them.

- The normal start and stop signals, the start and stop signals of the
machines with remote control (light and/or sound signals), as well as the
risks of accidents involved with the machines and equipment have been
presented to the personnel.

- Only duly trained operating personnel may operate the equipment.

- The operating personnel has to know well the performance values and
properties of the machines.

- The machines and equipment must not be used for other purposes or in
other conditions than intented.

- The machines and equipment must have adequate lighting, and the
passages and service platforms have to be open.

- The machines have to be inspected and serviced at the recommended

intervals. The effected measures must be registered in the maintenance
book. On request, the maintenance registrations have to be presented to
the representative of Sandvik Hollola. The guarantee is valid only if the
inspections and maintenance are carried out according to the instructions.

- The defects notified by the operator, maintenance personnel or inspector

are to be registered and remedied without delay.

- The machine or equipment stopped due to a defect, malfunction and

emergency must not be started before the cause of the stop has been
cleared.

- There has always to be sufficiently qualified and duly trained operating,

maintenance and inspection personnel available.

- The plant may be expanded or modified only by Sandvik Hollola or an

enterprise authorized by it. If the plant is modified, it is always necessary to
take into account the strength, effect, capacity and other factors of the
equipment.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION ROX 11-01-01

3. REGULATIONS AND INSTRUCTIONS CONCERNING THE MAINTENANCE

AND INSPECTION PERSONNEL

- The condition of the machines and equipment has to be checked daily and
all discovered defects are to be remedied without delay.

- The maintenance and inspections are performed when the machines

are at a standstill and the start is prevented by means of a safety
switch or by other reliable method.

- Only measures determined by the separate instructions may be performed

when the machines are running. Even then the safety devices have to be in
place, and it is necessary to exercise extreme caution.

- The maintenance and inspections have to be performed at recommended

intervals (see inspection and lubrication charts and instructions). The
performed measures have to be entered in the maintenance book.

- Mechanical and electrical regulations may be performed only by authorized

personnel.

- The service platforms and stairs of the equipment have to be kept clean and
in good condition.

- In the end of the maintenance and inspection it has to be checked that the
safety devices are duly in place, the machine is clean and that all foreign
objects (tools, instruments etc.) have been removed.

- Use only original spare parts of Sandvik Hollola.

- Wearing parts are to be changed in due time.

 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION ROX 11-01-01

4. REGULATIONS AND INSTRUCTIONS CONCERNING THE MACHINE

OPERATOR

4.1 Measures before the start

- Read through carefully the operation instructions of the machines and

equipment.

- Make sure that no maintenance or operating personnel or unauthorized

persons are staying in the vicinity of the machines to be started, in order
that the start of the equipment cannot cause a danger for them.

- Make sure that all safety, protecting and security devices are in place and in
working order.

- Make sure that there are no foreign objects in the operating zone of the
machines and that dust, dirt, ice, etc. has not made the equipment out of
order.

- Select the control and operation mode of the machines and systems (see
operation instructions).

- Observe during the start that the machines start normally and that they
function properly.

4.2 Measures during operation

- Observe the material flow.

- Observe that the material does not go to places where it causes

malfunctions.

- See to that unauthorized persons cannot come near the running machines.

- Observe the functioning of the machines and report the discovered defects
and malfunctions to the maintenance personnel without delay.

4.3 Measures when the machines are stopped

- Run the machines empty of material if possible.

- Stop the machines as determined in the operation instructions.

- Report all discovered malfunctions of the machines to the next operator and
the maintenance personnel.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION ROX 11-01-01

5. SAFETY

- The general safety instructions and regulations in force in the plant are to be
observed when the equipment and machines are operated and serviced.

- In addition to these, the maintenance and operating personnel has to read

through carefully the safety instructions and regulations contained by this
maintenance and operation manual and observe them in all situations and
conditions.

- The operating and maintenance personnel has to know the hazards involved
in the equipment, such as :
- risk of being squeezed and caught by moving and rotating parts of the
machine
- accidental and automatic starts
- hazards and injurious effects caused by dust and noise
- fire and explosion hazards caused by material

- Unauthorized persons must stay out, in the immediate vicinity of the

equipment it is necessary to use due protections.

- The safety and security devices must not be removed, they must always be
in place and in working order when the equipment is operated.

- The covers and doors of the electrical equipment and boxes have to be
closed.

- Before the maintenance, inspection and cleaning of the equipment it is

necessary to stop the machines and their start has to be prevented with a
safety switch or similar.

6. GUARANTEE

- The guarantee conditions and period of the equipment and systems are
determined in the supply contract or other documents.

- A general precondition for the guarantee is that the equipment is operated,

serviced and inspected according to these maintenance and operation
instructions, and that only original spare parts of Sandvik Hollola are used.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION ROX 11-01-07

SAFETY INSTRUCTIONS FOR CONVEYOR SYSTEMS AND MATERIAL HANDLING

EQUIPMENT

1. DANGEROUS PLACES

Dangerous places of conveyor systems and material handling equipment are,

e.g. the following ones:

- pulleys and sprockets, especially gaps between the pulley and the belt / the
sprockets and chains
- on belt conveyors rollers, gaps between rollers and the belt, especially in
places with boards
- on chain conveyors chains and sprockets
- hatches when open
- drive mechanism, rotating and moving parts
- counterweight take-up devices, moving take-up carriage
- generally, a running or starting belt is dangerous
- falling and rolling material
- electrical accidents, e.g. during repair work
- falling or slipping of persons
- hazardous dust and noise
- fire and explosion hazard caused by the material to be handled

2. DANGEROUS SITUATIONS

2.1 Dangerous situations and the most common causes to accidents

are e.g.:

- the equipment is started when there are persons near to the dangerous
places of the conveyor system
- accidental starts, remote and automatic starts
- maintenance, repair and cleaning near to a running or starting machine
- accidental start has not been prevented (the safety switch has not been
used, no warning sign or lock)
- clearing of a jam on a equipment or hopper
- safety or security device is missing or it does not function
- material on the passage or walkway, uncleanliness
- first start and trial runs in the installation phase

If it is necessary to go near the equipment, pulleys or drive mechanism

during the maintenance, cleaning etc., or if it is necessary to remove
some guards or open doors, the equipment has to be stopped and the
start before beginning the work has to be prevented by means of a
safety switch. The safety switch has always to be locked in the position
"0" with a separate lock, and the key has be kept by the person who is
carrying out the above measures or by the person in charge.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION ROX 11-01-07

2.2 Especially it has to be noted that:

- Never try to remove any objects or material from a running machine.

- Never try to clean shafts, sprockets, chains, pulleys, rollers or belt cleaners
when the conveyor is running.

- Never go to a conveyor belt before an accidental start has been prevented

by a safety switch.

- E.g. in case of jam the conveyor belt or chain can be still under tension
which can rotate the belt/chain and pulleys/shafts when being discharged
despite the safety switch. That is why make always sure before clearing a
jam that the chain, belt or the counterweight will not cause a hazard when
the possible tension will be discharged. The tension can be eliminated from
the belt, e.g. by detaching the back-rotation preventing brake.

- When maintaining ascending chain conveyors take into account that chains
must be locked to prevent the crash of chains. The locking of the chains
must be done for example when shorten or repairing chains and always if
someone goes inside the chain conveyor.

- When the feed hopper is entered, it is also necessary to prevent the running
of the feeding device by means of a safety switch.

- When the mobile conveyor are serviced, it is necessary to prevent also the
operation of the transfer mechanism by means of a safety switch.

- The use of belt conveyors for transport of persons as an "elevator or

escalator" is absolutely forbidden.

- If the conveyor has a source of radioactive radiation, e.g. blockage detectors

of hoppers or belt scales, shut the radiation sources before entering their
zone of influence. Observe the instructions and regulations given by the
manufacturers of these devices or the person in charge of radiation
questions in the plant.

- The covers and doors of electrical equipment and boxes have to be kept
closed. The electrical installation and repair work may be performed only by
an authorized firm.

- Risk of rolling or falling material may occur with some materials and
equipment in special situations. In this case it is forbidden to stay under the
machine; wear a protecting helmet and goggles.

- Hazardous noise. Noise occurring near drive mechanisms and hoppers

may be hazardous; wear ear protectors.

- Hazardous dust. Dust eventually occurring near machines may be

hazardous for health depending on the material to be handled; wear
suitable respiratory protective devices.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 3 (4)

GENERAL INSTRUCTION ROX 11-01-07

- Hazard of being caught by moving and rotating parts of the machine if you
do wear unproper clothing near them, e.g. hanging pieces of cloth; wear
appropriate protective clothing.

3. SAFETY AND PROTECTIVE DEVICES

3.1 Mechanical safety and protective devices

Mechanical safety devices are e.g.

- guards in gaps between belt and pulleys and rollers (nip points)
- safety nets around the shafts, pulleys and belt
- safety nets inside hatches possible open without tool
- locking devices and parts for hatches
- handrails and safety nets around the moving parts
- guards of drive mechanism, e.g. around V-belts and couplings
- handrails and safety nets along walkways and passages
- back-rotation preventing brakes and other brakes

The safety and protective devices must not be removed.

When the conveyor equipment/system is operated, the safety and
protective devices must always be in place and in working order.

3.2 Electrical safety and warning devices

- emergency stop of the conveyor equipment:

the belt conveyor can be stopped when there is a risk of a personal or
material damage by pulling at the red emergency stop pull cord located
along the conveyor. On the control board/in the control room there is
generally also an emergency stop push-button which stops the equipment
when being pressed.

- start pre-warning:
a device giving an acoustic alarm and/or light signal which warns of the start
of the conveyor system/equipment

- safety switch:
by turning the safety switch to the position "0" the start of the drive motor of
the machine can be prevented reliably, e.g. for the maintenance.
The safety switch can be locked in the position "0" by a padlock.

The safety and warning devices must not be removed.

When the conveyor equipment/system operated, the safety and warning
devices must always be in place and in working order.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 4 (4)

GENERAL INSTRUCTION ROX 11-01-07

4. FIRE AND EXPLOSION HAZARD

Normally conveyor equipment do not involve operation or materials causing a

special hazard of fire or explosion. It has, however, a lot of e.g. bearings and
other possible friction points with high temperature due to inadequate
maintenance and cleaning.

The material to be transported and its dust may require that the fire or
explosion hazard is taken into account. In this case the fire protection
regulations and instructions given for the plant are to be observed.

The fire alarm and extinction devices must always be at the disposal and in
working order when the conveyor is operated.

The conveyor belts may be different as to the fire resistance and burning
properties. This must be taken into account when making the plans for fire
protection.

In case of fire, the equipment frame may be exposed to so big a thermal

stress that the whole frame structure of the machine (e.g. conveyor bridge)
may collapse.

5. MATERIAL DUST

The dust leaking out from the conveyor equipment, mainly near the hoppers,
can cause a hazard because the visibility will be worse. Depending on the
material to be handled, the dust can be hazardous for health when inhaled
continuously.

The emission of dust outside the equipment is caused by the construction of

the conveyor system, and often by an inadequate maintenance of sealings
etc.

The dust extraction devices must always be switched on and in working order
when the conveyor system is running.

If hazardous dust occurs in the vicinity of the conveyor system, it is necessary

to use appropriate respiratory protective devices.

6. NOISE

The noise level in hoppers and chutes integrated with equipment may be high
because of the material flow, depending on the material.
In some machine the noise level may be high near the drive machinery.

If the noise level at some points exceeds the allowable limits, these points
must be equipped with a warning sign, and it is necessary to wear ear
protectors.
 MAINTENANCE AND OPERATION INSTRUCTIONS

29.6.05/JPa 1 (1)
SPECIAL INSTRUCTION

DUST
Rock and stone crushing creates dust, which stays at the material handling site and its
surroundings, even when not handling the material. When conveying material by conveyors
dust is created often at loading and unloading points.

Dust may be so fine that it cannot be seen. It is hazardous to inhale the dust.

Breathing dust will cause death or severe injury. Always wear approved respirator.
See enclosed appendix “Danger”.

Protection from dust

• Always use an approved respirator when outdoor (outside the cabin). Make sure that
the respirator is in good condition.
• Always keep the cabin door closed.
• Keep the cabin clean. Clean the cabin with a vacuum cleaner daily
• Change the cabin air filter regularly with original spare part.

Dust suppression system

Make sure that dust suppression system at your site is working properly. Keep the dusting
at minimum level at site.

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 MAINTENANCE AND OPERATION INSTRUCTIONS

29.6.05/JPa 1 (1)
SPECIAL INSTRUCTION

DANGER

BREATHING OR INHALING DUST PARTICLES WILL CAUSE DEATH OR SEVERE

INJURY.

ALWAYS WORK WITH A RESPIRATOR APPROVED BY THE RESPIRATOR

MANUFACTURER FOR THE JOB YOU ARE DOING. IT IS ESSENTIAL THAT THE
RESPIRATOR THAT YOU USE PROTECTS YOU FROM THE TINY DUST PARTICLES
WHICH CAUSE SILICOSIS AND WHICH MAY CAUSE OTHER SERIOUS LUNG DISEASES.
YOU SHOULD NOT USE THE EQUIPMENT UNTIL YOU ARE SURE YOUR RESPIRATOR IS
WORKING PROPERLY. THIS MEANS THE RESPIRATOR MUST BE CHECKED TO MAKE
SURE THAT IT IS CLEAN, THAT ITS FILTER HAS BEEN CHANGED, AND TO OTHERWISE
MAKE SURE THE RESPIRATOR WILL PROTECT YOU IN THE WAY IT IS MEANT TO.

MAKE SURE THE DUST SUPPRESSION SYSTEM IN YOUR EQUIPMENT IS WORKING

PROPERLY. IF THE DUST SUPPRESSION SYSTEM IS NOT WORKING PROPERLY,
STOP WORKING IMMEDIATELY.

ALWAYS MAKE SURE DUST HAS BEEN CLEANED OFF YOUR BOOTS AND CLOTHES
WHEN YOU LEAVE YOUR SHIFT.

THE SMALLEST PARTICLES OF DUST ARE THE MOST HARMFUL. THEY MAY BE SO
FINE THAT YOU CAN NOT SEE THEM.

REMEMBER, YOU MUST PROTECT YOURSELF FROM THE DANGER OF BREATHING OR

INHALING DUST.

AT:172618v2
 OPERATION AND MAINTENANCE FILE
SAFETY INSTRUCTION

Jukka Pajuranta 17.2.2006 1 (1)

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 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (2)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-05

COMMISSIONING

1. Commissioning inspections

The commissioning shall be begun with a commissioning inspection before

starting the belt conveyor for the first time.

In the inspection can be used commissioning forms made by Sandvik Hollola

especially for this purpose. There is a separate form for mechanical
inspection and one for electrical and automation inspection.

The inspection shall be carried out by a person who knows well the
equipment to be inspected, commissioner and/or installation supervisor.

The commissioning forms are used as a check list and instructions for the
inspection, and they will be documents concerning the inspections and
regulations carried out.

2. First start

It is very important to carry out the first start of the belt conveyor with
caution and control, because there is a big risk of various damages.

Before the first start the commissioning inspections have to be carried out to
the extent that it is possible without running the motor.

Special attention must be paid to the following:

- the belt has to be empty and it must be able to move freely

- the electrical and control system has been tested, especially the start
warning and emergency stop systems
- all mechanical guards are in place and other factors having an influence on
the personal safety are in order
- the direction of rotation of the drive motor is correct, this must be assured,
e.g. without oil in the fluid coupling or without V-belts (if the drive motor
rotates in the wrong direction, the return brake of the reducer may be
damaged)

Immediately after the first short start, make sure that the belt remains
sufficiently centered.
The belt is centered in accordance with the instruction ROX 11-02-20, par. 2.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (2)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-05

3. Trial run without material

The belt conveyor has to be run without material during several hours,
sometimes even during several days, before the run with material can be
started.

When the conveyor is run without material, check the function of all electrical
safety devices and lockings.

Check that the sound, tightness and temperature of the reducer are normal.

Make sure that all parts of the conveyor function normally.

4. Trial run with material

The trial run with material is started with a small quantity of material,
observing the function of the hoppers and the centering of the belt.

If the material is not guided to the center of the belt, adjust and repair the
hopper accordingly.

Increase the quantity of the material to be fed onto the conveyor until the
normal/maximum capacity is achieved, carry out the necessary adjustments
to the feed hopper and the belt.

Observe the temperatures of the reducer and bearings.

Perform a start test with a full loaded belt.

Measure the effect/current taken by the drive motor.

Observe the dust-tightness and function of the belt cleaners.

Commissioning performed carefully and with proficiency contributes to

troublefree and safe productional service.
 MAINTENANCE AND OPERATION INSTRUCTIONS

21.10.05/JPa 1 (2)

MOBILE FEEDER

1. Construction and principle of operation

Mobile Feeder is installed to chassis of Mobil unit. There are transport and
operation positions for the Feeder, see RRA4811-J2.

When finding out correct operation position for the Feeder the angle of ascent
is most important. The idea of adjustable angle of ascent is to have a free
material flow from hopper to next equipment. That means that the flow from
pile along the belt has proper material height (about 150 - 350 mm) without
cutting at gate after the hopper. More detailed instructions, see Functional
Description from this manual.

As to the construction and components, the mobile Feeders are in principle

similar to other belt feeders, the belt runs only in one direction. The belt can
be tensioned only by a screw or similar.

The frame of the mobile Feeder is equipped with rails, supporting wheels are
installed to the chassis of Mobile unit. The Feeder moves along rails by
means of separate lifting cylinder and support construction equipped with joint
mechanism.

The construction and components of your Feeder can be seen in the

drawings and parts lists of the equipment.

2. Safety

Respect all instructions given and general caution. Follow instructions issued
by local authorities. Perform all maintenance and repairs only when Feeder is
in transport position. Note all safety instructions in this manual like
ROX11-01-07 before any operations. Special dangerous points and situations
are among other things following:

• Breathing dust will cause death or severe injury. Always wear approved
respirator
• When lifting or declining the Feeder there are gaps between the chassis
of mobile and Feeder. Keep always safety distance to that risk zone
• When regulating Feeder from operation position to transport position the
Feeder moves along rails. The space at rear of Feeder decreases
producing a risk of clamping in case there is solid construction or similar
close to the Feeder. Keep always safety distance to that risk zone
• To prevent entanglement at a rotating part or moving part; ensure that the
gap guards are always installed when operating
• In case the hopper of Feeder is too full the falling stones are dangerous,
keep always the safety distance of 10 meters to the Feeder.
• Falling/rolling material from the belt or hopper. Keep safety distance and
prevent personnel enter to risk zone
• Unexpected starts; ensure the warning device function and use a safety
switch

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 MAINTENANCE AND OPERATION INSTRUCTIONS

21.10.05/JPa 2 (2)

• Noise from material handling and operation; use personal protective

devices
• Disuse of personal protective devices; train personal for proper use of
approved devices
• Back rotation of belt particularly when belt is loaded with material; prevent
the drive pulley rotation
• Loss of stability of Mobile unit and/or Feeder: Ensure the stability of
foundation where unit is standing, use anchoring and other adequate
means
• The Feeder must be on horizontal area of rails when running with material
to decrease loads to lifting mechanism (see enclosed drawing)
• The proper use of Belt Feeder will increase the lifetime of Feeder as well
as the safety of operation. Ensure that the material, capacity and material
particle size are according to the values given in Contract.

3. Maintenance

For safety reasons service and cleaning works can be carried out only when
the Feeder is on transport position.

Do not start the maintenance or inspection or remove any guards before

you have stopped the Feeder and transfer mechanism and prevented an
accidental start with the safety switch. Put the guards in place before
the restart.

The maintenance and periodic inspections of the mobile Feeder are to be

performed as described in the separate maintenance and operation
instructions. In addition it is necessary to service and inspect the transfer
mechanism and the devices related to it. The periodic inspections and
maintenance are to be performed at intervals determined in the maintenance
schedule. See instruction: Maintenance schedule (B).

Records

All actions related to the scheduled maintenance, part replacing and damages
must be recorded in the Maintenance Log.

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 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007

2 OPERATOR’S MANUAL

FOREWORD

GUARANTEE

RRA4811-J1 SERVICE DIAGRAM

INSTRUCTION FUNCTIONAL DESCRIPTION

RRA4811-OP12 FEEDER’S EXTREME POSITIONS

ROX 11-01-06 OPERATION OF MATERIALS HANDLING EQUIPMENT

ROX 11-01-81 LUBRICANTS

ROX 11-01-83 CLEANING

ROX 11-02-05 COMMISSIONING

ROX 11-02-20 CONVEYOR- AND FEEDER BELT

ROX 11-02-22 SCREW TAKE-UP DEVICE

ROX 11-02-24 CONVEYOR PULLEYS

ROX 11-02-25 BELT CLEANERS

ROX 11-02-26 CONVEYOR- AND FEEDER ROLLER SYSTEMS

ROX 11-02-28 GUIDING BOARDS

ROX 11-02-31 MAINTENANCE SCHEDULE, DIFFICULT CONDITIONS (B)

ROX 11-02-40 TROUBLESHOOTING INSTRUCTION FOR BELT

CONVEYOR/FEEDERS

INSTRUCTION JOINT TRANSFER MECHANISM

MAINTENANCE LOG
MAINTENANCE LOG FORM

FEEDBACK FORM

DESCRIPTION OF DAMAGE
DAMAGE DESCRIPTION FORM

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 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007 1 (1)

FOREWORD

This instruction manual is for the use of personnel engaged in the tasks of
assembly, inspection, operation and maintenance. It must be kept always in a
place of easy access and the people must carefully become familiar with it.

The instructions, guidance and illustrations contained in this manual are necessary
for proper assembly, inspection, adjusting, start-up, operation and maintenance of
the belt conveyor.

An operator new to the Sandvik Hollola conveyor will find from this manual all
basic information of conveyor and its operation. Operational skills develop as
experience increases.

In keeping with Sandvik Hollola's policy of continuous product development, some

technical details published in this manual might differ a little in the conveyor that
you have. We do try to update and improve the manual regularly in order to update
its contents all time.

However, Sandvik Mining and Construction Hollola Oy reserves the right to modify
the conveyor without notice.

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 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007 1 (1)

GUARANTEE

The using of Sandvik Hollola original spare parts as well as the recorded
Maintenance Log covering the guarantee period is precondition for the
guarantee.

The following of this manual in every respect is also absolutely the

precondition for the Sandvik Hollola guarantee.

The Feeder installation to CrawlMaster. Control and Power system are not in
the scope of Sandvik Hollola.

The Belt Feeder is supplied under the General Conditions

NL 01 E issued in 2001.

Wear parts are not including to Guarantee.

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 RRA 4811
FUNCTIONAL DESCRIPTION
rev. b 27.06.05

Jukka Pajuranta/JPa 27.06.2005 1 (2)

FUNCTIONAL DESCRIPTION OF BELT FEEDER

General

The Feeder has 2 basic positions: Transport and Operation position. See
drawing RRA 4811-J1. The Operation position must be adjusted case by case
to have a proper inclination of the belt Feeder and desired discharge point to
next equipment. The hopper of Feeder can be loaded by another conveyor or
by wheel louder.

The adjustment of the location of Feeder is in principle case-specific

depending on hopper feeding method, material to be handled, belt speed,
particle sizes, frictions, capacity, temperature etc. When finding out correct
operation position for the Feeder the inclination is most important, use
adjustment cylinders to regulate the inclination.

The idea of adjustable inclination is to have a free material flow from hopper to
next equipment without any cutting at gate after the hopper. That
arrangement is to minimising the wear and torque needed.

The Feeder must be on horizontal area of rails when running with material to
decrease loads to lifting mechanism (see RRA 4811-J1 longitudinal position)

Unnecessary starts with full load shall be avoided. With correct inclination and
belt speed the amounts of starts can be minimised.

When you need more detailed operation instructions or information from

control system, see documentation issued by SRP.

Safety in operation

Respect all instructions given and follow general caution. Follow instructions
issued by local authorities. Perform all maintenance and repairs only when
Feeder is in transport position. Note all safety instructions in this manual like
given in instructions “Mobile Feeder” and ROX11-01-07 before any operations.

Transport position

The Feeder is in transport position when lifting cylinder (1 PC) and adjustment
cylinders (2 PCs) have strokes completely in. The Feeder is in that case on its
lowest position above the chassis (angle of ascent is about 9 °)

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 RRA 4811
FUNCTIONAL DESCRIPTION
rev. b 27.06.05

Jukka Pajuranta/JPa 27.06.2005 2 (2)

Operation position

The Feeder is in operation position when it is lifted by lifting cylinder (1 PC) to

its upper or almost upper location and support wheels are on horizontal parts
of rails carrying the Feeder. See drawing RRA4811-OP12.

The inclination and longitudinal position

When adjusting the inclination of the Feeder the target is to find out the
Feeder location where the material height on the belt is as desired. When
using Lifting (1 PC) and Adjustment cylinders (2 PCs) the target can be
achieved (max. inclination is about 24 °).

The adjustment of inclination has also influence for discharge point of material
and therefore the longitudinal direction must be adjusted to have material
unloading in the desired point at next equipment like crusher.

Lifting cylinder will carry out the final adjustment of longitudinal direction. The
adjustment range is the same as the length of horizontal parts of rails.

The final operation position is a combination of inclination and longitudinal

positions, see drawing RRA4811-OP12.

Capacity adjustment

When unloading the material from hopper along the belt with a proper material
height the capacity adjustment during the regular running can be made by
adjusting the speed of the belt (speed range about 0,2 - 0,5 m/s).

APPENDIX RRA 4811-OP12

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 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (1)

GENERAL INSTRUCTION ROX 11-01-06

OPERATION OF THE MATERIALS HANDLING EQUIPMENT

1. Operation instructions

The general regulations and instructions applying to the operator of the

materials handling equipment are in the beginning of this file
ROX 11-01-01, par. 4.

If special operation instructions have been made for the equipment or the
whole system, also these instructions are in this file.

The start and stop of the equipment, as well as the failure alarms etc. have
been described in the operation instruction or other documents of the control
system of the equipment or plant in question.

When operating the equipment it is necessary to observe all instructions and

regulations of the control and electrical system given in manuals.

2. Operating conditions

Generally, the material handling systems have been designed for moving and
transporting various materials. Every equipment and system has, however,
been designed only for certain materials and capacities and certain
conditions.

Use the equipment only with the material for which it has been designed, and
do not exceed the design capacity.

Use the equipment only in such weather and ambient conditions as for which
it has been designed.

The capacity data etc. of the equipment and system can be seen in the main
drawing, technical specification or acquisition documents of the equipment.

3. Safety

When operating, servicing and inspecting the material handling system, it is

necessary to observe the safety regulations and instructions in force in the
country and the plant.

The general safety regulations and instructions are included in the instruction
ROX 11-01-01 which is in the beginning of this file.

When operating material handling equipment it is necessary in addition

to observe the special safety instructions: ROX 11-01-07
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (4)

GENERAL INSTRUCTION ROX 11-01-81

LUBRICANTS

1. GENERAL

When choosing lubricants or performing lubrication the lubrication

instructions of the component manufacturer in question must
absolutely be followed.

This instruction contains general instructions for choosing and handling of

lubricants for the material handling equipment delivered by Sandvik Hollola.
General information on lubricants and choosing of them is available also from
the suppliers of lubricants.

2. SAFETY

If during maintenance you have to detach some guards or go outside

the normal maintenance zone near the rotating parts, it is absolutely
necessary to stop the equipment and to prevent an accidental start.
Before restarting the equipment, the guards have to be put in place.

When handling industrial oils and lubricants long-term and repeated contact
with skin must be avoided, wear protective clothing and appropriate tools.

Normally the used lubricant is classified as problem waste, take care of

appropriate handling, storing and destroying of the lubricants removed from
service.

3. LUBRICANT GROUPS

The lubrication objects of the equipment delivered by Sandvik Hollola have

been divided in four main groups:

Group 1. Gears, oil lubrication

- toothed gearings - worm gears
- lubrication by splash - immersion lubrication
- pressure lubrication - transmission chains

Group 2. Bearings, grease lubrication

- rolling bearings - slide bearings
- grease lubricated gears

Group 3. Open gear wheels, Steel wire ropes

Group 4. Hydraulic systems

- hydraulic aggregates and systems
- electrohydraulic pushers - fluid couplings
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (4)

GENERAL INSTRUCTION ROX 11-01-81

4. CHOOSING OF LUBRICANT

Group 1: Gears, oil lubrication

The oil qualities recommended by the gear manufacturer must

absolutely always be used.
To the choosing of the oil viscosity influence the type of the gear, quality of
use and ambient temperature.

Rough selection of viscosity of lubrication oil for splash and immersion

lubricated gear wheels according to the ambient temperature.

ambient
temper- VISCOSITY CLASS ISO VG (cSt/40°C)
ature
C°
+60
+50 680
+40 460
+30 320
+20
+10 220
0 150
-10 100
-20 68
-30 46
-40

Under normal circumstances the same oil can according to consideration be

used around the year also in outdoors use.
In pressure lubricated gears lower viscosity classes are normally used than in
splash and immersion lubricated gears.
In worm gears higher viscosity classes are normally used than in gear wheels.

Oil types for gear wheels and worm gears:

MANUFACTURER mineral oils synthetic oils

BP Energol GR-PX SG XP
ESSO Spartan EP Spartan Synthetic EP
NESTE Vaihteisto EP Vaihteisto S-EP
MOBIL Mobilgear Mobil SHC
SHELL Omala Oil Tivela Oil
TEBOIL Pressure Oil Multi-Pressure Oil
When using synthetic oils the suitability of the oil in question for sealing etc.
materials of the gear must be checked.

Transmission chains: The same oil type is normally suitable as the one
chosen for the gears.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 3 (4)

GENERAL INSTRUCTION ROX 11-01-81

Group 2. Grease lubrication of bearings (and gears)

The lubricants recommended by the manufacturer of the bearing or

other lubrication object must absolutely always be used.

In the lubrication grease the viscosity of the lubricant corresponds its

penetration which indicates the hardness of the lubricant.
The hardness is indicated by NLGI-number, nine different classes (000 -6),
the bigger the number is the harder is the grease.

The operating temperature range of the lubrication greases is normally wide

enough for round-the-year use in almost all lubrication objects of material
handling equipment.

In central lubrication systems the pumping characteristics of the selected

grease must be checked, especially at outdoor locations the greases of
hardness class NLGI-1 or special cold resistant greases should be used.

In grease lubricated gears the lubricants of classes NLGI-00 or 0 are normally

used.

Lubrication grease types for rolling and slide bearings:

MANUFACTURER Brand name NLGI-class

ESSO Beacon EP 0, 1, 2
NESTE Yleisrasva EP 0, 1, 2, 3
MOBIL Mobilux EP 0, 1, 2
SHELL Alvania EP Grease 1, 2
TEBOIL Multi-purpose Grease 2

Mostly the hardness classes 1 and 2 are used.

Group 3. Open gear wheels and steel wire ropes

The lubricants and protective compounds recommended by the

manufacturer of the equipment or component must absolutely always
be used.

These greases are often quite stiff bitumen based greases which contain as
blend components e.g. molybdenum sulphide and graphite.
Good anti-corrosion protection properties are required from these lubricants.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 4 (4)

GENERAL INSTRUCTION ROX 11-01-81

Lubrication protective grease types for open gear wheels and steel wire
ropes

MANUFACTURER Open gear wheels Steel wire ropes

ESSO Dynagear Extra Grease WR
NESTE Avorasva Avorasva
MOBIL Mobiltac 81 Mobilarma 798
SHELL Kuggfett Ensis Fluid K
TEBOIL Gear Grease MDS Gear Grease MDS

Group 4. Hydraulic systems

The lubricants and protective compounds recommended by the

manufacturer of the hydraulic system or component must absolutely
always be used.

To the choosing of the oil viscosity influence the type of the pump and
actuator, quality of use and ambient temperature.

The viscosity classes of hydraulic oils vary in the range ISO VG 5 -150.

In hydraulic systems the classes VG 32, 46 or 68 are normally used

depending on the type of the pump as well as the ambient and operating
temperature.

The viscosity of the oil of fluid couplings is normally VG 32.

In electrohydraulic pushers more flexible oil e.g. VG 10 is used, sometimes

also transformer oil can be used, see manufacturer’s instructions.

Hydraulic oils:

Manufacturer Hydraulic systems Hydraulic pushers Fluid couplings

ESSO Nuto H, Univis HP Spinesso 10 Torque fluid 30

NESTE Neste Paine Neste Paine
MOBIL DTE, SHC D.T.E 21 tai Velocite6 Mobilfluid 125
SHELL Tellus Oil T, TX Tellus oel C10 Tegula Oil
TEBOIL Hydraulic oil Fluid TH 10254

Many manufacturers have several oil types for special circumstances and e.g.
lightly in the nature decomposable oil types, so called BIO-oils.
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GENERAL INSTRUCTION ROX 11-01-83

CLEANING

1. General

The material handling systems and equipment have to be cleaned regularly.

In addition, the covering constructions and structures, as well as the

walkways of the conveyors have to be cleaned from material and dust
regularly.

For the fire safety reasons, the cleaning of the equipment and their
surrounding areas is extremely important, especially if material or its dust is
flammable/explosive fuel, such as e.g. peat.

2. Cleaning intervals

It is very difficult to define any exact general cleaning intervals. The cleaning
intervals depend on the material to be handled, the dust-proof of the
equipment and the operation of the dust removal and ventilation systems.

The cleaning intervals have to be planned separately for each place on the
basis of the experience in the same kind of places. The intervals have to be
selected so that the dust in equipment and the surrounding area does not
harm the operation of the equipment. General safety must not be endangered
(N.B. fire safety).

Maintenance personnel has to prepare cleaning instructions with time tables

which have to be followed.

In some very difficult places or with very dusty materials, cleaning is needed
daily.
On the other hand, in not so dusty places and with non-flammable materials a
general cleaning once a year can be enough.
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GENERAL INSTRUCTION ROX 11-01-83

3. Safety

The cleaning of the equipment and the surrounding area has to be done when
the equipment is not operating.
By being extra carefull some cleaning work, such as floor cleaning, can be
done also when the equipment is operating. In that case the entire cleaning
personnel has to know the possible elements of danger connected with the
equipment.
The risks for using compressed air or strong water jet have to be known.

If covers have to be removed or if it is necessary to go outside the

normal service area near the moving parts or on the equipment during
the cleaning, the equipment has to be absolutely stopped and it has to
be made sure that the equipment will not start accidentally.
Before the restart, the covers have to be reinstalled.

4. Cleaning methods

The cleaning method depends on the place, material to be handled and the
available cleaning systems and equipment.

Traditional sweeping with a brush and shoveling (if needed) is in most cases
a sufficient cleaning method.
If vacuum cleaner system is available, cleaning will be, of course,
considerably better and faster.

Compressed air might be in some cases good, but cleaning with only
compressed air is usually not a sufficient cleaning method, because then dust
and dirt only move from one place to an other.

Generally material handling systems supplied by Sandvik Hollola are planned

so that they can be cleaned also with low-pressure water jet.

Before using a washer jet it has to be made sure that it is allowed to clean the
equipment with water jet, and that the accumulation of washer waste has
been arranged in a proper way.

Water jet can never be pointed to non-hardy parts of the equipment, such as
electric appliances or bearings or to their sealings.

When using water in cold circumstances, the possible problems caused by

freezing have to be taken into account.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-05

COMMISSIONING

1. Commissioning inspections

The commissioning shall be begun with a commissioning inspection before

starting the belt conveyor for the first time.

In the inspection can be used commissioning forms made by Sandvik Hollola

especially for this purpose. There is a separate form for mechanical
inspection and one for electrical and automation inspection.

The inspection shall be carried out by a person who knows well the
equipment to be inspected, commissioner and/or installation supervisor.

The commissioning forms are used as a check list and instructions for the
inspection, and they will be documents concerning the inspections and
regulations carried out.

2. First start

It is very important to carry out the first start of the belt conveyor with
caution and control, because there is a big risk of various damages.

Before the first start the commissioning inspections have to be carried out to
the extent that it is possible without running the motor.

Special attention must be paid to the following:

- the belt has to be empty and it must be able to move freely

- the electrical and control system has been tested, especially the start
warning and emergency stop systems
- all mechanical guards are in place and other factors having an influence on
the personal safety are in order
- the direction of rotation of the drive motor is correct, this must be assured,
e.g. without oil in the fluid coupling or without V-belts (if the drive motor
rotates in the wrong direction, the return brake of the reducer may be
damaged)

Immediately after the first short start, make sure that the belt remains
sufficiently centered.
The belt is centered in accordance with the instruction ROX 11-02-20, par. 2.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-05

3. Trial run without material

The belt conveyor has to be run without material during several hours,
sometimes even during several days, before the run with material can be
started.

When the conveyor is run without material, check the function of all electrical
safety devices and lockings.

Check that the sound, tightness and temperature of the reducer are normal.

Make sure that all parts of the conveyor function normally.

4. Trial run with material

The trial run with material is started with a small quantity of material,
observing the function of the hoppers and the centering of the belt.

If the material is not guided to the center of the belt, adjust and repair the
hopper accordingly.

Increase the quantity of the material to be fed onto the conveyor until the
normal/maximum capacity is achieved, carry out the necessary adjustments
to the feed hopper and the belt.

Observe the temperatures of the reducer and bearings.

Perform a start test with a full loaded belt.

Measure the effect/current taken by the drive motor.

Observe the dust-tightness and function of the belt cleaners.

Commissioning performed carefully and with proficiency contributes to

troublefree and safe productional service.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-20

CONVEYOR- AND FEEDER BELT

1 Construction

The conveyor belts are rubber belts with various fabric reinforcements. Belts
are used as conveyor belts in belt conveyors and feeders.
Belts are available in several structures, different rubber qualitites, layers of
reinforcement, and in different sizes and strengths.

The conveyor belt is always chosen individually for each case to resist the
forces and conditions in questions.

The type of your conveyor belt can be seen in the main assembly drawing or
technical specification.

1.1 Type marking of a conveyor belt: (example)

TRELLEX ANTIFLAME 800 EP 400/3 - 3/1 S 55,5

TRELLEX ANTIFLAME = manufacturer of belt (mark)

800 = width of belt (mm)
EP = reinforcement
400 = tensile strength at break (N/mm)
3 = number of reinforcements (pcs)
3/1 = thickness of upper/lower layer (mm)
S = properties of belt
55,5 = length of belt (m)

More information, see documents of the belt manufacturer.

2 Adjustment

The adjustment of the conveyor belt means here the centering of the belt, so
that the belt runs enough in the middle of the drums and roller systems.
The misalignment of the belt can be caused by several factors, see
troubleshooting instructions for belt conveyors ROX 11-02-40, par. 4 and 5.

2.1 When the conveyor is started for the first time after the installation or after
bigger repair and modification work, the belt can slip to one side despite of
the fact that the pulleys and the rollers have been aligned well and the belt
jointing has been carried out duly. This is often caused by the interaction of
the inaccuracies in the alignment and the rigidity of the new belt and the
tensions prevailing in it.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-20

In this case the belt has to be centered by turning the rollers as instructed
further.
The pulleys must not be turned off from the right line. The drive pulley must
never be left inclined with respect to the center line of the conveyor.
Sometimes it may be necessary to turn the tail and take-up pulleys a little,
especially in conveyors running in two directions.

2.2 The belt is always centered first with an empty belt, i.e. without material.
The centering is started from the lower belt, from the drive end towards the
other end, and from the point where the misalignment of the belt begins.

Principle of lateral control of the belt by turning the rollers:

This principle applies both upper and lower rollers, but in conveyors rotating
in two directions, generally this cannot be used.
The roller system can be turned in the desired direction either from both ends
or only from one end.

To begin, turn the first roller system only by a few millimeters and wait for
some belt turns.

If the desired effect is not sufficient, turn the next roller system in the belt
running direction in the same way, and if necessary, continue by roller system
after another, along the whole length where the belt goes to the side.

If the belt cannot be centered, start the adjustment from the beginning, i.e.
from the point where the misalignment of the belt begins.

Continue in this way, until the lower belt runs in the middle.
Do not adjust too much. Check that the belt does not go too much in the
desired direction at any point of the conveyor.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-20

2.3 On the take-up and tail pulleys the belt is centered by turning the preceding
rollers according to the principle described above.
If the return rollers cannot be turned, e.g. because of the belt running in two
directions, the adjustment can be made by turning the pulley.
On the pulleys the belt moves in the direction where the tightness of the belt
slackens when turning the pulley.

2.4 If the pulleys and rollers have originally been installed and aligned carelessly
and the belt is not centered systematically, the rollers will be before long in
disorder and out of the line so that it is inpossible to achieve a good result,
and it may take days, even weeks, before the belt will remain properly
centered. That is why, the centering of the belt must be carried out with
caution and patience.

2.5 If the belt goes immediately after the start so much to the side that it is
impossible to leave it to rotate and begin to adjust in the way described
above, the rollers located before the pulleys must be adjusted temporarily so
much that the belt can be rotated.

2.6 When the belt has been centered on the lower rollers and pulleys, the upper
belt has to be centered with the same principle. The final centering of the
upper belt takes place only when the conveyor is running with material. Then
the friction between the rollers and the belt is bigger, and the new belt adopts
finally to the form of the roller trough.

2.7 If the misalignment of the belt is caused by an oblique joint, it is impossible to

correct it by turning the rollers.
Generally the belt straightens and stretches a little during the trial run, but if
the hindrance caused by the oblique joint after this is still too big, the joint has
to be repaired.
The oblique joint can be easity noted by observing the edge of the belt when
the belt is running, e.g. at a certain roller. If the joint is oblique, the belt always
moves to the side a little before the joint or at the joint and returns back
always after the joint.
It has to be noted that the edge and joint of the belt are never absolutely
straight, and therefore the belt edge always "rows" a little.

2.8 If the belt goes to the side when being run with material because material is
loaded on one side of the belt, this cannot normally be corrected by turning
the rollers, but it is necessary to make the necessary adjustments and
corrections to the feed hopper so that the material is guided to the middle of
the belt.

2.9 If the factors related to the construction of the conveyor or other

circumstances cause repeatedly misalignment of the belt, as well as failures,
the conveyor can be equipped with forced-guidance rollers or guide roller
systems.
If you have problems with the centering, please do not hesitate to contact
Sandvik Hollola.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-20

3 Maintenance

To assure a long service life of the conveyor, it is important to observe the

condition of the belt during the operation and in periodic inspections. Even
small superficial damages have to be repaired, because even a small damage
or rupture can become a big damage which cannot be repaired easily.

If during maintenance you have to detach some guards or go outside

the normal maintenance zone near the rotating parts, it is absolutely
necessary to stop the equipment and to prevent an accidental start.
Before restarting the equipment, the guards have to be put in place.

It has to be seen to that, e.g. jammed rollers or too tight board rubber pieces
do not damage the belt.

In inspections pay attention also to that the belt runs in the middle and that
the strain is correct. Read through the maintenance instructions of the belt
manufacturer and observe them.

In periodic inspections check ocularly the belt joint and the belt; tracks on the
surface or edges of the belt can indicate that the belt chafes against some
fixed part.

The periodic inspections and maintenances are to be performed at intervals

determined by the maintenance schedule. See instruction: Maintenance
schedule.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-22

SCREW TAKE-UP DEVICE

1. Construction and principle of operation

The main parts of the screw take-up device of the belt conveyor are:

- take-up pulley with bearings

- pulley cleaner/gap guard
- slideways or grooves
- tensioning screws with counternuts and locking nuts
- protective nets

The bearing housings have been fastened to the tensioning screws. When
these are tightened, the bearing housings move along the guideways located
on the frame structures of the conveyor. So by moving the take-up pulley
backwards, the necessary initial tightness is obtained for the conveyor belt in
order to produce a sufficient friction between the drive pulley and the belt.

The structure of the screw take-up device and the types of the components
used in your conveyor can be seen in the drawings and parts lists.

2. Adjustment

In conveyors tensioned by screw, the take-up pulley is normally also the tail
pulley of the conveyor.
In order that the belt would run in the middle, it is important that the pulley is
perpendicularly to the center line of the conveyor.
When the tightness of the belt is changed, it is necessary to move both ends
of the pulley equally.
The fastening screws of the bearing housing have to be loosened for the
adjustment.

Do not start the adjustment or inspection or remove any guards before

you have stopped the conveyor and prevented an accidental start with
the safety switch. Put the guards in place before the restart.

Adjustment of the belt laterally on the pulley, see instruction: adjustment of a

conveyor belt ROX 11-02-20, par. 2.3
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-22

2.1 Tightness of the belt

The tightness of the conveyor belt has been adjusted to the right value during
the installation and commissioning, but due to the stretch of the belt it is
necessary to check the tightness regularly and the belt has to be tensioned if
necessary.

The right tightness of the belt is checked normally by the sag of the lower belt.
The sag must be 0.8 - 1.5% of the span, when the belt is not running, t.e. if
the distance between the return rollers is 3 m, the sag of the belt between
them must be 25 - 45 mm.

Do not tension the belt too much, because this could damage the belt or the
pulley and its bearings.

A too slack belt causes slipping of the drive pulley and other failures.

If there is no more margin for tensioning, it is necessary to shorten or renew

the belt.

If the belt will be out of use during a longer period, it is advisable to slacken
the belt for this period to achieve a longer service life of the belt.

3. Maintenance

In addition to the tensioning of the belt, perform the following measures in

periodic inspections and maintenance:
- check that the tightening screws and guides are clean and in working order,
lubricate or replace them, if necessary
- clean and inspect the pulley cleaner
- check that all guards are in place and properly fixed
- inspection and maintenance of the take-up pulley, see instruction:
conveyor pulleys ROX 11-02-24

The periodic inspections and maintenance are to be performed at intervals

determined in the maintenance schedule. See instruction: Maintenance
schedule.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-24

CONVEYOR PULLEYS

1. Construction and use

Conveyor pulleys are available in different sizes and structures, such as drive
pulleys, take-up pulleys and tail pulleys.
Similar pulleys are used also, e.g. in belt feeders.

Drive pulleys and in difficult conditions also other pulleys may have a rubber-
coated shell. The pulleys are often cambered, i.e. the diameter in the middle
of the pulley is a little bigger than at the ends.

The bearings of the pulleys are equipped with dust seals suitable for this
purpose.

The types of the pulleys and their bearings used in your conveyor can be
seen in the drawings and parts lists.

2. Adjustment

In conveyors with screw tensioning, the take-up pulley serves normally also
as the tail pulley of the conveyor.
In order that the belt would run in the middle, it is important that the pulley is
perpendicularly to the center line of the conveyor.
When the tightness of the belt is changed, it is necessary to move both ends
of the pulley equally.
The fastening screws of the bearing housings have to be loosened for the
adjustment.

Do not start the adjustment or inspection or remove any guards before

you have stopped the conveyor and prevented an accidental start with
the safety switch. Put the guards in place before the restart.

Adjustment of the belt laterally on the pulley, see instruction ROX 11-02-20
par. 2.3.

The main principle is, however, that the belt is not normally adjusted by
turning the pulleys but the pulleys have always to be perpendicularly to the
center line of the conveyor.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-24

3. Maintenance

Measures to be carried out in periodic inspections and maintenance:

- check that the surface of the pulley shell is clean and undamaged, clean it if
necessary, make repaired the worn rubber coating
- check the bolt and welded joints of the pulley
- check that the screws of the bearing housings are tight and that the dust
seals of the bearings are undamaged
- check that the bearings do not warm and that they rotate without noise
- the bearings have to be lubricated according to the instructions for the
bearing housing
- check that all guards are in place and properly fixed.

Periodic inspections and maintenance are to be performed at intervals

determined in the maintenance schedule. See instruction: Maintenance
schedule.

4. Lubrication of bearing housings

Follow the separate lubrication instruction for conveyor pulleys, where the
relubrication quantities and lubrication intervals have been determined.
The lubrication quantity and lubrication interval depend on the operating
conditions, bearing size and bearing type as well as lubrication method.

Lubricants, see instruction: LUBRICANTS ROX 11-01-81.

If it is necessary to detach some guards or to go outside the normal

maintenance zone near moving parts, it is absolutely necessary to stop
the equipment and to prevent an accidental start. Before the restart, the
guards have to be put in place.

When the bearing housings are lubricated, see to that the lubricant coming
out from the bearing housings is cleaned and prevent it from coming onto the
conveyor belt.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-25

BELT CLEANERS

1. Construction and use

Belt cleaners are used in conveyors usually on the "dirty" side of the belt at
the drive pulley or immediately after it so that the material coming off from the
belt falls into the discharge hopper.
Cleaners of the lower belt are used to remove the material which has possibly
collected onto the return belt. These are normally placed on the lower belt just
before the tail pulley.

Belt cleaners which are used at the discharge end of the conveyor are
available as scrapers of various types where the "knife" wiping the belt is
pressed against the belt by different spring solutions.

At some difficult points it is possible to use also motor driven belt brushes.

The cleaners of the return belt are usually ploughs and diagonal wipers which
press the lower belt by the force of their own weight.

The belt cleaning parts of the scrapers and ploughs are made of different
materials, and they are always chosen individually for each case. They are
replaceable wearing parts.

The location and type of the belt cleaners used in your conveyor can be seen
in the drawings of the conveyor, and the construction of the cleaner is
described in more detail in the product brochures or similar of the cleaner.

2. Regulation

More detailed regulating instructions for the belt cleaner are in the brochures
and instructions for the belt cleaner.

For the functioning and service life of the cleaners it is very important that the
position of the scraper knife or similar is correct with respect to the belt/
pulley.

As a general principle it can be noted that the cleaners are to be adjusted so

that the knife presses the belt evenly along the whole width, and it is
advisable to keep the pressing force just as big as it is necessary to obtain an
adequate cleaning result.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-25

3. Maintenance

Do not start the maintenance or inspection or remove any guards

before you have stopped the conveyor and prevented an accidental start
with the safety switch. Put the guards in place before the restart.

The function of the belt cleaners has to be observed daily during the normal
operation of the conveyor.

See maintenance instructions for each type.

During periodic inspections and maintenance, perform the following measures

and checks:

- clean the device

- check the wear of the knives, adjust or replace if necessary
- check the pressing force
- check the fixture of the device

The periodic inspections and maintenance are to be performed at intervals

determined in the maintenance schedule. See instruction: Maintenance
schedule.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-26

CONVEYOR- AND FEEDER ROLLER SYSTEMS

1. Construction and use

The conveyor roller system consists of roller supports, or roller fixing lugs, and
rollers.

Roller supports and fixing lugs are available in different sizes and types.

Conveyor rollers are available in many different sizes and structures, such as
supporting rollers, return rollers and guide rollers.

Rollers of the same type are used also, e.g. in belt feeders.

The return rollers and, e.g. the rollers at the conveyor loading point are often
equipped with rubber discs.

In addition, various special roller systems, such as guiding roller supports, are
integrated with roller systems.

The bearings of the rollers are equipped with dust seals suitable for this
purpose.

The structure of the rollers and their seals is presented in more detail in the
product brochures and catalogues of the roller manufacturer.

The types of the rollers used in your conveyor can be seen in the drawings
and parts lists.

2. Adjustment

In order that the conveyor would function flawlessly and the belt would remain
well centered, it is important that the roller systems are symmetrically
perpendicularly to the center line of the conveyor.

Adjustment of the belt laterally on the roller systems, see instruction:

adjustment of a conveyor belt ROX 11-02-20, par. 2.

Do not start the adjustment or inspection or remove any guards before

you have stopped the conveyor and prevented an accidental start with
the safety switch. Put the guards in place before the restart.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-26

3. Maintenance

The conveyor rollers are normally lubricated for life, so the bearings do not
require lubrication.

If your conveyor has rollers to be lubricated, i.e. they are equipped with
nipples, read through the roller manufacturer's lubricating instruction.

Regular periodic inspections and maintenance are very important for the
service life of the rollers and belt.

Measures to be performed during periodic inspections and maintenance:

- check that the roller supports are fixed properly, and that they have not bent
or moved
- clean the roller supports and rollers from material collected onto them, if it
may prevent the rollers from rotating or if the belt does not remain in the
centered position
- check that the rollers rotate easily and without noise
- check that the roller shell is undamaged, the defective and dangerously
worn rollers are to be replaced on time
- check the condition of the rubber discs of rollers equipped with discs; the
rollers whose rubber discs have moved or worn so that they are no more
round, have to be repaired or replaced

The periodic inspections and maintenance are to be performed at intervals

determined in the maintenance schedule. See chapter: Maintenance
schedule.

The conveyor rollers and their rotation must be observed also when the
conveyor is running. The rollers which do not rotate must be replaced as soon
as possible.

Sometimes, especially with an unloaded conveyor it may occur that there are
rollers which do not rotate owing to too light contact of the belt with the roller.
In very wearing conditions this may wear the belt and roller shell; it must be
assured that also these rollers rotate with a loaded belt.

To touch the rollers when the conveyor is running is highly dangerous

(even mortal) and absolutely forbidden. Stop the conveyor before
inspecting, replacing and cleaning the roller systems. Prevent an
accidental start with the safety switch.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-28

GUIDING BOARDS

1. Construction and use

The guiding boards are normally side plates of steel structure placed on the
side of the conveyor belt, e.g. at the loading point of the conveyor and after it.
They guide the material to the middle of the belt and serve as splash and dust
seals. The back board at the conveyor loading point belongs also to the
guiding boards.

Guiding boards comprise also sealing structures and wearing plates of

various types, as well as fixing parts and protective nets.

The structure and type of the guiding boards used in your conveyor can be
seen in the drawings and parts lists.

2. Maintenance

The condition of the rubber seals of the guiding boards is very important for
the dust-tightness of the plant. Therefore it is necessary to observe the
condition (dust-tightness) of the rubber seals of the guiding boards also
during the operation of the equipment.

Do not start the maintenance or inspection or remove any guards

before you have stopped the conveyor and prevented an accidental
start with the safety switch. Put the guards in place before the restart.

During the periodic inspections and maintenance check that the boards are
fixed properly, and that the rubber seals are duly tight.
If the seals are too loose, material and dust will leak; if they are too tight, the
belt will be damaged.
In most board rubber and seal structures it is possible to adjust the seals
closer to the belt, if they are worn. If the rubber has worn so low that it will not
touch the belt so that the fixture would be reliable, the rubber has to be
changed.
Check that the possible wearing plates of the guiding boards are in order,
renew the worn ones.

Check that the protective nets are in place and well fixed.

The periodic inspections and maintenance are to be performed at intevals

determined in the maintenance schedule. See instruction: Maintenance
schedule.
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GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-31

MAINTENANCE SCHEDULE BELT/CHAIN - CONVEYOR/FEEDER

DIFFICULT CONDITIONS ( B )

1. Periodic inspections and maintenance

In addition to periodic inspections and maintenance the plant operating

personnel must daily check that all protective and safety devices of the
equipment are in place and in working order.

The cleaning of the devices and the surrounding areas has to be performed
so often that the material collecting onto the devices and in the surrounding
area does not hinder the functioning of the equipment or endanger the
general safety.

MAINTENANCE NO. OF INSTRUCTION MAINTENANCE

OBJECT INTERVAL

Hoppers ROX 11-01-54 1-2 months (abt.500h )

Conveyor belt ROX 11-02-20 1-2 months (abt.500h )
Belt cleaning devices ROX 11-02-25 1-2 months (abt.500h )
Roller systems ROX 11-02-26 1-2 months (abt.500h )
Distribution gate ROX 11-02-27 1-2 months (abt.500h )
Belt scale ROX 11-02-29 1-2 months (abt.500h )

Electric motor ROX 11-01-50 3 months (abt.1000h )

Blockage detector
Drive mechanism
Screw take-up device
Counterw.t-up device
Pulleys
Guiding boards
Transfer mechanism
ROX 11-01-63 3 months (abt.1000h )
ROX 11-02-21 3 months (abt.1000h )
ROX 11-02-22 3 months (abt.1000h )
ROX 11-02-23 3 months (abt.1000h )
ROX 11-02-24 3 months (abt.1000h )
ROX 11-02-28 3 months (abt.1000h )
ROX 11-02-50 3 months (abt.1000h )

Gear ROX 11-01-51 6 months (abt.2000h )

V-belt drive ROX 11-01-52 6 months (abt.2000h )
Pull cord em. switch ROX 11-01-60 6 months (abt.2000h )
Misalignment switch ROX 11-01-62 6 months (abt.2000h )

Rotation detector ROX 11-01-64 12 months (abt.4000h )

Start warning device ROX 11-01-65 12 months (abt.4000h )
Fluid coupling ROX 11-01-53 12months (abt.4000h )
Safety switch ROX 11-01-61 12months (abt.4000h )
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (3)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-31

If a device or component of the equipment has separate maintenance and

inspection instructions given by the manufacturer, observe primarily the
maintenance schedules and oil change intervals given therein.

The maintenance intervals given in the maintenance schedule are maximum

guide values. If the experience from the operation and maintenace of some
objects, however, show it necessary, the maintenance and inspection
intervals have to be shortened.

In some objects it is also possible to lengthen the intervals, e.g. for cleaning, if
the experience has shown that it is not necessary to clean so often.

The measures to be performed in periodic inspections and maintenance are

described in the instructions of the device or component in question, see
number of the instruction in the table.

The performed maintenance measures and reparations have to be marked in

the maintenance register of the equipment.

The guarantee provides that the inspections and maintenances are

performed.

Before starting the maintenance, inspection or cleaning of the

equipment, it has always to be stopped and the safety switch has to be
turned to the position "0" and locked. The key has to be kept by the
person who is carrying out this work or by the person in charge.

2. Safety inspections of belt conveyors

A safety inspection of the belt conveyor has to be performed at least once a

year.
The person who carries out the inspection has to know well enough the
construction, safety devices and dangerous objects of the conveyors.
The safety inspections can be also performed at the same time as the
periodic inspections and maintenance, but it is necessary to mark the register
and draw up a separate record.
Enclosed a model of a safety inspection record for a belt conveyor:
 BELTCONVEYOR SAFETY INSPECTION PROTOCOL

COMPANY: NAME OF CONVEYOR:

PLANT: CONVEYOR NUMBER:

SAFETY AND CONTROL EQUIPMENT O.K. TO BE REPAIRED/REMARKS

emergency stop
safety switch
start warning
control push-buttons etc.
indicator ligths

To be inspected: function, condition, signs etc. (see maintenance manual).

SHIELDING OF DANGEROUS PLACES O.K. TO BE REPAIRED/REMARKS

drive end, drive mechanism

tail end
counterweight take-up device
carrying rollers
return rollers
transferable equipment
inspection doors

To be inspected: safety guards, cap guards, safety rails etc. (see maintenance manual).

WALKWAYS, AMBIENT CONDITIONS O.K. TO BE REPAIRED/REMARKS

service bridges, maintenance walkways

stairs, ladders
lightning
noise, dust
signs, maintenance manuals

To be inspected: condition, tidiness, signs (see maintenance manual).

Safety inspection shall be carried out at least once a year. The person carrying out this inspection must have
adequate knowledge of conveyors: structure, safety equipment and dangerous places.

Inspector: Date:
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

TROUBLESHOOTING INSTRUCTION FOR BELT CONVEYORS/FEEDERS

0. General

In this instruction are listed failures and problems which may occur in belt
conveyors or belt feeders (number 1 - 9).
After every title under subnumbers are listed possible failures or causes
which may cause this problem, whereafter is a brief description of measures
to be taken in this situation.

1. THE CONVEYOR/FEEDERS DOES NOT START OR IT STOPS

The motor does not run

1.1 One of the protective or safety devices of the conveyor/feeder or drive motor
has been activated.
- Check and repair, reset the failure.

1.2 Electrical failure.

- Check and repair.

2. THE MOTOR DOES NOT START OR IT STOPS

The motor "jurrs" and the conveyor does not start

2.1 Electric failure (electric network, motor protecting and starting devices, cable,
motor)
- Check and repair.

2.2 The conveyor is heavily overloaded.

- Check and remove the overload from the belt.

2.3 The belt or drum is jammed.

- E.g. material or foreign matter between the belt and the board.
The tail pulley or rollers are jammed.
- Check, clean and repair.

2.4 Drives, gear or brake are jammed.

- Check that the separate brake opens properly.
- Check and repair.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

3. THE MOTOR RUNS, BUT THE DRIVE PULLEY DOES NOT ROTATE
The transmission slips

3.1 V-belts slip.

- Check and repair, see instruction: V-belt transmission ROX 11-01-52.
- Check that the conveyor is not overloaded.

3.2 The fluid coupling slips.

- Check and repair, see instruction: Fluid coupling ROX 11-01-53.
- Check that the conveyor is not overloaded.

3.3 The pin coupling, or similar, between the motor and reducer is defective.
- Check and repair.

3.4 The joint or coupling between the reducer and drive pulley is defective.
- Check and repair.

3.5 The reducer is defective.

- Check and repair, see instruction: Reducer ROX 11-01-51.

4. THE DRIVE PULLEY ROTATES, BUT THE BELT DOES NOT MOVE
The pulley slips, the friction between the pulley and the belt is not
sufficient.

4.1 The belt is not tight enough.

- Check and tighten, see instruction: Screw take-up device ROX 11-02-22 or
instruction: Counterweight take-up device ROX 11-02-23.
- Check that the conveyor is not overloaded.

4.2 Between the belt and pulley is material, e.g. snow and ice.
- Check and clean.
- Prevent the access of material and snow between the belt and pulley,
improve the cleaning and cleanliness of the equipment.
- Improve the function and maintenance of the belt cleaners.
- Use anti-freeze agents.

4.3 The rubber coating of the drive pulley is worn out.

- Check, renew the coating or replace the whole drive pulley.

4.4 The conveyor belt has jammed somewhere, e.g. material or foreign matter
has jammed between the belt and board. The tail pulley or rollers have
jammed.
- Check, clean and repair.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 3 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

5. BELT RUNS ON ONE SIDE ALWAYS AT THE SAME POINT OF THE BELT

5.1 The belt joint is oblique.

- Check, see instruction: Conveyor belt Rox 11-02-20 par. 2.8.
- Make a new joint, if necessary.

5.2 The belt has a curve, this can occur normally only with new belts.
- Check, see instruction: Conveyor belt Rox 11-02-20 par. 2.8.
- Check the storing and transport of the belt.
- Change the belt if necessary.

6. THE BELT RUNS ON ONE SIDE AT THE SAME POINT OF THE

CONVEYOR
either within some part or along the whole length of the conveyor

6.1 The pulleys are not horizontal or they are not in the middle and perpendicular
to the center line of the conveyor.
- Check and correct, see instruction: Conveyor belt Rox11-02-20 par.2.

6.2 The roller systems and rollers are not in the middle and perpendicular to the
center line of the conveyor.
- Check and correct, see instruction: Conveyor belt Rox 11-02-20 p2.

6.3 The material is not loaded to the middle of the belt. If the material is on one
side of the belt, the belt tends to move towards the emptier side on the trough
rollers. If the material moves strongly laterally at the feed point, also this tends
to move the belt to one side.
- Check, adjust or correct the feeding hopper.

6.4 Trough roller systems have been mounted in the wrong way.
- Check if the supporting rollers of the conveyor have "ploughing" roller
supports; these must be mounted so that the outermost rollers have been
turned a little towards the belt running direction.

6.5 The belt is exposed to the influence of the wind.

- Check the tightness of the belt.
- Arrange wind protections, if necessary; if it is a conveyor bridge
construction, contact Sandvik Hollola in order to determine the wind loads.

6.6 The belt chafes against some fixed part or jammed rollers.
- Check and repair.
- Improve the cleaning and maintenance.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 4 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

6.7 A separate roller system moving on the conveyor, such as hopper or

discharge carriage, guides the belt to one side.
- Check the roller systems of the moving device.
- Check the spacings of the rails of the moving device and bearing wheels.

6.8 The conveyor/feeder frame is at a slant or bent.

- Check and repair.
- In case of mobile conveyors, the frame may change the form due to too big
inaccuracies in the rails, repair the rails.

6.9 Material or snow and ice collect onto the inner surface of the belt, pulleys or
rollers.
- Check and clean.
- Prevent the access of material and snow onto the lower belt, improve the
cleaning and cleanliness of the equipment.
- Improve the functioning and maintenance of the belt cleaners.
- Use anti-freeze agents.

7. THE BELT WEARS EXCEPTIONALLY MUCH OR IT GETS CRACKS,

RUPTURES OR OTHER UNNORMAL TRACKS

7.1 The belt chafes against the conveyor/feeder frame or some other fixed part,
e.g. jammed rollers, guiding boards or material jammed between them.

- Check and repair, see par. 6.

- Check and service the belt cleaners.

7.2 The material to be transported hits on the belt unevenly, at an unappropriate

angle or too strongly.
- Adjust or repair the feeding hopper.

7.3 The material tends to jam in hoppers and it is compressed at times between
the belt and hopper structures.
- Check and repair the hoppers enough wide.
- Check that the capacity is not too high.
- Check that the piece size of the material is not too big.

7.4 Material enters between the belt and pulley.

- Prevent the access of material between the pulley, seal the material leaks.
- Check and service the return belt cleaners.
- Check and adjust the pulley gap guards/cleaners.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 5 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

7.5 Oil or chemicals on the belt.

- Check and repair.
- See to that the grease coming out during lubrication does not get onto the
belt.

7.6 Thermal or fire damage.

- See to that, e.g. the welding and flame cutting splashes during repair work
do not get onto the belt.

8. THE BELT STRETCHES TOO MUCH

8.1 The belt is too tight.

- Check and adjust, see instruction: Screw take-up device ROX 11-02-22 or
instruction: Counterweight take-up device ROX 11-02-23.

8.2 The belt forces are too big.

- Check that the conveyor is not overloaded.

9. THE BELT BREAKS, THE BELT JOINT BREAKS

9.1 The belt joint has been made in the wrong way.
- Make a new joint according to the instructions.

9.2 The belt forces are too big.

- See 8.1 and 8.2.

9.3 Material enters between the belt and pulley.

- See 7.4
 MAINTENANCE AND OPERATION INSTRUCTIONS

3.5.2004 JPa 1 (1)

SPECIAL INSTRUCTION, BELT CONVEYOR

JOINT/TRANSFER MECHANISM

1. Construction and principle of operation

Mobile belt conveyors have special functions like telescope part and tail end
with adjustment of height.

These features are needed because of transportation and service.

Transfer/lifting mechanisms are available in various constructions and

principles. In transfer/lifting mechanisms normally hydraulic units and
cylinders are used.

The construction and components of the transfer mechanism of your

conveyor can be seen in the drawings and parts lists of the equipment.

2. Maintenance

Transfer/lifting mechanisms are always dangerous places!

See also ROX 11-01-07

Do not start the maintenance or inspection or remove any guards before

you have stopped the conveyor and transfer mechanism and prevented
an accidental start with the safety switch.
Put the guards in place before the restart.

The periodic inspections and maintenance are to be performed at intervals

determined in the maintenance schedule. See instruction: Maintenance
schedule.

See also Sandvik Rock Processing (SRP) instructions.

3. Operation of joint/transfer mechanism

See SRP instructions.

 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007 1 (1)

Maintenance Log

It is Owner’s obligation to maintain among other things the Maintenance Log, for other
obligations see ROX 11-01-01.

On the Maintenance Log inspections, service actions and other actions must be
recorded as an implementation of Sandvik Hollola instructions valid for the belt
conveyor.

When required records must be available for Sandvik Hollola.

Enclosed sheet is an example sheet for the Maintenance Log.

All Damage Reports, if any, must be stored up in the Maintenance Log.

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Maintenance log rev0.doc

MAINTENANCE LOG page ___
Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181
Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
Finland

Belt Feeder
RRA4811
Serial number: 4811 / 200…. / W…… / ….

Author:______________________________ Date: :______________________________

Describing
of
maintenance
work

Reference to
instruction
Rox 11-02- __
Rox 11-02- __
Rox 11-02- __

Author:______________________________ Date: :______________________________

Describing
of
maintenance
work

Reference to
instruction
Rox 11-02- __
Rox 11-02- __
Rox 11-02- __

Author:______________________________ Date: :______________________________

Describing
of
maintenance
work

Reference to
instruction
Rox 11-02- __
Rox 11-02- __
Rox 11-02- __

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Maintenance and feedback form rev0.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
FEEDBACK FORM
Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181
Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
Finland

Serial number: 4811 / 200…. / W…… / ….

1. COMPONENTS, SPARE and WEAR PARTS

S Your proposals for the development?

S What improvements are most urgent ones?

2. FRAME

S Your proposals for the development ?

S What improvements are most urgent ones?

3. OPERATION & MAINTENANCE

S Proposals for the better operation and availability?

4. OTHER S

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Maintenance and feedback form rev0.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007 1 (1)

Description of Damage

If damage takes place it must be described and drawn on paper. Filled Damage Report
must be also sent to Sandvik Mining and Construction Hollola Oy, who on this way has
detailed information from the Damage.

In case of guarantee the Damage Report is precondition for the reclamation handling.
Manufacturing number to be filled on the report is written on Type Plate locating on the
frame part of drive end.

Damage describer must be properly trained and authorised person, who can describe the
Damage in details. The Report shall include also photos.

There is enclosed an example from the Damage Report Form.

All Reports must be stored up in the maintenance log of Operator.

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Description of damage rev0.doc

DAMAGE DESCRIPTION FORM appendix
Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181
Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
Finland

RRA4811 Belt Feeder

Manufacturing number: 4811 / 200….. / W…… / ……

Author:______________________________/date :______________________________

Damage
description

Enclosere

Author:______________________________/date :______________________________

Damage
description

Enclosere

Author:______________________________/date :______________________________

Damage
description

Enclosere

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Damage description form rev0.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007

3 ELECTRICAL DOCUMENTATION
ELECTRIFICATION AND CONTROL SYSTEM

ZG2 PULL CORD EMERGENCY SYSTEM

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\RRA4811 Interleafs_rev0.doc

 MAINTENANCE AND OPERATION INSTRUCTIONS

13.04.2006/JPa 1 (1)
SPECIAL INSTRUCTION, BELT CONVEYOR

ELECTRIFICATION AND CONTROL SYSTEM

1. Scope of Sandvik Hollola

The drive unit of Mobile belt conveyors is normally hydraulic motor, gearbox
with electric motor or drum motor and included to the scope.

Design of electrification and control system, control system, safety switches,

start alarm devices, hydraulic systems and electrical cabling are excluded and
will be specified, installed and tested by Sandvik Rock Processing (SRP).

Speed detectors and pull cord emergency switches are normally included in
the scope, but emergency stop push buttons can be also used. Because of
the conveyor installation to the chassis at SRP workshop, particularly the pull
cord emergency system must be installed and tested at workshop before the
delivery to Customer takes place.

2. Operation of Conveyor

To have more information for the operation, see SRP documentation.

Assembly illustration ZG2 Pull cord emergency switch

Cord length L = 8 m

14 C ORD D 3 / 5 - 6 x7 x( L = 8 m ) R E D 1
13 HOOK E S 1 -H 1
12 S P R IN G E S 1 -D 1
11 SLEEVE E S 1 -F 3
10 G U ID E R O L L E R E S 1 -E 2
9 C O R D G U ID E E S 1 -S -5 0 3
8 C A B L E T IE W ID T H 2 . 5 L E NG TH 1 0 0 8
7 E M E R G E N C Y S T O P S IG N NÖ D S TO P P ( S W E ) 2
6 E M E R G E N C Y S T O P S IG N E M E RG E NC Y S TO P 2
5 TURNB UC K L E E S 1 -G 1
4 F A S T C O U P L IN G E S 1 -P 1
3 C ORD L OC K D 5 E L L IP T IC A L L O C K 4
2 T H IM B L E S D 5 D IN 6 8 9 9 - A G A L V A N IZ E D 4
1 S W IT C H X Y2 - C E 2 C 2 5 0 T E L E M . 1

P art N ame Code Pcs

We reserve the right for modifications without prior notice.

 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007

4 PRODUCT DOCUMENTATION

ROX 11-01-60 PULL CORD EMERGENCY SWITCH

ROX 11-01-64 ROTATION DETECTOR

BREVINI GEAR UNITS

PWD3150 + H1CR30

MCR10 HYDRAULIC MOTOR, ALTERNATIVE

ZD DRIVE PULLEY

BP TAIL PULLEY

INFO CONVEYOR IDLERS

TS-E STEEL IDLERS

RB(S) RETURN IDLERS

LA IMPACT IDLERS

MR2 RETURN BELT PLOUGH

MU10 BELT CLEANER

INSTRUCTION HYDRAULIC FITTINGS AND DATA

HPS50- HYDRAULIC CYLINDER

HPS100- HYDRAULIC CYLINDER

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 MAINTENANCE AND OPERATION INSTRUCTIONS
02.01.95/JP/ms 1 (2)

GENERAL INSTRUCTION ROX 11-01-60

PULL CORD EMERGENCY SWITCH

1. Construction

The pull cord emergency switch is a mechanical emergency stop device

operating by a cord designed and approved for this purpose.

The pull cord is located at the side of the equipment, generally between the
service passage and the equipment, along the whole length of the equipment,
at least in the zone where is a service passage or where the access near the
equipment is otherwise possible.

The cord has been suspended on special rings, and pulleys are used in
curved areas.

Several types of switches from various manufacturers are used. The type and
location of the pull cord emergency switches used in your equipment can be
seen in the parts lists and drawings.

2. Principle of operation

The purpose of the pull cord emergency switch is to stop the equipment when
one pulls at the cord.

The pull cord emergency switch is to be used only in emergency situations,

where is a hazard of personal injury or material damage. The pull cord
emergency switch must not be used for normal stop of the equipment or to
prevent accidental start of the equipment.

When you pull at the cord, the lever or stem of the switch moves, and the
contact of the switch will open, whereat the control system stops the
equipment.

The emergency stop wire switch is always mechanically locked in the open
position, and this can be released only by pressing the reset pushbutton of
the switch or similar.

In most pull cord emergency stop systems, the switch functions in two
directions, and the pull cord has been tensioned by means of a spring to an
appropriate tightness, so the slackening or breaking of the cord will cause
also an emergency stop.
 MAINTENANCE AND OPERATION INSTRUCTIONS
02.01.95/JP/ms 2 (2)

GENERAL INSTRUCTION ROX 11-01-60

3. Regulation

The emergency stop switches and cords have been regulated to the right
tightness when being installed and taken into use.

For some types of switches are separate regulating instructions given by the
manufacturer of the device.

In systems where is a control of so called breaking cord, the cord is tensioned

so that the lever or the stem of the switch is in the middle of its zone of
movement.

4. Maintenance

The pull cord emergency stop system does not require any special
maintenance, but cleaning and regular periodic inspections are necessary.

In periodic inspections it has to be checked that the switch and its cables are
fixed properly. Check that the cord, its locks and fixtures are OK. Check that
the cord is tensioned to the right tightness, and that it can move freely.

Periodic inspections and maintenance are to perfomed at intervals

determined in the maintenance schedule. See instruction : Maintenance
schedule.

In the functioning inspection it has to be checked that the switch functions

well also when one pulls at the farthest point of the cord. Check that the
locking of the switch in the open position and its resetting function flawlessly.
Check that the control system effects the necessary stops and alarm
indications when one pulls at the cord.
 MAINTENANCE AND OPERATION INSTRUCTIONS
25.05.98/JP/ms 1 (2)

GENERAL INSTRUCTION ROX 11-01-64

ROTATION DETECTOR

1. Construction

The control of rotation consists in principle of three parts: "recognition

pieces", detector with fixture and control system.
The recognition pieces are metal pieces, bolts, openings etc. on the drive
shaft after the transmission mechanism, in conveyors on the freely rotating
pulley or roller.
The most often used detector is an inductive compact detector Ø 30mm with
inbuilt impulse counter and potentiometer with which the impulse frequency is
regulated.
It is possible to use also an ordinary inductive detector. In that case the
counting of impulses and setting of frequency take place in the control
system (logic control or special relay).
The type and location of the rotation detector used in your equipment can be
seen in the parts lists and drawings.

2. Principle of operation

When the recognition pieces pass by the detector at a frequency which is

superior to the set value, the control system has the information that the
device is rotating.

The purpose of the rotation control is also to stop the drive motor of the
device in question if the frequency is below the set value. So it is possible to
get an alarm of the stop of the device or failures in, e.g. transmission, slipping
belt and some defects in the electric and control system.
In order to start the device normally, the rotation control is by-passed during
the start. This is effected by the control system or the properties of the
detector itself.

3. Adjustment

The installation distance of the detector from the recognition pieces is 4-6
mm. The maximum reliable detecting distance is 8 mm.

The setting of the impulse frequency of compact detectors is performed by

means of a small screw potentiometer which is in the detector. (some model
under a plastic protecting screw)

The LED of the detector is on when the impulse value exceeds the set value,
and 10s. after energized (start time delay).
 MAINTENANCE AND OPERATION INSTRUCTIONS
25.05.98/JP/ms 2 (2)

GENERAL INSTRUCTION ROX 11-01-64

If during maintenance you have to detach some guards or go outside

the normal maintenance zone near the rotating parts, it is absolutely
necessary to stop the equipment and to prevent an accidental start.
Before restarting the equipment, the guards have to be put in place.

When the screw is turned clockwise, the impulse value increases and vice
versa.
Try to find out the screw setting which is as near the normal rotational speed
of the device as possible, i.e. the point where the LED just lights up/goes out
when the device is rotating at the normal speed. From this point the setting is
decreased by ¼ - 1½ turns. So the alarm point can be set 10 - 60% below
the normal speed of rotation. The amount of turns depends on the impulse
value in question.
The number of impulses for rotation detectors equipped with a separate relay
unit is set by means of the relay according to the manufacturer's instructions.
If impulses are counted in the logic program, also the setting takes place by
programming.

4. Maintenance

The rotation detector does not require any special maintenance, but cleaning
and regular periodic inspections are necessary.
The detector and recognition pieces have to be kept enough clean so that
material or foreign matter does not damage the detector when being between
them. The detector itself is very tight against humidity and dust.

In periodic maintenance check that the fixture of the detector, its cables and
recognition pieces are OK.
The periodic inspections and maintenance are to be performed at intervals
determined by the maintenance schedule. See instruction: Maintenance
schedule.

The function is checked by four separate way, arranging a failure in rotation,

e.g. as follows:
- by changing the detecting distance too big
- by increasing the frequency setting over the normal speed of rotation
- by preventing the rotation of the device or the recognition pieces
- by disconnecting the detector electrically
Check that the control system effects the necessary stops and alarms in case
of failure.

After checking the function, set the detector and the possible adjustments
back to the right values where they were before causing the failure in rotation.
 COMPONENT PART LIST DB0002130/A

Date: 03-03-2006

Description: WINCH DRIVE GEAR

Business Code: PWD3150/CF-AP/../A.D.646
Discriminating:
Pos Code Denomination Q.ty Notes
001 9002357 SPINDLE 1
PWD3150/CF/../AD28-32
002 9002356 HUB 1
PWD3150/IF340_F18/../Z76_M3
003 32025800000 COVER 1
CTU3150.1/IF254/../Z77M2
004 36135400000 THRUST WASHER 1
CTU3150.1/32/M8/7
005 43181800103 WASHER 3
PS22x30x0,3 DIN988
006 36135300000 THRUST WASHER 1 1a Rid.
CTU3150.1/62_1D/2F/2,5
007 4252613000K BEARING 1
BA2.7032.A_SKF Obliquo a sfere
011 3541632000K COVER 1
CTU3150/IF282_20F/../..
012 41577300000 FACE SEAL 1 Goetze
7690 H24-A3
013 46213900600 SCREW 8
M12x40 UNI5931-67-12.9
014 462078006L0 SCREW 20
M8x25 UNI5931-67-12.9 Frenafiletti applicato
015 46408000000 SCREW 3
M10x10 UNI5923-67-12.9
017 3690644000K PIN 7
D.16X40
018 46107800000 SCREW 8
M8x25 UNI5739-65-8.8
019 46701000101 WASHER 8
8,4x14x1,6 UNI6592-93-HV300
021 41222300000 O-RING 1
2-178 247,32x2,62
022 41221800000 O-RING 1
2-176 234,62x2,62
023 45128700000 PLUG 2
M18x1,5 DIN908
024 41701200100 WASHER 2
DIN7603-A 18x24 - Al
038 327B9400000 SUN PINION 1 1a Rid.
i=4,08
039 327B9500000 SUN PINION 1 1a Rid.
i=4,50
040 327B9600000 SUN PINION 1 1a Rid.
i=5,05
041 327B9700000 SUN PINION 1 1a Rid.
i=5,81
042 327B9800000 SUN PINION 1 1a Rid.
i=6,92
043 327B9900000 SUN PINION 1 1a Rid.
CTU3150.1/Z10M3/8,7/B14
052 327B202000K SUN PINION 1 2a Rid.
CTU3150/Z26M3/3,92/B23
060 9005095 PLANET CARRIER 1
PWD3150/../4,17/3R
061 3406904000K PLANET GEAR CTU3150.1/../4,17/.. 4 3a Rid.
062 43103500000 CIRCLIP 4
Est.32 UNI7435-75
065 3613124000K THRUST WASHER 1 3a Rid.
CTU3150/62_1T/28/3
067 43331200000 RETAINING RING 1
A24 UNI7433-75
DB0002130/A 1/2
Pos Code Denomination Q.ty Notes
068 43104500000 CIRCLIP 1
Est.40 UNI7435-75
069 43315100000 DISK 1
Int. SB 68
070 42114700000 BEARING 1
16008 DIN625
090 3174603000K SHAFT 1
CTU3150/A14/FL3,5/A45
091 3722544000K WASHER 1
CTU3150/125/70/7
092 36710640000 SPRING 18
FL635/D12/F2,3/Su7,25
093 36714500000 SPRING 9
CWD2050.1/D7/F1,3/Su14,5
094 38910630000 DISK 6
FL635/Z36M2,5/H1/..
095 38910530000 DISK 5
FL635/SINT/../..
096 3623084000K SHIM 1
FL3,5/90,5/71,5/2,5
098 3892453000K PISTON 1
FL3,5/De120/../18M
099 43210300000 CIRCLIP 1
Int.125 UNI7437-75
103 41233800000 O-RING 1
2-248 120,24x3,53
104 41232600000 O-RING 1
2-242 101,19x3,53
109 41233800800 BLOCKING RING 1
8-248
110 41232600800 BLOCKING RING 1
8-242
120 45153040000 EXTENSION 3
MF/G38/H30/Gj38
121 4000943 PLUG 2 Ottone
"Magnetic" G3/8 O-Ring
122 4001527 NIPPLE 1
Occhio Femmina G3/8 (OR_ OW05060600)
123 45153700000 NIPPLE 1
Forato G3/8 (OR_RF05060000)
124 41700300200 WASHER 3
DIN7603-A 17x23 - Cu
126 45106400000 PLUG 1 Ottone
Sfiato G3/8
510 214L9233600 1a REDUCTION STAGE CTU3150.1/../4,08/SGC 1
(PM102)
511 214L9243600 1a REDUCTION STAGE CTU3150.1/../4,5/SGC 1
(PM102)
512 214L9253600 1a REDUCTION STAGE CTU3150.1/../5,05/SGC 1
(PM102)
513 214L9993600 1a REDUCTION STAGE CTU3150.1/../5,81/SGC 1
(PM102)
514 214L9293600 1a REDUCTION STAGE CTU3150.1/../6,92/SGC 1
(PM102)
515 214L9C63600 1a REDUCTION STAGE CTU3150.1/../8,7/SGC 1
(PM102)
520 214K3233500 2a REDUCTION STAGE CTU3150/../3,92/GC24 1
+GC i=4 3R

Exploded View SE0002130

DB0002130/A 2/2

CONVEYOR IDLERS
INSTALLATION
Conveyor idlers must be installed carefully because
installation has an essential importance for the belt to stay in
center line and lasting time of idler:
Belt
direction
Belt
direction
Touch carefully the idlers. Installation shall be made with lightly
knock by hands or carefully with rubber- or plastic hammer.
Never use metal hammer, because then the knocking load to
the bearing can damage the bearing and result in shorter
lasting time.
While installation of return idlers with rubber discs also take
into consideration following factors which secure operation,
staying at place and lasting of idlers:
Sandvik
Conveyor Components
1/1999 1(2)
INFO
Conveyor idlers shall be installed symmetrically cross
direction with center line of conveyor. Idler brackets and/or
idler supports must be well- fastened onto frame in order to
counteract turning and loosening.
Ploughing can appear in outmost idlers caused by bracket
type or they are in cross direction with center line of conveyor
like middle idler. Ploughing direction of outmost idlers on
one-way conveyor.
Elimination of outmost idlers ploughing on two-way conveyor.
Install idler bracket cross direction with frame.
Disc return idler do not bend the belt before pulley and in
curves. In minor pendings it is allowed (1..3 degrees), but
also then secure the idler load. When bending the belt strongly
downwards with the disc return idler there is a risk of gliding
of the discs on idler because of high radial load.
As a result is the belt moving sidewards, inner steel tube rub
against the belt and the discs wear out. In bending points of
return side belt always use the straight steel idler. If dirt is
considerable use the rubber coated steel idler.
We reserve the right for modifications without prior notice.

Equip the conveyor with guiding idlers if belt travels unsteady
(because of load eccentricity or sidewind on open conveyors)
or when using light belts on long conveyors.
While installation of guiding idler brackets it must be inspected
that they can turn freely.
OPERATION
If there is noted a broken idler during the running, stop the
conveyor immediately and replace the broken one.
If idler is rolling among the conveyed material partly or wholly,
clean the material round the idler immediately. As a result of
dirt can be:
- Material wear the idler while rubbing it.
MAINTENANCE
Target for the inspection and maintenance of idler is that
maintenance interval could be run without stoppages caused
by idler damages.
Inspection of idler condition and maintenance must be done
systematically at agreed intervals according to operating
conditions. Definition of operating conditions must be agreed
by idler supplier and user.
While maintenance of idlers it must be inspected that
- Idlers run smoothly, steady and noiseless. If there is any
stiffness, unevenness or noise, replace the idler.
- Idler mantel is solid. Replace idler if the mantel is broken or
badly worn out.
- Idler mantel is clean.
- Rubber discs on return idlers are solid and firmly at original
places. Replace or repair the idler with damaged rubber
discs.
Inspection of idler condition and maintenance is two-stage:
1. Estimation of idler condition must be done by going
conveyor lines carefully through while the conveyor is in
running. Mark the observations to the service card which will
be fixed on idler bracket:
STORAGE
If idlers are required to be stored before installation, they must
be stored in covered, dry and preferably indoor space.
Transportation packages must be opened before stocking and
condition of idlers inspected to be sure that there are no
damages.
Sandvik
Conveyor Components
1/1999 2(2)
While installation of fixed, downwards bending guiding idler
brackets it must be started with light power. Use more only
if there is need for increasing of guiding power. Then it is
possible to minimize the idler loads.
- Idler freezes among the material during the stoppage and
wears quickly after starting the conveyor.
- Because of material idler can not cool off from the air;
overheating and fire danger.
- Material come through the sealing and cause an early
bearing damage.
- Unnormal noises
- Strong radial cast
- Stuck idlers
- Rubber disc damages
TO TOUCH OR REPLACE THE IDLERS DURING
THE RUNNING IS ABSOLUTELY FORBIDDEN
2. Run through the marked idlers during the conveyor
stoppage and estimate the need of replacement. Also
unmarked idlers must be inspected. This because some of
the inspections are easier to make when the idlers do not roll.
(worn-out of mantel surface, quantity of radial gap, condition
of rubber discs).
In throughing idlers belt edge and ploughing of outmost idlers
cause worn-out more than normally in mantel. Lasting time of
mantel can be lengthened by turning the outmost idlers
occasionally vice versa.
If conveyor system has after-lubricated idlers, see lubrication
instructions.
We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components
2/2006

STEEL IDLER TS-E

Roxon TS-E idler is a competitive standard idler for belt ORDERING EXAMPLE: TS108 E - 20 B - 380 K
conveyors. TS-E idler is used as carrying idler and also as a
return idler for non-sticky materials.
Type code
The steel sealing casing and the weather seal form a reliable
cover against the splashwater. The multiple sealing Idler diameter D (mm)
labyrinth efficiently prevents the dirt from getting inside the Sealing alternative E
idler. The standard surface treatment is shot-blasting
and epoxypowder coating RAL3000, red. Special surface Shaft diameter d (mm)
treatment is also available for sticky materials. Shaft end alternative, see separate sheet
Idler length L (mm)
Special surface treatment, see separate sheet

Example: Total weight 7,2 kg

Idler weight (kg) Weight of rotating parts 3,8 kg

L
D d
200 250 315 380 465 530 600 670 750 950 1150 1400 1600 1800 2000
1,4 1,6 1,9 2,3 2,7 3,0 3,3 3,7 4,1 5,0 6,0 7,2 8,2 9,2 10,1
51 20
0,9 1,0 1,2 1,3 1,5 1,7 1,8 2,0 2,2 2,7 3,2 3,8 4,2 4,7 5,2
1,6 1,9 2,2 2,6 3,0 3,3 3,7 4,1 4,5 5,5 6,5 7,8 8,9 9,9 10,9
63 20
1,1 1,3 1,5 1,6 1,9 2,0 2,2 2,4 2,6 3,2 3,7 4,4 4,9 5,5 6,0
2,5 3,0 3,5 4,1 4,8 5,4 6,0 6,6 7,3 9,0 10,7 12,9 14,6 16,3 18,0
20
2,0 2,3 2,7 3,1 3,7 4,1 4,5 4,9 5,4 6,6 7,9 9,4 10,6 11,9 13,1
3,2 3,7 4,4 5,0 5,9 6,5 7,2 7,9 8,7 10,7 12,7 15,2 17,2 19,2 21,2
89 25
2,4 2,7 3,1 3,5 4,1 4,5 4,9 5,3 5,8 7,0 8,3 9,8 11,0 12,3 13,5
3,6 4,2 4,9 5,7 6,7 7,5 8,3 9,1 10,0 12,4 14,7 17,6 20,0 22,3 24,7
30
2,5 2,8 3,2 3,6 4,1 4,5 4,9 5,4 5,9 7,1 8,3 9,9 11,1 12,3 13,6
2,7 3,1 3,7 4,3 5,1 5,7 6,3 6,9 7,6 9,4 11,2 13,5 15,3 17,0 18,8
20
2,2 2,5 2,9 3,4 3,9 4,3 4,8 5,3 5,8 7,1 8,4 10,0 11,3 12,6 13,9
3,4 3,9 4,6 5,3 6,1 6,8 7,5 8,3 9,1 11,2 13,2 15,8 17,9 20,0 22,0
25
2,6 2,9 3,4 3,8 4,3 4,8 5,2 5,7 6,2 7,5 8,8 10,4 11,7 13,0 14,3
108
3,8 4,4 5,2 6,0 7,0 7,8 8,6 9,5 10,4 12,8 15,3 18,3 20,7 23,1 25,5
30
2,7 3,0 3,4 3,9 4,4 4,8 5,3 5,8 6,3 7,6 8,9 10,5 11,8 13,1 14,4
9,2 10,0 11,1 12,1 13,5 14,6 15,7 16,9 18,2 21,4 24,7 28,8 32,1 35,3 38,6
40
7,2 7,5 7,9 8,4 8,9 9,3 9,8 10,3 10,8 12,1 13,4 15,0 16,3 17,6 18,9
4,1 4,8 5,7 6,7 7,8 8,7 9,7 10,7 11,8 14,6 17,4 20,9 23,7 26,5 29,3
20
3,6 4,2 5,0 5,7 6,7 7,4 8,2 9,0 10,0 12,3 14,6 17,4 19,7 22,0 24,3
4,8 5,5 6,5 7,5 8,8 9,8 10,9 12,0 13,2 16,3 19,3 23,2 26,2 29,3 32,4
25
4,0 4,6 5,3 6,1 7,0 7,8 8,6 9,4 10,3 12,6 14,9 17,8 20,1 22,4 24,7
133
5,2 6,0 7,1 8,2 9,7 10,8 12,0 13,2 14,5 17,9 21,3 25,6 29,0 32,4 35,8
30
4,0 4,6 5,4 6,1 7,1 7,8 8,6 9,4 10,4 12,7 15,0 17,8 20,1 22,4 24,7
10,6 11,6 13,0 14,4 16,2 17,6 19,1 20,6 22,3 26,6 30,9 36,2 40,5 44,7 49,0
40
8,6 9,2 9,9 10,7 11,6 12,4 13,2 14,0 14,9 17,2 19,5 22,4 24,7 27,0 29,3
5,5 6,5 7,8 9,0 10,7 12,0 13,4 14,7 16,3 20,2 24,1 29,0 33,0 36,9 40,8
20
5,0 5,9 7,0 8,1 9,6 10,7 11,9 13,1 14,4 17,9 21,3 25,6 29,0 32,5 35,9
6,2 7,2 8,6 10,0 11,7 13,1 14,6 16,1 17,7 21,9 26,1 31,4 35,6 39,8 44,0
25
5,4 6,3 7,4 8,5 10,0 11,1 12,3 13,5 14,8 18,3 21,7 26,0 29,4 32,9 36,3
159
6,6 7,7 9,2 10,6 12,6 14,1 15,6 17,2 19,0 23,6 28,1 33,8 38,3 42,9 47,4
30
5,5 6,3 7,4 8,5 10,0 11,1 12,3 13,5 14,9 18,3 21,7 26,0 29,5 32,9 36,3
12,2 13,6 15,3 17,1 19,4 21,1 23,0 24,9 27,1 32,5 37,9 44,6 50,0 55,4 60,8
40
10,2 11,1 12,2 13,3 14,8 15,9 17,1 18,3 19,7 23,1 26,5 30,8 34,2 37,7 41,1
10,5 12,2 14,3 16,5 19,4 21,6 23,9 26,3 29,0 35,7 42,5 50,9 57,6 64,4 71,1
30
8,5 9,7 11,2 12,8 14,8 16,4 18,0 19,7 21,6 26,4 31,1 37,1 41,8 46,6 51,4
219
15,1 16,8 19,0 21,2 24,0 26,2 28,6 30,9 33,6 40,4 47,1 55,5 62,3 69,0 75,7
40
13,1 14,3 15,9 17,4 19,5 21,0 22,7 24,3 26,2 31,0 35,8 41,7 46,5 51,3 56,0

We reserve the right for modifications without prior notice.

 Sandvik
Conveyor Components
3/2004

RETURN IDLER RB(S)

L B D P L1 L2 L3 Discs Idler weight / Weight of rotating parts (kg)

(pcs) L d D108 D133 D159 D219
108 40 20 4.5 / 3.2 6.7 / 5.8 8.2 / 7.3
500 400 133 40 50 100 80 5
500 25 5.1 / 3.1 7.8 / 5.9 9.3 / 7.4
159 40 30 8.7 / 5.5 10.2 / 7.0
108 40 20 5.0 / 3.5 7.5 / 6.4 9.0 / 7.9
600 500 133 40 50 105 125 5 600 25 5.7 / 3.4 8.8 / 6.5 10.3 / 8.0
159 40 30 9.9 / 6.1 11.4 / 7.6
108 40 20 6.0 / 4.2 9.1 / 7.7 10.9 / 9.5
750 650 133 40 50 110 110 6 750 25 6.9 / 4.1 10.6 / 7.7 12.4 / 9.5
159 40 30 11.9 / 7.4 13.7 / 9.2
108 40 20 7.6 / 5.2 11.4 / 9.5 13.8 / 11.9
133 40 60 155 145 8 950 25 8.8 / 5.1 13.2 / 9.6 15.6 / 12.0
950 800
159 40 30 14.8 / 9.2 17.2 / 11.6 26.7 / 26.0
40 35.3 / 21.4
219 50 60 190 115 8
20 8.8 / 6.0 13.5 / 11.0 16.2 / 13.7
108 40
60 155 150 9 1150 25 10.3 / 5.9 15.5 / 11.1 18.2 / 13.8
1150 1000 133 40
30 17.5 / 10.7 20.2 / 13.4 31.0 / 29.1
159 40
40 40.5 / 24.6
219 50 60 190 125 9 20 10.9 / 7.4 16.5 / 13.5 20.1 / 17.1
108 40 25 12.7 / 7.3 18.9 / 13.5 22.5 / 17.1
65 195 145 12 1400
1400 1200 133 40 30 21.3 / 13.2 24.9 / 16.8 36.0 / 32.7
159 40 40 46.5 / 28.2
219 50 70 195 135 10 20 18.5 / 15.0 22.4 / 18.9
133 40 1600 25 21.2 / 15.1 25.1 / 19.0
70 195 145 13
1600 1400 159 40 30 24.0 / 14.7 27.9 / 18.6 40.3 / 35.9
219 50 70 200 135 11 40 51.7 / 31.3
133 40 20 24.8 / 20.7
70 200 145 14
1800 1600 159 40 1800 25 23.5 / 16.6 27.7 / 20.8
219 50 70 195 140 12 30 26.6 / 16.2 30.8 / 20.4 44.6 / 39.1
133 40 40 56.8 / 34.5
60 200 150 15
2000 1800 159 40 20
219 50 70 195 140 13 2000 25 30.3 / 22.6
133 40 30 33.7 / 22.3 48.9 / 42.3
60 200 150 16 40 62.0 / 37.7
2200 2000 159 40
25
219 50 70 195 140 14 2200 30 36.7 / 24.1 53.2 / 45.5
* For technical reasons in production the discs may 40 67.2 / 40.9
be differently spaced in the middle of the idler.

We reserve the right for modifications without prior notice.

 Sandvik
Conveyor Components
9/98

IMPACT IDLER LA
ROXON LA-idler is designed for an impact idler to ORDERING EXAMPLE: LA 108E - 20 B - 380
absorb impact shocks at belt conveyor loading points.
The LA-idler is also suitable for a snub pulley for the
dirty side of the belt as well as for an impact idler for Idler type
unit goods conveyors.
Idler diameter D (mm)
LA-idler is based on the sturdy TS-idler.
E = steel idler type TS-E
Blank = steel idler type TS
(see steel idlers)
Shaft diameter d (mm)
Shaft end type, see separate information page
Idler length L (mm)

Example: Total weight 11.6 kg

Idler weight (kg) Weight of rotating parts 8.3 kg
L
D d
250 315 380 465 530 600 670 750 800 950 1150 1400 1600 1800 2000

20 2.3 2.9 3.3 3.9 4.4 4.9 5.4 6.0

89 * 1.7 2.1 2.4 2.8 3.1 3.5 3.7 4.2
25 2.6 3.2 3.7 4.5 5.0 5.7 6.2 6.9
1.6 2.0 2.3 2.7 3.0 3.4 3.6 4.1
20 2.9 3.6 4.2 5.0 5.7 6.3 7.0 7.8 8.2 9.7 11.6
108 2.3 2.8 3.3 3.9 4.4 4.9 5.3 6.0 6.2 7.3 8.3
25 3.2 3.9 4.6 5.6 6.3 7.1 7.8 8.7 9.2 10.9 13.1
2.2 2.7 3.2 3.8 4.3 4.8 5.2 5.9 6.1 7.2 8.2
20 4.8 5.8 6.7 8.3 9.2 10.2 11.4 12.7 13.5 15.8 19.2 23.1 26.4 29.6
4.6 5.4 6.2 7.5 8.3 9.1 10.2 11.3 12.0 13.9 15.8 18.5 21.7 24.3
133 25 5.6 6.6 7.7 9.3 10.4 11.5 12.8 14.2 15.1 17.6 21.2 25.5 29.1 32.5
4.7 5.5 6.3 7.6 8.4 9.2 10.3 11.3 12.1 14.0 15.9 18.6 21.7 24.4
30 6.1 7.2 8.4 10.2 11.3 12.6 14.0 15.5 16.5 19.2 23.2 27.9 31.9 35.6
4.3 5.1 5.9 7.2 8.0 8.8 9.9 11.0 11.7 13.6 15.5 18.2 21.4 24.0
20 5.7 6.9 8.0 10.0 11.1 12.3 13.8 15.4 16.4 19.2 23.4 28.2 32.3 36.2
5.5 6.5 7.5 9.2 10.2 11.2 12.6 14.0 14.9 17.3 20.0 23.6 27.6 30.9
159 25 6.5 7.7 9.0 11.0 12.3 13.6 15.2 16.9 18.0 21.0 25.4 30.6 35.0 39.1
5.6 6.6 7.6 9.3 10.3 11.3 12.7 14.0 15.0 17.4 20.1 23.7 27.6 31.0
30 7.0 8.3 9.7 11.9 13.2 14.7 16.4 18.2 19.4 22.6 27.4 33.0 37.8 42.2
5.2 6.2 7.2 8.9 9.9 10.9 12.3 13.7 14.6 17.0 19.7 23.3 27.3 30.6
30 11.5 14.7 17.8 21.1 24.3 27.4 30.6 33.9 35.7 43.3 49.5 59.3 68.3 77.7 87.1
219 10.2 12.9 15.7 18.6 21.3 24.1 26.9 29.8 31.3 38.0 44.0 52.9 60.5 68.8 77.1
40 17.1 20.5 23.9 27.7 31.1 34.5 38.0 41.7 43.7 51.9 58.3 68.8 78.8 89.1 99.3
10.1 12.8 15.6 18.5 21.2 24.0 26.8 29.7 31.2 38.0 43.9 52.9 60.5 68.7 77.0
* Roller is equipped with C-type rubber disc
We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components
5/98

RETURN BELT PLOUGH MR2

The plough-type return belt cleaner MR2 effectively ORDERING EXAMPLE: MR2 - 1200 - U
cleans the dropped material on the belt. Due to the
jointed support bar the plough follows the belt surface
well. The scraper blade is fixed to the frame using a Type code
friction joint enabling an easy and quick replacement. Belt width B (mm)
Scraper blade material
U = polyurethane
A = polyurethane filled with
aluminium oxide (Al2O3)
M = polyethene (UHMWPE)

B L M N P R Weight (kg)
500 390 594 574 298 343 9.0
650 500 749 730 376 343 10.5
800 600 891 871 447 343 12.5
1000 750 1094 1075 573 452 18.5
1200 920 1335 1315 693 452 22.5
1400 1060 1533 1513 806 452 31.0
1600 1200 1731 1711 905 452 35.0

FASTENING ALTERNATIVES INSTALLATION ON THE CONVEYOR SPARE PARTS

Fastener elements can be turned to Spare part blades to be ordered by
different positions depending on the metres. See length L of the blade from
location and steel construction. the table. The most economic way is to
Belt straightening return idler buy the blade as 3 meter long bars.

Material code of the Ordering code of

scraper blade the scraper blade
MR5-U-(Length L);
U
2 pcs
ø14 / 2 pcs
MR5-A-(Length L);
A
2 pcs
MR5-M-(Length L);
M
2 pcs

We reserve the right for modifications without prior notice.

 RRA4811
HYDRAULIC

Jukka Pajuranta/JPa 27.06.05 1 (1)

HYDRAULIC FITTINGS AND DATA

A) RELATED TO LIFTING/LOWERING

1. Hydraulic cylinder ø100/ø70-1550 PP

2. Operating pressures; lifting max. 250 bar, lowering max. ~30 bar (must be steering
pressure for the valve)
3. Piston stroke speed; about 0,04 m/s, final adjustment when start-up
4. Hydraulic valve close to cylinder to control movement in case there is a leak in
hoses/pipes (safety matter!). Note the movement of cylinder when installing hoses etc.
5. Hydraulic valves; throttle valve (speed regulation), pressure control valve, directional
valve (manual operating)

Adjustments when testing:

The piston stroke speed adjustment by throttle valve

Operating pressures controls for + and – movement (note different values)

Delivery limits: Sandvik Hollola supplies cylinder 1 PC

There are no limit switches controlling the strokes of cylinder.

B) RELATED TO ADJUSTMENT

1. Hydraulic cylinders ø50/ø28-250 , 2 PCs

2. Operating pressures max. 250 bar
3. Piston stroke speed; about 0,03 m/s, final adjustment when start-up
4. Note the movement of cylinders when installing hoses etc.
5. Hydraulic valves; throttle valve (speed regulation), pressure control valve, directional
valve (manual operating)

Adjustments when testing:

The piston stroke speed adjustment by throttle valve

Operating pressures controls for + and – movement (note different values)

Delivery limits: Sandvik Hollola supplies cylinders 2 PCs (item 1)

There are no limit switches controlling the strokes of cylinders.

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\Hydraulic fittings and data.doc

 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007

5 WEAR PARTS CATALOQUE

WEAR AND SPARE PARTS RECOMMENDATION

RRA4811-J3 WEAR PARTS

WEAR PARTS FORM

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\RRA4811 Interleafs_rev0.doc

 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007 1 (1)

WEAR AND SPARE PARTS RECOMMENDATION FOR RRA4811 FEEDER

General

Use only original Sandvik Hollola spare and wear parts. Using of original Sandvik Hollola
parts is also precondition for Sandvik Hollola guarantee. Update the Maintenance Log
when replacing parts.

The drawing number, type, etc. of the parts are given in the enclosed drawings.

RRA 4811-J3
RRA 4811-J4

When ordering parts, always specify exactly the drawing number and type code of the part.
Kindly find enclosed a sheet when ordering parts.

Note the manufacturing number of Feeder!

Recommendation

Wear parts

It is recommended that one set of wear parts presented in RRA 4811-J3 is in your store to
ensure best possible availability for the Feeder. Wear parts are made only based on orders
and therefore delivery time can be long.

Spare parts

Following parts are recommended as spare parts (RRA 4811-J4):

- Return idler 1 Pc
- Carrying idlers 3 Pcs
- Impact idlers 3 Pcs
- Tail pulley 1 Pc
- Drive pulley 1 Pc
- Hydraulic cylinder HPS50-30-250PP 1 Pc
- Hydraulic cylinder HPS100-70-1550PP 1 Pc

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Spare part recommendation rev0.doc

WEAR AND SPARE PARTS

RRA4811 Belt Feeder

Manufacturing number: 4811 / 200…. / W…… / ….

Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181

Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
FINLAND

SENDER
ADDRESS
CITY
COUNTRY
TEL/FAX TEL FAX

Position Description of Parts reference to Dwg Quantity

OTHER INFORMATION

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Wear and spare parts form.doc

 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007

6 SPARE PARTS CATALOQUE

WEAR AND SPARE PARTS RECOMMENDATION

RRA4811-J4 SPARE PARTS

SPARE PARTS FORM

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\RRA4811 Interleafs_rev0.doc

 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007 1 (1)

WEAR AND SPARE PARTS RECOMMENDATION FOR RRA4811 FEEDER

General

Use only original Sandvik Hollola spare and wear parts. Using of original Sandvik Hollola
parts is also precondition for Sandvik Hollola guarantee. Update the Maintenance Log
when replacing parts.

The drawing number, type, etc. of the parts are given in the enclosed drawings.

RRA 4811-J3
RRA 4811-J4

When ordering parts, always specify exactly the drawing number and type code of the part.
Kindly find enclosed a sheet when ordering parts.

Note the manufacturing number of Feeder!

Recommendation

Wear parts

It is recommended that one set of wear parts presented in RRA 4811-J3 is in your store to
ensure best possible availability for the Feeder. Wear parts are made only based on orders
and therefore delivery time can be long.

Spare parts

Following parts are recommended as spare parts (RRA 4811-J4):

- Return idler 1 Pc
- Carrying idlers 3 Pcs
- Impact idlers 3 Pcs
- Tail pulley 1 Pc
- Drive pulley 1 Pc
- Hydraulic cylinder HPS50-30-250PP 1 Pc
- Hydraulic cylinder HPS100-70-1550PP 1 Pc

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Spare part recommendation rev0.doc

WEAR AND SPARE PARTS

RRA4811 Belt Feeder

Manufacturing number: 4811 / 200…. / W…… / ….

Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181

Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
FINLAND

SENDER
ADDRESS
CITY
COUNTRY
TEL/FAX TEL FAX

Position Description of Parts reference to Dwg Quantity

OTHER INFORMATION

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Wear and spare parts form.doc

 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007

7 MAINTENANCE MANUAL

RRA4811-J1 SERVICE DIAGRAM

ROX 11-01-01 GENERAL REGULATIONS AND INSTRUCTIONS

ROX 11-01-81 LUBRICANTS

ROX 11-01-83 CLEANING

ROX 11-01-90 REMOVING FROM SERVICE, STORING AND DESTROYING

ROX 11-02-05 COMMISSIONING

ROX 11-02-31 MAINTENANCE SCHEDULE, DIFFICULT CONDITIONS (B)

ROX 11-02-40 TROUBLESHOOTING INSTRUCTION FOR BELT

CONVEYORS

INFO CONVEYOR PULLEYS

INSTRUCTION ADJUSTMENTS

MAINTENANCE LOG
MAINTENANCE LOG FORM

FEEDBACK FORM

DESCRIPTION OF DAMAGE
DAMAGE DESCRIPTION FORM

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 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (5)

GENERAL INSTRUCTION ROX 11-01-01

GENERAL REGULATIONS AND INSTRUCTIONS

1. INTRODUCTION

This maintenance and operation manual is intented for the operating,

inspection and maintenance personnel.

This manual has to be read through carefully, and it has to be always at the
disposal of the personnel.

The instructions and descriptions of this manual are necessary when the
equipment is inspected, regulated, started, operated and serviced.

A new operator obtains from this manual the basic information about the
equipment and its operation. The skill to operate the equipment develops with
experience.

Sandvik Hollola has a principle of continuous development of machines and

equipment. That is way why your equipment and the data presented in this
manual may differ somewhat from each other.

There may be several versions and delivery alternatives of the machines and
equipment, and therefore in these general instructions may be described
equipment and functions which are not included in the delivery in your case.

The maintenance and operation manual is continually modified and improved

in order that its content would be up-to-date.

Sandvik Hollola reserves the right to alterations in machines and equipment

without prior notice in maintenance and operation instructions and other
corresponding documents.

If you have any questions concerning this manual or the equipment, machines
or systems delivered by Sandvik Hollola, please contact Sandvik Hollola.
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GENERAL INSTRUCTION ROX 11-01-01

2. OBLIGATIONS OF THE OWNER

The owner is obliged to see to that:

- The safety, operation, maintenance and inspection instructions in force are

observed in the operation of the machines and equipment. These
instructions have to be at the disposal of those who need them.

- The normal start and stop signals, the start and stop signals of the
machines with remote control (light and/or sound signals), as well as the
risks of accidents involved with the machines and equipment have been
presented to the personnel.

- Only duly trained operating personnel may operate the equipment.

- The operating personnel has to know well the performance values and
properties of the machines.

- The machines and equipment must not be used for other purposes or in
other conditions than intented.

- The machines and equipment must have adequate lighting, and the
passages and service platforms have to be open.

- The machines have to be inspected and serviced at the recommended

intervals. The effected measures must be registered in the maintenance
book. On request, the maintenance registrations have to be presented to
the representative of Sandvik Hollola. The guarantee is valid only if the
inspections and maintenance are carried out according to the instructions.

- The defects notified by the operator, maintenance personnel or inspector

are to be registered and remedied without delay.

- The machine or equipment stopped due to a defect, malfunction and

emergency must not be started before the cause of the stop has been
cleared.

- There has always to be sufficiently qualified and duly trained operating,

maintenance and inspection personnel available.

- The plant may be expanded or modified only by Sandvik Hollola or an

enterprise authorized by it. If the plant is modified, it is always necessary to
take into account the strength, effect, capacity and other factors of the
equipment.
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GENERAL INSTRUCTION ROX 11-01-01

3. REGULATIONS AND INSTRUCTIONS CONCERNING THE MAINTENANCE

AND INSPECTION PERSONNEL

- The condition of the machines and equipment has to be checked daily and
all discovered defects are to be remedied without delay.

- The maintenance and inspections are performed when the machines

are at a standstill and the start is prevented by means of a safety
switch or by other reliable method.

- Only measures determined by the separate instructions may be performed

when the machines are running. Even then the safety devices have to be in
place, and it is necessary to exercise extreme caution.

- The maintenance and inspections have to be performed at recommended

intervals (see inspection and lubrication charts and instructions). The
performed measures have to be entered in the maintenance book.

- Mechanical and electrical regulations may be performed only by authorized

personnel.

- The service platforms and stairs of the equipment have to be kept clean and
in good condition.

- In the end of the maintenance and inspection it has to be checked that the
safety devices are duly in place, the machine is clean and that all foreign
objects (tools, instruments etc.) have been removed.

- Use only original spare parts of Sandvik Hollola.

- Wearing parts are to be changed in due time.

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GENERAL INSTRUCTION ROX 11-01-01

4. REGULATIONS AND INSTRUCTIONS CONCERNING THE MACHINE

OPERATOR

4.1 Measures before the start

- Read through carefully the operation instructions of the machines and

equipment.

- Make sure that no maintenance or operating personnel or unauthorized

persons are staying in the vicinity of the machines to be started, in order
that the start of the equipment cannot cause a danger for them.

- Make sure that all safety, protecting and security devices are in place and in
working order.

- Make sure that there are no foreign objects in the operating zone of the
machines and that dust, dirt, ice, etc. has not made the equipment out of
order.

- Select the control and operation mode of the machines and systems (see
operation instructions).

- Observe during the start that the machines start normally and that they
function properly.

4.2 Measures during operation

- Observe the material flow.

- Observe that the material does not go to places where it causes

malfunctions.

- See to that unauthorized persons cannot come near the running machines.

- Observe the functioning of the machines and report the discovered defects
and malfunctions to the maintenance personnel without delay.

4.3 Measures when the machines are stopped

- Run the machines empty of material if possible.

- Stop the machines as determined in the operation instructions.

- Report all discovered malfunctions of the machines to the next operator and
the maintenance personnel.
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GENERAL INSTRUCTION ROX 11-01-01

5. SAFETY

- The general safety instructions and regulations in force in the plant are to be
observed when the equipment and machines are operated and serviced.

- In addition to these, the maintenance and operating personnel has to read

through carefully the safety instructions and regulations contained by this
maintenance and operation manual and observe them in all situations and
conditions.

- The operating and maintenance personnel has to know the hazards involved
in the equipment, such as :
- risk of being squeezed and caught by moving and rotating parts of the
machine
- accidental and automatic starts
- hazards and injurious effects caused by dust and noise
- fire and explosion hazards caused by material

- Unauthorized persons must stay out, in the immediate vicinity of the

equipment it is necessary to use due protections.

- The safety and security devices must not be removed, they must always be
in place and in working order when the equipment is operated.

- The covers and doors of the electrical equipment and boxes have to be
closed.

- Before the maintenance, inspection and cleaning of the equipment it is

necessary to stop the machines and their start has to be prevented with a
safety switch or similar.

6. GUARANTEE

- The guarantee conditions and period of the equipment and systems are
determined in the supply contract or other documents.

- A general precondition for the guarantee is that the equipment is operated,

serviced and inspected according to these maintenance and operation
instructions, and that only original spare parts of Sandvik Hollola are used.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (4)

GENERAL INSTRUCTION ROX 11-01-81

LUBRICANTS

1. GENERAL

When choosing lubricants or performing lubrication the lubrication

instructions of the component manufacturer in question must
absolutely be followed.

This instruction contains general instructions for choosing and handling of

lubricants for the material handling equipment delivered by Sandvik Hollola.
General information on lubricants and choosing of them is available also from
the suppliers of lubricants.

2. SAFETY

If during maintenance you have to detach some guards or go outside

the normal maintenance zone near the rotating parts, it is absolutely
necessary to stop the equipment and to prevent an accidental start.
Before restarting the equipment, the guards have to be put in place.

When handling industrial oils and lubricants long-term and repeated contact
with skin must be avoided, wear protective clothing and appropriate tools.

Normally the used lubricant is classified as problem waste, take care of

appropriate handling, storing and destroying of the lubricants removed from
service.

3. LUBRICANT GROUPS

The lubrication objects of the equipment delivered by Sandvik Hollola have

been divided in four main groups:

Group 1. Gears, oil lubrication

- toothed gearings - worm gears
- lubrication by splash - immersion lubrication
- pressure lubrication - transmission chains

Group 2. Bearings, grease lubrication

- rolling bearings - slide bearings
- grease lubricated gears

Group 3. Open gear wheels, Steel wire ropes

Group 4. Hydraulic systems

- hydraulic aggregates and systems
- electrohydraulic pushers - fluid couplings
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION ROX 11-01-81

4. CHOOSING OF LUBRICANT

Group 1: Gears, oil lubrication

The oil qualities recommended by the gear manufacturer must

absolutely always be used.
To the choosing of the oil viscosity influence the type of the gear, quality of
use and ambient temperature.

Rough selection of viscosity of lubrication oil for splash and immersion

lubricated gear wheels according to the ambient temperature.

ambient
temper- VISCOSITY CLASS ISO VG (cSt/40°C)
ature
C°
+60
+50 680
+40 460
+30 320
+20
+10 220
0 150
-10 100
-20 68
-30 46
-40

Under normal circumstances the same oil can according to consideration be

used around the year also in outdoors use.
In pressure lubricated gears lower viscosity classes are normally used than in
splash and immersion lubricated gears.
In worm gears higher viscosity classes are normally used than in gear wheels.

Oil types for gear wheels and worm gears:

MANUFACTURER mineral oils synthetic oils

BP Energol GR-PX SG XP
ESSO Spartan EP Spartan Synthetic EP
NESTE Vaihteisto EP Vaihteisto S-EP
MOBIL Mobilgear Mobil SHC
SHELL Omala Oil Tivela Oil
TEBOIL Pressure Oil Multi-Pressure Oil
When using synthetic oils the suitability of the oil in question for sealing etc.
materials of the gear must be checked.

Transmission chains: The same oil type is normally suitable as the one
chosen for the gears.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION ROX 11-01-81

Group 2. Grease lubrication of bearings (and gears)

The lubricants recommended by the manufacturer of the bearing or

other lubrication object must absolutely always be used.

In the lubrication grease the viscosity of the lubricant corresponds its

penetration which indicates the hardness of the lubricant.
The hardness is indicated by NLGI-number, nine different classes (000 -6),
the bigger the number is the harder is the grease.

The operating temperature range of the lubrication greases is normally wide

enough for round-the-year use in almost all lubrication objects of material
handling equipment.

In central lubrication systems the pumping characteristics of the selected

grease must be checked, especially at outdoor locations the greases of
hardness class NLGI-1 or special cold resistant greases should be used.

In grease lubricated gears the lubricants of classes NLGI-00 or 0 are normally

used.

Lubrication grease types for rolling and slide bearings:

MANUFACTURER Brand name NLGI-class

ESSO Beacon EP 0, 1, 2
NESTE Yleisrasva EP 0, 1, 2, 3
MOBIL Mobilux EP 0, 1, 2
SHELL Alvania EP Grease 1, 2
TEBOIL Multi-purpose Grease 2

Mostly the hardness classes 1 and 2 are used.

Group 3. Open gear wheels and steel wire ropes

The lubricants and protective compounds recommended by the

manufacturer of the equipment or component must absolutely always
be used.

These greases are often quite stiff bitumen based greases which contain as
blend components e.g. molybdenum sulphide and graphite.
Good anti-corrosion protection properties are required from these lubricants.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION ROX 11-01-81

Lubrication protective grease types for open gear wheels and steel wire
ropes

MANUFACTURER Open gear wheels Steel wire ropes

ESSO Dynagear Extra Grease WR
NESTE Avorasva Avorasva
MOBIL Mobiltac 81 Mobilarma 798
SHELL Kuggfett Ensis Fluid K
TEBOIL Gear Grease MDS Gear Grease MDS

Group 4. Hydraulic systems

The lubricants and protective compounds recommended by the

manufacturer of the hydraulic system or component must absolutely
always be used.

To the choosing of the oil viscosity influence the type of the pump and
actuator, quality of use and ambient temperature.

The viscosity classes of hydraulic oils vary in the range ISO VG 5 -150.

In hydraulic systems the classes VG 32, 46 or 68 are normally used

depending on the type of the pump as well as the ambient and operating
temperature.

The viscosity of the oil of fluid couplings is normally VG 32.

In electrohydraulic pushers more flexible oil e.g. VG 10 is used, sometimes

also transformer oil can be used, see manufacturer’s instructions.

Hydraulic oils:

Manufacturer Hydraulic systems Hydraulic pushers Fluid couplings

ESSO Nuto H, Univis HP Spinesso 10 Torque fluid 30

NESTE Neste Paine Neste Paine
MOBIL DTE, SHC D.T.E 21 tai Velocite6 Mobilfluid 125
SHELL Tellus Oil T, TX Tellus oel C10 Tegula Oil
TEBOIL Hydraulic oil Fluid TH 10254

Many manufacturers have several oil types for special circumstances and e.g.
lightly in the nature decomposable oil types, so called BIO-oils.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (2)

GENERAL INSTRUCTION ROX 11-01-83

CLEANING

1. General

The material handling systems and equipment have to be cleaned regularly.

In addition, the covering constructions and structures, as well as the

walkways of the conveyors have to be cleaned from material and dust
regularly.

For the fire safety reasons, the cleaning of the equipment and their
surrounding areas is extremely important, especially if material or its dust is
flammable/explosive fuel, such as e.g. peat.

2. Cleaning intervals

It is very difficult to define any exact general cleaning intervals. The cleaning
intervals depend on the material to be handled, the dust-proof of the
equipment and the operation of the dust removal and ventilation systems.

The cleaning intervals have to be planned separately for each place on the
basis of the experience in the same kind of places. The intervals have to be
selected so that the dust in equipment and the surrounding area does not
harm the operation of the equipment. General safety must not be endangered
(N.B. fire safety).

Maintenance personnel has to prepare cleaning instructions with time tables

which have to be followed.

In some very difficult places or with very dusty materials, cleaning is needed
daily.
On the other hand, in not so dusty places and with non-flammable materials a
general cleaning once a year can be enough.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION ROX 11-01-83

3. Safety

The cleaning of the equipment and the surrounding area has to be done when
the equipment is not operating.
By being extra carefull some cleaning work, such as floor cleaning, can be
done also when the equipment is operating. In that case the entire cleaning
personnel has to know the possible elements of danger connected with the
equipment.
The risks for using compressed air or strong water jet have to be known.

If covers have to be removed or if it is necessary to go outside the

normal service area near the moving parts or on the equipment during
the cleaning, the equipment has to be absolutely stopped and it has to
be made sure that the equipment will not start accidentally.
Before the restart, the covers have to be reinstalled.

4. Cleaning methods

The cleaning method depends on the place, material to be handled and the
available cleaning systems and equipment.

Traditional sweeping with a brush and shoveling (if needed) is in most cases
a sufficient cleaning method.
If vacuum cleaner system is available, cleaning will be, of course,
considerably better and faster.

Compressed air might be in some cases good, but cleaning with only
compressed air is usually not a sufficient cleaning method, because then dust
and dirt only move from one place to an other.

Generally material handling systems supplied by Sandvik Hollola are planned

so that they can be cleaned also with low-pressure water jet.

Before using a washer jet it has to be made sure that it is allowed to clean the
equipment with water jet, and that the accumulation of washer waste has
been arranged in a proper way.

Water jet can never be pointed to non-hardy parts of the equipment, such as
electric appliances or bearings or to their sealings.

When using water in cold circumstances, the possible problems caused by

freezing have to be taken into account.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (2)

GENERAL INSTRUCTION ROX 11-01-90

REMOVING FROM SERVICE, STORING AND DESTROYING

1. General

This instruction can applied be used as a general instruction for removing

from service, storing and destroying of all machines and equipment delivered
by Sandvik Hollola.

The instructions relating to the devices of some machines may contain more
detailed instructions.

The special measures when dismounting and destroying the equipment

removed from service include the recovery of oils and handling and
destroying of possible radioactive materials in an appropriate way.

E.g. gears, fluid couplings and hydraulic systems may contain oils. E.g. with
radiometric principle operating belt scales and the level indicators of material
may contain radioactive materials.

2. Dismounting

Check before starting dismounting whether the equipment in question

contains the problem waste mentioned above and start dismounting by
handling them in an appropriate way.

Ensure also that the electric current has been switched off from the
equipment and all cables attached to it before starting the work.

Clean the equipment and surrounding from combustible material if it is

necessary to use flame cutting or other corresponding equipment causing fire
hazard.

Follow the general security and work instructions when dismounting.

 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION ROX 11-01-90

3. Storing

If the equipment or its parts are stored for later use, this must be considered
when dismounting the equipment so that the equipment will not be damaged
during the dismounting work.

The parts exposed to corrosion are protected with anti-rust compound, the
lubrication points are lubricated, the belts of the V-belt drives are loosened
and the tensioning of the conveyor belt is loosened in the whole belt
conveyors.

The gears and shaft mechanisms of e.g. screens are filled with lubrication oil
quite full in order to avoid corrosion damages.

When storing the equipment and machines moisture must be avoided and the
protections and storing of electric equipment must be performed according to
their own instructions.

The place of storing must be selected so that it is sheltered and as clean as

possible.
Pay attention also to that e.g. frost or long-term direct sunlight may damage
some equipment or components.

4. Destroying

The problem waste like oils are destroyed according to the general
regulations and instructions. (Treatment plant of problem waste)

The supplying of equipment containing radioactive materials to their collection

place and their destroying is done according to the instructions of the
manufacturer/importer of the equipment. Read the instructions of the
equipment carefully, contact the supplier of the equipment or the local
authorities if needed.

The rubber parts like e.g. conveyor belts must be delivered to be destroyed to
the waste treatment plant.

Generally for the part of other constructions the instructions for destroying,
sorting and recycling of different materials are followed.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-05

COMMISSIONING

1. Commissioning inspections

The commissioning shall be begun with a commissioning inspection before

starting the belt conveyor for the first time.

In the inspection can be used commissioning forms made by Sandvik Hollola

especially for this purpose. There is a separate form for mechanical
inspection and one for electrical and automation inspection.

The inspection shall be carried out by a person who knows well the
equipment to be inspected, commissioner and/or installation supervisor.

The commissioning forms are used as a check list and instructions for the
inspection, and they will be documents concerning the inspections and
regulations carried out.

2. First start

It is very important to carry out the first start of the belt conveyor with
caution and control, because there is a big risk of various damages.

Before the first start the commissioning inspections have to be carried out to
the extent that it is possible without running the motor.

Special attention must be paid to the following:

- the belt has to be empty and it must be able to move freely

- the electrical and control system has been tested, especially the start
warning and emergency stop systems
- all mechanical guards are in place and other factors having an influence on
the personal safety are in order
- the direction of rotation of the drive motor is correct, this must be assured,
e.g. without oil in the fluid coupling or without V-belts (if the drive motor
rotates in the wrong direction, the return brake of the reducer may be
damaged)

Immediately after the first short start, make sure that the belt remains
sufficiently centered.
The belt is centered in accordance with the instruction ROX 11-02-20, par. 2.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-05

3. Trial run without material

The belt conveyor has to be run without material during several hours,
sometimes even during several days, before the run with material can be
started.

When the conveyor is run without material, check the function of all electrical
safety devices and lockings.

Check that the sound, tightness and temperature of the reducer are normal.

Make sure that all parts of the conveyor function normally.

4. Trial run with material

The trial run with material is started with a small quantity of material,
observing the function of the hoppers and the centering of the belt.

If the material is not guided to the center of the belt, adjust and repair the
hopper accordingly.

Increase the quantity of the material to be fed onto the conveyor until the
normal/maximum capacity is achieved, carry out the necessary adjustments
to the feed hopper and the belt.

Observe the temperatures of the reducer and bearings.

Perform a start test with a full loaded belt.

Measure the effect/current taken by the drive motor.

Observe the dust-tightness and function of the belt cleaners.

Commissioning performed carefully and with proficiency contributes to

troublefree and safe productional service.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-31

MAINTENANCE SCHEDULE BELT/CHAIN - CONVEYOR/FEEDER

DIFFICULT CONDITIONS ( B )

1. Periodic inspections and maintenance

In addition to periodic inspections and maintenance the plant operating

personnel must daily check that all protective and safety devices of the
equipment are in place and in working order.

The cleaning of the devices and the surrounding areas has to be performed
so often that the material collecting onto the devices and in the surrounding
area does not hinder the functioning of the equipment or endanger the
general safety.

MAINTENANCE NO. OF INSTRUCTION MAINTENANCE

OBJECT INTERVAL

Hoppers ROX 11-01-54 1-2 months (abt.500h )

Conveyor belt ROX 11-02-20 1-2 months (abt.500h )
Belt cleaning devices ROX 11-02-25 1-2 months (abt.500h )
Roller systems ROX 11-02-26 1-2 months (abt.500h )
Distribution gate ROX 11-02-27 1-2 months (abt.500h )
Belt scale ROX 11-02-29 1-2 months (abt.500h )

Electric motor ROX 11-01-50 3 months (abt.1000h )

Blockage detector
Drive mechanism
Screw take-up device
Counterw.t-up device
Pulleys
Guiding boards
Transfer mechanism
ROX 11-01-63 3 months (abt.1000h )
ROX 11-02-21 3 months (abt.1000h )
ROX 11-02-22 3 months (abt.1000h )
ROX 11-02-23 3 months (abt.1000h )
ROX 11-02-24 3 months (abt.1000h )
ROX 11-02-28 3 months (abt.1000h )
ROX 11-02-50 3 months (abt.1000h )

Gear ROX 11-01-51 6 months (abt.2000h )

V-belt drive ROX 11-01-52 6 months (abt.2000h )
Pull cord em. switch ROX 11-01-60 6 months (abt.2000h )
Misalignment switch ROX 11-01-62 6 months (abt.2000h )

Rotation detector ROX 11-01-64 12 months (abt.4000h )

Start warning device ROX 11-01-65 12 months (abt.4000h )
Fluid coupling ROX 11-01-53 12months (abt.4000h )
Safety switch ROX 11-01-61 12months (abt.4000h )
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (3)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-31

If a device or component of the equipment has separate maintenance and

inspection instructions given by the manufacturer, observe primarily the
maintenance schedules and oil change intervals given therein.

The maintenance intervals given in the maintenance schedule are maximum

guide values. If the experience from the operation and maintenace of some
objects, however, show it necessary, the maintenance and inspection
intervals have to be shortened.

In some objects it is also possible to lengthen the intervals, e.g. for cleaning, if
the experience has shown that it is not necessary to clean so often.

The measures to be performed in periodic inspections and maintenance are

described in the instructions of the device or component in question, see
number of the instruction in the table.

The performed maintenance measures and reparations have to be marked in

the maintenance register of the equipment.

The guarantee provides that the inspections and maintenances are

performed.

Before starting the maintenance, inspection or cleaning of the

equipment, it has always to be stopped and the safety switch has to be
turned to the position "0" and locked. The key has to be kept by the
person who is carrying out this work or by the person in charge.

2. Safety inspections of belt conveyors

A safety inspection of the belt conveyor has to be performed at least once a

year.
The person who carries out the inspection has to know well enough the
construction, safety devices and dangerous objects of the conveyors.
The safety inspections can be also performed at the same time as the
periodic inspections and maintenance, but it is necessary to mark the register
and draw up a separate record.
Enclosed a model of a safety inspection record for a belt conveyor:
 BELTCONVEYOR SAFETY INSPECTION PROTOCOL

COMPANY: NAME OF CONVEYOR:

PLANT: CONVEYOR NUMBER:

SAFETY AND CONTROL EQUIPMENT O.K. TO BE REPAIRED/REMARKS

emergency stop
safety switch
start warning
control push-buttons etc.
indicator ligths

To be inspected: function, condition, signs etc. (see maintenance manual).

SHIELDING OF DANGEROUS PLACES O.K. TO BE REPAIRED/REMARKS

drive end, drive mechanism

tail end
counterweight take-up device
carrying rollers
return rollers
transferable equipment
inspection doors

To be inspected: safety guards, cap guards, safety rails etc. (see maintenance manual).

WALKWAYS, AMBIENT CONDITIONS O.K. TO BE REPAIRED/REMARKS

service bridges, maintenance walkways

stairs, ladders
lightning
noise, dust
signs, maintenance manuals

To be inspected: condition, tidiness, signs (see maintenance manual).

Safety inspection shall be carried out at least once a year. The person carrying out this inspection must have
adequate knowledge of conveyors: structure, safety equipment and dangerous places.

Inspector: Date:
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

TROUBLESHOOTING INSTRUCTION FOR BELT CONVEYORS/FEEDERS

0. General

In this instruction are listed failures and problems which may occur in belt
conveyors or belt feeders (number 1 - 9).
After every title under subnumbers are listed possible failures or causes
which may cause this problem, whereafter is a brief description of measures
to be taken in this situation.

1. THE CONVEYOR/FEEDERS DOES NOT START OR IT STOPS

The motor does not run

1.1 One of the protective or safety devices of the conveyor/feeder or drive motor
has been activated.
- Check and repair, reset the failure.

1.2 Electrical failure.

- Check and repair.

2. THE MOTOR DOES NOT START OR IT STOPS

The motor "jurrs" and the conveyor does not start

2.1 Electric failure (electric network, motor protecting and starting devices, cable,
motor)
- Check and repair.

2.2 The conveyor is heavily overloaded.

- Check and remove the overload from the belt.

2.3 The belt or drum is jammed.

- E.g. material or foreign matter between the belt and the board.
The tail pulley or rollers are jammed.
- Check, clean and repair.

2.4 Drives, gear or brake are jammed.

- Check that the separate brake opens properly.
- Check and repair.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

3. THE MOTOR RUNS, BUT THE DRIVE PULLEY DOES NOT ROTATE
The transmission slips

3.1 V-belts slip.

- Check and repair, see instruction: V-belt transmission ROX 11-01-52.
- Check that the conveyor is not overloaded.

3.2 The fluid coupling slips.

- Check and repair, see instruction: Fluid coupling ROX 11-01-53.
- Check that the conveyor is not overloaded.

3.3 The pin coupling, or similar, between the motor and reducer is defective.
- Check and repair.

3.4 The joint or coupling between the reducer and drive pulley is defective.
- Check and repair.

3.5 The reducer is defective.

- Check and repair, see instruction: Reducer ROX 11-01-51.

4. THE DRIVE PULLEY ROTATES, BUT THE BELT DOES NOT MOVE
The pulley slips, the friction between the pulley and the belt is not
sufficient.

4.1 The belt is not tight enough.

- Check and tighten, see instruction: Screw take-up device ROX 11-02-22 or
instruction: Counterweight take-up device ROX 11-02-23.
- Check that the conveyor is not overloaded.

4.2 Between the belt and pulley is material, e.g. snow and ice.
- Check and clean.
- Prevent the access of material and snow between the belt and pulley,
improve the cleaning and cleanliness of the equipment.
- Improve the function and maintenance of the belt cleaners.
- Use anti-freeze agents.

4.3 The rubber coating of the drive pulley is worn out.

- Check, renew the coating or replace the whole drive pulley.

4.4 The conveyor belt has jammed somewhere, e.g. material or foreign matter
has jammed between the belt and board. The tail pulley or rollers have
jammed.
- Check, clean and repair.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 3 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

5. BELT RUNS ON ONE SIDE ALWAYS AT THE SAME POINT OF THE BELT

5.1 The belt joint is oblique.

- Check, see instruction: Conveyor belt Rox 11-02-20 par. 2.8.
- Make a new joint, if necessary.

5.2 The belt has a curve, this can occur normally only with new belts.
- Check, see instruction: Conveyor belt Rox 11-02-20 par. 2.8.
- Check the storing and transport of the belt.
- Change the belt if necessary.

6. THE BELT RUNS ON ONE SIDE AT THE SAME POINT OF THE

CONVEYOR
either within some part or along the whole length of the conveyor

6.1 The pulleys are not horizontal or they are not in the middle and perpendicular
to the center line of the conveyor.
- Check and correct, see instruction: Conveyor belt Rox11-02-20 par.2.

6.2 The roller systems and rollers are not in the middle and perpendicular to the
center line of the conveyor.
- Check and correct, see instruction: Conveyor belt Rox 11-02-20 p2.

6.3 The material is not loaded to the middle of the belt. If the material is on one
side of the belt, the belt tends to move towards the emptier side on the trough
rollers. If the material moves strongly laterally at the feed point, also this tends
to move the belt to one side.
- Check, adjust or correct the feeding hopper.

6.4 Trough roller systems have been mounted in the wrong way.
- Check if the supporting rollers of the conveyor have "ploughing" roller
supports; these must be mounted so that the outermost rollers have been
turned a little towards the belt running direction.

6.5 The belt is exposed to the influence of the wind.

- Check the tightness of the belt.
- Arrange wind protections, if necessary; if it is a conveyor bridge
construction, contact Sandvik Hollola in order to determine the wind loads.

6.6 The belt chafes against some fixed part or jammed rollers.
- Check and repair.
- Improve the cleaning and maintenance.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 4 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

6.7 A separate roller system moving on the conveyor, such as hopper or

discharge carriage, guides the belt to one side.
- Check the roller systems of the moving device.
- Check the spacings of the rails of the moving device and bearing wheels.

6.8 The conveyor/feeder frame is at a slant or bent.

- Check and repair.
- In case of mobile conveyors, the frame may change the form due to too big
inaccuracies in the rails, repair the rails.

6.9 Material or snow and ice collect onto the inner surface of the belt, pulleys or
rollers.
- Check and clean.
- Prevent the access of material and snow onto the lower belt, improve the
cleaning and cleanliness of the equipment.
- Improve the functioning and maintenance of the belt cleaners.
- Use anti-freeze agents.

7. THE BELT WEARS EXCEPTIONALLY MUCH OR IT GETS CRACKS,

RUPTURES OR OTHER UNNORMAL TRACKS

7.1 The belt chafes against the conveyor/feeder frame or some other fixed part,
e.g. jammed rollers, guiding boards or material jammed between them.

- Check and repair, see par. 6.

- Check and service the belt cleaners.

7.2 The material to be transported hits on the belt unevenly, at an unappropriate

angle or too strongly.
- Adjust or repair the feeding hopper.

7.3 The material tends to jam in hoppers and it is compressed at times between
the belt and hopper structures.
- Check and repair the hoppers enough wide.
- Check that the capacity is not too high.
- Check that the piece size of the material is not too big.

7.4 Material enters between the belt and pulley.

- Prevent the access of material between the pulley, seal the material leaks.
- Check and service the return belt cleaners.
- Check and adjust the pulley gap guards/cleaners.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 5 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

7.5 Oil or chemicals on the belt.

- Check and repair.
- See to that the grease coming out during lubrication does not get onto the
belt.

7.6 Thermal or fire damage.

- See to that, e.g. the welding and flame cutting splashes during repair work
do not get onto the belt.

8. THE BELT STRETCHES TOO MUCH

8.1 The belt is too tight.

- Check and adjust, see instruction: Screw take-up device ROX 11-02-22 or
instruction: Counterweight take-up device ROX 11-02-23.

8.2 The belt forces are too big.

- Check that the conveyor is not overloaded.

9. THE BELT BREAKS, THE BELT JOINT BREAKS

9.1 The belt joint has been made in the wrong way.
- Make a new joint according to the instructions.

9.2 The belt forces are too big.

- See 8.1 and 8.2.

9.3 Material enters between the belt and pulley.

- See 7.4
 Sandvik
Conveyor Components
9/2003 1(3)

CONVEYOR PULLEYS INFO

This maintenance instruction is valid, when the Roxon pulley is in a normal use in the belt or elevator
conveyor and in a normal conveyor conditions. In special cases, please contact Roxon.

Pulleys shall be installed crossright with centre line of conveyor (can be turned while centralizing the belt,
see maintenance instruction for conveyor belts).Pulleys must be fastened firmly and safely. In case
strengths going in bearing housing’s base direction turn up, securing plates or other firmness must be used
in order to counteract moving of bearing housing.

1. GENERAL MAINTENANCE OF PULLEY

During maintenance work of pulleys it must be inspected that

- Mantle surface is clean and solid. Unclean pulley must be cleaned and broken places of mantle
repaired. Strongly worn rubbercoating is a sign of slack belt, which must now been tightened.

- Both welding and screw couplings are solid and tight. Brokenwelding couplings are generally
caused by overloaded conveyor or a too much tightened belt.

- Bearings will not warm up and they are noiseless. Warmed and loud bearings as well as leaky
sealings must be replaced by new ones.

- Bearings are well-fastened.

Pulleys must not be loaded more that permitted values provide either by ecsess capacity or a too
much tightened belt, because that will result in shorter lasting time of bearings or breaking of pulley.

2. MAINTENANCE ACTIONS AND INTERVALS

Service and inspection intervals Inspection methods

Object: Condition for use
A B C D E F G
Fastening 4 5 7 X X
Shell + end 4 5 7 X X
Bearings 2 3 4 X X X
Lubrication of bearings 4 5 6
Rubber coat 4 5 7 X X

Condition for use: Service and inspection intervals: Inspection methods:

A = very bad conditions 1 = daily D = look (dust, dirt or similar)

B = bad conditions 2 = once a week E = listen (rattling,
C = good conditions 3 = once a fortnight squaeking or similar)
4 = once a month F = touch (heat,
5 = every three months vibration or similar)
6 = semiannually G = measure (quantity)
7 = once a year

2.1 Specification of conditions for use

A = Very bad conditions B = Bad conditions C = Good conditions

Combinations: Combinations: Combinations:

- wetness, dust, corrosion and frost - moisture and frost - dry and clean, temperature
- wetness, steam, corrosion and frost - moisture and dust + 5 ... + 40 °C
- wetness, steam, corrosion and heat - covered outdoor spaces and rural
climate

Examples. Examples. Examples.

- peat conveyors
- chemical factories
- outdoor wood handling equipment
- wood handling equipment in a barking
plant in contact with water
- mining equipment above ground
- coal conveyors - paper roll conveyors and other
- undergroung mining equipment unit goods conveyors
- indoor mining equipment
- indoor bark conveyors
- indoor chip conveyors
We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components
9/2003 2(3)

3. AFTER-LUBRICATION OF PULLEY BEARINGS

In after-lubrication of pulley bearings must be chosen lubrication type suitable for respective operation
and after-lubrication way. (hand lubrication table 4 and continuos lubrication table 5).

Lubrication of pulley must always be done while pulley is revolving, except BR-pulleys, type A. Therefore pul-
leys must be protected so and lubrication points piped so that the lubrication can be made safely.

If during maintenance you have to detach some guards or go outside

the normal maintenance zone near the rotating parts, it is absolutely
necessary to stop the equipment and to prevent an accidental start.
Before restarting the equipment, the guards have to be put in place.

When handling industrial oils and lubricants long-term and repeated contact with skin must be
avoided, wear protective clothing and appropriate tools.

Normally the used lubricant is classified as problem waste, take care of appropriate handling, storing
and destroying of the lubricants removed from service.

After-lubrication made while pulley is revolving guarantee that lubricant divide steadily in bearing and
sealing. Also the sealing pressure do not turn into excessiveness.

3.1 After-lubrication quantities and lubrication interval

TABLE 1. Lubricant quantities (gram = gr) TABLE 2. Hand lubrication

Shaft P CONDITION LUBRICATION LUBRICATION Lubricant quantity
dimension L SKF - HOUSING ROXON - HOUSING QUANTITIES PERIOD P correspond to
(mm) at (SNL / SNH-housing) (BZC11), (BR/BP-housings) (gr / housing) overall volume.
P-values in table 1.
bearing (SD-housing) (BZC12 / MZC1) A P 1 month
40 0.08 65 80 B P 3 month
50 0.10 100 90 C P 6 month
60 0.15 180 180
70 0.18 280 230 TABLE 3. Continuous lubrication
80 0.26 430 270 CONDITION CONTINUOUSLY SINGLE PORTION
90 0.33 630 - Lubrication Lubrication Lubrication Lubrication
100 0.42 850 500 quantities period quantities period
110 0.50 1000 - (gr / housing) (gr / housing)
115 / 120 0.59 1100 620 A 1.5 x L 1 hour P 3 month
125 0.68 1400 - B 1.3 x L 1 hour P 6 month
135 0.79 1700 - C 1.0 x L 1 hour P 12 month
140 0.93 2000 600
160 1.10 2300 930 Continuous lubrication is made continuously so that a small quantity is dosed
hourly and besides it at 3-12 months interval is made cleaning lubrication
180 1.41 2600 1520
(according condition).
200 1.73 3000 3410
220 2.11 5500 4170 L- values correspond to bearings theoretical lubricant needs.
240 2.50 7000 5200 L- and P-values in table 1.
260 2.60 7400 6880
280 3.02 10500 7280 Pulley type shows
the shaft diameter.
300 3.48 13000 7720
320 4.41 19100 8180 Example: DS 80 -
340 4.61 19300 8550 DK 100 -
BR 80 -
360 4.81 24500 8640
BED 120 -
MEF 160 -
Shaft diameter
(mm) by the bearing

Example: Pulley types BED / BEE / BR / BP / BT / BW

Example: Pulley types DS / BD / DK / BK / BE / DT

We reserve the right for modifications without prior notice.

 Sandvik
Conveyor Components
9/2003 3(3)

3.2 Lubrication types

TABLE 4. Hand lubrication of pulleys

Manufacturer’s Ambient temperature °C Drop point Operating temperature Note
product name -40 ... +5 -5 ... +35 +15 ... +60 °C range °C
Shell Alvania G2 X X X 180 -30 ... +130
A. Teboil Multipurpose Grease X 180 -30 ... +110
Esso Beacon EP 2 X X 185 -30 ... +125
Multi- Mobil Mobilux EP 2 X X 180 -20 ... +230
purpose Mobil Mobilith SHC PM X X X 290 -40 ... +230 Synt.
greases Neste Yleisrasva EP 2 X X X 198 -30 ... +120
BP Energrease LS 2 X X X 190 -30 ... +130
Texaco Multifak 2 X X X 200 -30 ... +120
Shell Syntix 100 X X X >260 -40 ... +140 Synt.
Shell Alvania EPGrease W0 X X 167 -25 ... +80
B. Teboil Syntec Grease X X X 260 -40 ... +140 Synt.
Esso Unirex LotempEP X 260 -80 ... +80
Cold Esso Unirex S 2 X X X >260 -50 ... +220
resistant Mobil Mobilith SHC PM X X X 290 -40 ... +230 Synt.
greases Mobil Mobilgrease 28 X X X 260 -55 ... +180 Synt.
Neste Yleisrasva EO 1 X X X 188 -30 ... +120
BP Energrease LS 1 X X 170 -50 ... +80
Texaco All Temp Grease X X 282 -54 ... +80
Shell Darina R2 X X - -25 ... +200
C. Teboil Syntec Grease X X X 260 -40 ... +140
Esso Unirex N 2 X X 304 -30 ... +165
Hot Esso Unirex S 2 X X X >260 -50 ... +220
resistant Mobil Mobiltemp 1 X 260 0 ... +170
greases Mobil Mobilith SHC PM X X X 290 -40 ... +230 Synt.
Neste Kuumarasva X X 285 -20 ... +175

TABLE 5. Continuous lubrication of pulleys

Manufacturer’s Ambient temperature °C Drop point Operating temperature Note
product name -40 ... +5 -5 ... +35 +15 ... +60 °C range °C
Shell Alvania EP1 X X 180 -30 ... +100
A. Teboil Universal CLS X 170 -35 ... +100 NLG100
ESSO Beacon EP 1 X X 180 -30 ... +125
Multi- ESSO Beacon EP 0 X 180 -30 ... +125
purpose Mobil Mobilux EP 0 X X 170 -30 ... +120
greases Mobil Mobilux EP 2 X X 180 -20 ... +130
Neste Yleisrasva EP 1 X X 188 -30 ... +120
Shell Cenra W X X >170
B. Shell Alvania EP Grease WO X X 167 -25 ... +80
Teboil Universal CLS X 170 -35 ... +100 NLG100
Cold ESSO Unirex LotempEP X X 260 -40 ... +80 Not for slowly rotating

resistant Mobil Mobilith SHC 007 X X X 290 -50 ... +230 Synt.
greases Neste Yleisrasva EP 0 X X 182 -40 ... +100
Shell Lix 1 285 -20 ... +175
C. Shell Parina R2 -25 ... +200
Teboil Universal X 170 -35 ... +100 NLG100
Hot Esso Ronex Extra Duty 1 X >260 -10 ... +150
resistant Esso Unirex S 2 X >260 -50 ... +220
greases Mobil Mobilith SHC 007 X X X 290 -50 ... +230 Synt.
Mobil Mobilith SHC PM X X 290 -40 ... +230 Synt.
Neste Kuumarasva X X 285 -20 ... +175

We reserve the right for modifications without prior notice.

SOCIETE FRANCAISE DE
BANDES TRANSPORTEUSES

Splicing and Repair

of Textile Carcass Belting

SOCIETE FRANCAISE DE
BANDES TRANSPORTEUSES
October 2003

SPLICING AND REPAIR OF

TEXTILE CARCASS CONVEYOR BELTING

CONTENTS

1- GENERAL INSTRUCTIONS

-Tools and equipment

- Raw Materials for Splicing

- Cleanliness of Work

- Stripping

2- STEPPED SPLICING PROCEDURE

3- TEXTILE BELTING REPAIRS PROCEDURE

SOCIETE FRANCAISE DE
BANDES TRANSPORTEUSES GENERAL INSTRUCTIONS
October 2003

- GENERAL INSTRUCTIONS

- TOOLS AND EQUIPMENT

The following tables list the recommended quantities of tools and equipment for a team of
vulcanizers.
The code number indicates that the item concerned may be obtained from S.F.B.T.

Tools for Stripping

Code No. Designation Quantity Remarks

980.051 Rotary buffing machine (220 V) 1
980.006 Sanding disc(coarse-grained) 2
980.004 Rotary wire brushes (set of 4) 1 set
980.055 Adaptor for rotary brush 1
980.035 Thickness micrometer gauge 1
980.033 White chalk 1 box
980.034 Chalk line 1
Steel tape measure (2m) 1
980.003 Drawing rule (2,000 X 60 X 10 mm) 1
980.045 Set square (500 X 500 mm) 1
980.015 Carborundum stone 1
980.013 C. clamp 4
980.017 One-ply knife 2 For stepped
splices
and repairs
980.050 Awl 1
980.019 Hand knife (short blade) 2
980.022 Pen knife (curved blade) 2
980.016 Prodder (for loosening plies and rubber) 2
980.025 Tailors’ scissors 2
980.026 Roller (40 mm wide) 2
980.044 Stitcher (non-toothed type) 2
980.009 Soft brush 1
980.028 Wire brush 1
980.032 Flat paint brush (40 mm wide) 2
980.030 Pliers for stripping 2
980.023 Fork (for edge trimming) 2
980.021 Offset knife (for trimming rubber) 2
SOCIETE FRANCAISE DE
BANDES TRANSPORTEUSES GENERAL INSTRUCTIONS
Page 1.2 - T
September 1990

- Tensioning Equipment

Code No. DESIGNATION Recommended Remarks

Quantity
* Belt clamp 3
980.047 Hand winch, TU 16, capacity 1500 kgf (daN) 2
980.124 Dynamometer, capacity 3000 kgf (daN) 2
980.131 Small sling 2
980.132 Large sling 4

* Depending on belt type and dimensions - please consult us.

SOCIETE FRANCAISE DE
BANDES TRANSPORTEUSES GENERAL INSTRUCTIONS
Page 1.18 - T
September 1991

- CLEANLINESS OF WORK

Cleanliness in the execution of splices very largely governs the success of this work.
'Cleanliness' must be understood as protection:

- of belting

- of raw materials

- of tools

against all types of dirt or pollution, i.e. against contact with any solid, liquid or gaseous substance
which may attack either the rubber or the carcass and thus create the risk of insufficient bond
between the various constituents of the splice upon vulcanization.

The only materials which may be brought into direct contact with the rubber or carcass, without risk,
are as follows:

• Clean polythene sheeting, very useful for protecting working surfaces

• Clean non-finished fabrics

• Non oxidised or non surface-treated metals

• Solvents stipulated in § 1.2 (Raw Materials for Splicing)

The entire working area covering the conveyor and the belt over a length of 3 m on either side of the
splice area must be protected against:

- Weather, when working outside

- Dust

by means of a cover, hood or some other method.

Throughout the time work is in progress, no cleaning, welding or any other work should be carried
out near or above the splice area.

Care must be taken to avoid trailing on the ground the ends of the belt on which work is being
carried out.

During the splicing operation, operatives must ensure that their hands are clean.

CLEANING WITH SOLVENT IS NOT RELIABLE AND CONSIDERED INSUFFICIENT. IT MAY

CONCEAL THE PRESENCE OF DUST. EXCESS SOLVENT MAY IMPAIR SPLICE
RESISTANCE.

A brush and container should be kept solely for use with solvent. Empty cement cans or
containers must not be used.
SOCIETE FRANCAISE DE
BANDES TRANSPORTEUSES GENERAL INSTRUCTIONS
October 2003

- STRIPPING: GENERAL GUIDELINES FOR PREPARATION OF ENDS

Whatever the splicing method recommended, certain general rules are applicable to the different
operations involved in the preparation of the belt ends.

- Marking out

• Mark out the longitudinal axis of the belt on both ends and over a minimum distance of 1.5 m,
LIGNING UP 3 POINTS on each end.

• Square-off the two belt ends and adjust them for length. Squaring-off is done from reference
points marked perpendicular to the axis and traced.

a) Either with a compass, preferably (see Sheet 1.I, Figure 1)

b) Or using a set-square, marking sure to turn it over (see Sheet 1.I -Figure 2), and taking the
axis of the belt as reference.

• All lines marked out subsequently, for cutting out and stripping the covers, will be based on these
references.

- Stripping

• For cover thickness not exceeding 8 mm, cut out cover at 90° to belt surface. (To make clean cut,
abut against a ruler).
• For cover thickness exceeding 8 mm, cover must be cut in steps (see relevant stripping procedures).
• Begin stripping by cutting out of the cover a strip 25 to 30 mm wide across the width of the belt, using
a pen knife (curved blade) or hand knife (short blade), and pliers for stripping. Tear off strips as shown
in Figure 1, sheet 1.II.

CARE IS REQUIRED TO AVOID THE KNIFE CUTTING INTO CARCASS FABRIC

• Cut out longitudinal strips 25 to 35 mm wide starting from edge of carcass but leaving belt edges
intact.
Again care is required to avoid damaging carcass fabric.
• Tear off strips as shown in Figure 2. sheet 1. II.
• If belt has sealed edges, pare belt edges to be level with the carcass.

- Brushing
• Carefully brush by hand cut cover edges using a wire brush.
• Complete by scraping cut edges with the hand knife (short blade).
• Carefully brush the covers, with rotary brush, over a distance of 15 mm from the cut edges.
• Always brush exposed carcass with wire brush to remove dust, taking care not to damage carcass
fabric.
SOCIETE FRANCAISE DE
BANDES TRANSPORTEUSES GENERAL INSTRUCTIONS
October 2003

xx': longitudinal axis of belt OA = 0B

yy' = reference points

a: greater than splice length

The resultant reference line yy' is used as base line for all
subsequent marking-out.

Figure 1

xx': longitudinal axis of belt

The resultant reference line yy’ is obtained

by joining points A and B obtained from (1)

and (2)

a: greater than splice length

Figure 2
SOCIETE FRANCAISE DE
BANDES TRANSPORTEUSES GENERAL INSTRUCTIONS
October 2003

Tear off a transversal strip 25 to 30

mm wide

Cut out cover cut with pen knife

(curved blade) without
damaging carcass

Figure 1

Cover cut with pen knife (curved blade)

without damaging carcass

Tear off longitudinal

strips. 25 to 35 mm
wide

Figure 2
SOCIETE FRANCAISE DE
BANDES TRANSPORTEUSES GENERAL INSTRUCTIONS
October 2003

- PREPARATION OF CEMENT, APPLICATION, POSITIONING OF COVERS

1.6.1 - Preparation of Cement

• Cement must always be thoroughly stirred before use.

• Cement in two parts TRS 2002 and R 40

Mix the two elements thoroughly by stirring well in a CLEAN receptacle.

NEVER REDUCE THE QUANTITIES STIPULATED

Respect the life of the product once mixed:

- 2 hours
• Cement TRS 2002 with catalyser R 40
Add the 40 g catalyser to the tin containing 1 kg cement. MIX WELL. Keep the tin closed when not in use.
NEVER REDUCE THE QUANTITIES STIPULATED
Respect the life of the product:
- 2 hours during splice assembly
- at least 6 hours between assembly and vulcanization.
1.6.2 - Instructions for Cement Application

NOTE: For cement always use a NEW BRUSH and DISCARD AFTER USE.
• Exposed, stripped areas require two coats of cement after brushing and cleaning with solvent. Apply
cement carefully and evenly, especially in the interstices, steps cut in covers, etc.
• Before applying cement, ensure that the surface is not 'tacky' but perfectly dry from the previous
application of solvent or cement.
• Non-vulcanized raw materials require cleaning or reactivating with solvent, but only ONE coat of cement.
NOTE: Cement should be applied immediately before positioning of raw materials. It is essential that cement
should dry in the shade.
- Excess cement will prevent complete drying and thus impair proper splice strength.
- Where special instructions are applicable, these are indicated in the relevant splicing procedures.

- Instructions for Positioning Subassemblies

Unless otherwise stipulated, the subassemblies consisting of fabric and skim gum should be positioned with
the skim gum side marked with thread facing towards the carcass.
 OPERATION AND MAINTENANCE INSTRUCTION
ADJUSTMENTS

JPa 08.09.04 1 (1)

General

Belt conveyors have not been tested at workshop but certain adjustments are carried out
based on tests done earlier. Anyway The tests were carried out without material. The
material weight and location on the belt may change the situation and therefore some
adjustments can be actual due to misalignment of the belt.

The position of Mobil unit has also influence for the belt misalignment. Operation in position
where pulleys are in ”hand level” is optimal for belt conveyor.

1. Belt take-up

The length of belt can be adjusted by using screw take-up locating at drive end of
conveyor. Note; adjust both sides as much to avoid misalignment of belt.

2. Adjusting of belt

In the case of the continuous misalignment of the belt there are few possibilities for the
adjustments. Before any adjustment, see first ROX11-02-40 instructions from the
Maintenance and Operation file.

Adjustments available in order to be carried out:

- adjust the position of Drive Pulley
- adjust the position of Tail Pulley
- adjust the position of return idler

3. Belt replacing

The belt is wear part and shall be replaced when needed. See separate instruction made
by belt supplier.

4. Belt cleaner

Adjust the cleaner acc. to the instruction. Replace the wear part in time.

5. Fastenings (bolts, nuts etc.)

Ensure regularly that fastenings are tightened. Retighten them acc. to given torques when
needed (replace damaged fittings with new ones). Extensive inspection shall be done at
least every year.

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.11_Yhteiset omat ohjeet\Adjustments belt conveyors.doc

 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007 1 (1)

Maintenance Log

It is Owner’s obligation to maintain among other things the Maintenance Log, for other
obligations see ROX 11-01-01.

On the Maintenance Log inspections, service actions and other actions must be
recorded as an implementation of Sandvik Hollola instructions valid for the belt
conveyor.

When required records must be available for Sandvik Hollola.

Enclosed sheet is an example sheet for the Maintenance Log.

All Damage Reports, if any, must be stored up in the Maintenance Log.

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Maintenance log rev0.doc

MAINTENANCE LOG page ___
Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181
Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
Finland

Belt Feeder
RRA4811
Serial number: 4811 / 200…. / W…… / ….

Author:______________________________ Date: :______________________________

Describing
of
maintenance
work

Reference to
instruction
Rox 11-02- __
Rox 11-02- __
Rox 11-02- __

Author:______________________________ Date: :______________________________

Describing
of
maintenance
work

Reference to
instruction
Rox 11-02- __
Rox 11-02- __
Rox 11-02- __

Author:______________________________ Date: :______________________________

Describing
of
maintenance
work

Reference to
instruction
Rox 11-02- __
Rox 11-02- __
Rox 11-02- __

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Maintenance and feedback form rev0.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
FEEDBACK FORM
Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181
Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
Finland

Serial number: 4811 / 200…. / W…… / ….

1. COMPONENTS, SPARE and WEAR PARTS

S Your proposals for the development?

S What improvements are most urgent ones?

2. FRAME

S Your proposals for the development ?

S What improvements are most urgent ones?

3. OPERATION & MAINTENANCE

S Proposals for the better operation and availability?

4. OTHER S

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Maintenance and feedback form rev0.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 OPERATION AND MAINTENANCE FILE

RRA4811 BELT FEEDER

09.08.2007 1 (1)

Description of Damage

If damage takes place it must be described and drawn on paper. Filled Damage Report
must be also sent to Sandvik Mining and Construction Hollola Oy, who on this way has
detailed information from the Damage.

In case of guarantee the Damage Report is precondition for the reclamation handling.
Manufacturing number to be filled on the report is written on Type Plate locating on the
frame part of drive end.

Damage describer must be properly trained and authorised person, who can describe the
Damage in details. The Report shall include also photos.

There is enclosed an example from the Damage Report Form.

All Reports must be stored up in the maintenance log of Operator.

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Description of damage rev0.doc

DAMAGE DESCRIPTION FORM appendix
Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181
Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
Finland

RRA4811 Belt Feeder

Manufacturing number: 4811 / 200….. / W…… / ……

Author:______________________________/date :______________________________

Damage
description

Enclosere

Author:______________________________/date :______________________________

Damage
description

Enclosere

Author:______________________________/date :______________________________

Damage
description

Enclosere

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRA4811\Työfilet_rev.0\4811 Damage description form rev0.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 METAL DETECTOR
System 3000

Technical Manual MDV-MDS

EGE-Elektronik Spezial-Sensoren GmbH • Tel. +49 (0)4346/41580 • Fax +49 (0)4346/5658 • www.ege-elektronik.com
METAL DETECTOR System 3000
Technical Manual MDV - MDS

Contents

1. General Notes

2. Installation
2.1 Amplifier MDV 3172
2.1.1 Installation of MDV 3172 with up to 3m distance to the coil
2.1.2 Installation of MDV 3172 with distance more than 3m to the coil
2.2 Detector coil MDS ...: Mounting underneath the conveyor belt
2.3 Detector coil MDS ...: Mounting underneath or above the conveyor belt
2.4 Selection of detector coil
2.5 Overvoltage protection-supply isolation unit NTG 251/255

3. Function

4. Adjustment
4.1 Checking the amplifier
4.2 Adjusting of the sensitivity

5. Troubleshooting
5.1 Checking the amplifier
5.2 Malfunction without extensions cable
5.3 Malfunction with extensions cable

6. Technical Data
6.1 Amplifier MDV 3172
6.2 Detector coil MDS
6.3 Supply isolation unit NTG
6.4 Accessories (optional)
6.5 Installation-Hints

EGE-Elektronik Spezial-Sensoren GmbH • Tel. +49 (0)4346/41580 • Fax +49 (0)4346/5658 • www.ege-elektronik.com BE81004 2
METAL DETECTOR System 3000
Technical Manual MDV - MDS

1. General Notes
This instruction manual refers to following model of the Metal Detector System 3000

Amplifier MDV 3172 Detector coil Type MDS...

Optional
Supply isolation unit Typ NTG 251/255
Extensions cable Type K 031...

The metal detector System 3000 is designed to detect medium size and larger pieces of metal and
to protect jaw crushers, stone mills and to monitor conveyor belts. The metal detector is insensitive
to small parts as nails, nuts etc. It will respond only to larger pieces of metal like teeth from an
excavator bucket, tools, or metal panelling which could destroy plants when being processed. If the
detection of smaller parts is necessary, the Amplifier type MU 3300 is recommended.

This manual contains instructions how the metal detector should be installed. In order to have the
unit work properly it is important to notice how it is to be handled and how it is operating inside the
plant.

Note
If problems should occur which cannot be solved with help of this instruction manual, please
contact your distributor or our technical support in Getttorf, phone +49 (0)4346/41580 or fax
+49 (0)4346-5658.

2. Installation
2.1 Amplifier MDV 3172

2.1.1 Installation of MDV 3172 with up to 3m distance to the coil

The amplifier MDV 3172 can be installed in the vicinity of the detector coil because it has a fixed
cable with a plug connector. The amplifier has a 2m long supply cable which can be connected to
a connection box (Fig. 1).

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METAL DETECTOR System 3000
Technical Manual MDV - MDS

Figure 1 MDV 3172

1
MDS 7

4
3
5
6
2

1. detector coil 5. connection box

2. 3 m fixed cable 6. to the control room
3. connection plug 7. amplifier
4. 2 m supply cable

The amplifier MDV 3172 will operate a relay (relay contact closed) when metal is detected, but no
further analysis functions are included. The number of control units is reduced to a minimum in
order to make the unit resistant in extreme environmental conditions as moisture, dust, changing
temperatures and vibrations.

2.1.2 Installation of MDV 3172 with distance larger than 3m to the coil

By using an extensions cable it is possible to install the amplifier in larger distances as 3,00 m
from the detector coil. The extensions cable has a connector on both sides of the cable. An
extension up to 30 m is admissible. Such cables can be made with the connection plug K031-D/S
and a special shielded PUR cable K032. In many cases the ready made cable KS031-DS05 with
a length of 5m is a good solution. (Fig. 2)

Figure 2

MDV 3172

1
8
MDS

K031 DS05
3m 5m 4
5

6 7
3

1. detector coil 5. 2 m fixed cable

2. 3 m fixed cable 6. connection box
3. plug-and-socket connector 7. to the control room
4. plug 8. amplifier

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METAL DETECTOR System 3000
Technical Manual MDV - MDS

2.2 Detector coil MDS ...: Mounting underneath the conveyor belt

The detector coil is preferably mounted between two rollers underneath the conveyor belt. This is
reducing the risk of mechanical damage of the coil. The distance between the rollers and the coil
must be at least as long as the width of the coil. In order to reach the maximal sensitivity, a metal
free zone with a diameter of 1.5 - 2 times the coil's width should be chosen around the center of
the coil (fig. 3). This mounting is the most common used method and should be preferred to other
installations.

Figure 3
1,5-2 x b 1,5-2 x b

min. 1 x b min. 1 x b

b
30-50mm
Security rod (wood)
Warning
In order to reduce the risk that a hanging or swinging belt is hitting the detector coil, the
installation of a wooden security rod is recommended which will absorb the hits.

2.3 Detector coil MDS... : Mounting above the conveyor belt

When the detector coil is mounted above the conveyor belt, it must be made sure that the iron
construction of the plant is not too close to the detector coil. In such cases the sensitivity has to
be reduced. This means that the detection range is reduced and only larger metal pieces can be
detected.

Because two detector coils, which are each connected to an amplifier MDV, interfere with each
other, the minimum distance between the coils must be 2m.

Warning
Precautions have to be taken that stacked material on the conveyor belt will not bump against
the detectors coil resulting in damages. (fig 4)

Figure 4

300 - 400

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METAL DETECTOR System 3000
Technical Manual MDV - MDS

The detector coil is mounted with distance pieces on a aluminium plate, which shields
electromagnetic interference from beneath and ensures a robust installation of the coil. The metal
plate has double sided 10mm bores. At places with strong electromagnetic interference, it is
recommended to shield the sides of the metal detector with aluminum plates or other means.

Warning
The detector coil must not be mounted hanging from tethers or by other instable means.
It must be mounted in a fixed position free of vibration.

Note
The mounting above the conveyor belt is used seldom and is recommended only for special
cases, where other mounting options are not available.

2.4 Selection of the detector coil

The detector coil with a width of 650mm is recommended for conveyor belts with width
up to 800 mm.

Conveyor belts with widths of 1000 mm up to 1200 mm are monitored with coils which have
a width of 950 mm.

2.5 AC-Overvoltage protection - supply isolation unit NTG 251/255

The supply isolation unit NTG 251/255 is connected between the amplifier MDV and the power
supply, especially when AC-overvoltage is to be expected. The unit NTG 251/255 also has a built
in EMC filter and dampens interfering impulse coming from the network. It must be observed that
the load of the output relay does not exceed 4 A 250 V AC(Fig. 5). The NTG... limits the voltage
and current amplitudes for the amplifier MDV 3172, so that its fuse cannot be overloaded.

Figure 5
NTG 251/255
30 16

28 18
L1 L1
F1,0 AT

Network Amplifier
U
29 U 17
N N
19
25 L1
26 TEST
24
20
S

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METAL DETECTOR System 3000
Technical Manual MDV - MDS

3. Function
The metal detector transforms the electromagnetic influences on the detector coil into a electrical
impulse. The detector coil acts as oscillator and creates an electromagnetic alternating field. As
soon as metal parts pass by this electromagnetic field the amplitude of the oscillator is affected.
The sensitivity of the oscillator is adjusted by means of a potentiometer. The level of sensitivity,
that can be set, is dependant of various factors: the environment of the coil as vicinity of metal
construction parts, its electromagnetical properties and the conveyor belt speed. (Fig. 6)

Note
In applications where increased AC-power line interference is to be expected, the MDV-fuse might
blow. Then the MDV will not be able to operate its output-relay. Because of this behaviour, the
usage of the overvoltage protection NTG 251/255 is recommended.

Figure 6
Sensitivity plot of MDV...

Switching distance / mm
500

400

300

200

100

0
0 50 100 150 200 250 300 350 400
Edge length / mm

The sensitivity plot shows the distance where a object with a given edge length can be detected.
This plot is based on a measurement with the detector coil MDS 3065 and the amplifier MDV...in a
metal free environment. For edges shorter than 50mm a steel cube was used. For larger objects, a
2mm thick steel plate (ST 37) was used. During the measurement the objects passed above the
detection coil´s center with a speed of 0,5/sec.

Metals differ in electromagnetic properties, leading to different sensing ranges. For example,
Aluminium has a smaller detection range than a part of iron (ST 37) of the same dimensions. The
factor by which the sensitivity is reduced compared to iron is given in table 1 (correction factors) for
different metals.

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METAL DETECTOR System 3000
Technical Manual MDV - MDS

Correction factors Cube 50x50x50mm Plate 120x120mm

Steel ST 37 1 1
The correction factors Stainless steel 0.5 1
are depending on the part´s
ZN 0.5 0.9
size and form.
AL 0.4 0.85
CU 0.45 0.85
Brass 0.6 0.9
Example:
Assuming that a steel cube ( 50x50x50 mm, ST 37) can be detected in distance up to 130 mm.

Under the same conditions, an aluminium cube will only be detected in a distance of 52 mm
(130 x 0,4 = 52 mm).

4. Adjusting
4.1 Checking the amplifier

After mounting the metal detector and establishment of the electrical connections to the
power supply and the detector coil, the detector must be adjusted.

1. Make sure the green LED for power supply is lit. (Fig. 7, Pos. A)

2. After having switched on the power supply the amplifier is performing a self test which takes
about 3-10 seconds.

During the self test the amplifier sets the output to "metal detected" in order to test its own
output. If a self holding relay is connected to this output, it must be reset in order to
activate the metal detector.

4.2 Adjusting of the sensitivity

The sensitivity is adjusted by means of a potentiometer. The potentiometer is protected

by a plastic screw, which must be removed in order to operate it.(Fig. 7, Pos. B)

The highest sensitivity is reached when the potentiometer is turned clockwise 20 times.

The default sensitivity is set by turning the potentiometer 20 turns clockwise followed by
10 turns counter-clockwise.

With this setting, a medium sensitivity is archieved. Turning the potentiometer clockwise
increases sensitivity, turning it counter-clockwise decreases sensitivity.

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METAL DETECTOR System 3000
Technical Manual MDV - MDS

Note

The potentiometer has no mechanical stop. The electrical end position is reached after 20 turns.
Further turning in the same direction will not change the sensitivity.

If the yellow LED for "metal detected" is blinking during the running of the conveyor belt, the
sensitivity is set too high or the detector coil is not connected properly.

B
Figure 7
A

A Green LED is lit when the power supply is connected

B Adjusting potentiometer (with protecting screw)
C Yellow LED for metal detection
D Fuse 1 A, slow

5. Troubleshooting
5.1 Checking the amplifier
1. Check if the green LED for power supply is lit
2. Check if the fuse is installed and functional (Fig. 7, Pos. D)
3. Check power supply: Are there voltage dropouts >0.5 seconds ?

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METAL DETECTOR System 3000
Technical Manual MDV - MDS

5.2 Faults without extension cable

1. Check if the amplifier is connected to the proper supply voltage.

2. Remove coil plug from the amplifier and measure the coil-cable resistance with a ohm
meter between pin 1 and pin 3. The normal resistance is between 2.5 to 4 Ohm. (Fig. 8).

Figure 8
6

1 5
1: (1) 2 4
2: (2)
3
3: (3) 7
4: - -
5: - - top view
6: Shield / ground
7: - -

5.3 Faults with extension cable.

1. Remove coil plug and measure net resistance (detector coil + cable) according to section 5.2.

Note
For building your own extension cable, it is important to connect pin 4 and pin 7 internally
inside the connector housing, at the end that is connected to the amplifier MDV. The
connection is important for the correct function for the shielding system between detector
coil and amplifier (fig 9).

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METAL DETECTOR System 3000
Technical Manual MDV - MDS

2. With a resistance measurement you can check the extensions-cable that connects the
amplifier with the detector coil. This is done by measuring the resistance between
the corresponding line ends or plug pins of the same color and number, respectively.

Figure 9

1: (1) top view

2: (2)
3: (3) MDS MDV
4: - -
6 6
5: - -
6: Shield/ ground 1 5 5 1

7: - - 2 4 4 2

3 3
7 7

3. Between lines of the same number / same color, as (1-1) for examble, the resistance
must be 0 Ohm (table 2). Between different lines / different colors, as (1-2) for
examble, the resistance must be infinite.

Table 2

line resistance
1-1 0 Ohm
2-2 0 Ohm
3-3 0 Ohm
6-6 0 Ohm
4 - 7* 0 Ohm

* Because of the bridge between the contacs (4-7) they are assigned to the same cable.

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METAL DETECTOR System 3000
Technical Manual MDV - MDS

6. Technical Data
6.1. Amplifier MDV 3172

Ambient temperature -25 °C bis +70 °C

Protection IP 67
Housing material PBT
Connection PUR/PVC 0,5 mm²

Nominal-Data (25 °C) AC DC

Supply voltage 115 alt. 230 V AC 24 V DC

Tolerance +10 / -15 % + 20 %
Current consumption max. 20 mA 100 mA

Output NO-Relay-change over

Switching voltage max. 250 V AC / 220 V DC
Switching current max. 1 A AC / 2 A DC
Switching power max. 125 V A / 60 W
Weight 1,85 kg

(1)
MDV 3172 L1(+) Note
(2) The amplifier MDV 3172 has a
(5) Output NO-function.
(4) During metal detection, the
relay is activated and contact 4-
(3) 5 is closed (2-5 is open).
N( -)

Type ID-No. Design

MDV 3172 WR 1 P81017 Amplifier 115 V AC

MDV 3172 WR 2 P81010 Amplifier 230 V AC
MDV 3172 GR P81011 Amplifier 24 V DC

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METAL DETECTOR System 3000
Technical Manual MDV - MDS

6.2 Detector coil MDS

300
270 137
55

270
5
L2
L3

L1

10

Type ID-No. L1 L2 L3

MDS 3065-S P81007 650 700 670 3 m Connection-cable with plug

MDS 3095-S P81009 950 1000 970 3 m Connection-cable with plug

Technical Data Coil MDS

Protection EN 60529: IP 67
Ambient temperature: -25°C...+70°C
Housing material: Aluminium, PVC, GFK
Connection: 3m shielded PUR-cable 4 x 0,75mm
Weight (650): 10 kg
Weight (950): 12kg

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METAL DETECTOR System 3000
Technical Manual MDV - MDS

6.3 Supply isolation unit NTG 251 / 255

Type ID-No. 1 Fuse 1A / slow, primary circuit
2 LED green Supply voltage indication
NTG 251 P81030 3 LED green Secondary voltage indication
NTG 255 P81032 4 Test Button simulates output
5 LED yellow, Relay activated

75 10
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Rel.1

5 Fuse
1.0A T

NTG 251 4 1
Test 3 2
Amplifier Rel.1 Power supply
N L1 L1 S L1 N
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

2
4
5 Amplifier
MDV 3172 WR
1
3
YE/GN

Technical Data NTG 251 NTG 255

Supply voltage 230 V AC + 15% 50 - 60 Hz 115 V AC + 15% 50 - 60 Hz

Interfering impulse max. 1500 V / 2 s 1500 V / 2 s
Power consumption max. 8VA 8VA
Output 4 A, 250 V AC 1 4 A, 250 V AC 1
Fuse 1.0 A slow 1.0 A slow
Ambient temperature -30°C....+60°C -30°C....+60°C
Protection IP 20 IP 20

6.4 Accessories (optional)

Type ID-No.
K031-DS05 Z01040 5m Extensions-cable with plug-and-socket connector
K031-S05 Z01041 5m Extensions-cable with a cable-box and free connectorend
K031-D Z01042 Separate plug- and socket connector
K031-S Z01043 Separate plug- and socket connector
KS031 Z01164 Special-cable PUR shielded

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METAL DETECTOR System 3000
Technical Manual MDV - MDS

6.5 Installation-Hints

Amplifier Supply isolation unit

MDV 3172 NTG 251 / 255

NTG 251
C

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

1
B (3)

N L1 L1 S

2
Amplifier
(1)

3
A
(5)

4
D (4)

5
(2)

Test

Rel.1

6
7
8
9
Output
Rel.1

10 11 12 13 14 15
Power supply
L1 N

1.0A T
Power supply Fuse

Detector coil MDS...

A Green LED is lit when the power supply is connected

B Adjusting potentiometer (with protecting screw)
C Yellow LED for metal detection
D Fuse 1 A, slow

Note
After switching on the power supply the switching output is activated for 3 - 10 seconds
(contacts 5 and 4 connected). This test impulse can be used together with an additional
evaluation electronic for a functional test of the metal detector (see 4. Adjusting).

EGE-Elektronik Spezial-Sensoren GmbH • Tel. +49 (0)4346/41580 • Fax +49 (0)4346/5658 • www.ege-elektronik.com BE81004 15
 METAL DETECTOR System 3000
Technical Manual MDV - MDS

Possible Test-Installation Supply isolation unit

NTG 251 / 255

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Amplifier
MDV 3172
Rel.1

C Fuse
1.0A T
B
NTG 251 Test
A Amplifier Rel.1 Power supply
N L1 L1 S L1 N
D
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
(3)

(1)
(5)
(4)

(2)

TEST

L1
RESET

green Signal
(L1)
red
Detector coil MDS... N

A simple test-installation with hold-function is shown here. This installation usally is done when installing
the metal-detector. It is not part of delivery.

When metal is detected, a self-test at startup was successful, or a manual test is performed, the red lamp
is lit and the output "Signal" is connected to L1 permanently. This activation holds on until the "RESET"
button is pushed.

The manual test is performed by pushing the test button for more than 2 seconds. The test is successful if
the red lamp is lit after approx. 2 seconds after releasing the button.

If there is no activation of the red lamp after start-up or after performing the manual test, the MDV or the
NTG is defective and should be serviced.

The green lamp lights up when no metal is presently detected and no self-test is performed.

EGE-Elektronik Spezial-Sensoren GmbH • Tel. +49 (0)4346/41580 • Fax +49 (0)4346/5658 • www.ege-elektronik.com BE81004 16
METALLDETEKTOR
System 3000

Instruktioner MDV-MDS

www.specialsensorer.se
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

Skötselinstruktion
Innehåll

1. Allmänt

2. Installation
2.1 Förstärkare MDV 3172
2.1.1 MDV 3172 placering < 3 m från spole
2.1.2 MDV 3172 placering > 3 m från spole
2.2 Spole MDS montage under transportband
2.3 Spole MDS montage ovanför transportband
2.4 Val av spole
2.5 Överspänningsskydd NTG 251/255 (Option)

3. Funktion

4. Injustering
4.1 Kontroll
4.2 Inställning av känslighet

5. Felorsaker
5.1 Kontroll av förstärkare
5.2 Åtgärder vid fel utan förlängningskabel
5.3 Åtgärder vid fel med förlängningskabel

6. Tekniska Data
6.1 Förstärkare MDV 3172
6.2 Detektorspole MDS
6.3 Överspänningsskydd NTG
6.4 Tillbehör
6.5 Installationstips

www.specialsensorer.se BS81004 2
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

1. Allmänt

Denna skötselinstruktion gäller för metalldetektorsystem innehållande:

Standard

· Förstärkare MDV 3172

· Detektorspole typ MDS

Tillval

· Överspänningsskydd NTG 251/255

· Förlängningskabel K 031...

Metalldetektorsystemet är konstruerat för att detektera metalliska föremål och för att användas
som skydd vid grovkrossar, siktar och flistuggar. Den reagerar ej för mindre föremål såsom spik,
muttrar etc, men väl för skoptänder,skiftnycklar och annat som kan skada anläggningen.

Vid behov av att detektera mindre föremål vid t.ex. finkrossar rekommenderas att använda
förstärkare typ MU 3300.

Denna manual innehåller instruktioner om hur metalldetektorn skall installeras. För att få enheten
att fungera på ett riktigt sätt, är det viktigt att veta hur den skall hanteras och hur anläggningen
drivs.

Notera
Om det skulle dyka upp problem som inte kan lösas med hjälp av denna manual, var vänlig
kontakta din leverantör eller vår tekniska support i S-512 23 Svenljunga, Box 137, telefon
0325/120 60 eller fax 0325/120 64.

2. Installation
2.1 Förstärkare MDV 3172

2.1.1 MDV 3172 placering < 3 m från spole

Förstärkare MDV 3172 bör placeras i nära anslutning till detektorspolen, då denna har en
färdigingjuten kabel på 3 m med kontaktdon. Förstärkaren har även den en färdigingjuten kabel på
2 m och skarvas lämpligen i dosa, se fig.1.

www.specialsensorer.se BS81004 3
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

Figur 1 MDV 3172

1
MDS 7

4
3
5
6
2

1. Spole 5. Dosa
2. 3 m färdigingjuten kabel 6. Till elcentral
3. Kontaktdon 7. Förstäkare
4. 2 m färdigingjuten kabel

Förstärkaren MDV 3172 bryter ett relä (relä kontakt stängs) när metall detekteras. Inga vidare
analysfunktioner finns. MDV 3172 är konstruerad för att klara av att appliceras i extremt svåra
miljöer där väta, smuts, temperaturförändringar och vibrationer ofta är förekommande.

2.1.2 MDV 3172 placering > 3 m från spole

Det är möjligt att placera förstärkaren mer än 3 m från detektorspolen. Man använder då en färdig
förlängningskabel med 2 st kontaktdon typ KS031-DS05. Längder upp till 30 m är tillåtet. Här
krävs då separata kontaktdon typ K031-S05 och kabel av typ PUR skärmad 4x0,75. I många fall
är den färdiga kabeln KS031-DS05 med en längd av 5 m en bra lösning, se fig 2.

Figur 2

MDV 3172

1
8
MDS

K031 DS05
3m 5m 4
5

6 7
3

1. Spole 5. 2 m färdigingjuten kabel

2. 3 m färdigingjuten kabel 6. Dosa
3. Kontaktdon 7. Till elcentral
4. Kontaktdon 8. Förstäkare

www.specialsensorer.se BS81004 4
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

2.2 Spole MDS montage under transportband

Detektorspolen monteras bäst mellan rullarna under transportbandet, där minskar risken för att
spolen utsätts för mekanisk åverkan. Avståndet mellan spole och rullar bör vara minst spolens
bredd, men för att utnyttja detektorns känslighet till fullo krävs att det från spolens centrum är en
metallfri zon som är ca. 1,5-2 x spolens bredd, se fig.3 Denna typ av montering är den mest
vanligt förekommande och skall föredras före andra typer av installationer.

Figur 3
1,5-2 x b 1,5-2 x b

min. 1 x b min. 1 x b

b
30-50mm
Säkerhetskloss (trä)
Obs !

Vid risk för svaj / svikt i bandet rekommenderas en säkerhetskloss som tar upp stötarna.

2.3 Spole MDS montage ovanför transportband

När detektor spolen är monterad ovanför transportbandet, måste det vara helt säkert att
anläggningens stålkontruktion inte är för nära detektor spolen. I sådana fall måste spolens
känslighet reduceras. Detta medför att detektionskänslighet reduceras och enbart större
metallbitar kan detekteras.

Eftersom två detektor spolar, som var för sig är kopplade till en förstärkare MDV, stör varandra,
måste avståndet vara minimum 2 m.

Obs !

Försiktighetsåtgärder måste vidtas mot att högt staplat material på transportbandet inte stöter
emot detektorspolen och ger skador, se fig.4

Figur 4

300 - 400

www.specialsensorer.se BS81004 5
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

Detektor spolen är monterad med distanser på en aluminium platta, som skyddar från
elektromagnetiska störningar underifrån och säkrar en robust installation av spolen. Metalplattan
har 10 mm borrhål på bägge sidorna. På platser med starka elektromagnetiska störningar,
rekomenderas att man skyddar metaldetektorns sidor med t ex aluminiumplattor.

Obs !
Detektorspolen får ej monteras hängande i kätting eller annat instabilt hjälpmedel. Den måste
monteras på en fast plats som är fri från vibrationer.

Notera
Montering ovanför transportband används sällan, och rekommenderas enbart i specialfall när
andra monteringsmöjligheter ej är möjliga.

2.4 Val av spole

Detektorspole med 650 mm bredd rekommenderas till bandtransportörer på upp till 800 mm
bredd.

Bandtransportörer med 1000 mm till 1200 mm och uppåt rekommenderas en detektorspole

med 950 mm bredd.

2.5 Överspänningsskydd NTG 251/255

NTG 251 ansluts mellan förstärkare och manöverspänning vid applikationer där särskild risk för
överspänningar förekommer. NTG 251 fungerar också som EMC-filter och dämpar eventuella
störningspulser från nätet. Observera att utgångsreläet kan belastas med max. 4 A, 250 V AC, se
fig. 5. NTG... begränsar spänning- och strömamplituden till förstärkare MDV 3172, så att inte dess
säkring kan brinna.

NTG 251/255
30 16

28 18
L1 L1
F1,0 AT

Nät Förstärkare
U
29 U 17
N N
19
25 L1
26 TEST
24
20
S

www.specialsensorer.se BS81004 6
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

3. Funktion

En av metalldetektorsystemets uppgifter är att omvandla amplitudförändringar till elektronisk puls.

Amplitudförändringen sker när ett metallföremål passerar spolens elektromagnetiska fält och som
då påverkar oscillatorns svängningskrets. Detektorns känslighet ställs in med en vridpotentiometer.
Hur hög känslighet som kan inställas styrs av flera faktorer i spolens omgivning, metallföremålets
elektromagnetiska egenskaper och transporthastigheten, se fig. 6.

Notera
Vid applikationer där man kan förväntas få förhöjd interferens vid AC-matning,kan säkringen lösa
ut på MDV:n. Då driver inte MDV längre sitt utgångsrelä. På grund av detta beteende,
rekommenderas användning av överspänningsskydd NTG 251/255

Figur 6
Känslighetskurva gällande MDV...

Kopplingsavstånd / mm
500

400

300

200

100

0
0 50 100 150 200 250 300 350 400
Kantbredd på objekt / mm

Känslighetsdiagrammet visar hur långt avstånd det kan vara mellan objekt av olika storlekar och
detektorspolen. Diagrammets utfall är baserat på mätningar där detektorspolens (MDS 3065)
omgivning varit fri från metall. Vid mätningar där objektets kantbredd har understigit 50 mm har en
stålkub använts, för bredare objekt en 2 mm tjock metallplatta (ST 37 / ASTM A36). Objektet har
vid mätningen passerat detektorspolens centrum med en hastighet på 0,5 m/s.

Metall skiljer sig i elektromagnetiska egenskaper, vilket leder till olika detektionsavstånd.
Aluminium t ex har ett mindre detektionsavstånd än en bit järn (ST 37 / ASTM A36) i samma
storlek. Känsligheten i förhållande till reduceringsfaktorn jämförd med järn visas i tabell 1
(korrigeringsfaktorer) för olika metaller.

www.specialsensorer.se BS81004 7
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

Korrigeringsfaktorer Kub 50x50x50mm Platta 120x120mm

Stål ST 37 1 1
Korrigeringsfaktorn är beroende av Rostfritt stål 0,5 1
delarnas storlek och form.
ZN 0,5 0,9
AL 0,4 0,85
CU 0,45 0,85
Mässing 0,6 0,9
Exempel:
Antag att en stålkub (50 x 50 x 50 mm, ST 37 / ASTM A36) detekteras på ett avstånd upp till
130 mm.

Under samma förhållande kan då en aluminiumkub detekteras på ett avstånd av 52 mm

(130 x 0,4 = 52 mm).

4. Injustering
4.1 Kontroll

Efter det att metalldetektorsystemet är rätt monterat och inkopplat kan systemet justeras in:

1. Kontrollera att den undre gröna lysdioden för "manöverspänning" lyser

se fig. 7, position A.

2. När manöverspänningen ansluts behöver förstärkaren ca 3-10 sekunder för att kontrollera om
några störningar eller fel finns i systemet.

Under självtesten ställer förstärkaren utgången på "metall detekterad" för att kontrollera sig själv.
Om ett självutlösande relä är kopplat till denna utgång, måste det nollställas för att aktivera
metalldetektorn.

4.2 Inställning av känslighet

Känsligheten justeras genom en potentiometer. Potentiometern skyddas av en plastskruv, som

måste tas bort före justeringen. (Se fig. 7, Pos. B)

Högst känslighet nås när potentiometern har snurrats medsols 20 varv.

Lägst känslighet fås genom att först vrida potentiometern 20 varv medsols, därefter 10 varv
motsols.

Genom denna inställning uppnås en medelkänslighet. Om man vrider potentiometern medsols

ökas känsligheten, vrids den motsols minskas känsligheten.

www.specialsensorer.se BS81004 8
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

Notera

Potentiometern har inget mekaniskt stop. Den elektriska slutpositionen nås efter 20 vridningar.
Fler vridningar åt samma håll ändrar inte känsligheten.

Om den gula LED för "metall detekterad" blinkar under körningar av transportbandet, är antingen
känsligheten för högt ställd eller så är detektorspolen inte korrekt inkopplad.

B
Figur 7
A

A Grön LED tänds när strömtillförseln är inkopplad

B Inställningspotentiometer (med skyddande skruv)
C Gul LED vid metall detektion
D Säkring 1 A, trög

5. Felorsaker
5.1 Kontroll av förstärkare
1. Kontrollera om den gröna lysdioden för manöverspänning är tänd.
2. Kontrollera att säkringen är installerad och funktionell (Fig. 7, Pos. D)
3. Kontrollera strömtillförseln: Finns det spänningsfall >0.5 sekunder?

www.specialsensorer.se BS81004 9
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

5.2 Åtgärder vid fel utan förlängningskabel

1. Kontrollera om manöverspänning finns fram till förstärkaren och att grön lysdiod är tänd,
se fig. 7 (position A) i kapitel 4.1.

2. Kontrollera finsäkringen som är placerad i säkringshållaren, se fig. 7 (position D)

i kapitel 4.1.

Figur 8
6

1 5
1: (1) 2 4
2: (2)
3
3: (3) 7
4: - -
5: - -
6: skärm / jord
7: - -

5.3 Åtgärder vid fel med förlängningskabel

1. Koppla loss kontaktdonet och resistansmät spole och kabel enligt kapitel 5.2

Obs !
Vid egen tillverkning av förlängningskabel skall stift 4 och 7 kortslutas i kontaktdonet som
skall anslutas i förstärkaren. Detta för att förstärkarens interna skärmsystem skall fungera.
Se fig. 9.

www.specialsensorer.se BS81004 10
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

2. Resistansmät även kabeln mellan skarven och förstärkaren genom att koppla loss
kontaktdonet i skarven mät enligt fig. 9

Figur 9

1: (1)
2: (2)
3: (3) MDS MDV
4: - -
6 6
5: - -
6: skärm / jord 1 5 5 1

7: - - 2 4 4 2

3 3
7 7

3. Mellan respektive ledare (1-1) skall resistansen vara 0 Ohm.

Mellan ledare 1-2 eller någon annan (ej 1) skall resistansen vara oändlig, se tabell 2

Tabell 2

Ledera Resistans
1-1 0 Ohm
2-2 0 Ohm
3-3 0 Ohm
6-6 0 Ohm
4 - 7* 0 Ohm

* Pga bryggan mellan kontakterna (4-7) är de tilldelade samma kabel.

www.specialsensorer.se BS81004 11
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

6. Tekniska Data
6.1. Förstärkare MDV 3172

Omgivningstemperatur -25 °C bis +70 °C

Kapslingsklass IP 67
Material PBT
Anslutningskabel PUR/PVC 0,5 mm²

Nominal-Data (25 °C) AC DC

Manöverspänning 115 alt. 230 V AC 24 V DC

Tolerans + 10 / -15 % + 20 %
Strömförbrukning max. 20 mA 100 mA

Utgång Normalt öppet reläomslag

Kopplingsspänning max. 250 V AC / 220 V DC
Kopplingsström max. 1 A AC / 2 A DC
Kopplingseffekt max. 125 V A / 60 W
Vikt 1,85 kg

(1)
MDV 3172 L1(+) Notera
(2) Förstärkaren MDV 3172 har en
(5) Utgång slutare-funktion. När metall
(4) detekteras, aktvieras relät och
kontakt 4-5 stängs (2-5 är då
(3) öppen)
N( - )

Type ID-No. Design

MDV 3172 WR 1 P81017 Förstärkare 115 V AC

MDV 3172 WR 2 P81010 Förstärkare 230 V AC
MDV 3172 GR P81011 Förstärkare 24 V DC

www.specialsensorer.se BS81004 12
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

6.2 Detektorspole MDS

300
270 137
55

270
5
L2
L3

L1

10

Type ID-No. L1 L2 L3

MDS 3065-S P81007 650 700 670 3 m Förbindningskabel med stickpropp

MDS 3095-S P81009 950 1000 970 3 m Förbindningskabel med stickpropp

Tekniska Data Spole MDS

EN 60529 skydd: IP 67
Omgivningstemperatur: -25 °C...+70 °C
Material: Aluminium, PVC, GFK
Anslutning 3 m skärmad PUR-kabel 4 x 0,75 mm²
Vikt (650): 10 kg
Vikt (950): 12 kg

www.specialsensorer.se BS81004 13
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

6.3 Överspänningsskydd NTG 251 / 255

Type ID-No. 1 Säkring 1A / trög, grundläggande krets
2 LED grön indikerar spänning
NTG 251 P81030 3 LED grön indikerar sekundär spänning
NTG 255 P81032 4 Testknapp simulerar uteffekt
5 LED gul, relä aktiverat

75 10
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Rel.1

5 Fuse
1.0A T

NTG 251 4 1
Test 3 2
Amplifier Rel.1 Power supply
N L1 L1 S L1 N
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

2
4
5 förstärkare
MDV 3172 WR
1
3
YE/GN

Tekniska Data NTG 251 NTG 255

Manöverspänning 230 V AC + 15% 50 - 60 Hz 115 V AC + 15% 50 - 60 Hz

Störning impuls max. 1500 V / 2 s 1500 V / 2 s
Energiförbrukning max. 8VA 8VA
Utgång 4 A, 250 V AC 1 4 A, 250 V AC 1
Säkring 1.0 A trög 1.0 A trög
Omgivningstemperatur -30°C....+60°C -30°C....+60°C
Kapslingsklass IP 20 IP 20

6.4 Tillbehör (optional)

Type ID-No.
K031-DS05 Z01040 5 m förlängningskabel med stickförbindning
K031-S05 Z01041 5 m förlängningskabel med kabellåda och ledig kontaktände
K031-D Z01042 Separat stickförbindning
K031-S Z01043 Separat stickförbindning
KS031 Z01164 PUR-skärmad specialkabel

www.specialsensorer.se BS81004 14
METALLDETEKTOR System 3000
Instruktioner MDV - MDS

6.5 Installationtips

Förstärkare Överspänningsskydd
MDV 3172 NTG 251 / 255

NTG 251
C

16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

1
B (3)

N L1 L1 S

2
Amplifier
(1)

3
A
(5)

4
D (4)

5
(2)

Test

Rel.1

6
7
8
9
Utgång
Rel.1

10 11 12 13 14 15
Power supply
L1 N

1.0A T
Fuse
Strömtillförseln

Detektospole MDS...

A Grön LED tänds när strömtillförseln är inkopplad

B Inställningspotentiometer (med skyddande skruv)
C Gul LED vid metall detektion
D Säkring 1 A, trög

Notera
Efter att du sätter på strömförsörjningen aktiveras utgång i 3 - 10 sekunder (kontakter 5 och 4
slutna). Testimpulsen kan användas tillsammans med ytterligare utvärderingelektronik för ett
funktionstest av metalldetektorn (se 4 Justering).

www.specialsensorer.se BS81004 15
 METALLDETEKTOR System 3000
Instruktioner MDV - MDS

Tänkbar Test-Installation Överspänningsskydd NTG 251 / 255

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Förstärkare MDV 3172

Rel.1

C Fuse
1.0A T
B
NTG 251 Test
A Amplifier Rel.1 Power supply
N L1 L1 S L1 N
D
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
(3)

(1)
(5)
(4)

(2)

TEST

L1
RESET

green Signal
(L1)
red
Detektorspole MDS... N

En enkel testinstallation med stop-funktion en visas här: Denna installation utförs vanligtvis när metall-
detektorn installeras. Den är ej del av leveransen.

När metall upptäcks, när ett självtest vid start lyckas eller när ett manuellt test utförs tänds den röda
lampan och uteffekten "Signal" ansluts permanent till L1. Denna aktivering bibehålls tills att "RESET"-
knappen trycks in.

Det manuella testet utförs genom att trycka på testknappen mer än 2 sekunder. Testet lyckas om den röda
lampan tänds ungefär 2 sekunder efter att knappen släppts.

Om den röda lampan inte aktiveras efter start eller efter att ett manuellt test utförts är MDV eller NTG
defekt och ska underhållas.

Den gröna lampan tänds när ingen metall för tillfället upptäcks och inget självtest utförs.

www.specialsensorer.se BS81004 16
 1 TRANSPORT & COMMISSIONING MANUAL

SANDVIK HOLLOLA
Hanging Screen module
for UH440i / US440i
2 OPERATOR’S MANUAL

BELT CONVEYORS
RRH1212, RRH1213U, RRH1214U
RRH1209 (open circuit option) 3 ELECTRICAL DOCUMENTATION

OPERATION AND
MAINTENANCE 4 PRODUCT DOCUMENTATION
INSTRUCTIONS
REV. 2, 15122007

5 WEAR PARTS CATALOQUE

6 SPARE PARTS CATALOQUE

7 MAINTENANCE MANUAL

10
 OPERATION AND MAINTENANCE FILE
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OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007

1 TRANSPORT & COMMISSIONING MANUAL

ROX 11-01-01 GENERAL REGULATIONS AND INSTRUCTIONS

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INSTRUCTION DUST

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 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (5)

GENERAL INSTRUCTION ROX 11-01-01

GENERAL REGULATIONS AND INSTRUCTIONS

1. INTRODUCTION

This maintenance and operation manual is intented for the operating,

inspection and maintenance personnel.

This manual has to be read through carefully, and it has to be always at the
disposal of the personnel.

The instructions and descriptions of this manual are necessary when the
equipment is inspected, regulated, started, operated and serviced.

A new operator obtains from this manual the basic information about the
equipment and its operation. The skill to operate the equipment develops with
experience.

Sandvik Hollola has a principle of continuous development of machines and

equipment. That is way why your equipment and the data presented in this
manual may differ somewhat from each other.

There may be several versions and delivery alternatives of the machines and
equipment, and therefore in these general instructions may be described
equipment and functions which are not included in the delivery in your case.

The maintenance and operation manual is continually modified and improved

in order that its content would be up-to-date.

Sandvik Hollola reserves the right to alterations in machines and equipment

without prior notice in maintenance and operation instructions and other
corresponding documents.

If you have any questions concerning this manual or the equipment, machines
or systems delivered by Sandvik Hollola, please contact Sandvik Hollola.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (5)

GENERAL INSTRUCTION ROX 11-01-01

2. OBLIGATIONS OF THE OWNER

The owner is obliged to see to that:

- The safety, operation, maintenance and inspection instructions in force are

observed in the operation of the machines and equipment. These
instructions have to be at the disposal of those who need them.

- The normal start and stop signals, the start and stop signals of the
machines with remote control (light and/or sound signals), as well as the
risks of accidents involved with the machines and equipment have been
presented to the personnel.

- Only duly trained operating personnel may operate the equipment.

- The operating personnel has to know well the performance values and
properties of the machines.

- The machines and equipment must not be used for other purposes or in
other conditions than intented.

- The machines and equipment must have adequate lighting, and the
passages and service platforms have to be open.

- The machines have to be inspected and serviced at the recommended

intervals. The effected measures must be registered in the maintenance
book. On request, the maintenance registrations have to be presented to
the representative of Sandvik Hollola. The guarantee is valid only if the
inspections and maintenance are carried out according to the instructions.

- The defects notified by the operator, maintenance personnel or inspector

are to be registered and remedied without delay.

- The machine or equipment stopped due to a defect, malfunction and

emergency must not be started before the cause of the stop has been
cleared.

- There has always to be sufficiently qualified and duly trained operating,

maintenance and inspection personnel available.

- The plant may be expanded or modified only by Sandvik Hollola or an

enterprise authorized by it. If the plant is modified, it is always necessary to
take into account the strength, effect, capacity and other factors of the
equipment.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 3 (5)

GENERAL INSTRUCTION ROX 11-01-01

3. REGULATIONS AND INSTRUCTIONS CONCERNING THE MAINTENANCE

AND INSPECTION PERSONNEL

- The condition of the machines and equipment has to be checked daily and
all discovered defects are to be remedied without delay.

- The maintenance and inspections are performed when the machines

are at a standstill and the start is prevented by means of a safety
switch or by other reliable method.

- Only measures determined by the separate instructions may be performed

when the machines are running. Even then the safety devices have to be in
place, and it is necessary to exercise extreme caution.

- The maintenance and inspections have to be performed at recommended

intervals (see inspection and lubrication charts and instructions). The
performed measures have to be entered in the maintenance book.

- Mechanical and electrical regulations may be performed only by authorized

personnel.

- The service platforms and stairs of the equipment have to be kept clean and
in good condition.

- In the end of the maintenance and inspection it has to be checked that the
safety devices are duly in place, the machine is clean and that all foreign
objects (tools, instruments etc.) have been removed.

- Use only original spare parts of Sandvik Hollola.

- Wearing parts are to be changed in due time.

 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 4 (5)

GENERAL INSTRUCTION ROX 11-01-01

4. REGULATIONS AND INSTRUCTIONS CONCERNING THE MACHINE

OPERATOR

4.1 Measures before the start

- Read through carefully the operation instructions of the machines and

equipment.

- Make sure that no maintenance or operating personnel or unauthorized

persons are staying in the vicinity of the machines to be started, in order
that the start of the equipment cannot cause a danger for them.

- Make sure that all safety, protecting and security devices are in place and in
working order.

- Make sure that there are no foreign objects in the operating zone of the
machines and that dust, dirt, ice, etc. has not made the equipment out of
order.

- Select the control and operation mode of the machines and systems (see
operation instructions).

- Observe during the start that the machines start normally and that they
function properly.

4.2 Measures during operation

- Observe the material flow.

- Observe that the material does not go to places where it causes

malfunctions.

- See to that unauthorized persons cannot come near the running machines.

- Observe the functioning of the machines and report the discovered defects
and malfunctions to the maintenance personnel without delay.

4.3 Measures when the machines are stopped

- Run the machines empty of material if possible.

- Stop the machines as determined in the operation instructions.

- Report all discovered malfunctions of the machines to the next operator and
the maintenance personnel.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 5 (5)

GENERAL INSTRUCTION ROX 11-01-01

5. SAFETY

- The general safety instructions and regulations in force in the plant are to be
observed when the equipment and machines are operated and serviced.

- In addition to these, the maintenance and operating personnel has to read

through carefully the safety instructions and regulations contained by this
maintenance and operation manual and observe them in all situations and
conditions.

- The operating and maintenance personnel has to know the hazards involved
in the equipment, such as :
- risk of being squeezed and caught by moving and rotating parts of the
machine
- accidental and automatic starts
- hazards and injurious effects caused by dust and noise
- fire and explosion hazards caused by material

- Unauthorized persons must stay out, in the immediate vicinity of the

equipment it is necessary to use due protections.

- The safety and security devices must not be removed, they must always be
in place and in working order when the equipment is operated.

- The covers and doors of the electrical equipment and boxes have to be
closed.

- Before the maintenance, inspection and cleaning of the equipment it is

necessary to stop the machines and their start has to be prevented with a
safety switch or similar.

6. GUARANTEE

- The guarantee conditions and period of the equipment and systems are
determined in the supply contract or other documents.

- A general precondition for the guarantee is that the equipment is operated,

serviced and inspected according to these maintenance and operation
instructions, and that only original spare parts of Sandvik Hollola are used.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (4)

GENERAL INSTRUCTION ROX 11-01-07

SAFETY INSTRUCTIONS FOR CONVEYOR SYSTEMS AND MATERIAL HANDLING

EQUIPMENT

1. DANGEROUS PLACES

Dangerous places of conveyor systems and material handling equipment are,

e.g. the following ones:

- pulleys and sprockets, especially gaps between the pulley and the belt / the
sprockets and chains
- on belt conveyors rollers, gaps between rollers and the belt, especially in
places with boards
- on chain conveyors chains and sprockets
- hatches when open
- drive mechanism, rotating and moving parts
- counterweight take-up devices, moving take-up carriage
- generally, a running or starting belt is dangerous
- falling and rolling material
- electrical accidents, e.g. during repair work
- falling or slipping of persons
- hazardous dust and noise
- fire and explosion hazard caused by the material to be handled

2. DANGEROUS SITUATIONS

2.1 Dangerous situations and the most common causes to accidents

are e.g.:

- the equipment is started when there are persons near to the dangerous
places of the conveyor system
- accidental starts, remote and automatic starts
- maintenance, repair and cleaning near to a running or starting machine
- accidental start has not been prevented (the safety switch has not been
used, no warning sign or lock)
- clearing of a jam on a equipment or hopper
- safety or security device is missing or it does not function
- material on the passage or walkway, uncleanliness
- first start and trial runs in the installation phase

If it is necessary to go near the equipment, pulleys or drive mechanism

during the maintenance, cleaning etc., or if it is necessary to remove
some guards or open doors, the equipment has to be stopped and the
start before beginning the work has to be prevented by means of a
safety switch. The safety switch has always to be locked in the position
"0" with a separate lock, and the key has be kept by the person who is
carrying out the above measures or by the person in charge.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (4)

GENERAL INSTRUCTION ROX 11-01-07

2.2 Especially it has to be noted that:

- Never try to remove any objects or material from a running machine.

- Never try to clean shafts, sprockets, chains, pulleys, rollers or belt cleaners
when the conveyor is running.

- Never go to a conveyor belt before an accidental start has been prevented

by a safety switch.

- E.g. in case of jam the conveyor belt or chain can be still under tension
which can rotate the belt/chain and pulleys/shafts when being discharged
despite the safety switch. That is why make always sure before clearing a
jam that the chain, belt or the counterweight will not cause a hazard when
the possible tension will be discharged. The tension can be eliminated from
the belt, e.g. by detaching the back-rotation preventing brake.

- When maintaining ascending chain conveyors take into account that chains
must be locked to prevent the crash of chains. The locking of the chains
must be done for example when shorten or repairing chains and always if
someone goes inside the chain conveyor.

- When the feed hopper is entered, it is also necessary to prevent the running
of the feeding device by means of a safety switch.

- When the mobile conveyor are serviced, it is necessary to prevent also the
operation of the transfer mechanism by means of a safety switch.

- The use of belt conveyors for transport of persons as an "elevator or

escalator" is absolutely forbidden.

- If the conveyor has a source of radioactive radiation, e.g. blockage detectors

of hoppers or belt scales, shut the radiation sources before entering their
zone of influence. Observe the instructions and regulations given by the
manufacturers of these devices or the person in charge of radiation
questions in the plant.

- The covers and doors of electrical equipment and boxes have to be kept
closed. The electrical installation and repair work may be performed only by
an authorized firm.

- Risk of rolling or falling material may occur with some materials and
equipment in special situations. In this case it is forbidden to stay under the
machine; wear a protecting helmet and goggles.

- Hazardous noise. Noise occurring near drive mechanisms and hoppers

may be hazardous; wear ear protectors.

- Hazardous dust. Dust eventually occurring near machines may be

hazardous for health depending on the material to be handled; wear
suitable respiratory protective devices.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 3 (4)

GENERAL INSTRUCTION ROX 11-01-07

- Hazard of being caught by moving and rotating parts of the machine if you
do wear unproper clothing near them, e.g. hanging pieces of cloth; wear
appropriate protective clothing.

3. SAFETY AND PROTECTIVE DEVICES

3.1 Mechanical safety and protective devices

Mechanical safety devices are e.g.

- guards in gaps between belt and pulleys and rollers (nip points)
- safety nets around the shafts, pulleys and belt
- safety nets inside hatches possible open without tool
- locking devices and parts for hatches
- handrails and safety nets around the moving parts
- guards of drive mechanism, e.g. around V-belts and couplings
- handrails and safety nets along walkways and passages
- back-rotation preventing brakes and other brakes

The safety and protective devices must not be removed.

When the conveyor equipment/system is operated, the safety and
protective devices must always be in place and in working order.

3.2 Electrical safety and warning devices

- emergency stop of the conveyor equipment:

the belt conveyor can be stopped when there is a risk of a personal or
material damage by pulling at the red emergency stop pull cord located
along the conveyor. On the control board/in the control room there is
generally also an emergency stop push-button which stops the equipment
when being pressed.

- start pre-warning:
a device giving an acoustic alarm and/or light signal which warns of the start
of the conveyor system/equipment

- safety switch:
by turning the safety switch to the position "0" the start of the drive motor of
the machine can be prevented reliably, e.g. for the maintenance.
The safety switch can be locked in the position "0" by a padlock.

The safety and warning devices must not be removed.

When the conveyor equipment/system operated, the safety and warning
devices must always be in place and in working order.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 4 (4)

GENERAL INSTRUCTION ROX 11-01-07

4. FIRE AND EXPLOSION HAZARD

Normally conveyor equipment do not involve operation or materials causing a

special hazard of fire or explosion. It has, however, a lot of e.g. bearings and
other possible friction points with high temperature due to inadequate
maintenance and cleaning.

The material to be transported and its dust may require that the fire or
explosion hazard is taken into account. In this case the fire protection
regulations and instructions given for the plant are to be observed.

The fire alarm and extinction devices must always be at the disposal and in
working order when the conveyor is operated.

The conveyor belts may be different as to the fire resistance and burning
properties. This must be taken into account when making the plans for fire
protection.

In case of fire, the equipment frame may be exposed to so big a thermal

stress that the whole frame structure of the machine (e.g. conveyor bridge)
may collapse.

5. MATERIAL DUST

The dust leaking out from the conveyor equipment, mainly near the hoppers,
can cause a hazard because the visibility will be worse. Depending on the
material to be handled, the dust can be hazardous for health when inhaled
continuously.

The emission of dust outside the equipment is caused by the construction of

the conveyor system, and often by an inadequate maintenance of sealings
etc.

The dust extraction devices must always be switched on and in working order
when the conveyor system is running.

If hazardous dust occurs in the vicinity of the conveyor system, it is necessary

to use appropriate respiratory protective devices.

6. NOISE

The noise level in hoppers and chutes integrated with equipment may be high
because of the material flow, depending on the material.
In some machine the noise level may be high near the drive machinery.

If the noise level at some points exceeds the allowable limits, these points
must be equipped with a warning sign, and it is necessary to wear ear
protectors.
 MAINTENANCE AND OPERATION INSTRUCTIONS

29.6.05/JPa 1 (1)
SPECIAL INSTRUCTION

DUST
Rock and stone crushing creates dust, which stays at the material handling site and its
surroundings, even when not handling the material. When conveying material by conveyors
dust is created often at loading and unloading points.

Dust may be so fine that it cannot be seen. It is hazardous to inhale the dust.

Breathing dust will cause death or severe injury. Always wear approved respirator.
See enclosed appendix “Danger”.

Protection from dust

• Always use an approved respirator when outdoor (outside the cabin). Make sure that
the respirator is in good condition.
• Always keep the cabin door closed.
• Keep the cabin clean. Clean the cabin with a vacuum cleaner daily
• Change the cabin air filter regularly with original spare part.

Dust suppression system

Make sure that dust suppression system at your site is working properly. Keep the dusting
at minimum level at site.

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 MAINTENANCE AND OPERATION INSTRUCTIONS

29.6.05/JPa 1 (1)
SPECIAL INSTRUCTION

DANGER

BREATHING OR INHALING DUST PARTICLES WILL CAUSE DEATH OR SEVERE

INJURY.

ALWAYS WORK WITH A RESPIRATOR APPROVED BY THE RESPIRATOR

MANUFACTURER FOR THE JOB YOU ARE DOING. IT IS ESSENTIAL THAT THE
RESPIRATOR THAT YOU USE PROTECTS YOU FROM THE TINY DUST PARTICLES
WHICH CAUSE SILICOSIS AND WHICH MAY CAUSE OTHER SERIOUS LUNG DISEASES.
YOU SHOULD NOT USE THE EQUIPMENT UNTIL YOU ARE SURE YOUR RESPIRATOR IS
WORKING PROPERLY. THIS MEANS THE RESPIRATOR MUST BE CHECKED TO MAKE
SURE THAT IT IS CLEAN, THAT ITS FILTER HAS BEEN CHANGED, AND TO OTHERWISE
MAKE SURE THE RESPIRATOR WILL PROTECT YOU IN THE WAY IT IS MEANT TO.

MAKE SURE THE DUST SUPPRESSION SYSTEM IN YOUR EQUIPMENT IS WORKING

PROPERLY. IF THE DUST SUPPRESSION SYSTEM IS NOT WORKING PROPERLY,
STOP WORKING IMMEDIATELY.

ALWAYS MAKE SURE DUST HAS BEEN CLEANED OFF YOUR BOOTS AND CLOTHES
WHEN YOU LEAVE YOUR SHIFT.

THE SMALLEST PARTICLES OF DUST ARE THE MOST HARMFUL. THEY MAY BE SO
FINE THAT YOU CAN NOT SEE THEM.

REMEMBER, YOU MUST PROTECT YOURSELF FROM THE DANGER OF BREATHING OR

INHALING DUST.

AT:172618v2
 OPERATION AND MAINTENANCE FILE
SAFETY INSTRUCTION

Jukka Pajuranta 17.2.2006 1 (1)

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 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (2)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-05

COMMISSIONING

1. Commissioning inspections

The commissioning shall be begun with a commissioning inspection before

starting the belt conveyor for the first time.

In the inspection can be used commissioning forms made by Sandvik Hollola

especially for this purpose. There is a separate form for mechanical
inspection and one for electrical and automation inspection.

The inspection shall be carried out by a person who knows well the
equipment to be inspected, commissioner and/or installation supervisor.

The commissioning forms are used as a check list and instructions for the
inspection, and they will be documents concerning the inspections and
regulations carried out.

2. First start

It is very important to carry out the first start of the belt conveyor with
caution and control, because there is a big risk of various damages.

Before the first start the commissioning inspections have to be carried out to
the extent that it is possible without running the motor.

Special attention must be paid to the following:

- the belt has to be empty and it must be able to move freely

- the electrical and control system has been tested, especially the start
warning and emergency stop systems
- all mechanical guards are in place and other factors having an influence on
the personal safety are in order
- the direction of rotation of the drive motor is correct, this must be assured,
e.g. without oil in the fluid coupling or without V-belts (if the drive motor
rotates in the wrong direction, the return brake of the reducer may be
damaged)

Immediately after the first short start, make sure that the belt remains
sufficiently centered.
The belt is centered in accordance with the instruction ROX 11-02-20, par. 2.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (2)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-05

3. Trial run without material

The belt conveyor has to be run without material during several hours,
sometimes even during several days, before the run with material can be
started.

When the conveyor is run without material, check the function of all electrical
safety devices and lockings.

Check that the sound, tightness and temperature of the reducer are normal.

Make sure that all parts of the conveyor function normally.

4. Trial run with material

The trial run with material is started with a small quantity of material,
observing the function of the hoppers and the centering of the belt.

If the material is not guided to the center of the belt, adjust and repair the
hopper accordingly.

Increase the quantity of the material to be fed onto the conveyor until the
normal/maximum capacity is achieved, carry out the necessary adjustments
to the feed hopper and the belt.

Observe the temperatures of the reducer and bearings.

Perform a start test with a full loaded belt.

Measure the effect/current taken by the drive motor.

Observe the dust-tightness and function of the belt cleaners.

Commissioning performed carefully and with proficiency contributes to

troublefree and safe productional service.
 MAINTENANCE AND OPERATION INSTRUCTIONS

21.10.05/JPa 1 (3)

BELT CONVEYOR, BELT FEEDER

MOBILE BELT CONVEYOR EQUIPMENT

1. Construction and principle of operation

The belt conveyor equipment has been designed for transporting and moving
gravel, crushed rock and stone materials. The material is moved by means of
a conveyor belt, which has been mounted, on rollers and pulleys.

Belt conveyor equipment is installed onto chassis of Mobil unit. Belt conveyor
equipment can be equipped with turning joints, which makes adjustment of
height possible for loading and unloading sections. Adjustment is often
carried out by hydraulic cylinders but also by using separate lifting device in
certain belt conveyor equipment. Adjustments are needed normally to put belt
conveyor equipment in transport or to operation position. Also jam at loading
area and some maintenance works can be carried out easier when having
loading section on lowest position.

As to the construction and components, the belt conveyor equipment are in

principle similar to other belt conveyors and feeders but special features
related to the Mobil have taken into consideration. A drive pulley rotated by a
drive unit runs conveyor belt only in one direction. The belt is tensioned
normally by a screw or similar.

The misalignment of the belt is taken into consideration when designing.

There is only a small misalignment possible due to the space available. It is
acceptable that belt is in side against certain wear plates.

The belt conveyor equipment are always tailor-made but made in series
production. The structural solutions have been made by using standard
components and standardised construction models when possible. The
construction and components of your belt conveyor equipment can be seen in
the drawings and parts lists of the equipment.

The main parts of the belt conveyor equipment are:

- Frame construction is generally made from special or normal

construction steel by bolting or welding
- Drive, tail and take-up pulleys are steel or rubber coated pulleys the
main dimensions of which conform to ISO-standards. The bearings of the
pulleys are equipped with dust seals suitable for this purpose
- Conveyor roller system consists of garland type supporting rollers with
hanging links, the main dimensions of the rollers conform to ISO-
standards. Return rollers are normally equipped with extra rubber disks.
Also steel and plastic shells are in use.
- Conveyor belt (wear part) is a rubber belt which has been chosen so
that it endures well the forces and conditions in different cases
- Drive unit is normally hydraulic motor, drum motor or hydraulic/electric
driven reducer.
- Belt take-up devices: screw take-up device is normally used
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 MAINTENANCE AND OPERATION INSTRUCTIONS

21.10.05/JPa 2 (3)

BELT CONVEYOR, BELT FEEDER

- Belt cleaning devices are various scrapers or ploughs including

replaceable wear parts. Together with Wing-pulley there is a plough to
remove only bigger particles away before pulley
- Protecting, safety and security devices are e.g. different protecting nets
or guards of openings which have been placed around the dangerous
moving parts, such as pulleys and drives. Emergency stop devices, start
pre-warning devices and devices preventing an accidental start are also
safety and security devices. In addition the belt conveyor equipment can
have security devices protecting the device itself or controlling the
process, such as belt rotation detectors, level and blockage detectors
- Chutes and boards are steel sheet structures chosen and constructed
individually for each case, with seals of different types (wear parts) and
wear plates. The belt conveyor equipment can comprise also different
encapsulations, wind and dust protections and coverings.

2. Safety

Respect all instructions given and general caution. Follow instructions issued
by local authorities. Perform all maintenance and repairs only when conveyor
is not running. Note all safety instructions in this manual like ROX11-01-07
before any operations. Special dangerous points and situations are among
other things following:

• Breathing dust will cause death or severe injury. Always wear approved
respirator
• When lifting or lowering belt conveyor equipment there are gaps between
the chassis of mobile and belt conveyor equipment. Note also the risk
zone area between the moving belt conveyor equipment and another
construction (like wheel loader). Keep safety distance and prevent
personnel enter to risk zone
• To prevent entanglement at a rotating part or moving part; ensure that the
gap guards are always installed when operating
• Falling/rolling material from the belt or hopper. Keep safety distance and
prevent personnel enter to risk zone
• Unexpected starts; ensure the warning device function and use a safety
switch
• Noise from material handling and operation; use personal protective
devices
• Disuse of personal protective devices; train personal for proper use of
approved devices
• Back rotation of belt particularly when belt is loaded with material; prevent
the drive pulley rotation and belt movement
• Loss of stability of Mobile unit and/or belt conveyor equipment: Ensure the
stability of foundation where unit is standing, use anchoring and other
adequate means
• The proper use of belt conveyor equipment will increase the lifetime of
belt conveyor equipment as well as the safety of operation. Ensure that
the material, capacity and material particle size are according to the
values given in Contract.

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 MAINTENANCE AND OPERATION INSTRUCTIONS

21.10.05/JPa 3 (3)

BELT CONVEYOR, BELT FEEDER

3. Maintenance

For safety reasons service and cleaning works can be carried out only when
the belt conveyor equipment is not running.

Do not start the maintenance, inspection, repairing, cleaning or

removing any guards before you have stopped the belt conveyor
equipment and equipment feeding it.

Prevent an accidental start with the safety switch.

Put the guards in place before the restart.

The maintenance and periodic inspections of the conveyor are to be

performed as described in the separate maintenance and operation
instructions.

In cases where periodic inspections and maintenance are not defined follow
instruction: Maintenance schedule (B).

Records

All actions related to the scheduled maintenance, repairs, part replacing and
damages must be recorded in the Maintenance Log. When demanding
guarantee also Maintenance log must be presented.

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 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007

2 OPERATOR’S MANUAL

FOREWORD

GUARANTEE

RRH 1212-J1 SERVICE DIAGRAM

RRH 1213U-J1 SERVICE DIAGRAM

RRH 1214U-J1 SERVICE DIAGRAM

RRH 1209-J1 SERVICE DIAGRAM

ROX 11-01-06 OPERATION OF MATERIALS HANDLING EQUIPMENT

ROX 11-01-81 LUBRICANTS

ROX 11-01-83 CLEANING

ROX 11-02-05 COMMISSIONING

ROX 11-02-20 CONVEYOR BELT

ROX 11-02-22 SCREW TAKE-UP DEVICE

ROX 11-02-24 CONVEYOR PULLEYS

ROX 11-02-25 BELT CLEANERS

ROX 11-02-26 CONVEYOR ROLLER SYSTEM

ROX 11-02-28 GUIDING BOARDS

ROX 11-02-31 MAINTENANCE SCHEDULE, DIFFICULT CONDITIONS (B)

ROX 11-02-40 TROUBLESHOOTING INSTRUCTION FOR BELT

CONVEYOR/FEEDERS

JOINT/TRANSFER MECHANISM

MAINTENANCE LOG
MAINTENANCE LOG FORM

FEEDBACK FORM

DESCRIPTION OF DAMAGE
DAMAGE DESCRIPTION FORM

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Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007 1 (1)

FOREWORD

This instruction manual is for the use of personnel engaged in the tasks of
assembly, inspection, operation and maintenance. It must be kept always in a
place of easy access and the people must carefully become familiar with it.

The instructions, guidance and illustrations contained in this manual are necessary
for proper assembly, inspection, adjusting, start-up, operation and maintenance of
the belt conveyor.

An operator new to the Sandvik Hollola conveyor will find from this manual all
basic information of conveyor and its operation. Operational skills develop as
experience increases.

In keeping with Sandvik Hollola’s policy of continuous product development, some

technical details published in this manual might differ a little in the conveyor that you
have. We do try to update and improve the manual regularly in order to update its
contents all time.

However, Sandvik Mining and Construction Hollola Oy reserves the right to modify
the conveyor without notice.

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Foreword rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007 1 (1)

GUARANTEE

The using of Sandvik Hollola original spare parts as well as the recorded
Maintenance Log covering the guarantee period is precondition for the
guarantee.

The following of this manual in every respect is also absolutely the

precondition for the Sandvik Hollola guarantee.

The Conveyor installation to Crawl Master. Control and Power system are not
in the scope of Sandvik Hollola.

The Belt Conveyors is supplied under the General Conditions

NL 01 E issued in 2001.

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Guarantee rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (1)

GENERAL INSTRUCTION ROX 11-01-06

OPERATION OF THE MATERIALS HANDLING EQUIPMENT

1. Operation instructions

The general regulations and instructions applying to the operator of the

materials handling equipment are in the beginning of this file
ROX 11-01-01, par. 4.

If special operation instructions have been made for the equipment or the
whole system, also these instructions are in this file.

The start and stop of the equipment, as well as the failure alarms etc. have
been described in the operation instruction or other documents of the control
system of the equipment or plant in question.

When operating the equipment it is necessary to observe all instructions and

regulations of the control and electrical system given in manuals.

2. Operating conditions

Generally, the material handling systems have been designed for moving and
transporting various materials. Every equipment and system has, however,
been designed only for certain materials and capacities and certain
conditions.

Use the equipment only with the material for which it has been designed, and
do not exceed the design capacity.

Use the equipment only in such weather and ambient conditions as for which
it has been designed.

The capacity data etc. of the equipment and system can be seen in the main
drawing, technical specification or acquisition documents of the equipment.

3. Safety

When operating, servicing and inspecting the material handling system, it is

necessary to observe the safety regulations and instructions in force in the
country and the plant.

The general safety regulations and instructions are included in the instruction
ROX 11-01-01 which is in the beginning of this file.

When operating material handling equipment it is necessary in addition

to observe the special safety instructions: ROX 11-01-07
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (4)

GENERAL INSTRUCTION ROX 11-01-81

LUBRICANTS

1. GENERAL

When choosing lubricants or performing lubrication the lubrication

instructions of the component manufacturer in question must
absolutely be followed.

This instruction contains general instructions for choosing and handling of

lubricants for the material handling equipment delivered by Sandvik Hollola.
General information on lubricants and choosing of them is available also from
the suppliers of lubricants.

2. SAFETY

If during maintenance you have to detach some guards or go outside

the normal maintenance zone near the rotating parts, it is absolutely
necessary to stop the equipment and to prevent an accidental start.
Before restarting the equipment, the guards have to be put in place.

When handling industrial oils and lubricants long-term and repeated contact
with skin must be avoided, wear protective clothing and appropriate tools.

Normally the used lubricant is classified as problem waste, take care of

appropriate handling, storing and destroying of the lubricants removed from
service.

3. LUBRICANT GROUPS

The lubrication objects of the equipment delivered by Sandvik Hollola have

been divided in four main groups:

Group 1. Gears, oil lubrication

- toothed gearings - worm gears
- lubrication by splash - immersion lubrication
- pressure lubrication - transmission chains

Group 2. Bearings, grease lubrication

- rolling bearings - slide bearings
- grease lubricated gears

Group 3. Open gear wheels, Steel wire ropes

Group 4. Hydraulic systems

- hydraulic aggregates and systems
- electrohydraulic pushers - fluid couplings
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (4)

GENERAL INSTRUCTION ROX 11-01-81

4. CHOOSING OF LUBRICANT

Group 1: Gears, oil lubrication

The oil qualities recommended by the gear manufacturer must

absolutely always be used.
To the choosing of the oil viscosity influence the type of the gear, quality of
use and ambient temperature.

Rough selection of viscosity of lubrication oil for splash and immersion

lubricated gear wheels according to the ambient temperature.

ambient
temper- VISCOSITY CLASS ISO VG (cSt/40°C)
ature
C°
+60
+50 680
+40 460
+30 320
+20
+10 220
0 150
-10 100
-20 68
-30 46
-40

Under normal circumstances the same oil can according to consideration be

used around the year also in outdoors use.
In pressure lubricated gears lower viscosity classes are normally used than in
splash and immersion lubricated gears.
In worm gears higher viscosity classes are normally used than in gear wheels.

Oil types for gear wheels and worm gears:

MANUFACTURER mineral oils synthetic oils

BP Energol GR-PX SG XP
ESSO Spartan EP Spartan Synthetic EP
NESTE Vaihteisto EP Vaihteisto S-EP
MOBIL Mobilgear Mobil SHC
SHELL Omala Oil Tivela Oil
TEBOIL Pressure Oil Multi-Pressure Oil
When using synthetic oils the suitability of the oil in question for sealing etc.
materials of the gear must be checked.

Transmission chains: The same oil type is normally suitable as the one
chosen for the gears.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 3 (4)

GENERAL INSTRUCTION ROX 11-01-81

Group 2. Grease lubrication of bearings (and gears)

The lubricants recommended by the manufacturer of the bearing or

other lubrication object must absolutely always be used.

In the lubrication grease the viscosity of the lubricant corresponds its

penetration which indicates the hardness of the lubricant.
The hardness is indicated by NLGI-number, nine different classes (000 -6),
the bigger the number is the harder is the grease.

The operating temperature range of the lubrication greases is normally wide

enough for round-the-year use in almost all lubrication objects of material
handling equipment.

In central lubrication systems the pumping characteristics of the selected

grease must be checked, especially at outdoor locations the greases of
hardness class NLGI-1 or special cold resistant greases should be used.

In grease lubricated gears the lubricants of classes NLGI-00 or 0 are normally

used.

Lubrication grease types for rolling and slide bearings:

MANUFACTURER Brand name NLGI-class

ESSO Beacon EP 0, 1, 2
NESTE Yleisrasva EP 0, 1, 2, 3
MOBIL Mobilux EP 0, 1, 2
SHELL Alvania EP Grease 1, 2
TEBOIL Multi-purpose Grease 2

Mostly the hardness classes 1 and 2 are used.

Group 3. Open gear wheels and steel wire ropes

The lubricants and protective compounds recommended by the

manufacturer of the equipment or component must absolutely always
be used.

These greases are often quite stiff bitumen based greases which contain as
blend components e.g. molybdenum sulphide and graphite.
Good anti-corrosion protection properties are required from these lubricants.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 4 (4)

GENERAL INSTRUCTION ROX 11-01-81

Lubrication protective grease types for open gear wheels and steel wire
ropes

MANUFACTURER Open gear wheels Steel wire ropes

ESSO Dynagear Extra Grease WR
NESTE Avorasva Avorasva
MOBIL Mobiltac 81 Mobilarma 798
SHELL Kuggfett Ensis Fluid K
TEBOIL Gear Grease MDS Gear Grease MDS

Group 4. Hydraulic systems

The lubricants and protective compounds recommended by the

manufacturer of the hydraulic system or component must absolutely
always be used.

To the choosing of the oil viscosity influence the type of the pump and
actuator, quality of use and ambient temperature.

The viscosity classes of hydraulic oils vary in the range ISO VG 5 -150.

In hydraulic systems the classes VG 32, 46 or 68 are normally used

depending on the type of the pump as well as the ambient and operating
temperature.

The viscosity of the oil of fluid couplings is normally VG 32.

In electrohydraulic pushers more flexible oil e.g. VG 10 is used, sometimes

also transformer oil can be used, see manufacturer’s instructions.

Hydraulic oils:

Manufacturer Hydraulic systems Hydraulic pushers Fluid couplings

ESSO Nuto H, Univis HP Spinesso 10 Torque fluid 30

NESTE Neste Paine Neste Paine
MOBIL DTE, SHC D.T.E 21 tai Velocite6 Mobilfluid 125
SHELL Tellus Oil T, TX Tellus oel C10 Tegula Oil
TEBOIL Hydraulic oil Fluid TH 10254

Many manufacturers have several oil types for special circumstances and e.g.
lightly in the nature decomposable oil types, so called BIO-oils.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (2)

GENERAL INSTRUCTION ROX 11-01-83

CLEANING

1. General

The material handling systems and equipment have to be cleaned regularly.

In addition, the covering constructions and structures, as well as the

walkways of the conveyors have to be cleaned from material and dust
regularly.

For the fire safety reasons, the cleaning of the equipment and their
surrounding areas is extremely important, especially if material or its dust is
flammable/explosive fuel, such as e.g. peat.

2. Cleaning intervals

It is very difficult to define any exact general cleaning intervals. The cleaning
intervals depend on the material to be handled, the dust-proof of the
equipment and the operation of the dust removal and ventilation systems.

The cleaning intervals have to be planned separately for each place on the
basis of the experience in the same kind of places. The intervals have to be
selected so that the dust in equipment and the surrounding area does not
harm the operation of the equipment. General safety must not be endangered
(N.B. fire safety).

Maintenance personnel has to prepare cleaning instructions with time tables

which have to be followed.

In some very difficult places or with very dusty materials, cleaning is needed
daily.
On the other hand, in not so dusty places and with non-flammable materials a
general cleaning once a year can be enough.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (2)

GENERAL INSTRUCTION ROX 11-01-83

3. Safety

The cleaning of the equipment and the surrounding area has to be done when
the equipment is not operating.
By being extra carefull some cleaning work, such as floor cleaning, can be
done also when the equipment is operating. In that case the entire cleaning
personnel has to know the possible elements of danger connected with the
equipment.
The risks for using compressed air or strong water jet have to be known.

If covers have to be removed or if it is necessary to go outside the

normal service area near the moving parts or on the equipment during
the cleaning, the equipment has to be absolutely stopped and it has to
be made sure that the equipment will not start accidentally.
Before the restart, the covers have to be reinstalled.

4. Cleaning methods

The cleaning method depends on the place, material to be handled and the
available cleaning systems and equipment.

Traditional sweeping with a brush and shoveling (if needed) is in most cases
a sufficient cleaning method.
If vacuum cleaner system is available, cleaning will be, of course,
considerably better and faster.

Compressed air might be in some cases good, but cleaning with only
compressed air is usually not a sufficient cleaning method, because then dust
and dirt only move from one place to an other.

Generally material handling systems supplied by Sandvik Hollola are planned

so that they can be cleaned also with low-pressure water jet.

Before using a washer jet it has to be made sure that it is allowed to clean the
equipment with water jet, and that the accumulation of washer waste has
been arranged in a proper way.

Water jet can never be pointed to non-hardy parts of the equipment, such as
electric appliances or bearings or to their sealings.

When using water in cold circumstances, the possible problems caused by

freezing have to be taken into account.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (2)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-05

COMMISSIONING

1. Commissioning inspections

The commissioning shall be begun with a commissioning inspection before

starting the belt conveyor for the first time.

In the inspection can be used commissioning forms made by Sandvik Hollola

especially for this purpose. There is a separate form for mechanical
inspection and one for electrical and automation inspection.

The inspection shall be carried out by a person who knows well the
equipment to be inspected, commissioner and/or installation supervisor.

The commissioning forms are used as a check list and instructions for the
inspection, and they will be documents concerning the inspections and
regulations carried out.

2. First start

It is very important to carry out the first start of the belt conveyor with
caution and control, because there is a big risk of various damages.

Before the first start the commissioning inspections have to be carried out to
the extent that it is possible without running the motor.

Special attention must be paid to the following:

- the belt has to be empty and it must be able to move freely

- the electrical and control system has been tested, especially the start
warning and emergency stop systems
- all mechanical guards are in place and other factors having an influence on
the personal safety are in order
- the direction of rotation of the drive motor is correct, this must be assured,
e.g. without oil in the fluid coupling or without V-belts (if the drive motor
rotates in the wrong direction, the return brake of the reducer may be
damaged)

Immediately after the first short start, make sure that the belt remains
sufficiently centered.
The belt is centered in accordance with the instruction ROX 11-02-20, par. 2.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-05

3. Trial run without material

The belt conveyor has to be run without material during several hours,
sometimes even during several days, before the run with material can be
started.

When the conveyor is run without material, check the function of all electrical
safety devices and lockings.

Check that the sound, tightness and temperature of the reducer are normal.

Make sure that all parts of the conveyor function normally.

4. Trial run with material

The trial run with material is started with a small quantity of material,
observing the function of the hoppers and the centering of the belt.

If the material is not guided to the center of the belt, adjust and repair the
hopper accordingly.

Increase the quantity of the material to be fed onto the conveyor until the
normal/maximum capacity is achieved, carry out the necessary adjustments
to the feed hopper and the belt.

Observe the temperatures of the reducer and bearings.

Perform a start test with a full loaded belt.

Measure the effect/current taken by the drive motor.

Observe the dust-tightness and function of the belt cleaners.

Commissioning performed carefully and with proficiency contributes to

troublefree and safe productional service.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (4)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-20

CONVEYOR- AND FEEDER BELT

1 Construction

The conveyor belts are rubber belts with various fabric reinforcements. Belts
are used as conveyor belts in belt conveyors and feeders.
Belts are available in several structures, different rubber qualitites, layers of
reinforcement, and in different sizes and strengths.

The conveyor belt is always chosen individually for each case to resist the
forces and conditions in questions.

The type of your conveyor belt can be seen in the main assembly drawing or
technical specification.

1.1 Type marking of a conveyor belt: (example)

TRELLEX ANTIFLAME 800 EP 400/3 - 3/1 S 55,5

TRELLEX ANTIFLAME = manufacturer of belt (mark)

800 = width of belt (mm)
EP = reinforcement
400 = tensile strength at break (N/mm)
3 = number of reinforcements (pcs)
3/1 = thickness of upper/lower layer (mm)
S = properties of belt
55,5 = length of belt (m)

More information, see documents of the belt manufacturer.

2 Adjustment

The adjustment of the conveyor belt means here the centering of the belt, so
that the belt runs enough in the middle of the drums and roller systems.
The misalignment of the belt can be caused by several factors, see
troubleshooting instructions for belt conveyors ROX 11-02-40, par. 4 and 5.

2.1 When the conveyor is started for the first time after the installation or after
bigger repair and modification work, the belt can slip to one side despite of
the fact that the pulleys and the rollers have been aligned well and the belt
jointing has been carried out duly. This is often caused by the interaction of
the inaccuracies in the alignment and the rigidity of the new belt and the
tensions prevailing in it.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (4)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-20

In this case the belt has to be centered by turning the rollers as instructed
further.
The pulleys must not be turned off from the right line. The drive pulley must
never be left inclined with respect to the center line of the conveyor.
Sometimes it may be necessary to turn the tail and take-up pulleys a little,
especially in conveyors running in two directions.

2.2 The belt is always centered first with an empty belt, i.e. without material.
The centering is started from the lower belt, from the drive end towards the
other end, and from the point where the misalignment of the belt begins.

Principle of lateral control of the belt by turning the rollers:

This principle applies both upper and lower rollers, but in conveyors rotating
in two directions, generally this cannot be used.
The roller system can be turned in the desired direction either from both ends
or only from one end.

To begin, turn the first roller system only by a few millimeters and wait for
some belt turns.

If the desired effect is not sufficient, turn the next roller system in the belt
running direction in the same way, and if necessary, continue by roller system
after another, along the whole length where the belt goes to the side.

If the belt cannot be centered, start the adjustment from the beginning, i.e.
from the point where the misalignment of the belt begins.

Continue in this way, until the lower belt runs in the middle.
Do not adjust too much. Check that the belt does not go too much in the
desired direction at any point of the conveyor.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-20

2.3 On the take-up and tail pulleys the belt is centered by turning the preceding
rollers according to the principle described above.
If the return rollers cannot be turned, e.g. because of the belt running in two
directions, the adjustment can be made by turning the pulley.
On the pulleys the belt moves in the direction where the tightness of the belt
slackens when turning the pulley.

2.4 If the pulleys and rollers have originally been installed and aligned carelessly
and the belt is not centered systematically, the rollers will be before long in
disorder and out of the line so that it is inpossible to achieve a good result,
and it may take days, even weeks, before the belt will remain properly
centered. That is why, the centering of the belt must be carried out with
caution and patience.

2.5 If the belt goes immediately after the start so much to the side that it is
impossible to leave it to rotate and begin to adjust in the way described
above, the rollers located before the pulleys must be adjusted temporarily so
much that the belt can be rotated.

2.6 When the belt has been centered on the lower rollers and pulleys, the upper
belt has to be centered with the same principle. The final centering of the
upper belt takes place only when the conveyor is running with material. Then
the friction between the rollers and the belt is bigger, and the new belt adopts
finally to the form of the roller trough.

2.7 If the misalignment of the belt is caused by an oblique joint, it is impossible to

correct it by turning the rollers.
Generally the belt straightens and stretches a little during the trial run, but if
the hindrance caused by the oblique joint after this is still too big, the joint has
to be repaired.
The oblique joint can be easity noted by observing the edge of the belt when
the belt is running, e.g. at a certain roller. If the joint is oblique, the belt always
moves to the side a little before the joint or at the joint and returns back
always after the joint.
It has to be noted that the edge and joint of the belt are never absolutely
straight, and therefore the belt edge always "rows" a little.

2.8 If the belt goes to the side when being run with material because material is
loaded on one side of the belt, this cannot normally be corrected by turning
the rollers, but it is necessary to make the necessary adjustments and
corrections to the feed hopper so that the material is guided to the middle of
the belt.

2.9 If the factors related to the construction of the conveyor or other

circumstances cause repeatedly misalignment of the belt, as well as failures,
the conveyor can be equipped with forced-guidance rollers or guide roller
systems.
If you have problems with the centering, please do not hesitate to contact
Sandvik Hollola.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-20

3 Maintenance

To assure a long service life of the conveyor, it is important to observe the

condition of the belt during the operation and in periodic inspections. Even
small superficial damages have to be repaired, because even a small damage
or rupture can become a big damage which cannot be repaired easily.

If during maintenance you have to detach some guards or go outside

the normal maintenance zone near the rotating parts, it is absolutely
necessary to stop the equipment and to prevent an accidental start.
Before restarting the equipment, the guards have to be put in place.

It has to be seen to that, e.g. jammed rollers or too tight board rubber pieces
do not damage the belt.

In inspections pay attention also to that the belt runs in the middle and that
the strain is correct. Read through the maintenance instructions of the belt
manufacturer and observe them.

In periodic inspections check ocularly the belt joint and the belt; tracks on the
surface or edges of the belt can indicate that the belt chafes against some
fixed part.

The periodic inspections and maintenances are to be performed at intervals

determined by the maintenance schedule. See instruction: Maintenance
schedule.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (2)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-22

SCREW TAKE-UP DEVICE

1. Construction and principle of operation

The main parts of the screw take-up device of the belt conveyor are:

- take-up pulley with bearings

- pulley cleaner/gap guard
- slideways or grooves
- tensioning screws with counternuts and locking nuts
- protective nets

The bearing housings have been fastened to the tensioning screws. When
these are tightened, the bearing housings move along the guideways located
on the frame structures of the conveyor. So by moving the take-up pulley
backwards, the necessary initial tightness is obtained for the conveyor belt in
order to produce a sufficient friction between the drive pulley and the belt.

The structure of the screw take-up device and the types of the components
used in your conveyor can be seen in the drawings and parts lists.

2. Adjustment

In conveyors tensioned by screw, the take-up pulley is normally also the tail
pulley of the conveyor.
In order that the belt would run in the middle, it is important that the pulley is
perpendicularly to the center line of the conveyor.
When the tightness of the belt is changed, it is necessary to move both ends
of the pulley equally.
The fastening screws of the bearing housing have to be loosened for the
adjustment.

Do not start the adjustment or inspection or remove any guards before

you have stopped the conveyor and prevented an accidental start with
the safety switch. Put the guards in place before the restart.

Adjustment of the belt laterally on the pulley, see instruction: adjustment of a

conveyor belt ROX 11-02-20, par. 2.3
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-22

2.1 Tightness of the belt

The tightness of the conveyor belt has been adjusted to the right value during
the installation and commissioning, but due to the stretch of the belt it is
necessary to check the tightness regularly and the belt has to be tensioned if
necessary.

The right tightness of the belt is checked normally by the sag of the lower belt.
The sag must be 0.8 - 1.5% of the span, when the belt is not running, t.e. if
the distance between the return rollers is 3 m, the sag of the belt between
them must be 25 - 45 mm.

Do not tension the belt too much, because this could damage the belt or the
pulley and its bearings.

A too slack belt causes slipping of the drive pulley and other failures.

If there is no more margin for tensioning, it is necessary to shorten or renew

the belt.

If the belt will be out of use during a longer period, it is advisable to slacken
the belt for this period to achieve a longer service life of the belt.

3. Maintenance

In addition to the tensioning of the belt, perform the following measures in

periodic inspections and maintenance:
- check that the tightening screws and guides are clean and in working order,
lubricate or replace them, if necessary
- clean and inspect the pulley cleaner
- check that all guards are in place and properly fixed
- inspection and maintenance of the take-up pulley, see instruction:
conveyor pulleys ROX 11-02-24

The periodic inspections and maintenance are to be performed at intervals

determined in the maintenance schedule. See instruction: Maintenance
schedule.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-24

CONVEYOR PULLEYS

1. Construction and use

Conveyor pulleys are available in different sizes and structures, such as drive
pulleys, take-up pulleys and tail pulleys.
Similar pulleys are used also, e.g. in belt feeders.

Drive pulleys and in difficult conditions also other pulleys may have a rubber-
coated shell. The pulleys are often cambered, i.e. the diameter in the middle
of the pulley is a little bigger than at the ends.

The bearings of the pulleys are equipped with dust seals suitable for this
purpose.

The types of the pulleys and their bearings used in your conveyor can be
seen in the drawings and parts lists.

2. Adjustment

In conveyors with screw tensioning, the take-up pulley serves normally also
as the tail pulley of the conveyor.
In order that the belt would run in the middle, it is important that the pulley is
perpendicularly to the center line of the conveyor.
When the tightness of the belt is changed, it is necessary to move both ends
of the pulley equally.
The fastening screws of the bearing housings have to be loosened for the
adjustment.

Do not start the adjustment or inspection or remove any guards before

you have stopped the conveyor and prevented an accidental start with
the safety switch. Put the guards in place before the restart.

Adjustment of the belt laterally on the pulley, see instruction ROX 11-02-20
par. 2.3.

The main principle is, however, that the belt is not normally adjusted by
turning the pulleys but the pulleys have always to be perpendicularly to the
center line of the conveyor.
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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-24

3. Maintenance

Measures to be carried out in periodic inspections and maintenance:

- check that the surface of the pulley shell is clean and undamaged, clean it if
necessary, make repaired the worn rubber coating
- check the bolt and welded joints of the pulley
- check that the screws of the bearing housings are tight and that the dust
seals of the bearings are undamaged
- check that the bearings do not warm and that they rotate without noise
- the bearings have to be lubricated according to the instructions for the
bearing housing
- check that all guards are in place and properly fixed.

Periodic inspections and maintenance are to be performed at intervals

determined in the maintenance schedule. See instruction: Maintenance
schedule.

4. Lubrication of bearing housings

Follow the separate lubrication instruction for conveyor pulleys, where the
relubrication quantities and lubrication intervals have been determined.
The lubrication quantity and lubrication interval depend on the operating
conditions, bearing size and bearing type as well as lubrication method.

Lubricants, see instruction: LUBRICANTS ROX 11-01-81.

If it is necessary to detach some guards or to go outside the normal

maintenance zone near moving parts, it is absolutely necessary to stop
the equipment and to prevent an accidental start. Before the restart, the
guards have to be put in place.

When the bearing housings are lubricated, see to that the lubricant coming
out from the bearing housings is cleaned and prevent it from coming onto the
conveyor belt.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-25

BELT CLEANERS

1. Construction and use

Belt cleaners are used in conveyors usually on the "dirty" side of the belt at
the drive pulley or immediately after it so that the material coming off from the
belt falls into the discharge hopper.
Cleaners of the lower belt are used to remove the material which has possibly
collected onto the return belt. These are normally placed on the lower belt just
before the tail pulley.

Belt cleaners which are used at the discharge end of the conveyor are
available as scrapers of various types where the "knife" wiping the belt is
pressed against the belt by different spring solutions.

At some difficult points it is possible to use also motor driven belt brushes.

The cleaners of the return belt are usually ploughs and diagonal wipers which
press the lower belt by the force of their own weight.

The belt cleaning parts of the scrapers and ploughs are made of different
materials, and they are always chosen individually for each case. They are
replaceable wearing parts.

The location and type of the belt cleaners used in your conveyor can be seen
in the drawings of the conveyor, and the construction of the cleaner is
described in more detail in the product brochures or similar of the cleaner.

2. Regulation

More detailed regulating instructions for the belt cleaner are in the brochures
and instructions for the belt cleaner.

For the functioning and service life of the cleaners it is very important that the
position of the scraper knife or similar is correct with respect to the belt/
pulley.

As a general principle it can be noted that the cleaners are to be adjusted so

that the knife presses the belt evenly along the whole width, and it is
advisable to keep the pressing force just as big as it is necessary to obtain an
adequate cleaning result.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (2)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-25

3. Maintenance

Do not start the maintenance or inspection or remove any guards

before you have stopped the conveyor and prevented an accidental start
with the safety switch. Put the guards in place before the restart.

The function of the belt cleaners has to be observed daily during the normal
operation of the conveyor.

See maintenance instructions for each type.

During periodic inspections and maintenance, perform the following measures

and checks:

- clean the device

- check the wear of the knives, adjust or replace if necessary
- check the pressing force
- check the fixture of the device

The periodic inspections and maintenance are to be performed at intervals

determined in the maintenance schedule. See instruction: Maintenance
schedule.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (2)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-26

CONVEYOR- AND FEEDER ROLLER SYSTEMS

1. Construction and use

The conveyor roller system consists of roller supports, or roller fixing lugs, and
rollers.

Roller supports and fixing lugs are available in different sizes and types.

Conveyor rollers are available in many different sizes and structures, such as
supporting rollers, return rollers and guide rollers.

Rollers of the same type are used also, e.g. in belt feeders.

The return rollers and, e.g. the rollers at the conveyor loading point are often
equipped with rubber discs.

In addition, various special roller systems, such as guiding roller supports, are
integrated with roller systems.

The bearings of the rollers are equipped with dust seals suitable for this
purpose.

The structure of the rollers and their seals is presented in more detail in the
product brochures and catalogues of the roller manufacturer.

The types of the rollers used in your conveyor can be seen in the drawings
and parts lists.

2. Adjustment

In order that the conveyor would function flawlessly and the belt would remain
well centered, it is important that the roller systems are symmetrically
perpendicularly to the center line of the conveyor.

Adjustment of the belt laterally on the roller systems, see instruction:

adjustment of a conveyor belt ROX 11-02-20, par. 2.

Do not start the adjustment or inspection or remove any guards before

you have stopped the conveyor and prevented an accidental start with
the safety switch. Put the guards in place before the restart.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (2)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-26

3. Maintenance

The conveyor rollers are normally lubricated for life, so the bearings do not
require lubrication.

If your conveyor has rollers to be lubricated, i.e. they are equipped with
nipples, read through the roller manufacturer's lubricating instruction.

Regular periodic inspections and maintenance are very important for the
service life of the rollers and belt.

Measures to be performed during periodic inspections and maintenance:

- check that the roller supports are fixed properly, and that they have not bent
or moved
- clean the roller supports and rollers from material collected onto them, if it
may prevent the rollers from rotating or if the belt does not remain in the
centered position
- check that the rollers rotate easily and without noise
- check that the roller shell is undamaged, the defective and dangerously
worn rollers are to be replaced on time
- check the condition of the rubber discs of rollers equipped with discs; the
rollers whose rubber discs have moved or worn so that they are no more
round, have to be repaired or replaced

The periodic inspections and maintenance are to be performed at intervals

determined in the maintenance schedule. See chapter: Maintenance
schedule.

The conveyor rollers and their rotation must be observed also when the
conveyor is running. The rollers which do not rotate must be replaced as soon
as possible.

Sometimes, especially with an unloaded conveyor it may occur that there are
rollers which do not rotate owing to too light contact of the belt with the roller.
In very wearing conditions this may wear the belt and roller shell; it must be
assured that also these rollers rotate with a loaded belt.

To touch the rollers when the conveyor is running is highly dangerous

(even mortal) and absolutely forbidden. Stop the conveyor before
inspecting, replacing and cleaning the roller systems. Prevent an
accidental start with the safety switch.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (1)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-28

GUIDING BOARDS

1. Construction and use

The guiding boards are normally side plates of steel structure placed on the
side of the conveyor belt, e.g. at the loading point of the conveyor and after it.
They guide the material to the middle of the belt and serve as splash and dust
seals. The back board at the conveyor loading point belongs also to the
guiding boards.

Guiding boards comprise also sealing structures and wearing plates of

various types, as well as fixing parts and protective nets.

The structure and type of the guiding boards used in your conveyor can be
seen in the drawings and parts lists.

2. Maintenance

The condition of the rubber seals of the guiding boards is very important for
the dust-tightness of the plant. Therefore it is necessary to observe the
condition (dust-tightness) of the rubber seals of the guiding boards also
during the operation of the equipment.

Do not start the maintenance or inspection or remove any guards

before you have stopped the conveyor and prevented an accidental
start with the safety switch. Put the guards in place before the restart.

During the periodic inspections and maintenance check that the boards are
fixed properly, and that the rubber seals are duly tight.
If the seals are too loose, material and dust will leak; if they are too tight, the
belt will be damaged.
In most board rubber and seal structures it is possible to adjust the seals
closer to the belt, if they are worn. If the rubber has worn so low that it will not
touch the belt so that the fixture would be reliable, the rubber has to be
changed.
Check that the possible wearing plates of the guiding boards are in order,
renew the worn ones.

Check that the protective nets are in place and well fixed.

The periodic inspections and maintenance are to be performed at intevals

determined in the maintenance schedule. See instruction: Maintenance
schedule.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (3)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-31

MAINTENANCE SCHEDULE BELT/CHAIN - CONVEYOR/FEEDER

DIFFICULT CONDITIONS ( B )

1. Periodic inspections and maintenance

In addition to periodic inspections and maintenance the plant operating

personnel must daily check that all protective and safety devices of the
equipment are in place and in working order.

The cleaning of the devices and the surrounding areas has to be performed
so often that the material collecting onto the devices and in the surrounding
area does not hinder the functioning of the equipment or endanger the
general safety.

MAINTENANCE NO. OF INSTRUCTION MAINTENANCE

OBJECT INTERVAL

Hoppers ROX 11-01-54 1-2 months (abt.500h )

Conveyor belt ROX 11-02-20 1-2 months (abt.500h )
Belt cleaning devices ROX 11-02-25 1-2 months (abt.500h )
Roller systems ROX 11-02-26 1-2 months (abt.500h )
Distribution gate ROX 11-02-27 1-2 months (abt.500h )
Belt scale ROX 11-02-29 1-2 months (abt.500h )

Electric motor ROX 11-01-50 3 months (abt.1000h )

Blockage detector
Drive mechanism
Screw take-up device
Counterw.t-up device
Pulleys
Guiding boards
Transfer mechanism
ROX 11-01-63 3 months (abt.1000h )
ROX 11-02-21 3 months (abt.1000h )
ROX 11-02-22 3 months (abt.1000h )
ROX 11-02-23 3 months (abt.1000h )
ROX 11-02-24 3 months (abt.1000h )
ROX 11-02-28 3 months (abt.1000h )
ROX 11-02-50 3 months (abt.1000h )

Gear ROX 11-01-51 6 months (abt.2000h )

V-belt drive ROX 11-01-52 6 months (abt.2000h )
Pull cord em. switch ROX 11-01-60 6 months (abt.2000h )
Misalignment switch ROX 11-01-62 6 months (abt.2000h )

Rotation detector ROX 11-01-64 12 months (abt.4000h )

Start warning device ROX 11-01-65 12 months (abt.4000h )
Fluid coupling ROX 11-01-53 12months (abt.4000h )
Safety switch ROX 11-01-61 12months (abt.4000h )
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (3)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-31

If a device or component of the equipment has separate maintenance and

inspection instructions given by the manufacturer, observe primarily the
maintenance schedules and oil change intervals given therein.

The maintenance intervals given in the maintenance schedule are maximum

guide values. If the experience from the operation and maintenace of some
objects, however, show it necessary, the maintenance and inspection
intervals have to be shortened.

In some objects it is also possible to lengthen the intervals, e.g. for cleaning, if
the experience has shown that it is not necessary to clean so often.

The measures to be performed in periodic inspections and maintenance are

described in the instructions of the device or component in question, see
number of the instruction in the table.

The performed maintenance measures and reparations have to be marked in

the maintenance register of the equipment.

The guarantee provides that the inspections and maintenances are

performed.

Before starting the maintenance, inspection or cleaning of the

equipment, it has always to be stopped and the safety switch has to be
turned to the position "0" and locked. The key has to be kept by the
person who is carrying out this work or by the person in charge.

2. Safety inspections of belt conveyors

A safety inspection of the belt conveyor has to be performed at least once a

year.
The person who carries out the inspection has to know well enough the
construction, safety devices and dangerous objects of the conveyors.
The safety inspections can be also performed at the same time as the
periodic inspections and maintenance, but it is necessary to mark the register
and draw up a separate record.
Enclosed a model of a safety inspection record for a belt conveyor:
 BELTCONVEYOR SAFETY INSPECTION PROTOCOL

COMPANY: NAME OF CONVEYOR:

PLANT: CONVEYOR NUMBER:

SAFETY AND CONTROL EQUIPMENT O.K. TO BE REPAIRED/REMARKS

emergency stop
safety switch
start warning
control push-buttons etc.
indicator ligths

To be inspected: function, condition, signs etc. (see maintenance manual).

SHIELDING OF DANGEROUS PLACES O.K. TO BE REPAIRED/REMARKS

drive end, drive mechanism

tail end
counterweight take-up device
carrying rollers
return rollers
transferable equipment
inspection doors

To be inspected: safety guards, cap guards, safety rails etc. (see maintenance manual).

WALKWAYS, AMBIENT CONDITIONS O.K. TO BE REPAIRED/REMARKS

service bridges, maintenance walkways

stairs, ladders
lightning
noise, dust
signs, maintenance manuals

To be inspected: condition, tidiness, signs (see maintenance manual).

Safety inspection shall be carried out at least once a year. The person carrying out this inspection must have
adequate knowledge of conveyors: structure, safety equipment and dangerous places.

Inspector: Date:
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

TROUBLESHOOTING INSTRUCTION FOR BELT CONVEYORS/FEEDERS

0. General

In this instruction are listed failures and problems which may occur in belt
conveyors or belt feeders (number 1 - 9).
After every title under subnumbers are listed possible failures or causes
which may cause this problem, whereafter is a brief description of measures
to be taken in this situation.

1. THE CONVEYOR/FEEDERS DOES NOT START OR IT STOPS

The motor does not run

1.1 One of the protective or safety devices of the conveyor/feeder or drive motor
has been activated.
- Check and repair, reset the failure.

1.2 Electrical failure.

- Check and repair.

2. THE MOTOR DOES NOT START OR IT STOPS

The motor "jurrs" and the conveyor does not start

2.1 Electric failure (electric network, motor protecting and starting devices, cable,
motor)
- Check and repair.

2.2 The conveyor is heavily overloaded.

- Check and remove the overload from the belt.

2.3 The belt or drum is jammed.

- E.g. material or foreign matter between the belt and the board.
The tail pulley or rollers are jammed.
- Check, clean and repair.

2.4 Drives, gear or brake are jammed.

- Check that the separate brake opens properly.
- Check and repair.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

3. THE MOTOR RUNS, BUT THE DRIVE PULLEY DOES NOT ROTATE
The transmission slips

3.1 V-belts slip.

- Check and repair, see instruction: V-belt transmission ROX 11-01-52.
- Check that the conveyor is not overloaded.

3.2 The fluid coupling slips.

- Check and repair, see instruction: Fluid coupling ROX 11-01-53.
- Check that the conveyor is not overloaded.

3.3 The pin coupling, or similar, between the motor and reducer is defective.
- Check and repair.

3.4 The joint or coupling between the reducer and drive pulley is defective.
- Check and repair.

3.5 The reducer is defective.

- Check and repair, see instruction: Reducer ROX 11-01-51.

4. THE DRIVE PULLEY ROTATES, BUT THE BELT DOES NOT MOVE
The pulley slips, the friction between the pulley and the belt is not
sufficient.

4.1 The belt is not tight enough.

- Check and tighten, see instruction: Screw take-up device ROX 11-02-22 or
instruction: Counterweight take-up device ROX 11-02-23.
- Check that the conveyor is not overloaded.

4.2 Between the belt and pulley is material, e.g. snow and ice.
- Check and clean.
- Prevent the access of material and snow between the belt and pulley,
improve the cleaning and cleanliness of the equipment.
- Improve the function and maintenance of the belt cleaners.
- Use anti-freeze agents.

4.3 The rubber coating of the drive pulley is worn out.

- Check, renew the coating or replace the whole drive pulley.

4.4 The conveyor belt has jammed somewhere, e.g. material or foreign matter
has jammed between the belt and board. The tail pulley or rollers have
jammed.
- Check, clean and repair.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 3 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

5. BELT RUNS ON ONE SIDE ALWAYS AT THE SAME POINT OF THE BELT

5.1 The belt joint is oblique.

- Check, see instruction: Conveyor belt Rox 11-02-20 par. 2.8.
- Make a new joint, if necessary.

5.2 The belt has a curve, this can occur normally only with new belts.
- Check, see instruction: Conveyor belt Rox 11-02-20 par. 2.8.
- Check the storing and transport of the belt.
- Change the belt if necessary.

6. THE BELT RUNS ON ONE SIDE AT THE SAME POINT OF THE

CONVEYOR
either within some part or along the whole length of the conveyor

6.1 The pulleys are not horizontal or they are not in the middle and perpendicular
to the center line of the conveyor.
- Check and correct, see instruction: Conveyor belt Rox11-02-20 par.2.

6.2 The roller systems and rollers are not in the middle and perpendicular to the
center line of the conveyor.
- Check and correct, see instruction: Conveyor belt Rox 11-02-20 p2.

6.3 The material is not loaded to the middle of the belt. If the material is on one
side of the belt, the belt tends to move towards the emptier side on the trough
rollers. If the material moves strongly laterally at the feed point, also this tends
to move the belt to one side.
- Check, adjust or correct the feeding hopper.

6.4 Trough roller systems have been mounted in the wrong way.
- Check if the supporting rollers of the conveyor have "ploughing" roller
supports; these must be mounted so that the outermost rollers have been
turned a little towards the belt running direction.

6.5 The belt is exposed to the influence of the wind.

- Check the tightness of the belt.
- Arrange wind protections, if necessary; if it is a conveyor bridge
construction, contact Sandvik Hollola in order to determine the wind loads.

6.6 The belt chafes against some fixed part or jammed rollers.
- Check and repair.
- Improve the cleaning and maintenance.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 4 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

6.7 A separate roller system moving on the conveyor, such as hopper or

discharge carriage, guides the belt to one side.
- Check the roller systems of the moving device.
- Check the spacings of the rails of the moving device and bearing wheels.

6.8 The conveyor/feeder frame is at a slant or bent.

- Check and repair.
- In case of mobile conveyors, the frame may change the form due to too big
inaccuracies in the rails, repair the rails.

6.9 Material or snow and ice collect onto the inner surface of the belt, pulleys or
rollers.
- Check and clean.
- Prevent the access of material and snow onto the lower belt, improve the
cleaning and cleanliness of the equipment.
- Improve the functioning and maintenance of the belt cleaners.
- Use anti-freeze agents.

7. THE BELT WEARS EXCEPTIONALLY MUCH OR IT GETS CRACKS,

RUPTURES OR OTHER UNNORMAL TRACKS

7.1 The belt chafes against the conveyor/feeder frame or some other fixed part,
e.g. jammed rollers, guiding boards or material jammed between them.

- Check and repair, see par. 6.

- Check and service the belt cleaners.

7.2 The material to be transported hits on the belt unevenly, at an unappropriate

angle or too strongly.
- Adjust or repair the feeding hopper.

7.3 The material tends to jam in hoppers and it is compressed at times between
the belt and hopper structures.
- Check and repair the hoppers enough wide.
- Check that the capacity is not too high.
- Check that the piece size of the material is not too big.

7.4 Material enters between the belt and pulley.

- Prevent the access of material between the pulley, seal the material leaks.
- Check and service the return belt cleaners.
- Check and adjust the pulley gap guards/cleaners.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 5 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

7.5 Oil or chemicals on the belt.

- Check and repair.
- See to that the grease coming out during lubrication does not get onto the
belt.

7.6 Thermal or fire damage.

- See to that, e.g. the welding and flame cutting splashes during repair work
do not get onto the belt.

8. THE BELT STRETCHES TOO MUCH

8.1 The belt is too tight.

- Check and adjust, see instruction: Screw take-up device ROX 11-02-22 or
instruction: Counterweight take-up device ROX 11-02-23.

8.2 The belt forces are too big.

- Check that the conveyor is not overloaded.

9. THE BELT BREAKS, THE BELT JOINT BREAKS

9.1 The belt joint has been made in the wrong way.
- Make a new joint according to the instructions.

9.2 The belt forces are too big.

- See 8.1 and 8.2.

9.3 Material enters between the belt and pulley.

- See 7.4
 MAINTENANCE AND OPERATION INSTRUCTIONS

3.5.2004 JPa 1 (1)

SPECIAL INSTRUCTION, BELT CONVEYOR

JOINT/TRANSFER MECHANISM

1. Construction and principle of operation

Mobile belt conveyors have special functions like telescope part and tail end
with adjustment of height.

These features are needed because of transportation and service.

Transfer/lifting mechanisms are available in various constructions and

principles. In transfer/lifting mechanisms normally hydraulic units and
cylinders are used.

The construction and components of the transfer mechanism of your

conveyor can be seen in the drawings and parts lists of the equipment.

2. Maintenance

Transfer/lifting mechanisms are always dangerous places!

See also ROX 11-01-07

Do not start the maintenance or inspection or remove any guards before

you have stopped the conveyor and transfer mechanism and prevented
an accidental start with the safety switch.
Put the guards in place before the restart.

The periodic inspections and maintenance are to be performed at intervals

determined in the maintenance schedule. See instruction: Maintenance
schedule.

See also Sandvik Rock Processing (SRP) instructions.

3. Operation of joint/transfer mechanism

See SRP instructions.

 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007 1 (1)

Maintenance Log

It is Owner’s obligation to maintain among other things the Maintenance Log, for
other obligations see ROX 11-01-01.

On the Maintenance Log inspections, service actions and other actions must be recorded
as an implementation of Sandvik Hollola instructions valid for the belt conveyor.

When required records must be available for Sandvik Hollola.

Enclosed sheet is an example sheet for the Maintenance Log.

All Damage Reports, if any, must be stored up in the Maintenance Log.

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Maintenance log

rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
MAINTENANCE LOG page ___
Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181
Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
Finland

Belt Conveyor
RRH1212, RRH1213U, RRH1214U, RRH1209
Manufacturing number: 12…. / 200…. / W…… / ….

Author:______________________________ Date: :______________________________

Describing
of
maintenance
work

Reference to
instruction
Rox 11-02- __
Rox 11-02- __
Rox 11-02- __

Author:______________________________ Date: :______________________________

Describing
of
maintenance
work

Reference to
instruction
Rox 11-02- __
Rox 11-02- __
Rox 11-02- __

Author:______________________________ Date: :______________________________

Describing
of
maintenance
work

Reference to
instruction
Rox 11-02- __
Rox 11-02- __
Rox 11-02- __

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Maintenance and feedback form rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
FEEDBACK FORM
Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181
Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
Finland

Manufacturing number: 12…. / 200…. / W…… / ….

1. COMPONENTS, SPARE and WEAR PARTS

S Your proposals for the development?

S What improvements are most urgent ones?

2. FRAME and TARPAULIN

S Your proposals for the development ?

S What improvements are most urgent ones?

3. OPERATION & MAINTENANCE

S Proposals for the better operation and availability?

4. OTHER S

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Maintenance and feedback form rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007 1 (1)

Description of Damage

If damage takes place it must be described and drawn on paper. Filled Damage Report
must be also sent to Sandvik Mining and Construction Hollola Oy, who on this way has
detailed information from the Damage.

In case of guarantee the Damage Report is precondition for the reclamation handling.
Manufacturing number to be filled on the report is written on Type Plate locating on the
frame part of drive end.

Damage describer must be properly trained and authorised person, who can describe the
Damage in details. The Report shall include also photos.

There is enclosed an example from the Damage Report Form.

All Reports must be stored up in the maintenance log of Operator.

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Description of damage rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
DAMAGE DESCRIPTION FORM appendix
Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181
Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
Finland

RRH1212, RRH1213U, RRH1214U, RRH1209 Belt Conveyor

Manufacturing number: 12…. / 200….. / W…… / ……

Author:______________________________/date :______________________________

Damage
description

Enclosere

Author:______________________________/date :______________________________

Damage
description

Enclosere

Author:______________________________/date :______________________________

Damage
description

Enclosere

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Damage description form rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007

3 ELECTRICAL DOCUMENTATION

ELECTRIFICATION AND CONTROL SYSTEM

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14 Interleafs rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 MAINTENANCE AND OPERATION INSTRUCTIONS

13.04.2006/JPa 1 (1)
SPECIAL INSTRUCTION, BELT CONVEYOR

ELECTRIFICATION AND CONTROL SYSTEM

1. Scope of Sandvik Hollola

The drive unit of Mobile belt conveyors is normally hydraulic motor, gearbox
with electric motor or drum motor and included to the scope.

Design of electrification and control system, control system, safety switches,

start alarm devices, hydraulic systems and electrical cabling are excluded and
will be specified, installed and tested by Sandvik Rock Processing (SRP).

Speed detectors and pull cord emergency switches are normally included in
the scope, but emergency stop push buttons can be also used. Because of
the conveyor installation to the chassis at SRP workshop, particularly the pull
cord emergency system must be installed and tested at workshop before the
delivery to Customer takes place.

2. Operation of Conveyor

To have more information for the operation, see SRP documentation.

 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007

4 PRODUCT DOCUMENTATION

ROX 11-01-60 PULL CORD EMERGENCY SWITCH

ROX 11-01-64 ROTATION DETECTOR

POCLAIN HYDRAULIC MOTOR

RRH1212 MSE05-8-133-R05-1220-DEJ0
RRH1213U MS02-0-123-R02-112E-5DEJM
RRH1214U MS05-8-133-R05-122R-E000
RRH1209 MSE05-8-133-R05-1220-DEJ0

BTF TAIL PULLEY

RRH1212 BTF50-250T-1250J
RRH1213U BTF50-250T-1030J
RRH1214U BTF50-250T- 870J
RRH1209 BTF50-250T-1030M

ZD DRIVE PULLEY
RRH1212 ZD30-320X-60-1305
RRH1213U ZD30-270X-60-1130
RRH1214U ZD30-320X-60- 880
RRH1209 ZD30-320X-60-1100

INFO CONVEYOR IDLERS

NT3 CARRYING IDLERS

TS STEEL IDLERS

RB RETURN IDLERS

LA IMPACT IDLERS

TV63 STEERING ROLLERS

MU30 BELT CLEANER

MU10 BELT CLEANER

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Interleafs rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (2)

GENERAL INSTRUCTION ROX 11-01-60

PULL CORD EMERGENCY SWITCH

1. Construction

The pull cord emergency switch is a mechanical emergency stop device

operating by a cord designed and approved for this purpose.

The pull cord is located at the side of the equipment, generally between the
service passage and the equipment, along the whole length of the equipment,
at least in the zone where is a service passage or where the access near the
equipment is otherwise possible.

The cord has been suspended on special rings, and pulleys are used in
curved areas.

Several types of switches from various manufacturers are used. The type and
location of the pull cord emergency switches used in your equipment can be
seen in the parts lists and drawings.

2. Principle of operation

The purpose of the pull cord emergency switch is to stop the equipment when
one pulls at the cord.

The pull cord emergency switch is to be used only in emergency situations,

where is a hazard of personal injury or material damage. The pull cord
emergency switch must not be used for normal stop of the equipment or to
prevent accidental start of the equipment.

When you pull at the cord, the lever or stem of the switch moves, and the
contact of the switch will open, whereat the control system stops the
equipment.

The emergency stop wire switch is always mechanically locked in the open
position, and this can be released only by pressing the reset pushbutton of
the switch or similar.

In most pull cord emergency stop systems, the switch functions in two
directions, and the pull cord has been tensioned by means of a spring to an
appropriate tightness, so the slackening or breaking of the cord will cause
also an emergency stop.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (2)

GENERAL INSTRUCTION ROX 11-01-60

3. Regulation

The emergency stop switches and cords have been regulated to the right
tightness when being installed and taken into use.

For some types of switches are separate regulating instructions given by the
manufacturer of the device.

In systems where is a control of so called breaking cord, the cord is tensioned

so that the lever or the stem of the switch is in the middle of its zone of
movement.

4. Maintenance

The pull cord emergency stop system does not require any special
maintenance, but cleaning and regular periodic inspections are necessary.

In periodic inspections it has to be checked that the switch and its cables are
fixed properly. Check that the cord, its locks and fixtures are OK. Check that
the cord is tensioned to the right tightness, and that it can move freely.

Periodic inspections and maintenance are to perfomed at intervals

determined in the maintenance schedule. See instruction : Maintenance
schedule.

In the functioning inspection it has to be checked that the switch functions

well also when one pulls at the farthest point of the cord. Check that the
locking of the switch in the open position and its resetting function flawlessly.
Check that the control system effects the necessary stops and alarm
indications when one pulls at the cord.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (2)

GENERAL INSTRUCTION ROX 11-01-64

ROTATION DETECTOR

1. Construction

The control of rotation consists in principle of three parts: "recognition pieces",

detector with fixture and control system.
The recognition pieces are metal pieces, bolts, openings etc. on the drive
shaft after the transmission mechanism, in conveyors on the freely rotating
pulley or roller.
The most often used detector is an inductive compact detector Ø 30mm with
inbuilt impulse counter and potentiometer with which the impulse frequency is
regulated.
It is possible to use also an ordinary inductive detector. In that case the
counting of impulses and setting of frequency take place in the control system
(logic control or special relay).
The type and location of the rotation detector used in your equipment can be
seen in the parts lists and drawings.

2. Principle of operation

When the recognition pieces pass by the detector at a frequency which is

superior to the set value, the control system has the information that the
device is rotating.

The purpose of the rotation control is also to stop the drive motor of the
device in question if the frequency is below the set value. So it is possible to
get an alarm of the stop of the device or failures in, e.g. transmission, slipping
belt and some defects in the electric and control system.
In order to start the device normally, the rotation control is by-passed during
the start. This is effected by the control system or the properties of the
detector itself.

3. Adjustment

The installation distance of the detector from the recognition pieces is

4-6 mm. The maximum reliable detecting distance is 8 mm.

The setting of the impulse frequency of compact detectors is performed by

means of a small screw potentiometer which is in the detector. (some model
under a plastic protecting screw)

The LED of the detector is on when the impulse value exceeds the set value,
and 10s. after energized (start time delay).
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (2)

GENERAL INSTRUCTION ROX 11-01-64

If during maintenance you have to detach some guards or go outside

the normal maintenance zone near the rotating parts, it is absolutely
necessary to stop the equipment and to prevent an accidental start.
Before restarting the equipment, the guards have to be put in place.

When the screw is turned clockwise, the impulse value increases and vice
versa.
Try to find out the screw setting which is as near the normal rotational speed
of the device as possible, i.e. the point where the LED just lights up/goes out
when the device is rotating at the normal speed. From this point the setting is
decreased by ¼ - 1½ turns. So the alarm point can be set 10 - 60% below
the normal speed of rotation. The amount of turns depends on the impulse
value in question.
The number of impulses for rotation detectors equipped with a separate relay
unit is set by means of the relay according to the manufacturer's instructions.
If impulses are counted in the logic program, also the setting takes place by
programming.

4. Maintenance

The rotation detector does not require any special maintenance, but cleaning
and regular periodic inspections are necessary.
The detector and recognition pieces have to be kept enough clean so that
material or foreign matter does not damage the detector when being between
them. The detector itself is very tight against humidity and dust.

In periodic maintenance check that the fixture of the detector, its cables and
recognition pieces are OK.
The periodic inspections and maintenance are to be performed at intervals
determined by the maintenance schedule. See instruction: Maintenance
schedule.

The function is checked by four separate way, arranging a failure in rotation,

e.g. as follows:
- by changing the detecting distance too big
- by increasing the frequency setting over the normal speed of rotation
- by preventing the rotation of the device or the recognition pieces
- by disconnecting the detector electrically
Check that the control system effects the necessary stops and alarms in case
of failure.

After checking the function, set the detector and the possible adjustments
back to the right values where they were before causing the failure in rotation.
 Lubrication instruction BTF Pulley bearings.

Lubrication and maintenance - Relubrication intervals for Y-bearings

Relubrication of Y-bearing units is not required if

– loads and speeds are moderate

– no vibrations occur
– operating temperature does not exceed +55 °C
or if they are not relubricable as e.g. all Y-bearing units with pressed steel housing. In case the Y-bearings
or Y-bearing units
– are exposed to high humidity or severe contamination
– have to carry high loads
– have to run at high speeds or at temperatures above +55 °C for longer time
relubrication is required to enable the whole Y-bearing service life.
When relubricating, the grease should be pressed in slowly to the bearing until fresh grease escapes from
the seal. Avoid excessive pressure as this can damage the seals.

Relubrication of standard Y-bearing units

For relubrication of standard Y-bearing units the use of SKF grease LGWA 2, which is fully compatible with
the original grease, is recommended. The multi-purpose SKF greases LGMT 2 and LGMT 3 are also
compatible with the original grease and may also be used for relubrication.

Relubrication intervals
The relubrication interval tf can be estimated from the diagram as a function of the rotational speed n
(r/min), the mean diameter of the bearing dm (table) and the operating temperature (°C).
The recommended intervals correspond to a time when 90 % of the bearings are still reliably lubricated,
and represent L10 grease life. When the L10 grease life is equivalent to or higher than the L10 basic rating
life of the Y-bearing or Y-bearing unit, bearing or unit can be considered as being lubricated for life and
relubrication is not required.
The intervals obtained from the diagram are valid for Y-bearings and Y-bearing units
– on horizontal shafts
– in stationary machines
– for operating temperatures between +40 and +55 °C
– at low loads (C/P ≥ 15).
If operating conditions differ it is necessary to reduce the relubrication intervals obtained from the
diagram, namely
– on vertical shafts by 50 %
– at higher loads, e.g. at C/P = 8 by roughly 50 %
– in severe, very dirty or damp environment by up to 90 %.
Vibrations have an influence on the grease life too. The extent cannot be quantified exactly but it is
noticeable at rising operating temperatures. Also when the operating temperatures are below +40 °C for
longer periods, the grease life is shortened because the oil separation is reduced.
The values for reducing the relubrication intervals are estimated values. In cases of doubt the SKF
application engineering service should be contacted.
In cases where machines and equipment are used for a limited period of time, it is recommended that
they should be relubricated at the end of the operational period, i.e. immediately before being laid up.

1
Sandvik Materials Handling

Roxon AB Branch office

Box 279 Box 812 Trade reg.No. 556189-4691
S-701 45 ÖREBRO S-953 28 HAPARANDA VAT No. SE556189469101
Tel. +46 19 219060 Tel. +46 922 298 00
Fax +46 19 104217 Fax +46 922 298 09 www.roxon.sandvik.com
 This text taken from:
SKF Catalogue 5001 E. September 2004

2
Sandvik Materials Handling

Roxon AB Branch office

Box 279 Box 812 Trade reg.No. 556189-4691
S-701 45 ÖREBRO S-953 28 HAPARANDA VAT No. SE556189469101
Tel. +46 19 219060 Tel. +46 922 298 00
Fax +46 19 104217 Fax +46 922 298 09 www.roxon.sandvik.com
 In heavy duty environments.
- High load
- High speeds
- High temperatur
- Wet environment
- Dirty environment

Environment is heavy, if one or more terms mentioned above is fulfilled.

Lubrcation interval should be less than 800/h

When relubricating, the grease should be pressed in slowly to the bearing until fresh grease escapes from
the seal. Avoid excessive pressure as this can damage the seals.

Grease
For relubrication of standard Y-bearing units the use of SKF grease LGWA 2, which is fully compatible with
the original grease, is recommended. The multi-purpose SKF greases LGMT 2 and LGMT 3 are also
compatible with the original grease and may also be used for relubrication.
An alternative grease is Shell Alvania RL2 or equal grease from other manufacurer.

Roxon AB

3
Sandvik Materials Handling

Roxon AB Branch office

Box 279 Box 812 Trade reg.No. 556189-4691
S-701 45 ÖREBRO S-953 28 HAPARANDA VAT No. SE556189469101
Tel. +46 19 219060 Tel. +46 922 298 00
Fax +46 19 104217 Fax +46 922 298 09 www.roxon.sandvik.com
 Spare parts for pulley bearings • Reservdelar till trummans lagring
Rummun laakeroinnin varaosat • Ersatzteile der Lagerung der Trommel
Pièces de rechange de roulement du tambour
Parti di scorta per cuscinetti delle pulegge

BTF – Tail and bend pulley • Bryttrumma • Taittorumpu • Belttrommel •

Tambour à plier • Puleggia condotta e puleggia a curva

d SKF KOYO HFB

40 FYC 40 TF UCFC 208 UCFC 208
50 FYC 50 TF UCFC 210 UCFC 210

Sandvik Materials Handling

Roxon AB Branch office

Box 279 Box 812 Trade reg.No. 556189-4691
S-701 45 ÖREBRO S-953 28 HAPARANDA VAT No. SE556189469101
Tel. +46 19 219060 Tel. +46 922 298 00
Fax +46 19 104217 Fax +46 922 298 09 www.roxon.sandvik.com

CONVEYOR IDLERS
INSTALLATION
Conveyor idlers must be installed carefully because
installation has an essential importance for the belt to stay in
center line and lasting time of idler:
Belt
direction
Belt
direction
Touch carefully the idlers. Installation shall be made with lightly
knock by hands or carefully with rubber- or plastic hammer.
Never use metal hammer, because then the knocking load to
the bearing can damage the bearing and result in shorter
lasting time.
While installation of return idlers with rubber discs also take
into consideration following factors which secure operation,
staying at place and lasting of idlers:
Sandvik
Conveyor Components
1/1999 1(2)
INFO
Conveyor idlers shall be installed symmetrically cross
direction with center line of conveyor. Idler brackets and/or
idler supports must be well- fastened onto frame in order to
counteract turning and loosening.
Ploughing can appear in outmost idlers caused by bracket
type or they are in cross direction with center line of conveyor
like middle idler. Ploughing direction of outmost idlers on
one-way conveyor.
Elimination of outmost idlers ploughing on two-way conveyor.
Install idler bracket cross direction with frame.
Disc return idler do not bend the belt before pulley and in
curves. In minor pendings it is allowed (1..3 degrees), but
also then secure the idler load. When bending the belt strongly
downwards with the disc return idler there is a risk of gliding
of the discs on idler because of high radial load.
As a result is the belt moving sidewards, inner steel tube rub
against the belt and the discs wear out. In bending points of
return side belt always use the straight steel idler. If dirt is
considerable use the rubber coated steel idler.
We reserve the right for modifications without prior notice.

Equip the conveyor with guiding idlers if belt travels unsteady
(because of load eccentricity or sidewind on open conveyors)
or when using light belts on long conveyors.
While installation of guiding idler brackets it must be inspected
that they can turn freely.
OPERATION
If there is noted a broken idler during the running, stop the
conveyor immediately and replace the broken one.
If idler is rolling among the conveyed material partly or wholly,
clean the material round the idler immediately. As a result of
dirt can be:
- Material wear the idler while rubbing it.
MAINTENANCE
Target for the inspection and maintenance of idler is that
maintenance interval could be run without stoppages caused
by idler damages.
Inspection of idler condition and maintenance must be done
systematically at agreed intervals according to operating
conditions. Definition of operating conditions must be agreed
by idler supplier and user.
While maintenance of idlers it must be inspected that
- Idlers run smoothly, steady and noiseless. If there is any
stiffness, unevenness or noise, replace the idler.
- Idler mantel is solid. Replace idler if the mantel is broken or
badly worn out.
- Idler mantel is clean.
- Rubber discs on return idlers are solid and firmly at original
places. Replace or repair the idler with damaged rubber
discs.
Inspection of idler condition and maintenance is two-stage:
1. Estimation of idler condition must be done by going
conveyor lines carefully through while the conveyor is in
running. Mark the observations to the service card which will
be fixed on idler bracket:
STORAGE
If idlers are required to be stored before installation, they must
be stored in covered, dry and preferably indoor space.
Transportation packages must be opened before stocking and
condition of idlers inspected to be sure that there are no
damages.
Sandvik
Conveyor Components
1/1999 2(2)
While installation of fixed, downwards bending guiding idler
brackets it must be started with light power. Use more only
if there is need for increasing of guiding power. Then it is
possible to minimize the idler loads.
- Idler freezes among the material during the stoppage and
wears quickly after starting the conveyor.
- Because of material idler can not cool off from the air;
overheating and fire danger.
- Material come through the sealing and cause an early
bearing damage.
- Unnormal noises
- Strong radial cast
- Stuck idlers
- Rubber disc damages
TO TOUCH OR REPLACE THE IDLERS DURING
THE RUNNING IS ABSOLUTELY FORBIDDEN
2. Run through the marked idlers during the conveyor
stoppage and estimate the need of replacement. Also
unmarked idlers must be inspected. This because some of
the inspections are easier to make when the idlers do not roll.
(worn-out of mantel surface, quantity of radial gap, condition
of rubber discs).
In throughing idlers belt edge and ploughing of outmost idlers
cause worn-out more than normally in mantel. Lasting time of
mantel can be lengthened by turning the outmost idlers
occasionally vice versa.
If conveyor system has after-lubricated idlers, see lubrication
instructions.
We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components
2/2006

STEEL IDLER TS
Roxon TS-idler is designed for very demanding environments. ORDERING EXAMPLE: TS108 - 20 B - 380 K
TS-idler is equipped with a special sealing against dirt, dust
and freezing. TS-idler is used in belt conveyors as a carrying
idler and also as return idler for non-sticky materials. Type code

The steel sealing casing and the weather seal form a reliable Idler diameter D (mm)
cover against the splashwater. The multiple sealing Shaft diameter d (mm)
labyrinth and rubbing double lipseal efficiently prevent the dirt
from getting inside the idler. The standard surface Shaft end alternative, see separate sheet
treatment is shot-blasting and epoxy powder coating Idler length L (mm)
RAL3000, red. Special surface treatment is also available for
sticky materials. Special surface treatment, see separate sheet

Example: Total weight 7,2 kg

Idler weight (kg) Weight of rotating parts 3,8 kg

L
D d
200 250 315 380 465 530 600 670 750 950 1150 1400 1600 1800 2000
1,4 1,6 1,9 2,3 2,7 3,0 3,3 3,7 4,1 5,0 6,0 7,2 8,2 9,2 10,1
51 20
0,9 1,0 1,2 1,3 1,5 1,7 1,8 2,0 2,2 2,7 3,2 3,8 4,2 4,7 5,2
1,6 1,9 2,2 2,6 3,0 3,3 3,7 4,1 4,5 5,5 6,5 7,8 8,9 9,9 10,9
63 20
1,1 1,3 1,5 1,6 1,9 2,0 2,2 2,4 2,6 3,2 3,7 4,4 4,9 5,5 6,0
2,5 3,0 3,5 4,1 4,8 5,4 6,0 6,6 7,3 9,0 10,7 12,9 14,6 16,3 18,0
20
2,0 2,3 2,7 3,1 3,7 4,1 4,5 4,9 5,4 6,6 7,9 9,4 10,6 11,9 13,1
3,2 3,7 4,4 5,0 5,9 6,5 7,2 7,9 8,7 10,7 12,7 15,2 17,2 19,2 21,2
89 25
2,4 2,7 3,1 3,5 4,1 4,5 4,9 5,3 5,8 7,0 8,3 9,8 11,0 12,3 13,5
3,6 4,2 4,9 5,7 6,7 7,5 8,3 9,1 10,0 12,4 14,7 17,6 20,0 22,3 24,7
30
2,5 2,8 3,2 3,6 4,1 4,5 4,9 5,4 5,9 7,1 8,3 9,9 11,1 12,3 13,6
2,7 3,1 3,7 4,3 5,1 5,7 6,3 6,9 7,6 9,4 11,2 13,5 15,3 17,0 18,8
20
2,2 2,5 2,9 3,4 3,9 4,3 4,8 5,3 5,8 7,1 8,4 10,0 11,3 12,6 13,9
3,4 3,9 4,6 5,3 6,1 6,8 7,5 8,3 9,1 11,2 13,2 15,8 17,9 20,0 22,0
25
2,6 2,9 3,4 3,8 4,3 4,8 5,2 5,7 6,2 7,5 8,8 10,4 11,7 13,0 14,3
108
3,8 4,4 5,2 6,0 7,0 7,8 8,6 9,5 10,4 12,8 15,3 18,3 20,7 23,1 25,5
30
2,7 3,0 3,4 3,9 4,4 4,8 5,3 5,8 6,3 7,6 8,9 10,5 11,8 13,1 14,4
9,2 10,0 11,1 12,1 13,5 14,6 15,7 16,9 18,2 21,4 24,7 28,8 32,1 35,3 38,6
40
7,2 7,5 7,9 8,4 8,9 9,3 9,8 10,3 10,8 12,1 13,4 15,0 16,3 17,6 18,9
4,1 4,8 5,7 6,7 7,8 8,7 9,7 10,7 11,8 14,6 17,4 20,9 23,7 26,5 29,3
20
3,6 4,2 5,0 5,7 6,7 7,4 8,2 9,0 10,0 12,3 14,6 17,4 19,7 22,0 24,3
4,8 5,5 6,5 7,5 8,8 9,8 10,9 12,0 13,2 16,3 19,3 23,2 26,2 29,3 32,4
25
4,0 4,6 5,3 6,1 7,0 7,8 8,6 9,4 10,3 12,6 14,9 17,8 20,1 22,4 24,7
133
5,2 6,0 7,1 8,2 9,7 10,8 12,0 13,2 14,5 17,9 21,3 25,6 29,0 32,4 35,8
30
4,0 4,6 5,4 6,1 7,1 7,8 8,6 9,4 10,4 12,7 15,0 17,8 20,1 22,4 24,7
10,6 11,6 13,0 14,4 16,2 17,6 19,1 20,6 22,3 26,6 30,9 36,2 40,5 44,7 49,0
40
8,6 9,2 9,9 10,7 11,6 12,4 13,2 14,0 14,9 17,2 19,5 22,4 24,7 27,0 29,3
5,5 6,5 7,8 9,0 10,7 12,0 13,4 14,7 16,3 20,2 24,1 29,0 33,0 36,9 40,8
20
5,0 5,9 7,0 8,1 9,6 10,7 11,9 13,1 14,4 17,9 21,3 25,6 29,0 32,5 35,9
6,2 7,2 8,6 10,0 11,7 13,1 14,6 16,1 17,7 21,9 26,1 31,4 35,6 39,8 44,0
25
5,4 6,3 7,4 8,5 10,0 11,1 12,3 13,5 14,8 18,3 21,7 26,0 29,4 32,9 36,3
159
6,6 7,7 9,2 10,6 12,6 14,1 15,6 17,2 19,0 23,6 28,1 33,8 38,3 42,9 47,4
30
5,5 6,3 7,4 8,5 10,0 11,1 12,3 13,5 14,9 18,3 21,7 26,0 29,5 32,9 36,3
12,2 13,6 15,3 17,1 19,4 21,1 23,0 24,9 27,1 32,5 37,9 44,6 50,0 55,4 60,8
40
10,2 11,1 12,2 13,3 14,8 15,9 17,1 18,3 19,7 23,1 26,5 30,8 34,2 37,7 41,1
10,5 12,2 14,3 16,5 19,4 21,6 23,9 26,3 29,0 35,7 42,5 50,9 57,6 64,4 71,1
30
8,5 9,7 11,2 12,8 14,8 16,4 18,0 19,7 21,6 26,4 31,1 37,1 41,8 46,6 51,4
219
15,1 16,8 19,0 21,2 24,0 26,2 28,6 30,9 33,6 40,4 47,1 55,5 62,3 69,0 75,7
40
13,1 14,3 15,9 17,4 19,5 21,0 22,7 24,3 26,2 31,0 35,8 41,7 46,5 51,3 56,0

We reserve the right for modifications without prior notice.

 Sandvik
Conveyor Components
9/98

IMPACT IDLER LA
ROXON LA-idler is designed for an impact idler to ORDERING EXAMPLE: LA 108E - 20 B - 380
absorb impact shocks at belt conveyor loading points.
The LA-idler is also suitable for a snub pulley for the
dirty side of the belt as well as for an impact idler for Idler type
unit goods conveyors.
Idler diameter D (mm)
LA-idler is based on the sturdy TS-idler.
E = steel idler type TS-E
Blank = steel idler type TS
(see steel idlers)
Shaft diameter d (mm)
Shaft end type, see separate information page
Idler length L (mm)

Example: Total weight 11.6 kg

Idler weight (kg) Weight of rotating parts 8.3 kg
L
D d
250 315 380 465 530 600 670 750 800 950 1150 1400 1600 1800 2000

20 2.3 2.9 3.3 3.9 4.4 4.9 5.4 6.0

89 * 1.7 2.1 2.4 2.8 3.1 3.5 3.7 4.2
25 2.6 3.2 3.7 4.5 5.0 5.7 6.2 6.9
1.6 2.0 2.3 2.7 3.0 3.4 3.6 4.1
20 2.9 3.6 4.2 5.0 5.7 6.3 7.0 7.8 8.2 9.7 11.6
108 2.3 2.8 3.3 3.9 4.4 4.9 5.3 6.0 6.2 7.3 8.3
25 3.2 3.9 4.6 5.6 6.3 7.1 7.8 8.7 9.2 10.9 13.1
2.2 2.7 3.2 3.8 4.3 4.8 5.2 5.9 6.1 7.2 8.2
20 4.8 5.8 6.7 8.3 9.2 10.2 11.4 12.7 13.5 15.8 19.2 23.1 26.4 29.6
4.6 5.4 6.2 7.5 8.3 9.1 10.2 11.3 12.0 13.9 15.8 18.5 21.7 24.3
133 25 5.6 6.6 7.7 9.3 10.4 11.5 12.8 14.2 15.1 17.6 21.2 25.5 29.1 32.5
4.7 5.5 6.3 7.6 8.4 9.2 10.3 11.3 12.1 14.0 15.9 18.6 21.7 24.4
30 6.1 7.2 8.4 10.2 11.3 12.6 14.0 15.5 16.5 19.2 23.2 27.9 31.9 35.6
4.3 5.1 5.9 7.2 8.0 8.8 9.9 11.0 11.7 13.6 15.5 18.2 21.4 24.0
20 5.7 6.9 8.0 10.0 11.1 12.3 13.8 15.4 16.4 19.2 23.4 28.2 32.3 36.2
5.5 6.5 7.5 9.2 10.2 11.2 12.6 14.0 14.9 17.3 20.0 23.6 27.6 30.9
159 25 6.5 7.7 9.0 11.0 12.3 13.6 15.2 16.9 18.0 21.0 25.4 30.6 35.0 39.1
5.6 6.6 7.6 9.3 10.3 11.3 12.7 14.0 15.0 17.4 20.1 23.7 27.6 31.0
30 7.0 8.3 9.7 11.9 13.2 14.7 16.4 18.2 19.4 22.6 27.4 33.0 37.8 42.2
5.2 6.2 7.2 8.9 9.9 10.9 12.3 13.7 14.6 17.0 19.7 23.3 27.3 30.6
30 11.5 14.7 17.8 21.1 24.3 27.4 30.6 33.9 35.7 43.3 49.5 59.3 68.3 77.7 87.1
219 10.2 12.9 15.7 18.6 21.3 24.1 26.9 29.8 31.3 38.0 44.0 52.9 60.5 68.8 77.1
40 17.1 20.5 23.9 27.7 31.1 34.5 38.0 41.7 43.7 51.9 58.3 68.8 78.8 89.1 99.3
10.1 12.8 15.6 18.5 21.2 24.0 26.8 29.7 31.2 38.0 43.9 52.9 60.5 68.7 77.0
* Roller is equipped with C-type rubber disc
We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components
3/2004

RETURN IDLER RB(S)

L B D P L1 L2 L3 Discs Idler weight / Weight of rotating parts (kg)

(pcs) L d D108 D133 D159 D219
108 40 20 4.5 / 3.2 6.7 / 5.8 8.2 / 7.3
500 400 133 40 50 100 80 5
500 25 5.1 / 3.1 7.8 / 5.9 9.3 / 7.4
159 40 30 8.7 / 5.5 10.2 / 7.0
108 40 20 5.0 / 3.5 7.5 / 6.4 9.0 / 7.9
600 500 133 40 50 105 125 5 600 25 5.7 / 3.4 8.8 / 6.5 10.3 / 8.0
159 40 30 9.9 / 6.1 11.4 / 7.6
108 40 20 6.0 / 4.2 9.1 / 7.7 10.9 / 9.5
750 650 133 40 50 110 110 6 750 25 6.9 / 4.1 10.6 / 7.7 12.4 / 9.5
159 40 30 11.9 / 7.4 13.7 / 9.2
108 40 20 7.6 / 5.2 11.4 / 9.5 13.8 / 11.9
133 40 60 155 145 8 950 25 8.8 / 5.1 13.2 / 9.6 15.6 / 12.0
950 800
159 40 30 14.8 / 9.2 17.2 / 11.6 26.7 / 26.0
40 35.3 / 21.4
219 50 60 190 115 8
20 8.8 / 6.0 13.5 / 11.0 16.2 / 13.7
108 40
60 155 150 9 1150 25 10.3 / 5.9 15.5 / 11.1 18.2 / 13.8
1150 1000 133 40
30 17.5 / 10.7 20.2 / 13.4 31.0 / 29.1
159 40
40 40.5 / 24.6
219 50 60 190 125 9 20 10.9 / 7.4 16.5 / 13.5 20.1 / 17.1
108 40 25 12.7 / 7.3 18.9 / 13.5 22.5 / 17.1
65 195 145 12 1400
1400 1200 133 40 30 21.3 / 13.2 24.9 / 16.8 36.0 / 32.7
159 40 40 46.5 / 28.2
219 50 70 195 135 10 20 18.5 / 15.0 22.4 / 18.9
133 40 1600 25 21.2 / 15.1 25.1 / 19.0
70 195 145 13
1600 1400 159 40 30 24.0 / 14.7 27.9 / 18.6 40.3 / 35.9
219 50 70 200 135 11 40 51.7 / 31.3
133 40 20 24.8 / 20.7
70 200 145 14
1800 1600 159 40 1800 25 23.5 / 16.6 27.7 / 20.8
219 50 70 195 140 12 30 26.6 / 16.2 30.8 / 20.4 44.6 / 39.1
133 40 40 56.8 / 34.5
60 200 150 15
2000 1800 159 40 20
219 50 70 195 140 13 2000 25 30.3 / 22.6
133 40 30 33.7 / 22.3 48.9 / 42.3
60 200 150 16 40 62.0 / 37.7
2200 2000 159 40
25
219 50 70 195 140 14 2200 30 36.7 / 24.1 53.2 / 45.5
* For technical reasons in production the discs may 40 67.2 / 40.9
be differently spaced in the middle of the idler.

We reserve the right for modifications without prior notice.

 Sandvik
Conveyor Components
6/98

GUIDING IDLERS TV
Cylindrical guiding idlers are designed for all belt ORDERING EXAMPLE: TV 89E - 130
conveyors in normal and light conditions. The idler
is easy to install to the steel frame. Idler type
Dimension A
is determined
Idler diameter D (mm)
by the motion
margin of the Sealing alternative E
belt.
Length L (mm)

D L H d1 L1min L1max Weight (kg)

63 130 205 M20 25 35 1.4
89 130 205 M20 25 35 2.0
108 160 265 M24 30 65 4.1

BELT SAVING GUIDING IDLER ’EVERGREEN’ TV95

Idler weight 4 kg
EVERGREEN of polyurethane
The pressure of the Evergreen -guide
idler against the belt is essentially less
than with a cylindrical idler. The belt is
trying to guide with power Fh sidewards.
ORDERING EXAMPLE: TV 95E - U
Type
Sealing alternative E
Material of the shell
U = polyurethane with steel bearing housing
T = steel
The load on the belt edge caused by the guiding idlers especially in heavy
conveyors is considerable. The advanced design of ROXON EVERGREEN
reduces these loads. It is equipped with a steel bearing housing and efficient
sealing.
ROXON EVERGREEN touches the belt edge for a distance of about 100
mm so the load is divided evenly. The load against the edge is minimal
compared to the traditional solution. Measure A is in maximum 10% of the
belt width B. To prevent the belt from damaging, choose it case by case so
that the belt will touch the idler before it touches the fixed frames of the
conveyor. ROXON EVERGREEN is made of polyurethane and has a high
wear resistance. Due to the high friction coefficient between the urethane
and rubber the belt stays straight and steady on the idler.

Cylindrical idler: high pressure peak

against the belt edge due to point contact.

Bracket included in delivery

Evergreen: low pressure against the belt

edge due to the long linear contact.

We reserve the right for modifications without prior notice.

 12/2007

BELT CLEANER MU30-

Service manual
 12/2007

TABLE OF CONTENTS

1. General regulations and instructions ........................................................................ 3

1.1 Foreword ......................................................................................... 3
1.2 Responsibilities of the owner .......................................................... 3
1.3 Safety .............................................................................................. 3
1.4 Warranty ......................................................................................... 4
1.5 Manufacturer’s contact information ................................................. 4

2. Introduction ....................................................................................................................... 4
2.1 General information about the MU30 belt cleaner .......................... 4
2.2 Measures to be taken before installation ........................................ 4

3. Installation of the cleaner ............................................................................................. 5

3.1 CM model (B800-1200) ................................................................... 5
3.2 CM model (B1400) .......................................................................... 6
3.3 LT and RM models .......................................................................... 7
3.4 TM model ........................................................................................ 8

4. Tightening the cleaner ................................................................................................... 9

4.1 CM models ...................................................................................... 9
4.2 LT and RM models .......................................................................... 10
4.3 TM model ........................................................................................ 11

5. Placement of the counter roller .................................................................................. 12

6. Maintenance of the cleaner ......................................................................................... 12

7. Spare parts ........................................................................................................................ 12

We reserve the right for modifications without prior notice.

 12/2007

1. General regulations and instructions

1.1 Foreword
This installation and maintenance manual is intended for installers, inspectors, operating and maintenance
personnel. This manual should be read carefully and should always kept close at hand.
This manual provides a new user with basic information about the machine and its use. Skill in using the machine
will develop with time.
The principle of Sandvik/Hollola is to continuously develop and improve machines and devices. For this reason, your
device and the devices presented in the manual may differ from each other slightly. The manual is, however,
constantly updated and improved.
Sandvik/Hollola reserves the right to make changes in the machines and devices without giving notice of the changes
separately in the maintenance and operating manual and other such documents.
If you have questions concerning the machines, devices, or systems supplied by Sandvik/Hollola, or questions
concerning this manual, please contact Sandvik/Hollola or a representative of the company.

1.2 Responsibilities of the owner

The responsibility of the owner is to make sure that,
- the instructions for safety, operation, maintenance and inspection of the machines and devices are complied
with during use. These instructions must be accessible to those who need them.
- both the normal and emergency stopping devices, the signals for operating and stopping remote-controlled
machines (light and/or sound signal), and the risks involved in operating the machines and devices have been
presented to the personnel.
- only personnel who has received proper training is permitted to use the devices.
- the personnel operating the devices have acquainted themselves well with the performance characteristics and
features of the machines.
- the machines or devices are not used for any other purpose or in any other circumstances for which they are not
intended.
- the machines and devices are well lit and both the passage to the machines and service space are free.
- the machines and devices are inspected and serviced at the recommended intervals. The procedures performed
are recorded in the maintenance book. The maintenance recordings must be presented to the Sandvik/Hollola
representative upon request.
- the malfunctions notified by the operator, maintenanceman, or inspector are recorded and the malfunction is fixed
immediately.
- a machine or device that has been stopped because of a malfunction, disturbance, or emergency is not started
again until the reason for the machine stopping is determined.
- there is always sufficient and qualified operating, maintenance, and inspection personnel who has received proper
training available.

1.3 Safety
The general safety instructions and regulations of the plant in question must be complied with when installing,
operating, and servicing the devices and machines.
In addition, the maintenanceman and operator must familiarize themselves with safety instructions and
regulations of the maintenance and operating manual and comply with them in all situations and circumstances.
The operating and maintenance personnel must know of the risks that may arise in the devices. These are
- pressure and entanglement risks in the movable and spinning parts of the device
- accidental and automatic start-up
- danger and harm caused by dust and noise
- fire and explosion hazards caused by material

3 We reserve the right for modifications without prior notice.

 12/2007

Loitering near the machines is forbidden. Proper safety equipment must be used when working near the machines.
The protective safety devices must not be removed from the machines. They must be in place and working properly when
the machines are being used.
The covers and doors of the electrical devices and cases must be kept closed.
The machines must be shut down and secured with a safety switch or its equivalent during maintenance, inspection, and
cleaning.

1.4 Warranty

The warranty clause and warranty period are specified in the purchase agreement or other such documents.
A general precondition for the warranty is that the components are installed, used, maintenanced, and inspected
according to the directions in this manual. Also, the accessories used must be original Sandvik/Hollola accessories.

1.5 Manufacturer’s contact information

Sandvik Mining and Construction Hollola Oy

Keskikankaantie 19
FIN-15860 Hollola
FINLAND
Tel. +358 (0)20 544 181
Fax. +358 (0)20 544 5600
www.miningandconstruction.sandvik.com

2. Introduction

2.1 General information about the MU30 belt cleaner

MU30 belt cleaner equipped with hard metal blades is used on the dirty side of the belt. It removes residue that has
adhered to the belt via a rubbing motion. It is developed for very abrasive materials. Cleaners operation is at its best with
the new, smooth belt. Do not install the cleaner on the belt which is teared, with holes or big roughness on the surface.

2.2 Measures to be taken before installation

Before removing MU30 from its package, take it to the place where it will be installed. Make sure that the package is not
damaged and procede then to unpack the cleaner from the package. You will find pictures of the cleaner’s parts from the
enclosed assemby illustrations. Please contact Sandvik/Hollola or a representative if parts are missing from the box or if
any of the parts are damaged.
Handle the parts with care. A damaged surface will easily rust if it comes in contact with moisture, especially in a maritime
climate. To eliminate this, transportation and handling of the cleaner must be done so as not to cause damage to the
surface.
NOTE! The conveyor must always be stopped, the main switch must be turned off and locked to prevent accidental
activation before any installation or maintenance work is to be performed on the conveyor.

4 We reserve the right for modifications without prior notice.

 12/2007

3. Installation of the cleaner

3.1 CM model (B800-B1200)
Install the side brackets (1) and the
brackets shown as (2) on the conveyor frame.
The side brackets must be able to move freely
from the attachment point (M16 x 100).
When installing the cleaner on a conveyor
M16 x 100
without mounting holes for the side brackets,
refer to subsection 4.1 (page 9) for positioning
of the cleaner.

M16 x 50

(2)
(1)

Install the blade (4) and the blade bracket type

C (3) on the brackets (2).
NOTE: If it is necessary to cut the blade
bracket and make more mounting holes, this
must be done using an angle grinder and/or M16 x 50
flame cutting machine. The blade bracket must (4)
not be cooled quickly; allow it to cool down in
its own time.

(3)

Attach the tightening parts to the side

brackets (1) and to the conveyor frame. Cut
the eye screws (6) and screw supports (5) to
the correct measurement, if necessary.

(5) (6)

5 We reserve the right for modifications without prior notice.

 12/2007

3.2 CM model (B1400)

Attach the angle brackets (1) to the conveyor

frame, and then install the side brackets (2)
and brackets (3) on the angle brackets. The
side brackets must be able to move freely from
the attachment point (M16 x 100).
When installing the cleaner on a conveyor
without mounting holes for the side brackets, M16 x 100
refer to subsection 4.1 (page 9) for positioning
of the cleaner.

(1)

M16 x 50
(3)

(2)

Install the blade (5) and the blade bracket type

C (4) on the brackets (3).
NOTE: If it is necessary to cut the blade
bracket and make more mounting holes, this
must be done using an angle grinder and/or
flame cutting machine. The blade bracket must M16 x 50
(5)
not be cooled quickly; allow it to cool down in
its own time.

(4)

Attach the tightening parts to the side

brackets (2) and to the conveyor frame. Cut
the eye screws (7) and screw supports (6) to
the correct measurement, if necessary.

(6) (7)

6 We reserve the right for modifications without prior notice.

 12/2007

3.3 LT and RM models

Install the side brackets (1) and the

brackets shown as (2) on the conveyor frame.
The side brackets must be able to move freely
from the attachment point (M16 x 100).
When installing the cleaner on a conveyor
without mounting holes for the side M16 x 100
brackets, refer to subsection 4.2 (page 10) for
positioning of the cleaner.

M16 x 50
(2)
(1)

Install the blade (4) and the blade bracket (3)

on the brackets (2). The blade bracket to be
used is type A for the LT model and type B for
the RM model.
NOTE: If it is necessary to cut the blade
bracket and make more mounting holes, this
must be done using an angle grinder and/or (4)
flame cutting machine. The blade bracket must
not be cooled quickly; allow it to cool down in
its own time. M16 x 50

(3)

Attach the tightening parts to the side brack-

ets (1) and to the conveyor frame. Cut the eye
screws (6) and screw supports (5) to the cor-
rect measurement, if necessary.

(5) (6)

7 We reserve the right for modifications without prior notice.

 12/2007

3.4 TM model
Type of the blade bracket D or E

Install the brackets (1) on the conveyor frame

(M16 x 100).
When installing the cleaner at the drive pulley,
refer to subsection 4.3 (page 11) for
positioning of the cleaner. If the cleaner is not
M16 x 50
installed at the drive pulley, the counter roller
must be installed; refer to Section 5 (page 12)
for positioning.

(1)

Install the blade (3) and the blade bracket

type D (2) on the brackets (1) with bolt joint
(M16x50).
NOTE: If it is necessary to cut the blade
bracket and make more mounting holes, this
must be done using an angle grinder and/or
flame cutting machine. The blade bracket must
not be cooled quickly; allow it to cool down in
its own time.
(3)

M16 x 50

(2)

Fasten the blade (3) and type-E blade bracket

(4) to the angle brackets (1) via a friction joint
with the clamping plates (5).

M16 x 50

(3)

(5)

(4)

8 We reserve the right for modifications without prior notice.

 12/2007

4. Tightening the cleaner

4.1 CM models
Attach the cleaner blade evenly to the belt by
turning the turnbuckle. Then you can increase
the blade pressure to the level required to
obtain a good cleaning result. However,
when the side bracket is pulled with the force
indicated in Table 1, the blade must move
clearly away from the belt surface.

Table 1

B F
800 150 N
1000 200 N
1200 250 N
1400 300 N

The drive pulley must not be directly behind

the blade. The distance must be at least 50
mm from the point at which the belt leaves the
drive pulley. This allows the belt to respond
more easily to the blade shape, and a better
cleaning result is obtained with lower blade
pressure.
Finally, after the tightening, check the angle
of the cleaner blade with respect to the belt. It
should be 85-89 degrees.

9 We reserve the right for modifications without prior notice.

 12/2007

4.2 LT and RM models

In the LT model, install the tightening parts on

the frame using the clamping angle brackets
(M12x50). In the RM model, fasten an eye bolt clamping angle bracket
directly to the frame.
M12 x 50
Attach the cleaner blade evenly to the belt by
turning the turnbuckle. Then you can increase
the blade pressure to the level required to
obtain a good cleaning result. However,
when the side bracket is pulled with the force
indicated in Table 2, the blade must move
clearly away from the belt surface.

Table 2

B F
400 90 N
500 110 N
650 130 N
800 170 N
1000 210 N
1200 260 N
1400 310 N
1600 370 N

The drive pulley must not be directly behind LT model

the blade. The distance must be at least 50
mm from the point at which the belt leaves the
drive pulley. This allows the belt to respond
more easily to the blade shape, and a better
cleaning result is obtained with lower blade
pressure.
Finally, after the tightening, check the angle
of the cleaner blade with respect to the belt. It
should be 85–89 degrees.

RM model

10 We reserve the right for modifications without prior notice.

 12/2007

4.3 TM model
Type of the blade bracket D or E

Lift the cleaner blade evenly onto the belt

and pre-tighten the blade bracket mounting
bolts. Mark the position of the blade bracket
(1), and then increase the blade pressure (2)
to the level required (max.: 5 mm) to obtain a
good cleaning result. Finish by tightening the
mounting bolts the rest of the way.

(1)

(2)

The drive pulley must not be directly behind Blade bracket D

the blade. The distance must be at least 50
mm from the point at which the belt leaves the
drive pulley. This allows the belt to respond
more easily to the blade shape, and a better
cleaning result is obtained with lower blade
pressure.
Finally, after the tightening, check the angle
of the cleaner blade with respect to the belt. It
should be 85–89 degrees.

Blade bracket E

11 We reserve the right for modifications without prior notice.

 12/2007

5. Placement of the counter roller

When the cleaner is installed somewhere else

than at the pulley, the counter roller must be
installed as well. The counter roller must be
installed before the cleaner in the belt’s Belt direction
direction of travel.

6. Maintenance of the cleaner

The operation of the belt cleaner is to be

checked daily during normal use of the
conveyor.
The cleaner blade angle with respect to the belt
must be checked every 200 operating hours.
In addition, the wear of the blade, the
tightening of the fastening bolts, and the
cleaner blade pressure against the belt must
be checked every 200 operating hours.

MU30-T3-(B)

7. Spare parts

A worn blade must be replaced with a spare

blade. The order code is MU30-T3-(B), where
B = the belt width.

12 We reserve the right for modifications without prior notice.

 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007

5 WEAR PARTS CATALOQUE

WEAR AND SPARE PARTS RECOMMENDATION

RRH1212-J2 WEAR PARTS

RRH1213U-J2 WEAR PARTS

RRH1214U-J2 WEAR PARTS

RRH1209-J2 WEAR PARTS

WEAR PARTS FORM

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Interleafs rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007 1 (1)

WEAR AND SPARE PARTS RECOMMENDATION FOR RRH1212, RRH1213U,

RRH1214U AND RRH1209

General

Use only original Sandvik Hollola wear and spare parts. Using of original Sandvik Hollola
parts is also precondition for Sandvik Hollola guarantee. Update the Maintenance Log when
replacing parts.

The drawing number, type, etc. of the parts are given in the enclosed drawings:

RRH1212-J2 Wear parts

RRH1213U-J2 Wear parts
RRH1214U-J2 Wear parts
RRH1209-J2 Wear parts

RRH1212-J3 Spare parts

RRH1213U-J3 Spare parts
RRH1214U-J3 Spare parts
RRH1209-J3 Spare parts

When ordering parts, always specify exactly the drawing number and type code of the part.
Kindly find enclosed a sheet when ordering parts.

Note the manufacturing number of conveyor!

Recommendation

Wear parts

It is recommended that one set of wear parts presented RRH1212-J2, RRH1213U-J2,

RRH1214U-J2 and RRH1209J2 are in your store to ensure best possible availability for the
conveyor.

Spare parts

Following parts are recommended as spare parts (see RRH1212-J3, RRH1213U-J3,

RRH1214U-J3 and RRH1209-J3):

- Steel idlers 2 pcs/conveyor

- Return idlers 2 pcs/conveyor
- Carrying idlers 3 pcs/conveyor
- Impact idlers 3 pcs
- Tail pulley 1 pc/conveyor
- Drive pulley 1 pc/conveyor
- Bearing house 1 pc/pulley/conveyor
- Motor 1 pc/conveyor

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Spare part recommendation rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
WEAR AND SPARE PARTS

RRH1212, RRH1213U, RRH1214U, RRH1209 Belt conveyor

Manufacturing number: 12….. / 200….. / W…… / ….

SANDVIK MINING AND CONSTRUCTION HOLLOLA OY Tel + 358 205 44 181

Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
FINLAND

SENDER
ADDRESS
CITY
COUNTRY
TEL/FAX TEL FAX

Position Description of Parts reference to Dwg Quantity

OTHER INFORMATION

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Wear and spare parts form rev2.doc

 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007

6 SPARE PARTS CATALOQUE

WEAR AND SPARE PARTS RECOMMENDATION

RRH1212-J3 SPARE PARTS

RRH1213U-J3 SPARE PARTS

RRH1214U-J3 SPARE PARTS

RRH1209-J3 SPARE PARTS

SPARE PARTS FORM

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Interleafs rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007 1 (1)

WEAR AND SPARE PARTS RECOMMENDATION FOR RRH1212, RRH1213U,

RRH1214U AND RRH1209

General

Use only original Sandvik Hollola wear and spare parts. Using of original Sandvik Hollola
parts is also precondition for Sandvik Hollola guarantee. Update the Maintenance Log when
replacing parts.

The drawing number, type, etc. of the parts are given in the enclosed drawings:

RRH1212-J2 Wear parts

RRH1213U-J2 Wear parts
RRH1214U-J2 Wear parts
RRH1209-J2 Wear parts

RRH1212-J3 Spare parts

RRH1213U-J3 Spare parts
RRH1214U-J3 Spare parts
RRH1209-J3 Spare parts

When ordering parts, always specify exactly the drawing number and type code of the part.
Kindly find enclosed a sheet when ordering parts.

Note the manufacturing number of conveyor!

Recommendation

Wear parts

It is recommended that one set of wear parts presented RRH1212-J2, RRH1213U-J2,

RRH1214U-J2 and RRH1209J2 are in your store to ensure best possible availability for the
conveyor.

Spare parts

Following parts are recommended as spare parts (see RRH1212-J3, RRH1213U-J3,

RRH1214U-J3 and RRH1209-J3):

- Steel idlers 2 pcs/conveyor

- Return idlers 2 pcs/conveyor
- Carrying idlers 3 pcs/conveyor
- Impact idlers 3 pcs
- Tail pulley 1 pc/conveyor
- Drive pulley 1 pc/conveyor
- Bearing house 1 pc/pulley/conveyor
- Motor 1 pc/conveyor

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Spare part recommendation rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
WEAR AND SPARE PARTS

RRH1212, RRH1213U, RRH1214U, RRH1209 Belt conveyor

Manufacturing number: 12….. / 200….. / W…… / ….

SANDVIK MINING AND CONSTRUCTION HOLLOLA OY Tel + 358 205 44 181

Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
FINLAND

SENDER
ADDRESS
CITY
COUNTRY
TEL/FAX TEL FAX

Position Description of Parts reference to Dwg Quantity

OTHER INFORMATION

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Wear and spare parts form rev2.doc

 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007

7 MAINTENANCE MANUAL

RRH 1212-J1 SERVICE DIAGRAM

RRH 1213U-J1 SERVICE DIAGRAM

RRH 1214U-J1 SERVICE DIAGRAM

RRH 1209-J1 SERVICE DIAGRAM

ROX 11-01-01 GENERAL REGULATIONS AND INSTRUCTIONS

ROX 11-01-81 LUBRICANTS

ROX 11-01-83 CLEANING

ROX 11-01-90 REMOVING FROM SERVICE, STORING AND DESTROYING

ROX 11-02-05 COMMISSIONING

ROX 11-02-31 MAINTENANCE SCHEDULE, DIFFICULT CONDITIONS (B)

ROX 11-02-40 TROUBLESHOOTING INSTRUCTION FOR BELT

CONVEYORS

SERVICE MANUAL CONVEYOR PULLEYS

TYPICAL PULLEY REPLACING

PEPLACING OF GARLAND IDLER

INSTRUCTION ADJUSTMENTS

INSTRUCTION ADDITIONAL

MAINTENANCE LOG
MAINTENANCE LOG FORM

FEEDBACK FORM

DESCRIPTION OF DAMAGE
DAMAGE DESCRIPTION FORM

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Interleafs rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (5)

GENERAL INSTRUCTION ROX 11-01-01

GENERAL REGULATIONS AND INSTRUCTIONS

1. INTRODUCTION

This maintenance and operation manual is intented for the operating,

inspection and maintenance personnel.

This manual has to be read through carefully, and it has to be always at the
disposal of the personnel.

The instructions and descriptions of this manual are necessary when the
equipment is inspected, regulated, started, operated and serviced.

A new operator obtains from this manual the basic information about the
equipment and its operation. The skill to operate the equipment develops with
experience.

Sandvik Hollola has a principle of continuous development of machines and

equipment. That is way why your equipment and the data presented in this
manual may differ somewhat from each other.

There may be several versions and delivery alternatives of the machines and
equipment, and therefore in these general instructions may be described
equipment and functions which are not included in the delivery in your case.

The maintenance and operation manual is continually modified and improved

in order that its content would be up-to-date.

Sandvik Hollola reserves the right to alterations in machines and equipment

without prior notice in maintenance and operation instructions and other
corresponding documents.

If you have any questions concerning this manual or the equipment, machines
or systems delivered by Sandvik Hollola, please contact Sandvik Hollola.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (5)

GENERAL INSTRUCTION ROX 11-01-01

2. OBLIGATIONS OF THE OWNER

The owner is obliged to see to that:

- The safety, operation, maintenance and inspection instructions in force are

observed in the operation of the machines and equipment. These
instructions have to be at the disposal of those who need them.

- The normal start and stop signals, the start and stop signals of the
machines with remote control (light and/or sound signals), as well as the
risks of accidents involved with the machines and equipment have been
presented to the personnel.

- Only duly trained operating personnel may operate the equipment.

- The operating personnel has to know well the performance values and
properties of the machines.

- The machines and equipment must not be used for other purposes or in
other conditions than intented.

- The machines and equipment must have adequate lighting, and the
passages and service platforms have to be open.

- The machines have to be inspected and serviced at the recommended

intervals. The effected measures must be registered in the maintenance
book. On request, the maintenance registrations have to be presented to
the representative of Sandvik Hollola. The guarantee is valid only if the
inspections and maintenance are carried out according to the instructions.

- The defects notified by the operator, maintenance personnel or inspector

are to be registered and remedied without delay.

- The machine or equipment stopped due to a defect, malfunction and

emergency must not be started before the cause of the stop has been
cleared.

- There has always to be sufficiently qualified and duly trained operating,

maintenance and inspection personnel available.

- The plant may be expanded or modified only by Sandvik Hollola or an

enterprise authorized by it. If the plant is modified, it is always necessary to
take into account the strength, effect, capacity and other factors of the
equipment.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 3 (5)

GENERAL INSTRUCTION ROX 11-01-01

3. REGULATIONS AND INSTRUCTIONS CONCERNING THE MAINTENANCE

AND INSPECTION PERSONNEL

- The condition of the machines and equipment has to be checked daily and
all discovered defects are to be remedied without delay.

- The maintenance and inspections are performed when the machines

are at a standstill and the start is prevented by means of a safety
switch or by other reliable method.

- Only measures determined by the separate instructions may be performed

when the machines are running. Even then the safety devices have to be in
place, and it is necessary to exercise extreme caution.

- The maintenance and inspections have to be performed at recommended

intervals (see inspection and lubrication charts and instructions). The
performed measures have to be entered in the maintenance book.

- Mechanical and electrical regulations may be performed only by authorized

personnel.

- The service platforms and stairs of the equipment have to be kept clean and
in good condition.

- In the end of the maintenance and inspection it has to be checked that the
safety devices are duly in place, the machine is clean and that all foreign
objects (tools, instruments etc.) have been removed.

- Use only original spare parts of Sandvik Hollola.

- Wearing parts are to be changed in due time.

 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 4 (5)

GENERAL INSTRUCTION ROX 11-01-01

4. REGULATIONS AND INSTRUCTIONS CONCERNING THE MACHINE

OPERATOR

4.1 Measures before the start

- Read through carefully the operation instructions of the machines and

equipment.

- Make sure that no maintenance or operating personnel or unauthorized

persons are staying in the vicinity of the machines to be started, in order
that the start of the equipment cannot cause a danger for them.

- Make sure that all safety, protecting and security devices are in place and in
working order.

- Make sure that there are no foreign objects in the operating zone of the
machines and that dust, dirt, ice, etc. has not made the equipment out of
order.

- Select the control and operation mode of the machines and systems (see
operation instructions).

- Observe during the start that the machines start normally and that they
function properly.

4.2 Measures during operation

- Observe the material flow.

- Observe that the material does not go to places where it causes

malfunctions.

- See to that unauthorized persons cannot come near the running machines.

- Observe the functioning of the machines and report the discovered defects
and malfunctions to the maintenance personnel without delay.

4.3 Measures when the machines are stopped

- Run the machines empty of material if possible.

- Stop the machines as determined in the operation instructions.

- Report all discovered malfunctions of the machines to the next operator and
the maintenance personnel.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 5 (5)

GENERAL INSTRUCTION ROX 11-01-01

5. SAFETY

- The general safety instructions and regulations in force in the plant are to be
observed when the equipment and machines are operated and serviced.

- In addition to these, the maintenance and operating personnel has to read

through carefully the safety instructions and regulations contained by this
maintenance and operation manual and observe them in all situations and
conditions.

- The operating and maintenance personnel has to know the hazards involved
in the equipment, such as :
- risk of being squeezed and caught by moving and rotating parts of the
machine
- accidental and automatic starts
- hazards and injurious effects caused by dust and noise
- fire and explosion hazards caused by material

- Unauthorized persons must stay out, in the immediate vicinity of the

equipment it is necessary to use due protections.

- The safety and security devices must not be removed, they must always be
in place and in working order when the equipment is operated.

- The covers and doors of the electrical equipment and boxes have to be
closed.

- Before the maintenance, inspection and cleaning of the equipment it is

necessary to stop the machines and their start has to be prevented with a
safety switch or similar.

6. GUARANTEE

- The guarantee conditions and period of the equipment and systems are
determined in the supply contract or other documents.

- A general precondition for the guarantee is that the equipment is operated,

serviced and inspected according to these maintenance and operation
instructions, and that only original spare parts of Sandvik Hollola are used.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (4)

GENERAL INSTRUCTION ROX 11-01-81

LUBRICANTS

1. GENERAL

When choosing lubricants or performing lubrication the lubrication

instructions of the component manufacturer in question must
absolutely be followed.

This instruction contains general instructions for choosing and handling of

lubricants for the material handling equipment delivered by Sandvik Hollola.
General information on lubricants and choosing of them is available also from
the suppliers of lubricants.

2. SAFETY

If during maintenance you have to detach some guards or go outside

the normal maintenance zone near the rotating parts, it is absolutely
necessary to stop the equipment and to prevent an accidental start.
Before restarting the equipment, the guards have to be put in place.

When handling industrial oils and lubricants long-term and repeated contact
with skin must be avoided, wear protective clothing and appropriate tools.

Normally the used lubricant is classified as problem waste, take care of

appropriate handling, storing and destroying of the lubricants removed from
service.

3. LUBRICANT GROUPS

The lubrication objects of the equipment delivered by Sandvik Hollola have

been divided in four main groups:

Group 1. Gears, oil lubrication

- toothed gearings - worm gears
- lubrication by splash - immersion lubrication
- pressure lubrication - transmission chains

Group 2. Bearings, grease lubrication

- rolling bearings - slide bearings
- grease lubricated gears

Group 3. Open gear wheels, Steel wire ropes

Group 4. Hydraulic systems

- hydraulic aggregates and systems
- electrohydraulic pushers - fluid couplings
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (4)

GENERAL INSTRUCTION ROX 11-01-81

4. CHOOSING OF LUBRICANT

Group 1: Gears, oil lubrication

The oil qualities recommended by the gear manufacturer must

absolutely always be used.
To the choosing of the oil viscosity influence the type of the gear, quality of
use and ambient temperature.

Rough selection of viscosity of lubrication oil for splash and immersion

lubricated gear wheels according to the ambient temperature.

ambient
temper- VISCOSITY CLASS ISO VG (cSt/40°C)
ature
C°
+60
+50 680
+40 460
+30 320
+20
+10 220
0 150
-10 100
-20 68
-30 46
-40

Under normal circumstances the same oil can according to consideration be

used around the year also in outdoors use.
In pressure lubricated gears lower viscosity classes are normally used than in
splash and immersion lubricated gears.
In worm gears higher viscosity classes are normally used than in gear wheels.

Oil types for gear wheels and worm gears:

MANUFACTURER mineral oils synthetic oils

BP Energol GR-PX SG XP
ESSO Spartan EP Spartan Synthetic EP
NESTE Vaihteisto EP Vaihteisto S-EP
MOBIL Mobilgear Mobil SHC
SHELL Omala Oil Tivela Oil
TEBOIL Pressure Oil Multi-Pressure Oil
When using synthetic oils the suitability of the oil in question for sealing etc.
materials of the gear must be checked.

Transmission chains: The same oil type is normally suitable as the one
chosen for the gears.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 3 (4)

GENERAL INSTRUCTION ROX 11-01-81

Group 2. Grease lubrication of bearings (and gears)

The lubricants recommended by the manufacturer of the bearing or

other lubrication object must absolutely always be used.

In the lubrication grease the viscosity of the lubricant corresponds its

penetration which indicates the hardness of the lubricant.
The hardness is indicated by NLGI-number, nine different classes (000 -6),
the bigger the number is the harder is the grease.

The operating temperature range of the lubrication greases is normally wide

enough for round-the-year use in almost all lubrication objects of material
handling equipment.

In central lubrication systems the pumping characteristics of the selected

grease must be checked, especially at outdoor locations the greases of
hardness class NLGI-1 or special cold resistant greases should be used.

In grease lubricated gears the lubricants of classes NLGI-00 or 0 are normally

used.

Lubrication grease types for rolling and slide bearings:

MANUFACTURER Brand name NLGI-class

ESSO Beacon EP 0, 1, 2
NESTE Yleisrasva EP 0, 1, 2, 3
MOBIL Mobilux EP 0, 1, 2
SHELL Alvania EP Grease 1, 2
TEBOIL Multi-purpose Grease 2

Mostly the hardness classes 1 and 2 are used.

Group 3. Open gear wheels and steel wire ropes

The lubricants and protective compounds recommended by the

manufacturer of the equipment or component must absolutely always
be used.

These greases are often quite stiff bitumen based greases which contain as
blend components e.g. molybdenum sulphide and graphite.
Good anti-corrosion protection properties are required from these lubricants.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 4 (4)

GENERAL INSTRUCTION ROX 11-01-81

Lubrication protective grease types for open gear wheels and steel wire
ropes

MANUFACTURER Open gear wheels Steel wire ropes

ESSO Dynagear Extra Grease WR
NESTE Avorasva Avorasva
MOBIL Mobiltac 81 Mobilarma 798
SHELL Kuggfett Ensis Fluid K
TEBOIL Gear Grease MDS Gear Grease MDS

Group 4. Hydraulic systems

The lubricants and protective compounds recommended by the

manufacturer of the hydraulic system or component must absolutely
always be used.

To the choosing of the oil viscosity influence the type of the pump and
actuator, quality of use and ambient temperature.

The viscosity classes of hydraulic oils vary in the range ISO VG 5 -150.

In hydraulic systems the classes VG 32, 46 or 68 are normally used

depending on the type of the pump as well as the ambient and operating
temperature.

The viscosity of the oil of fluid couplings is normally VG 32.

In electrohydraulic pushers more flexible oil e.g. VG 10 is used, sometimes

also transformer oil can be used, see manufacturer’s instructions.

Hydraulic oils:

Manufacturer Hydraulic systems Hydraulic pushers Fluid couplings

ESSO Nuto H, Univis HP Spinesso 10 Torque fluid 30

NESTE Neste Paine Neste Paine
MOBIL DTE, SHC D.T.E 21 tai Velocite6 Mobilfluid 125
SHELL Tellus Oil T, TX Tellus oel C10 Tegula Oil
TEBOIL Hydraulic oil Fluid TH 10254

Many manufacturers have several oil types for special circumstances and e.g.
lightly in the nature decomposable oil types, so called BIO-oils.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (2)

GENERAL INSTRUCTION ROX 11-01-83

CLEANING

1. General

The material handling systems and equipment have to be cleaned regularly.

In addition, the covering constructions and structures, as well as the

walkways of the conveyors have to be cleaned from material and dust
regularly.

For the fire safety reasons, the cleaning of the equipment and their
surrounding areas is extremely important, especially if material or its dust is
flammable/explosive fuel, such as e.g. peat.

2. Cleaning intervals

It is very difficult to define any exact general cleaning intervals. The cleaning
intervals depend on the material to be handled, the dust-proof of the
equipment and the operation of the dust removal and ventilation systems.

The cleaning intervals have to be planned separately for each place on the
basis of the experience in the same kind of places. The intervals have to be
selected so that the dust in equipment and the surrounding area does not
harm the operation of the equipment. General safety must not be endangered
(N.B. fire safety).

Maintenance personnel has to prepare cleaning instructions with time tables

which have to be followed.

In some very difficult places or with very dusty materials, cleaning is needed
daily.
On the other hand, in not so dusty places and with non-flammable materials a
general cleaning once a year can be enough.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (2)

GENERAL INSTRUCTION ROX 11-01-83

3. Safety

The cleaning of the equipment and the surrounding area has to be done when
the equipment is not operating.
By being extra carefull some cleaning work, such as floor cleaning, can be
done also when the equipment is operating. In that case the entire cleaning
personnel has to know the possible elements of danger connected with the
equipment.
The risks for using compressed air or strong water jet have to be known.

If covers have to be removed or if it is necessary to go outside the

normal service area near the moving parts or on the equipment during
the cleaning, the equipment has to be absolutely stopped and it has to
be made sure that the equipment will not start accidentally.
Before the restart, the covers have to be reinstalled.

4. Cleaning methods

The cleaning method depends on the place, material to be handled and the
available cleaning systems and equipment.

Traditional sweeping with a brush and shoveling (if needed) is in most cases
a sufficient cleaning method.
If vacuum cleaner system is available, cleaning will be, of course,
considerably better and faster.

Compressed air might be in some cases good, but cleaning with only
compressed air is usually not a sufficient cleaning method, because then dust
and dirt only move from one place to an other.

Generally material handling systems supplied by Sandvik Hollola are planned

so that they can be cleaned also with low-pressure water jet.

Before using a washer jet it has to be made sure that it is allowed to clean the
equipment with water jet, and that the accumulation of washer waste has
been arranged in a proper way.

Water jet can never be pointed to non-hardy parts of the equipment, such as
electric appliances or bearings or to their sealings.

When using water in cold circumstances, the possible problems caused by

freezing have to be taken into account.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (2)

GENERAL INSTRUCTION ROX 11-01-90

REMOVING FROM SERVICE, STORING AND DESTROYING

1. General

This instruction can applied be used as a general instruction for removing

from service, storing and destroying of all machines and equipment delivered
by Sandvik Hollola.

The instructions relating to the devices of some machines may contain more
detailed instructions.

The special measures when dismounting and destroying the equipment

removed from service include the recovery of oils and handling and
destroying of possible radioactive materials in an appropriate way.

E.g. gears, fluid couplings and hydraulic systems may contain oils. E.g. with
radiometric principle operating belt scales and the level indicators of material
may contain radioactive materials.

2. Dismounting

Check before starting dismounting whether the equipment in question

contains the problem waste mentioned above and start dismounting by
handling them in an appropriate way.

Ensure also that the electric current has been switched off from the
equipment and all cables attached to it before starting the work.

Clean the equipment and surrounding from combustible material if it is

necessary to use flame cutting or other corresponding equipment causing fire
hazard.

Follow the general security and work instructions when dismounting.

 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (2)

GENERAL INSTRUCTION ROX 11-01-90

3. Storing

If the equipment or its parts are stored for later use, this must be considered
when dismounting the equipment so that the equipment will not be damaged
during the dismounting work.

The parts exposed to corrosion are protected with anti-rust compound, the
lubrication points are lubricated, the belts of the V-belt drives are loosened
and the tensioning of the conveyor belt is loosened in the whole belt
conveyors.

The gears and shaft mechanisms of e.g. screens are filled with lubrication oil
quite full in order to avoid corrosion damages.

When storing the equipment and machines moisture must be avoided and the
protections and storing of electric equipment must be performed according to
their own instructions.

The place of storing must be selected so that it is sheltered and as clean as

possible.
Pay attention also to that e.g. frost or long-term direct sunlight may damage
some equipment or components.

4. Destroying

The problem waste like oils are destroyed according to the general
regulations and instructions. (Treatment plant of problem waste)

The supplying of equipment containing radioactive materials to their collection

place and their destroying is done according to the instructions of the
manufacturer/importer of the equipment. Read the instructions of the
equipment carefully, contact the supplier of the equipment or the local
authorities if needed.

The rubber parts like e.g. conveyor belts must be delivered to be destroyed to
the waste treatment plant.

Generally for the part of other constructions the instructions for destroying,
sorting and recycling of different materials are followed.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (2)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-05

COMMISSIONING

1. Commissioning inspections

The commissioning shall be begun with a commissioning inspection before

starting the belt conveyor for the first time.

In the inspection can be used commissioning forms made by Sandvik Hollola

especially for this purpose. There is a separate form for mechanical
inspection and one for electrical and automation inspection.

The inspection shall be carried out by a person who knows well the
equipment to be inspected, commissioner and/or installation supervisor.

The commissioning forms are used as a check list and instructions for the
inspection, and they will be documents concerning the inspections and
regulations carried out.

2. First start

It is very important to carry out the first start of the belt conveyor with
caution and control, because there is a big risk of various damages.

Before the first start the commissioning inspections have to be carried out to
the extent that it is possible without running the motor.

Special attention must be paid to the following:

- the belt has to be empty and it must be able to move freely

- the electrical and control system has been tested, especially the start
warning and emergency stop systems
- all mechanical guards are in place and other factors having an influence on
the personal safety are in order
- the direction of rotation of the drive motor is correct, this must be assured,
e.g. without oil in the fluid coupling or without V-belts (if the drive motor
rotates in the wrong direction, the return brake of the reducer may be
damaged)

Immediately after the first short start, make sure that the belt remains
sufficiently centered.
The belt is centered in accordance with the instruction ROX 11-02-20, par. 2.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (2)

GENERAL INSTRUCTION, BELT CONVEYOR AND -FEEDER ROX 11-02-05

3. Trial run without material

The belt conveyor has to be run without material during several hours,
sometimes even during several days, before the run with material can be
started.

When the conveyor is run without material, check the function of all electrical
safety devices and lockings.

Check that the sound, tightness and temperature of the reducer are normal.

Make sure that all parts of the conveyor function normally.

4. Trial run with material

The trial run with material is started with a small quantity of material,
observing the function of the hoppers and the centering of the belt.

If the material is not guided to the center of the belt, adjust and repair the
hopper accordingly.

Increase the quantity of the material to be fed onto the conveyor until the
normal/maximum capacity is achieved, carry out the necessary adjustments
to the feed hopper and the belt.

Observe the temperatures of the reducer and bearings.

Perform a start test with a full loaded belt.

Measure the effect/current taken by the drive motor.

Observe the dust-tightness and function of the belt cleaners.

Commissioning performed carefully and with proficiency contributes to

troublefree and safe productional service.
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (3)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-31

MAINTENANCE SCHEDULE BELT/CHAIN - CONVEYOR/FEEDER

DIFFICULT CONDITIONS ( B )

1. Periodic inspections and maintenance

In addition to periodic inspections and maintenance the plant operating

personnel must daily check that all protective and safety devices of the
equipment are in place and in working order.

The cleaning of the devices and the surrounding areas has to be performed
so often that the material collecting onto the devices and in the surrounding
area does not hinder the functioning of the equipment or endanger the
general safety.

MAINTENANCE NO. OF INSTRUCTION MAINTENANCE

OBJECT INTERVAL

Hoppers ROX 11-01-54 1-2 months (abt.500h )

Conveyor belt ROX 11-02-20 1-2 months (abt.500h )
Belt cleaning devices ROX 11-02-25 1-2 months (abt.500h )
Roller systems ROX 11-02-26 1-2 months (abt.500h )
Distribution gate ROX 11-02-27 1-2 months (abt.500h )
Belt scale ROX 11-02-29 1-2 months (abt.500h )

Electric motor ROX 11-01-50 3 months (abt.1000h )

Blockage detector
Drive mechanism
Screw take-up device
Counterw.t-up device
Pulleys
Guiding boards
Transfer mechanism
ROX 11-01-63 3 months (abt.1000h )
ROX 11-02-21 3 months (abt.1000h )
ROX 11-02-22 3 months (abt.1000h )
ROX 11-02-23 3 months (abt.1000h )
ROX 11-02-24 3 months (abt.1000h )
ROX 11-02-28 3 months (abt.1000h )
ROX 11-02-50 3 months (abt.1000h )

Gear ROX 11-01-51 6 months (abt.2000h )

V-belt drive ROX 11-01-52 6 months (abt.2000h )
Pull cord em. switch ROX 11-01-60 6 months (abt.2000h )
Misalignment switch ROX 11-01-62 6 months (abt.2000h )

Rotation detector ROX 11-01-64 12 months (abt.4000h )

Start warning device ROX 11-01-65 12 months (abt.4000h )
Fluid coupling ROX 11-01-53 12months (abt.4000h )
Safety switch ROX 11-01-61 12months (abt.4000h )
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 2 (3)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-31

If a device or component of the equipment has separate maintenance and

inspection instructions given by the manufacturer, observe primarily the
maintenance schedules and oil change intervals given therein.

The maintenance intervals given in the maintenance schedule are maximum

guide values. If the experience from the operation and maintenace of some
objects, however, show it necessary, the maintenance and inspection
intervals have to be shortened.

In some objects it is also possible to lengthen the intervals, e.g. for cleaning, if
the experience has shown that it is not necessary to clean so often.

The measures to be performed in periodic inspections and maintenance are

described in the instructions of the device or component in question, see
number of the instruction in the table.

The performed maintenance measures and reparations have to be marked in

the maintenance register of the equipment.

The guarantee provides that the inspections and maintenances are

performed.

Before starting the maintenance, inspection or cleaning of the

equipment, it has always to be stopped and the safety switch has to be
turned to the position "0" and locked. The key has to be kept by the
person who is carrying out this work or by the person in charge.

2. Safety inspections of belt conveyors

A safety inspection of the belt conveyor has to be performed at least once a

year.
The person who carries out the inspection has to know well enough the
construction, safety devices and dangerous objects of the conveyors.
The safety inspections can be also performed at the same time as the
periodic inspections and maintenance, but it is necessary to mark the register
and draw up a separate record.
Enclosed a model of a safety inspection record for a belt conveyor:
 BELTCONVEYOR SAFETY INSPECTION PROTOCOL

COMPANY: NAME OF CONVEYOR:

PLANT: CONVEYOR NUMBER:

SAFETY AND CONTROL EQUIPMENT O.K. TO BE REPAIRED/REMARKS

emergency stop
safety switch
start warning
control push-buttons etc.
indicator ligths

To be inspected: function, condition, signs etc. (see maintenance manual).

SHIELDING OF DANGEROUS PLACES O.K. TO BE REPAIRED/REMARKS

drive end, drive mechanism

tail end
counterweight take-up device
carrying rollers
return rollers
transferable equipment
inspection doors

To be inspected: safety guards, cap guards, safety rails etc. (see maintenance manual).

WALKWAYS, AMBIENT CONDITIONS O.K. TO BE REPAIRED/REMARKS

service bridges, maintenance walkways

stairs, ladders
lightning
noise, dust
signs, maintenance manuals

To be inspected: condition, tidiness, signs (see maintenance manual).

Safety inspection shall be carried out at least once a year. The person carrying out this inspection must have
adequate knowledge of conveyors: structure, safety equipment and dangerous places.

Inspector: Date:
 MAINTENANCE AND OPERATION INSTRUCTIONS

3/2007 1 (5)

GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

TROUBLESHOOTING INSTRUCTION FOR BELT CONVEYORS/FEEDERS

0. General

In this instruction are listed failures and problems which may occur in belt
conveyors or belt feeders (number 1 - 9).
After every title under subnumbers are listed possible failures or causes
which may cause this problem, whereafter is a brief description of measures
to be taken in this situation.

1. THE CONVEYOR/FEEDERS DOES NOT START OR IT STOPS

The motor does not run

1.1 One of the protective or safety devices of the conveyor/feeder or drive motor
has been activated.
- Check and repair, reset the failure.

1.2 Electrical failure.

- Check and repair.

2. THE MOTOR DOES NOT START OR IT STOPS

The motor "jurrs" and the conveyor does not start

2.1 Electric failure (electric network, motor protecting and starting devices, cable,
motor)
- Check and repair.

2.2 The conveyor is heavily overloaded.

- Check and remove the overload from the belt.

2.3 The belt or drum is jammed.

- E.g. material or foreign matter between the belt and the board.
The tail pulley or rollers are jammed.
- Check, clean and repair.

2.4 Drives, gear or brake are jammed.

- Check that the separate brake opens properly.
- Check and repair.
 MAINTENANCE AND OPERATION INSTRUCTIONS

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GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

3. THE MOTOR RUNS, BUT THE DRIVE PULLEY DOES NOT ROTATE
The transmission slips

3.1 V-belts slip.

- Check and repair, see instruction: V-belt transmission ROX 11-01-52.
- Check that the conveyor is not overloaded.

3.2 The fluid coupling slips.

- Check and repair, see instruction: Fluid coupling ROX 11-01-53.
- Check that the conveyor is not overloaded.

3.3 The pin coupling, or similar, between the motor and reducer is defective.
- Check and repair.

3.4 The joint or coupling between the reducer and drive pulley is defective.
- Check and repair.

3.5 The reducer is defective.

- Check and repair, see instruction: Reducer ROX 11-01-51.

4. THE DRIVE PULLEY ROTATES, BUT THE BELT DOES NOT MOVE
The pulley slips, the friction between the pulley and the belt is not
sufficient.

4.1 The belt is not tight enough.

- Check and tighten, see instruction: Screw take-up device ROX 11-02-22 or
instruction: Counterweight take-up device ROX 11-02-23.
- Check that the conveyor is not overloaded.

4.2 Between the belt and pulley is material, e.g. snow and ice.
- Check and clean.
- Prevent the access of material and snow between the belt and pulley,
improve the cleaning and cleanliness of the equipment.
- Improve the function and maintenance of the belt cleaners.
- Use anti-freeze agents.

4.3 The rubber coating of the drive pulley is worn out.

- Check, renew the coating or replace the whole drive pulley.

4.4 The conveyor belt has jammed somewhere, e.g. material or foreign matter
has jammed between the belt and board. The tail pulley or rollers have
jammed.
- Check, clean and repair.
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GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

5. BELT RUNS ON ONE SIDE ALWAYS AT THE SAME POINT OF THE BELT

5.1 The belt joint is oblique.

- Check, see instruction: Conveyor belt Rox 11-02-20 par. 2.8.
- Make a new joint, if necessary.

5.2 The belt has a curve, this can occur normally only with new belts.
- Check, see instruction: Conveyor belt Rox 11-02-20 par. 2.8.
- Check the storing and transport of the belt.
- Change the belt if necessary.

6. THE BELT RUNS ON ONE SIDE AT THE SAME POINT OF THE

CONVEYOR
either within some part or along the whole length of the conveyor

6.1 The pulleys are not horizontal or they are not in the middle and perpendicular
to the center line of the conveyor.
- Check and correct, see instruction: Conveyor belt Rox11-02-20 par.2.

6.2 The roller systems and rollers are not in the middle and perpendicular to the
center line of the conveyor.
- Check and correct, see instruction: Conveyor belt Rox 11-02-20 p2.

6.3 The material is not loaded to the middle of the belt. If the material is on one
side of the belt, the belt tends to move towards the emptier side on the trough
rollers. If the material moves strongly laterally at the feed point, also this tends
to move the belt to one side.
- Check, adjust or correct the feeding hopper.

6.4 Trough roller systems have been mounted in the wrong way.
- Check if the supporting rollers of the conveyor have "ploughing" roller
supports; these must be mounted so that the outermost rollers have been
turned a little towards the belt running direction.

6.5 The belt is exposed to the influence of the wind.

- Check the tightness of the belt.
- Arrange wind protections, if necessary; if it is a conveyor bridge
construction, contact Sandvik Hollola in order to determine the wind loads.

6.6 The belt chafes against some fixed part or jammed rollers.
- Check and repair.
- Improve the cleaning and maintenance.
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GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

6.7 A separate roller system moving on the conveyor, such as hopper or

discharge carriage, guides the belt to one side.
- Check the roller systems of the moving device.
- Check the spacings of the rails of the moving device and bearing wheels.

6.8 The conveyor/feeder frame is at a slant or bent.

- Check and repair.
- In case of mobile conveyors, the frame may change the form due to too big
inaccuracies in the rails, repair the rails.

6.9 Material or snow and ice collect onto the inner surface of the belt, pulleys or
rollers.
- Check and clean.
- Prevent the access of material and snow onto the lower belt, improve the
cleaning and cleanliness of the equipment.
- Improve the functioning and maintenance of the belt cleaners.
- Use anti-freeze agents.

7. THE BELT WEARS EXCEPTIONALLY MUCH OR IT GETS CRACKS,

RUPTURES OR OTHER UNNORMAL TRACKS

7.1 The belt chafes against the conveyor/feeder frame or some other fixed part,
e.g. jammed rollers, guiding boards or material jammed between them.

- Check and repair, see par. 6.

- Check and service the belt cleaners.

7.2 The material to be transported hits on the belt unevenly, at an unappropriate

angle or too strongly.
- Adjust or repair the feeding hopper.

7.3 The material tends to jam in hoppers and it is compressed at times between
the belt and hopper structures.
- Check and repair the hoppers enough wide.
- Check that the capacity is not too high.
- Check that the piece size of the material is not too big.

7.4 Material enters between the belt and pulley.

- Prevent the access of material between the pulley, seal the material leaks.
- Check and service the return belt cleaners.
- Check and adjust the pulley gap guards/cleaners.
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GENERAL INSTRUCTION, BELT CONVEYOR AND FEEDER ROX 11-02-40

7.5 Oil or chemicals on the belt.

- Check and repair.
- See to that the grease coming out during lubrication does not get onto the
belt.

7.6 Thermal or fire damage.

- See to that, e.g. the welding and flame cutting splashes during repair work
do not get onto the belt.

8. THE BELT STRETCHES TOO MUCH

8.1 The belt is too tight.

- Check and adjust, see instruction: Screw take-up device ROX 11-02-22 or
instruction: Counterweight take-up device ROX 11-02-23.

8.2 The belt forces are too big.

- Check that the conveyor is not overloaded.

9. THE BELT BREAKS, THE BELT JOINT BREAKS

9.1 The belt joint has been made in the wrong way.
- Make a new joint according to the instructions.

9.2 The belt forces are too big.

- See 8.1 and 8.2.

9.3 Material enters between the belt and pulley.

- See 7.4
 Sandvik
Conveyor Components

Service Manual
Conveyor pulleys

BK
BP
BT
DK
DT

Type marking of components

delivered to explosive atmospheres
is equipped with the prefix EX

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

1. General information ...................................................................................................................................................................... 2

1.1 General information about the operating manual ...................................................................................................... 2
1.2 Manufacturer’s contact information ............................................................................................................................. 2
1.3 Warranty .............................................................................................................................................................................. 2
1.4 Types and markings .......................................................................................................................................................... 2

2. Prerequisites .................................................................................................................................................................................. 2
3. Safety ................................................................................................................................................................................................ 3
4. Storage and transportation ......................................................................................................................................................... 4
5. Installation ....................................................................................................................................................................................... 8
6. Inspections and service ............................................................................................................................................................... 9
6.1 Operating conditions and inspection procedures ..................................................................................................... 9

6.2 Regular inspection when the conveyor is running .................................................................................................... 11

6.3 Inspections during downtime ......................................................................................................................................... 12
6.4 Monitoring the rubber coating ........................................................................................................................................ 12
6.5 Lubricating the pulley bearings ...................................................................................................................................... 13
6.6 Recommended lubricants ............................................................................................................................................... 13
6.7 Post-lubrication .................................................................................................................................................................. 14

7. Spare parts ...................................................................................................................................................................................... 15

APPENDICES

Appendix Assembly figures

Appendix Attachment element
Appendix Bearing spare parts
Appendix Placing the conveyor pulley in an explosive space (Ex)

Appendix Bearing life and need for a balancing

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 1 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

1. General information

1.1 General information about the operating manual

This installation, operating, and service manual is intended for the installation, operation, inspection, and service personnel.
Read this manual carefully and keep it available at all times.

1.2 Manufacturer’s contact information

Sandvik Mining and Construction Haparanda AB Tel. +46 922 298 00 www.miningandconstruction.sandvik.com
Box 812 Fax +46 922 298 09
SE-953 28 Haparanda
SVERIGE

1.3 Warranty

Warranty clauses and period are defined in the documents related to the purchase agreement.
The general warranty requirement is that the pulleys are installed, serviced, and inspected in accordance with this manual.
The warranty also requires that the spare parts be genuine Sandvik spare parts.
The conveyed materials cause wear of the pulley coating. This is normal wear caused by operation, not a manufacturing
defect in the coating, and thus it will not be compensated.
The warranty for the pulleys becomes void if the regular inspections and service required for the appropriate operation
cannot be performed due to the position of the pulley. Inspections and service measures are to be recorded in the track
sheet.

1.4 Types and markings

The conveyor pulley must be selected on a case-specific basis in accordance with the selection criteria for the conveyor
pulley in the Sandvik Conveyor Components product catalogue.
The pulley type plate is equipped with a label containing the type marking code and special requirements for the order.
Type marking, e.g., DK80-400X-1400
The pulleys delivered to explosive atmospheres are equipped with the prefix EX and Ex marking code in accordance with
directive 94/9/EC.
Type marking, e.g., EX-DK80-400X-1400
‘Ex’ marking, e.g. Ex ll 2GD T85°C or Ex l M2 (for mining conditions)
The correspondence between ‘Ex’ marking code and conditions must be ensured on a case-specific base before installation
of the pulley. Only pulleys coated with antistatic rubber coating are delivered to explosive atmospheres.

2. Prerequisites
The pulleys must be used in the conditions defined in the original selection criteria. The capacity of the conveyor, belt speed,
and conveyed materials must not differ from the agreed ratings. The operator must verify the voltage compensation in the
installation position.
The personnel responsible for the operation, service, and inspections of the plant’s machines and equipment is appropriately
trained and familiarised with the properties and performance characteristics of the equipment. A sufficient number of trained
and familiarized personnel must always be present. Installations, inspections, and services may be performed by trained and
familiarised personnel only.
The machines and equipment must be serviced and inspected as defined in the agreed timetable, which is compiled in
accordance with the conditions. The services and inspections and the measurements involved in them must be recorded in
the track sheet. The track sheets must be presented to the Sandvik/Haparanda representative as required. Inspections in
accordance with the instructions are the prerequisite for the warranty to be valid.
The work (installations, services, adjustments) must be performed in accordance with the applicable directives,
requirements of the specifying standards, and the local laws and regulations.

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 2 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

3. Safety

The explosive spaces must be appropriately marked.

The spaces and equipment must be sufficiently illuminated and access to the working platform must be unobstructed.
People are not allowed to remain in the immediate vicinity of the equipment. Moving and rotating parts create a danger of
compression and sticking.
Appropriate protective equipment must always be used when working.
Shields and protective devices must not be removed. They must be in place and in good working order when operating the
machine.
Covers and doors of electrical appliances / boxes must be kept closed when the machine is in operation.

NOTE:
Carefully read the occupational safety instructions before commencing the installation work.
Comply with the instructions concerning protective devices and personal protective equipment given by the person
responsible for safety.

NOTE:
When the machine is installed in an explosive area, the composition and concentration of dust/gases must be
examined before flame cutting and welding. Flame cutting and welding may cause an explosion, which can result
in severe injuries and danger to life.

NOTE:
The conveyor must be stopped, start-up prevented, and voltage shut off, also in all auxiliary equipment of the conveyor,
before commencing the installation, service, or adjustment measures.

NOTE:
The belt must be covered with a fire-proof material (e.g., fabric) before flame cutting or welding. The burst of sparks
and molten metal may damage the belt.

NOTE:
All loose parts and tools must be removed from the belt before starting the conveyor. The loose parts may cause
severe injuries to the persons working near the conveyor and damage the conveyor.

NOTE:
Touching the conveyor belt and the moving parts of the conveyor is prohibited when the conveyor is running. Clothes
may be caught get in the gap between the belt and idler, or get entangled in the belt. As a result of this, the clothes
may be torn or the person working too near the conveyor may be driven with the belt.

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 3 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

4. Storage and transportation

The general storage conditions must match the subsequent use of the pulleys, and the conditions must not cause
premature damage to the pulleys. The packages must be opened after marine transport and checked to ensure that the
pulleys are undamaged.
Transporting loose pulleys is not allowed. The pulleys must be packed in their own transport containers or bound in
pallets with steel or plastic bands for transportation. A max. of two crates may be stacked one on top of the other while
maintaining a constant crate-specific load. Stacking on unstrengthened underlay is not allowed.
The pulleys must be stored in a covered and dry location before installation. The flatness and stability of the underlay must
be ensured if the pulleys have to be stored outdoors. The pulleys must be completely shielded from the weather during
storage. The condensation of water must be prevented by selecting a suitable shield.
When changing the storage location, appropriate load-lifting devices must be used. The min. ground clearance is 100 mm.
The pulleys can be stored in their transport containers in supported piles. A max. of two crates may be stacked one on top
of the other.
When lifting, the packages must be hung in balance. The load-lifting devices may not be attached to suspension straps;
instead the lifting straps/chains must be positioned below the pallet/crate (see the figure below).
Unloading and reloading must be performed with load-lifting devices that comply with the appropriate and valid
regulations. Loading and unloading are not allowed with a lifting bucket or an electric magnet. When storing and
transporting individual pulleys, avoid impact load on axles and damages in the shell. No deflections to the pulley axle
are allowed.

Examples of the recommended lifting methods (pulleys equipped with external bearing housings).

The load of the lift must be applied to the pulley shell - not to the bearings and axle.

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 4 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

The load of the lift must be applied to the pulley shell and not to the bearings and axle. The recommended lifting method in
the installation.

Examples of the forbidden lifting methods.

The lifting strap must not be threaded around the axle between the bearing housings and shell. The lifting strap
pushes to the side of the bearing housing and it damages the bearing housing sealing when removing the belt.
The lifting method loads the axle in the wrong way and causes a deflection.

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 5 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

Examples of the recommended lifting methods (tail pulleys equipped with internal bearing
housings).

The load of the lift must be applied to the pulley shell - not to the bearings and axle.

Examples of the forbidden lifting methods.

The lifting strap must not be threaded around the axle. The lifting strap slips from the end of the axle or applies an incorrect
load to the axle/bearings, thus causing a deflection.

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 6 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

If an assembled tail or drive end is lifted during installation, the lift must be performed with support from the structures - not
by applying the load to the axle and bearings.

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 7 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

5. Installation of the pulley

Move the pulley to the installation site in the transport packaging, if possible. Check that the package is not damaged.
Unpack the pulley. The parts of the pulley are presented and listed in the enclosed assembly figures. If the contents of the
delivery is incomplete or parts of it are damaged, we ask you to contact your Sandvik/Haparanda representative.
Installation of the conveyor pulley must be performed carefully at all times. The installation plays a crucial role in holding
the belt in the middle of the conveyor in the travel direction, and in the life span of the pulley. The installation position of the
pulley affects the load applied to the bearings depending on the load condition.
The conveyor pulleys must be installed symmetrically and perpendicular in relation to the centre line of the conveyor. This
ensures that the belt stays in the centre line of the conveyor in the travel direction. The pulleys must be securely attached to
the conveyor frame structure. Note the tightening torques of the bearing housing screws. The position of the belt in the
centre line of the conveyor must not be corrected by placing the tail pulley in a skewed position.
Follow the bearing manufacturer’s instructions and use tools that are suitable for the installation of bearings.
Flanged seals are adapted to the axle through holes in the dust casing, see the appendix.
The conveyor must be equipped with guiding idlers if running of the belt is unstable (e.g., because of the eccentric load or,
in open conveyers, the wind, etc.) or when lightweight belts are used in long conveyors.

The allowable deviations of the bearing housings.

Ensure that the bearing housings are parallel
before the installation. If the deviation is too high,
the seals and bearings will be damaged and the
service life of the bearing will be shortened.
Contact between the lip seals and the axle is
insufficient. Parts of the labyrinth seal rub against
each other and cause a local temperature rise,
which may result in deformations and sparking.

The pulley must be installed perpendicular in

relation to the centre line of the conveyor.
If the deviation is too high, the belt will move
away from the centre line. The perpendicularity
must be verified before commissioning the
machine.

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 8 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

6. Inspections and service

Inspections and services of the pulleys must be performed on a case-specific basis as defined in the agreed timetable,
which is compiled in accordance with the conditions. The timetable is compiled by the pulley supplier and end user.
Continuous inspections are necessary to ensure that the conveyor runs the service interval without any shutdowns caused
by damage. The inspections are marked in the track sheet. Monitoring is a part of the preventive maintenance.
A faulty pulley must be inspected and serviced as soon as possible. The conveyor must not be used if one of the conveyor
pulleys is faulty or damaged.
The pulleys must be used in the conditions defined in the original selection criteria. The capacity, belt speed, and conveyed
materials must not differ from the agreed ratings.
Pulley bearings must be replaced when their calculated life span (usually 25,000 h or max. 10 years) is complete, even if
the bearings are visually in good working order. Particularly in explosive spaces, the agreed replacement interval must be
observed.
Fallen products must be removed so that they are not in contact with moving parts. Also any dust and/or materials layered
in the conveyor structures must be removed because of the danger of ignition.

6.1 Operating conditions and inspection procedures

The plant supplier or end user defines the operating conditions.

A = Very bad conditions

Dust, wetness, corrosive compounds, arctic conditions.
Wetness, steam, corrosive compounds, arctic conditions.
Wetness, steam, corrosive compounds, tropical conditions
Mining conditions
E.g.,
Mining equipment above ground
Chemical factories
Outdoor wood handling equipment
Peat conveyors
Chip conveyors
Wood handling equipment in a barking plant in contact with water.

B = Bad conditions
Moisture, frost.
Wetness, dust.
Mining conditions
E.g.,
Underground mining equipment
Indoor mining equipment
Indoor bark conveyors
Indoor chip conveyors

C = Normal conditions

Dry, no dust, impurities, or corrosive compounds.

Covered outdoor spaces
Temperature +5 …+40°C

E.g.,
Paper and other unit goods conveyors.

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 9 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

Explosive spaces
Explosive spaces are defined in directive 1999/92/EC and standards SFS-EN1127-1 and SFS-EN 13463 specify-
ing the directive. The standards are applied in air mixtures under pressure of 0.8...1.1 bar and temperature of -
20...+60°C. However, the danger of explosion cannot be excluded or ignored even if the operation is performed
outside the above mentioned tolerances.
An explosive air mixture can be present in any spaces defined in items A, B, and C. The definition of the explosive
space does not exclude any of the condition definitions (A, B, C), but it requires procedures/equipment that are in
accordance with the directive and standards, and specifies the operating condition selection (A, B, C).
The explosive spaces of the plant are discussed and defined in the explosion protection document.

Standard table for charting the service activities

Service/inspection periods Inspection methods

Item Operating condition

A B C EX D E F G

Attachments 4 5 7 1 X X

Bearings 2 3 4 1 X X X

Lubrication of
4 5 6 1
bearings

Shell and ends 4 5 7 2 X X

Rubber coating 4 5 7 2 X X

Inspection methods
D = Visual inspection
Accumulation of dust and material, condition and straightness of the belt, foreign objects in structures,
spillages of lubricants, operation of safety guards, etc.
E = Inspection by listening
Scratches, squeals, rubbing sounds, sounds from bearings, etc.
D = Inspection by touching
Vibration, heat, etc.
G = Measurements
Heat (thermographic camera monitoring), lubricant quantities, straightness of belt and shell, thickness of
coating, wear, etc.

Maintenance and inspection periods

1 = daily
2 = weekly
3 = every two weeks
4 = once a month
5 = every three months
6 = every six months
7= once a year
Pulleys operated in explosive spaces are also inspected during every shutdown.

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 10 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

6.2 Regular inspection when the conveyor is running

– Check that the pulley is firmly attached to the frame structure.

– Check that the pulley does not rub against the dust casing wall or steel structures. Bearing or axle may be damaged.
The conveyor must be stopped immediately.

– Check that the bearing housing seals are undamaged, and that the lubricant does not leak. The labyrinth seals must
not scrub against each other.

– Check that the flanged seals in the through holes of the dust casing are undamaged and in place (funnel structures).

– Monitor the condition and straightness of the axle.

– Test the operation of safety devices (e.g., vibration and temperature control, rotation sensors, moving-aside sensors).
Replace any faulty safety device at once.

– Monitor tightness of the belt. When it becomes hot, a slipping belt can cause a danger of explosion, particularly in
explosive spaces. A loose belt slips and causes wear on the pulley coating.

– Monitor the condition and running of the belt. The belt must not move aside from the centre line. Any tears or damage
on the edge must be repaired at once. The belt must be replaced as necessary.

– Monitor operation of the cleaners. The cleaners must be firmly attached and operate correctly. See care instructions for
the cleaner.

– Perform continuous temperature measurement/thermographic camera monitoring.

– Any dust and/or materials layered in the conveyor structures must be regularly removed, during the next shutdown at
the latest.

– Foreign objects must be immediately removed from structures. A foreign object may get caught between the pulley and
belt and cause damage.

– If the pulley/bearing housings/operating unit are partly or fully covered by the material, the material must be
immediately removed. The material penetrates through the bearing housing seals to the bearing space and causes
premature bearing damage. Bearing housings do not cool down but overheat because of the material which causes a
danger of ignition.

– All protecting structures must be appropriately attached in place.

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 11 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

6.3 Inspections during downtime

– Estimate the replacement need of the bearings. Check that the pulley rotates smoothly, easily, and silently. Follow the
replacement interval agreed upon in the life span calculation.

– Check and replace the bearing housing seals as necessary. Follow the seal and bearing manufacturer’s instructions
for service and replacement of the seals. Only genuine spare parts should be used.

– Check that the bearing housings are undamaged, and that the lubricant does not leak. Examine the consistency and
quantity of the lubricant. If the lubricant leaks out before the end of the calculated life span and the bearing runs without
lubrication or gets dusty, the bearing must be immediately replaced.

– Examine and repair any structural damages in the axle. Replace the pulley if the axle is damaged.

– Remove the flanged seal from the axle through hole before removing the dust casing. Reinstall the flanged seal before
restarting the conveyor.

– Check that the steel structure of the pulley is undamaged. Replace the pulley if the structure is damaged or the shell
worn out.

– Check that the coating is undamaged. Repair or replace the damaged coating before commencing work.

– Measure the parallelism between the pulley and belt at least during each shutdown. The belt must run in the center
line of the conveyor and the pulley must rotate perpendicular to the centre line of the conveyor.

– Check that the pulley shell is clean. Remove any material or dirt stuck there.

– Test the operation of safety devices (e.g., vibration and temperature control, rotation sensors, moving-aside sensors).
Replace any faulty safety device.

– Examine the condition of the cleaners at the same time in accordance with the care instructions of the cleaner.
Remove any material and foreign objects stuck in them.

– Remove any dust and/or materials layered in the conveyor structures and clean the area around the conveyor.

6.4 Monitoring the rubber coating

Rubber coating is a long-lasting friction surface with low service requirement. The conveyed materials always cause wear
on the pulley coating. This is normal wear caused by operation, not necessarily a manufacturing or material defect.
The chemical composition and the mechanical wear of the conveyed material cause changes and damage to the rubber
coating.
Examples of monitoring:
– Visual inspection. Chart the changes visually:
– Mechanical damage
– Traces and changes in the coating caused by local wear.
– Rubber surface changes (scaling, blistering, cracking, etc.).
– Grip damage (bubbles in the coating).
– Regular measurements in selected areas:
– Rubber hardness in accordance with, e.g., ASTM D 2240.
– Thickness of the coating.
– Electricity leak measurement
Ageing of the coating can be divided into two different phenomena:
– Changes in the rubber material during use.
– Adhesion of the coating in the shell surface.

Monitoring the rubber coating is part of the preventive maintenance. Items that require repair are marked in the track sheet
in the inspections and repaired during the following shutdown or as soon as possible, if necessary.

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 12 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

6.5 Lubricating the pulley bearings

The information in this manual about selection and service of the bearings are based on the instructions from the bearing
manufacturer (SKF). The bearing manufacturer’s information and instructions are valid in conflict situations (e.g.
information updates).
The pulley bearings must be lubricated with a lubricant type which is suitable to the operating conditions. The end user is
responsible for selecting the lubricant and the possible change of the grease type. Sandvik/Haparanda recommends
staying with the selected grease/thickener type in order to ensure the blending possibility between greases. The lubricant
must be selected on a case-specific basis. The grease characteristics must be determined from the manufacturer’s
information before changing the grease type.
Avoid recurring skin contact when handling the lubricants. Follow the instructions in the material safety data sheet
compiled by the lubricant manufacturer and use appropriate protective clothing. The material safety data sheets must be
enclosed with the pulley care instructions and updated when changing the lubricant type or when the manufacturer’s
product information is changed. The end user is responsible for updating the information.
The bearing housings are filled with lubricant in the assembly phase.
The pulleys must be protected and lubricating points piped in a way that ensures safe lubrication.
The lubrication of the pulley bearings during operation must always be performed when the pulley is rotating (except for BR
pulleys, type A). When the lubrication is performed during operation, the lubricant is distributed evenly to the bearings and
seals, and the seal pressure does not become too high.
The consistency and amount of the lubricant must be monitored regurarly during operation, at least in service procedures
during shutdown.
The used lubricant is hazardous waste. Lubricant removed from service must be stored and disposed of in accordance
with the national regulations prevailing at the operation site.

6.6 Recommended lubricants

The information in the table is provided by lubricant manufacturers. Sandvik/Haparanda takes no responsibility for
changes in the information published by manufacturers.
Standard
B a se o i l operating
NLGI Drop point Centralised
viscosity temperature Thickener B a se o i l
glass °C lubrication
mm2/s 40° C range for the
oi l ° C

Shell Alvania Grease RL2 2 100 190 -25…+120 Lithium/Calcium Mineral oil X

Shell Limona LX 1 1,5 550 285 -25…+150 Lithium complex Mineral oil X

Shell Albida Grease EMS2 2 100 >260 -50…+150 Lithium complex Synthetic

Teboil Multipurpose HT 2 200 >260 -30…+150 Lithium complex Mineral oil

Teboil Syntec Grease 2 160 >260 -40…+150 Lithium complex Synthetic

Mobil Mobilux EP 2 2 150 190 -20…+130 Lithium Mineral oil

Mobil Mobilux EP 0 0 150 190 -30…+120 Lithium Mineral oil X

Mobil Mobilith SHC PM 1,5 460 250 -40…+180 Lithium complex Synthetic X

Neste Allrex EP 2 2 200 198 -30…+120 Lithium Mineral oil

Neste Allrex EP 0 0 200 182 -40…+100 Lithium Mineral oil X

Neste Semilix 1,5 120 >250 -35…+150 Lithium complex Partially synthetic

BP Energrease LS-EP 2 2 180 >260 -25…+130 Lithium Mineral oil

BP Energrease SY 4601 1,5 460 195 -40…+180 Lithium complex Synthetic

BP Energrease LS-EP 00 0 90 170 -35…+120 Lithium Mineral oil X

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 13 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

6.7 Post-lubrication

Table 1. Lubricant quantities

P = total volume of the bearing housing
L = value corresponding to the bearing’s theoretical lubricant needs for creating a sufficiently thick lubricant
film.
L and P values for tables 2 and 3 are read from table 1.
Type marking of the pulley indicates the diameter of the axle (=inner diameter of the bearing) in millimetres.
E.g., DS 80- /DK 100- /BED 120-
SKF housings for pulley types DK/BK/BD/BE/DS/DT
Sandvik housings for pulley types BED/BEE/BP/BR/BT/BW

P
(lubricant quantity for the first lubrication,
Axle diameter = inner gr)
L
diameter of bearing
(gr) Sandvik housings
(mm) SKF housings
(BZC11),(BR/BP),
(SNL-/SNH-/SD-)
(BZC12/MZC1)

40 0,08 65 80

50 0,10 100 90

60 0,15 180 180

70 0,18 280 230

80 0,26 430 270

90 0.33 630 -

100 0,42 850 500

110 0,50 1000 -

115/120 0,59 1100 620

125 0,68 1400 -

135 0,79 1700 -

140 0,93 2000 600

160 1,10 2300 930

180 1,41 2600 1520

200 1,73 3000 3410

220 2,11 5500 4170

240 2,50 7000 5200

260 2,60 7400 6880

280 3,02 10500 7280

300 3,48 13000 7720

320 4,41 19100 8180

340 4,61 19300 8550

360 4,81 24500 86 40

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 14 We reserve the right for modifications without prior notice.
 Sandvik
Conveyor Components

Table 2. Hand lubrication - lubricant quantities and lubrication periods

Condition Lubricant quantity Lubrication

gr/housing period

A P 1 month

B P 3 months

C P 6 months

P = total volume of the bearing housing from table 1.

Table 3. Continuous lubrication - lubricant quantities and lubrication periods

Single dose of cleaning

Continuous lubrication
lubrication
Condition
Lubricant quantity Lubrication Lubricant quantity Lubrication
gr/housing period gr/housing period

A L x 1.5 1 hour P 3 months

B L x 1.3 1 hour P 6 months

C L x 1.0 1 hour P 12 months

P = total volume of the bearing housing

L = value corresponding to the bearing’s theoretical lubricant needs for creating a sufficiently thick lubricant film.
L and P values come from table 1.
A small quantity is dosed hourly and a cleaning lubrication is also performed in accordance with the operating conditions.
In the cleaning lubrication, all lubricant in the bearing housing is changed at the same time.

7. Spare parts

When ordering products, the type marking and the possible ‘Ex’ marking must be mentioned, if the product is installed in a
conveyor operated in an explosive space. Complete markings and the any delivery-specific special requirements must be
verified from the original delivery documents and mentioned in the order.
Type markings of the pulleys are presented in this manual, in “1.4 Types and markings” and in the selection criteria for the
conveyor pulley in the Sandvik Conveyor Components product catalogue.
Attachment elements and spare parts for the bearings with their type numbers are presented in the following appendices.

Copyright 2007 Sandvik Mining and Construction Haparanda AB

Pulleys 01.11.2007 15 We reserve the right for modifications without prior notice.
 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007 1 (1)

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U replacing of garland idler rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 OPERATION AND MAINTENANCE INSTRUCTION
ADJUSTMENTS

JPa 08.09.04 1 (1)

General

Belt conveyors have not been tested at workshop but certain adjustments are carried out
based on tests done eralier. Anayway The tests were carried out without material. The
material weight and location on the belt may change the situation and therefore some
adjustments can be actual due to misalignment of the belt.

The position of Mobil unit has also influence for the belt misalignment. Operation in
position where pulleys are in ”hand level” is optimal for belt conveyor.

1. Belt take-up

The length of belt can be adjusted by using screw take-up locating at drive end of
conveyor. Note; adjust both sides as much to avoid misalignment of belt.

2. Adjusting of belt

In the case of the continuous misalignment of the belt there are few possibilities for the
adjustments. Before any adjustment, see first ROX11-02-40 instructions from the
Maintenance and Operation file.

Adjustments available in order to be carried out:

- adjust the position of Drive Pulley
- adjust the position of Tail Pulley
- adjust the position of return idler

3. Belt replacing

The belt is wear part and shall be replaced when needed. See separate instruction made
by belt supplier.

4. Belt cleaner

Adjust the cleaner acc. to the instruction. Replace the wear part in time.

5. Fastenings (bolts, nuts etc.)

Ensure regularly that fastenings are tightened. Retighten them acc. to given torques when
needed (replace damaged fittings with new ones). Extensive inspection shall be done at
least every year.

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.11_Yhteiset omat ohjeet\Adjustments.doc

 OPERATION AND MAINTENANCE INSTRUCTION
ADDITIONAL – BELT CONVEYOR

JPa 11.08.03 rev. -/JPa 1 (1)

General

This additional instruction is a short summary of certain instructions underlined by

Sandvik Hollola.

Safety

Respect all instructions given and general caution. Follow instructions issued by local
authorities.

Take into consideration hazards generated by:

- entanglement at a rotating part or moving part; ensure that the gap guards are always
installed when operating
- falling/rolling material from the belt; prevent personnel enter to risk zone
- unexpected starts; ensure the warning device function and use a safety switch
- Noise from material and operation; use personal protective devices
- Material dusts; use personal protective devices
- Disuse of personal protective devices; train personal for proper use of devices
- Back rotation of belt particularly when belt is loaded with material (for example when
there is blockage on loading area below the crusher); prevent the motor rotation

Capacity

The proper use of Belt Conveyor will increase the lifetime of conveyor as well as the safety
of operation. Ensure that the capacity and material particle size on the belt do not exceed
given values (ton/h). The maximum particle size and capacity are defined on the main
drawing.

Records

All actions related to the scheduled maintenance, part replacing and damages must be
recorded in the Maintenance Log.

G:\Workgroup\TIIMIT\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.11_Yhteiset omat ohjeet\Additional.doc

 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007 1 (1)

Maintenance Log

It is Owner’s obligation to maintain among other things the Maintenance Log, for
other obligations see ROX 11-01-01.

On the Maintenance Log inspections, service actions and other actions must be recorded
as an implementation of Sandvik Hollola instructions valid for the belt conveyor.

When required records must be available for Sandvik Hollola.

Enclosed sheet is an example sheet for the Maintenance Log.

All Damage Reports, if any, must be stored up in the Maintenance Log.

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Maintenance log

rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
MAINTENANCE LOG page ___
Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181
Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
Finland

Belt Conveyor
RRH1212, RRH1213U, RRH1214U, RRH1209
Manufacturing number: 12…. / 200…. / W…… / ….

Author:______________________________ Date: :______________________________

Describing
of
maintenance
work

Reference to
instruction
Rox 11-02- __
Rox 11-02- __
Rox 11-02- __

Author:______________________________ Date: :______________________________

Describing
of
maintenance
work

Reference to
instruction
Rox 11-02- __
Rox 11-02- __
Rox 11-02- __

Author:______________________________ Date: :______________________________

Describing
of
maintenance
work

Reference to
instruction
Rox 11-02- __
Rox 11-02- __
Rox 11-02- __

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Maintenance and feedback form rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
FEEDBACK FORM
Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181
Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
Finland

Manufacturing number: 12…. / 200…. / W…… / ….

1. COMPONENTS, SPARE and WEAR PARTS

S Your proposals for the development?

S What improvements are most urgent ones?

2. FRAME and TARPAULIN

S Your proposals for the development ?

S What improvements are most urgent ones?

3. OPERATION & MAINTENANCE

S Proposals for the better operation and availability?

4. OTHER S

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Maintenance and feedback form rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 OPERATION AND MAINTENANCE FILE
RRH1212, RRH1213U, RRH1214U BELT CONVEYORS
OPTION CONVEYOR RRH1209 (for open circuit)

15.12.2007 1 (1)

Description of Damage

If damage takes place it must be described and drawn on paper. Filled Damage Report
must be also sent to Sandvik Mining and Construction Hollola Oy, who on this way has
detailed information from the Damage.

In case of guarantee the Damage Report is precondition for the reclamation handling.
Manufacturing number to be filled on the report is written on Type Plate locating on the
frame part of drive end.

Damage describer must be properly trained and authorised person, who can describe the
Damage in details. The Report shall include also photos.

There is enclosed an example from the Damage Report Form.

All Reports must be stored up in the maintenance log of Operator.

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Description of damage rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
DAMAGE DESCRIPTION FORM appendix
Sandvik Mining and Construction Hollola Oy Tel + 358 205 44 181
Keskikankaantie 19 Fax +358 205 44 180
FIN-15860 HOLLOLA
Finland

RRH1212, RRH1213U, RRH1214U, RRH1209 Belt Conveyor

Manufacturing number: 12…. / 200….. / W…… / ……

Author:______________________________/date :______________________________

Damage
description

Enclosere

Author:______________________________/date :______________________________

Damage
description

Enclosere

Author:______________________________/date :______________________________

Damage
description

Enclosere

L:\SRP_Mobil\B_Tuotearkistot\7_Huolto-ja_käyttöohjeet\7.2_EN pdf\RRH1212-14\Rev2_työfilet\RRH1212-14U Damage description form rev2.doc

Sandvik Mining and Construction Hollola Oy Tel. +358 205 44 181 Business ID/Y-tunnus 0625827-2
Keskikankaantie 19 Fax +358 205 44 180 Location/Kotipaikka Hollola, Finland
FI-15860 Hollola, Finland www.sandvik.com VAT No. FI 06258272
 ®

OPERATING INSTRUCTIONS

Planar-N
Planar-NL
R-16, R-CAN
Compact-M, Compact-V

Receiver Type / Version Transmitter Type / Version

Factory No. Factory No.

Frequency Frequency

X XX
1. STANDARD SPECIFICATION % Portable transmitter.
% Receiver with integrated mounting holes.
% Multi-pin connecting cable for the receiver according to your specifications.

The actual delivery specification is as detailed on the confirmation of order or

the delivery note accompanying the goods!

2. SAFETY PRECAUTIONS Even if you are accustomed to working with radio control systems, read these
operating instructions carefully before using this equipment. Only this docu-
ment contains the latest information relating to your NBB radio control system.

For explanatory notes on obtaining an operating permit please refer to registration docu-
ments enclosed in the appendix of this operating instruction. Observe all applicable work-
safety and accident prevention regulations carefully. Only fully trained, authorized per-
sonnel may use the NBB radio control equipment. Components, etc. built into the NBB
equipment for safety purposes must be regularly inspected.

If the NBB radio control unit develops a fault, it must be shut down immediately.
The transmitter should be switched off with the STOP key, resp. EMERGENCY
STOP switch. The connecting cable must be disconnected at the receiver from
the connecting socket (terminal) of the unit to be controlled . The repair of the
equipment must not be carried out other than by NBB or an NBB authorized tech-
nician.

Failure to observe these recommendations will put both you yourself and others at risk.
Under these circumstances, NBB rescinds the guarantee and any other form of liability.
This radio control unit is designed exclusively for the control of construction machines
and industrial plants. Only under these conditions are the safety systems (STOP, resp.
EMERGENCY STOP, zero setting) fully effective. No other form of use is permitted. Any
non-observance of this condition will relieve NBB of all liability.

3. TRANSMITTER Switching on: To make the unit ready for use, unscrew the screw plug of the battery com-
partment on the back of the transmitter and remove the cover. Insert 2 charged AA Mi-
gnon batteries 1,2V NiMH (or batteries 1,5V - not rechargeable) into the battery compart-
ment, close the cover and tighten the screw plug again.
Rechargeable batteries (NiMH or NiCd) must be fully charged before first use!
Never attempt to charge standard non rechargeable 1,5V AA batteries!

Page 1
3. TRANSMITTER Planar-N The power supply to the transmitter is activated with the “STOP” key, resp. EMERGENCY
STOP switch.
(When pressed, the EMERGENCY STOP switch can also be secured by removing the key
cap.)
ST

The green LED on the transmitter control panel must flash regularly.
O
P

ST Commands can now be put in by means of the controls.

AR

When the red "Battery" indicator lamp lights up, the batteries (rechargeable or not rechar-
T

geable) are nearly empty.

The transmitter can be operated for approximately 30 minutes more in this condition.
During this time, bring the unit to a safe position, switch off the transmitter and install 2
charged AA Mignon batteries 1,2V NiMH (or batteries 1,5V - not rechargeable).
STOP

Energy saving function: The transmitter switches off automatically, if the keys are not
pressed within a specified time. The LED goes out.
Optional: Transmitter for continuous operation possible.
*The duration of this stand-by can be specified when ordering.

Active/Passive-Routine: After pressing the “STOP” key on the transmitter further

STOP-telegrams will be sent for 2 more seconds*, until the unit to be controlled switches
LED FUNK EIN
LED AKKU

off. *The duration of this time to cut off can be specified when ordering.
START

3. TRANSMITTER Planar-NL The power supply to the transmitter is activated with the “STOP” key, resp. EMERGENCY
STOP switch.
(When pressed, the EMERGENCY STOP switch can also be secured by removing the key
cap.)
ST

A red dot flashes on the Planar-NL display during operation.

O
P

Commands can now be put in by means of the controls.

ST

When the letter "L" flashes quickly on the Planar-NL display, the batteries (rechargeable or
AR
T

not rechargeable) are nearly empty.

The transmitter can be operated for approximately 30 minutes more in this condition.
During this time, bring the unit to a safe position, switch off the transmitter and install 2
charged AA Mignon batteries 1,2V NiMH (or batteries 1,5V - not rechargeable).

Energy saving function: The transmitter switches off automatically, if the keys are not
L pressed within a specified time. The red dot goes out.
Optional: Transmitter for continuous operation possible.
*The duration of this stand-by can be specified when ordering.

. . Operation:
The red dot flashes.

. . Quickly flashing: Batteries

are nearly empty. Trans-
mitter can be operated
for appr. 30 minutes more.

Page 2
4. RECEIVER
R-16, R-CAN
Compact-M, Compact-V
Mounting possibility of the receiver
R-16, R-CAN or the Compact-M.
Mounting possibility of the receiver
Compact-V.
R-16 R-CAN Compact-M Compact-V
The receiver is connected to the unit to be controlled with the multi-pin connecting
cable supplied. Please observe the instructions issued by the manufacturer of the unit
to be controlled! We recommend urgently to realize this connection via a cen-
tral, well accessible, multi-pin plug connector (for example HTS-plug connec-
tor series HE/HB/HN/HA or comparable ones of other manufacturers) to
make possible a quick and clear fault diagnosis in the service case and to
take off the receiver without an expenditure of assembly.
The power supply of the receiver is generally effected by the connecting cable.
% In general, an earth lead is required in case the units to be controlled
have not previously been operated by radio control. Failing this, the
receiver electronic circuit will not receive any power supply. Ensure that
the operating voltage of the receiver complies with the electrical specifi-
cations of the unit to be controlled. The applicable operating voltage is
specified in the supplement.
% Never expose the receiver to a high pressure cleaning jet. This applies to
the transmitter also.
% The receiver should always be fixed vertically at the outside panel of the
switching cabinet. (The antenna should always reach over the top of the
panel.)
% You have to make sure that the antenna is not shielded by metal parts
totally or partly.
% Mounting the receiver in a cabine or in a switching cabinet the antenna
should be layed with an extension cable to the outside and be attached with
the fastening strapping as horizontally as possible with distance to the
shielding metal parts.
% In general the antenna should always be mounted in such a way so that the
antenna is still visible with each change of position of the transmitter.
WRONG
RIGHT
RIGHT
WRONG
Top slewing crane: Mount the antenna with
Mounting on a tower slewing crane. extension cable horizontally.
Page 3
5. OPERATING THE UNIT Safety equipment in the NBB-radio remote control:

In the transmitter, this comprises mainly:

% STOP, resp. EMERGENCY STOP with automatic disconnection of the power supply.
% Automatic zero positioning.
In the receiver:
% Two diversity units for evaluation of the STOP, resp. EMERGENCY STOP signal.
% Automatic zero setting when switching back on after radio interruption.
% Locking of the radio commands at relay level in the event of a defective STOP, resp.
EMERGENCY STOP circuit.

To ensure fault-free operation, please follow precisely the following rules for operation:
The unit to be controlled can only be switched on - it is assumed that the transmitter is
ready to operate - when no command unit is actuated. The command necessary to do so
is triggered by the key "ON/HORN". This triggers a horn signal in the unit to be controlled.
After switch-on of the facility to be controlled, this key is used for repeated emission of the
horn signal in accordance with working regulations.
If the NBB radio remote control is not used for a long period, it is urgently recom-
mended - if you use rechargeable batteries - that they should be charged now
and again (about every 4 weeks). This prevents deep discharges of the batteries
and prolongs their useful life. If you shut down the NBB radio remote control for a
ON/HORN

BRAKE

JUMPER

OFF

FREQUENCY
CHANGE

OPERATING STATUS
LOW BATTERY
RADIO ON/
EMERGENCY STOP

long period, we recommend you take the batteries out of the transmitter.

Frequency change:
To change the frequency, keep the "ON/HORN" key pressed down. Then operate the "FRE-
FREQUENCY CHANGE QUENCY CHANGE" key. If the receiver locks into the new frequency, a horn signal is given
(if present) and the unit to be controlled is ready for operation.
Please observe the particular postal approval regulations of the concerned country.

Channel number: When changing the frequency the channel number lights up shortly in
53 the display. During operation the choosen channel can be shown by pressing the “FRE-
QUENCY CHANGE” key.
(See example on the left)

Page 4
6. FUNCTION CHECK To maintain operational safety, a regular function check of the NBB radio remote control is
necessary. In single-shift day-to-day operation, we recommend performing this check at
least once a week. Checking is possible using the display lights provided on the receiver.
To do so, the transmitter must be set to the ready-to-operate state.

% First connect just the receiver - the transmitter remains switched off.
% Activate the transmitter by unlocking the EMERGENCY STOP switch, resp. pres-
sing the key "START/ON/HORN".
% Now check the commands (always start with the lowest stage) and check for cor-
rect reaction of the unit to be controlled.
% Ensure in particular that there is nobody in the danger area. ACCIDENT RISK!
% STOP, resp. EMERGENCY STOP check. Press the EMERGENCY STOP switch at
the transmitter until the switch engages, resp. press the STOP key. Then observe
if the unit to be controlled is switched off (time to switch off according to the appli-
cation).

Checking the LED display at the receiver R-16 and R-CAN:

(Optional with integrated charger)
R-16
The green LED flashes: RADIO PRESENT.
R-CAN
If the LED fails to come on:
1. Check that the transmitter is on.
LED RADIO ON SERVICE PLUG 2. Check the power supply of the receiver.
3. (Optional) Irregular flashing of the LED:
Check or change the current radio channel.

Checking the LED display at the receiver Compact-M:

COMPACT-M (Without integrated charger)
The green LED flashes: RADIO PRESENT.
If the LED fails to come on:
LED RADIO ON SERVICE PLUG 1. Check that the transmitter is on.
2. Check the power supply of the receiver.
3. (Optional) Irregular flashing of the LED:
Check or change the current radio channel.

Checking the LED's at the receiver Compact-V:

COMPACT-V % LED 1 green: POWER ON. If LED fails to come on, check the power supply.
1 2 3 4 LEDS If the power lead is OK, call in the after-sales service.
®
% LED 2 yellow: HF PRESENT. Steady light when transmitter is switched on
SERVICE PLUG
(insignificant for scanner operation).
% LED 3 green: Flashes evenly during fault-free operation.
X Irregular flashing means that the HF channel is probably at
fault - please set another channel.
www.nbb.de
3.820.1195
% LED 4 red: If this LED flashes, the HF channel is at fault (not in the
scanner operation).
Steady light notifies the operator that an output function
is critical due to over current.

Service plug: For NBB service only.

Page 5
7. RATING PLATES The rating plates state the type of transmitter or receiver, the factory number, the fre-
quency range and the approval number for non EU countries.
Always state the factory number in all your queries.
Example:

Transmitter Type / Version: Planar-N Receiver Type / Version: Compact-V

Factory No.: 999 899 4990 Factory No.: 999 899 4990
Frequency: 402 -470 Mhz Frequency: 402 -470 Mhz

XX X

8. MAINTENANCE Your NBB radio remote control is largely maintenance-free. Nevertheless, please bear in
mind the following points:
% The STOP key, resp.the EMERGENCY STOP switch must be easy to move.
% Remove any leftover building materials!
% During electro-welding work on the unit to be controlled, disconnect the receiver from
the current supply! Otherwise there is a risk of damage to the receiver's electronic sys-
tem!
% Check wear and tear parts like dust shield tops regular!

9. WARRANTY We grant a function warranty for 12 months after the sale date for all NBB radio remote
controls (transmitter, receiver, charger). The warranty covers working time and material
used. Shipping costs shall be charged to the customer. The warranty shall not cover:
wear and tear parts, relays and batteries. The function warranty shall be invalidated in the
case of damage, accident damage, negligence, incorrect use, non-compliance with ope-
rating conditions, non-compliance with operating, testing and maintenance instructions,
and repairs or unit modifications not authorised by NBB.
NBB shall not be liable for indirect damage and reserves the right to decide on repair or re-
placement.

10. IN CASE OF DEFECTS Do not attempt to continue working with a defective NBB radio remote control. Even initial-
ly minor defects might be the start of a more extensive defect.
Do not try to repair the NBB radio remote control yourself. If there is any fault please con-
tact your dealer or our company.

Page 6
 NBB Controls & Components AG AnlagenNr.: / Device No.:

999 389 8691 / Int. 61130

Receiver R-CAN
CANOpen Protocol

PROCESS DATA

Ausgestellt / issued Nr. / No.

2004-09-15 erstellt / written
CANOpen
Freigegeben / released Datei / file
ROMAN SOWADA ProzessData.doc
geändert / revised R&D Department Seite / page von / of
NBB Controls&Components Process data
2007-03-28 1 3
 NBB Controls & Components AG AnlagenNr.: / Device No.:

999 389 8691 / Int. 61130

Process data for Radio Receiver:

Node Id: 16 (decimal) => 0x10 (hexadecimal)
Standard frame at 125 KBaud
Receiver start message: Id=0 data={1,0}

After receiving the start message, two PDO’s are sent back to back at 60mS
intervals.

Digital PDO:
Id: 0x190 (hexadecimal) => 0x180 (hexadecimal) + Node-Id.
Data bytes: x=not used at present time

Byte Bit Function

1 0 Enable / Horn

1 1 Starttid

1 2 Matare Start

1 3 Matare Stop

1 4 Band Start

1 5 Band Stop

1 6 Sekvens Start

1 7 Sekvens Stop

2 0 Larvning Aktiveread

2 1 Pilot V. Joystick

2 2 Pilot H. Joystick

2 3 Diesel Stop (EM-Switch pushed!)

2 4 Not used

2 5 Not used

2 6 Not used

2 7 Not used

Data bytes 4-8 are not used at present.

Ausgestellt / issued Nr. / No.

2004-09-15 erstellt / written
CANOpen
Freigegeben / released Datei / file
ROMAN SOWADA ProzessData.doc
geändert / revised R&D Department Seite / page von / of
NBB Controls&Components Process data
2007-03-28 2 3
 NBB Controls & Components AG AnlagenNr.: / Device No.:

999 389 8691 / Int. 61130

Proportional PDO:
Id: 0x290 (hexadecimal) => 0x280 (hexadecimal) + Node-Id.

Byte Function

1 Channel 1 Joystick Left

2 Channel 2 Potentiometer

3 Channel 3 Joystick Right

Data bytes 4-8 are not used at present.

The PDO contains the analog values in the sign amount format. A set MSB
means a negative sign. The following bits represents the amount. So the
nummer 81 hex represents the value –1 for example.

Ausgestellt / issued Nr. / No.

2004-09-15 erstellt / written
CANOpen
Freigegeben / released Datei / file
ROMAN SOWADA ProzessData.doc
geändert / revised R&D Department Seite / page von / of
NBB Controls&Components Process data
2007-03-28 3 3
TECHNICAL DATA ®

Operating ambient temperature -20 to +70 °C

Insulation class - Protection IP 65

TRANSMITTER Planar-N, Planar-NL

Transmission frequency range 402 - 470 MHz (The actual frequency range depends on the regulations
of the concerning country !)
The use of synthesizer technology permits frequencies to be selected in accordance with the appropriate
waveband for the country of use.
Low frequency modulation GFSK
Data repetition rate about 15 ms / 60 ms
Baud rate 4800 Baud / 1200 Baud (Bit / sec.)
Range about 100 m
Power input about 60 mA
RF ouput < 10 mW

Weight (without battery) Size (L x W x H)

Planar-N 570 g 17,5 x 12,7 x 9,6 cm
Planar-NL 990 g 24,8 x 13,7 x 9,6 cm

Power supply 2 x rechargeable batteries 1,2V AA NiMH

(or 2 x batteries 1,5V - not rechargeable)
Operating duration >30h (2000mA/h NiMH batteries)

RECEIVER R-16, R-CAN, Compact-M, Compact-V

Reception frequency range 402 - 470 Mhz
Data security:
Generates a CRC code with a Hamming distance = 4. Generates a neutral position.
Addressing of each transmitter with its own, unique combination (max. 2 16 possible combinations).
Data reception security: Diversitary evaluators, CRC, EMERGENCY STOP and neutral position bits.
max. switching voltage 250V AC (12V / 24V DC - R-16, R-CAN, Compact-M, Compact-V)
max. switching current 4A AC (3A DC at 12V / 24V - R-16, R-CAN, Compact-M, Compact-V)
max. switching power 1000 VA

Weight Size (L x W x H)
R-16, R-CAN 640 g 18 x 9,7 x 4,4 cm
(potted) 800 g
Compact-M 640 g 18 x 9 x 7 cm
(potted) 800 g
Compact-V (potted) 1,5 kg 21,5 x 16 x 6,5 cm

Page 7
APPROVALS AND CERTIFICATES ®

Approvals EU countries: X X

Enclosure:

EC Declaration of Conformity

Obtainable at demand:

M-Zert mbH
Certificate DIN EN ISO 9001:2000-12 No. 03022

© NBB Controls + Components AG

Otto-Hahn-Straße 3-5
DE-75248 Ölbronn-Dürrn
Tel.: 0 72 37 / 9 99 - 0
Fax: 0 72 37 / 9 99 - 1 99
eMail: sales @ nbb.de
http://www.nbb.de

We reserve the right to alter specifications without notice.

Bedienungsanleitung Planar-N, Planar-NL, R-16, R-CAN, Compact-M, Compact-V,

Englisch, Teile-Nr. 3.150.1093, Stand 11.06

Page 9
 Filtro anti-poeira (opção)
O filtro anti-poeira reduz a dispersão da poeira originada pelo transportador
de descarga. O filtro é instalado sobre o transportador. O filtro anti-poeira é
um filtro de cassete, cuja limpeza é efetuada de forma mecânica e
automática.

Os fabricantes do motor do agitador e do motor da ventoinha podem ser

diferentes, dependendo do número de série da máquina. Para obter mais
informações, entre em contato com a empresa, agente, representante Sandvik
mais próximo ou diretamente com:
Sandvik SRP AB
Service Dept.
SE-233 81 Svedala, Suécia
Telefone +46 40-40 90 00
Fax +46 40-40 92 60

UH/US440i, UJ440i © Sandvik SRP AB – Nº Doc S281.971 pt-BR Ver. 1 1

Filtro anti-poeira (opção)

Esta página foi intencionalmente deixada em branco

2 © Sandvik SRP AB – Nº Doc S281.971 pt-BR Ver. 1 UH/US440i, UJ440i

 Dust filter (option)
The dust filter will reduce dust dispersion from the discharge conveyor. The
filter is installed on top of the conveyor. The dust filter is a mechanically and
automatically cleaned cassette filter.

Shaker motor and fan motor manufacturer may differ depending on the serial
number of the machine. For further information please 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

UH/US440i, UJ440i © Sandvik SRP AB – Doc. no. S281.971 en Ver. 1 1

Dust filter (option)

This page is intentionally left blank

2 © Sandvik SRP AB – Doc. no. S281.971 en Ver. 1 UH/US440i, UJ440i

Hydraulic

IMV-B 22_X0X 2007

 Delivery and installation
Deliie ry
The filters are normally delivered as follows:
- Filters with a filtering area of up to 22,5 m2 are normally delivered with completed
assembly.
- Filters with a filtering area larger than 22,5 m2are normally delivered with
mounted fan but with separate filter hopper.
- Larger filters are normally delivered in their principle parts.
- The filter cassettes are always delivered mounted in the filter casing.
- As for all deliveries of standard filters, the goods is fixed with bolts on pallets.
Immediately upon receipt of the goods, check for delivery damage.
Report all damages, if any, to the freighter and inform the supplier.
After receipt of the goods, the filter parts must be stored in such a way, that they
are not exposed to damage, atmospheric precipitation or other climatic conditions
before installation.

3.2 Handling
The filters must be handled in such a way that the risk of personal injury is
Warning minimized. The parts weighing more than 50 kgs are provided with a Iabel stating
0 the weight.
Most of the parts can be transported by truck. If hoisting crane must be used,
please follow the instructions below.

4 kg
Max. wight 1945

3.3 Installation
The filters must stand on firm surface and be attached as follows:
- Silo filter and filter without hopper are bolted on to counter flange
- Filters with hopper have as standard fixed legs or telescopic legs. The base
plates are fixed with expansion-shell b o b or similar and as for filters with
telescopic legs, the filter hopper is lifted to a certain height above the ground and
the telescopic legs are drilled and fixed with through bolts.

All flanges between the different filter parts must be provided with sealing strips
before they are joined together with bolts or eccentric locks.
----*------------------- -------"--I---

IWULSFIL TERAB, Filter IM

Installation and maintenance instruction Filter M
I- 5
IMV-B 22-X0X 2007
IMV-B 22-X0X 2007
 Substituição das
correias de acionamento do
britador
O UH440i / US440i utiliza correias em V pré-tensionadas1 (SPC, 22 × 18)
para acionamento da correia do britador. As correias são tensionadas apenas
duas vezes, durante a instalação e após 10 horas de funcionamento. O uso de
correias pré-tensionadas permite substituir uma única correia, em caso de
danos.
O tensionamento é obtido ajustando-se a posição de toda a unidade de força.
A posição é alterada por meio de dois parafusos de tensão (1), um em cada
lado da máquina, abaixo do motor.

1. Atualmente VECO 200® “label DYNAM”, SPC = 22 × 18

UH440i / US440i © Sandvik SRP AB – Nº Doc S 281.841 pt-BR Ver. 1 1

 Substituição das correias de acionamento do britador

Remoção das correias em V antigas

Risco de lesões e/ou danos ao equipamento
Certifique-se de que o motor e os demais equipamentos estejam
desligados e travados, antes de começar a efetuar serviços nas
AVISO! correias de acionamento do britador.

NOTA! Em caso de danos, é possível substituir uma das correias.

a) Remova as proteções da correia, protegendo as correias de acionamento

do britador.
b) Remova as tampas de inspeção abaixo da proteção da correia, para
acessar os parafusos de tensão e a polia do britador.
c) Solte os dois parafusos (1) em cada uma das quatro pernas da unidade de
força.
3 2
A

5
ESBOÇO

1 4

d) Introduza graxa nos pontos de lubrificação (2).

e) Limpe os rosqueamentos dos parafusos (3) de tensão.
f) Solte as porcas fixadoras internas (4) e mova-as na direção A. Consulte a
ilustração acima.
NOTA! Utilize uma chave de combinação de 65 mm.
g) Vire a cabeça dos dois parafusos de tensão no sentido horário para mover
toda a unidade de força e, assim, afrouxar as correias.

Risco de desalinhamento
Trabalhe paralelamente aos dois parafusos de tensão. Não mova-os
mais de 5 mm de cada vez, para não ficar com dois eixos não paralelos
AVISO! e/ou polias desalinhadas.

h) Erga as correias em V e remova-as, quando estiverem frouxas o

suficiente.

2 © Sandvik SRP AB – Nº Doc S 281.841 pt-BR Ver. 1 UH440i / US440i

 Substituição das correias de acionamento do britador

Instalação de correias em V novas

a) Instale as novas correias em V no acionamento, conectando-as às duas
polias.

Risco de danos ao equipamento

Não force a instalação da correia nas ranhuras das polias.
Qualquer esforço excessivo pode danificar o fio de tensão.
AVISO!
NOTA! Apenas oito das ranhuras serão utilizadas, se as duas polias tiverem nove
ranhuras. A ranhura mais externa de cada polia é deixada vazia.
b) Se necessário, solte as porcas fixadoras internas (1) e mova-as na
direção A. Consulte a ilustração abaixo.
c) Vire a cabeça (2) dos dois parafusos de tensão no sentido anti-horário
para movê-los na direção B. Consulte a ilustração abaixo.
A B

ESBOÇO
3 1

Risco de desalinhamento
Trabalhe paralelamente aos dois parafusos de tensão. Não mova-os
mais de 5 mm de cada vez, para não ficar com dois eixos não paralelos
AVISO! e/ou polias desalinhadas.

Diferença máxima entre os dois eixos = 0,5°

Desalinhamento máximo = 8 mm por metro de distância entre os eixos

d) Vire as porcas fixadoras internas (1) para movê-las na mesma direção (B,
consulte a ilustração acima). Isto moverá toda a unidade de força,
esticando progressivamente as correias.

UH440i / US440i © Sandvik SRP AB – Nº Doc S 281.841 pt-BR Ver. 1 3

 Substituição das correias de acionamento do britador

Tensionamento de correias novas

a) Verifique a tensão, observando as marcas indicadoras nas correias mais
interna e mais externa. Meça a distância entre a parte externa das duas
marcas.
As marcas indicadoras e o texto devem ter o seguinte aspecto:

I < Tension of the installation / Init tension = nnn mm > I

Se a tensão da correia precisar ser ajustada, vire a cabeça dos dois

parafusos de tensão no sentido anti-horário e vire as porcas fixadoras
internas, para virá-las na mesma direção.
b) Quando for atingido o comprimento certo entre as marcas, aperte
novamente os dois parafusos (3) em cada uma das quatro pernas da
ESBOÇO

unidade de força.
A B

3 1

c) Instale novamente todas as proteções da correia e tampas de inspeção.

d) Opere o britador vazio por alguns minutos, para acomodar as correias
nas ranhuras.
e) Verifique novamente a distância entre as marcas.
f) Se necessário, ajuste novamente a tensão das correias, para atingir a
distância correta entre as marcas.
g) Se necessário, ajuste novamente a tensão das correias, para atingir a
distância correta entre as marcas.
NOTA! Após 10 horas de funcionamento, reajuste a tensão das correias.

4 © Sandvik SRP AB – Nº Doc S 281.841 pt-BR Ver. 1 UH440i / US440i

 Substituição das correias de acionamento do britador

Reajuste da tensão de correias novas

As novas correias devem ter sua tensão reajustada depois de cerca de
10 horas de funcionamento. Utilize agora um testador de tensão (número de
peça 879.0662-00), em vez de medir a distância entre as marcas indicadoras
das correias.
a) Abra a última escotilha de inspeção à direita (em direção às dobradiças),
na proteção da correia.
b) Pressione cada correia 22 mm, usando o testador de tensão. A força
necessária deve ser de 5,2 kg em cada correia.

ESBOÇO
c) Feche a escotilha de inspeção.
d) Se necessário, ajuste novamente a tensão das correias, repetindo as
etapas de seção Tensionamento de correias novas.
NOTA! Não ajuste novamente a tensão das correias, após este ajuste.
Quando as correias ficarem muito frouxas, danificadas ou gastas, deverão
ser substituídas.

UH440i / US440i © Sandvik SRP AB – Nº Doc S 281.841 pt-BR Ver. 1 5

 Substituição das correias de acionamento do britador

Esta página foi intencionalmente deixada em branco

ESBOÇO

6 © Sandvik SRP AB – Nº Doc S 281.841 pt-BR Ver. 1 UH440i / US440i