s07 tramming axera robolt solo 5 en

MAINTENANCE MANUAL

5 RANGE TRAMMING

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

SANDVIK MINING AND CONSTRUCTION LYON S.A.S.19, av. De Lattre de TassignyB.P. 46 - 69881 MEYZIEU cedex, FRANCETel: +33 (0)4 72 45 22 00 Fax: +33 (0)4 78 31 79 80

C-24-01-2007 SR-RB-FLTRAMMING 5 RANGE


C-24-01-2007 SR-RB-FL TRAMMING 5 RANGE


CONTENTS

1 PRELIMINARY REMARKS 5

1/1 SAFETY 5

1/2 ABOUT THIS BOOKLET 7

2 DESCRIPTION 8

2/1 EXPLANATION 8

2/2 FEATURES 8

2/3 MAIN COMPONENTS 9

3 MAINTENANCE 10

3/1 FIRST ENTRY INTO SERVICE 10

3/2 OPERATIONS AT EACH SHIFT 10

3/3 50-HOURS OR WEEKLY OPERATIONS 10

3/4 600-HOURS OPERATIONS 10

3/5 1800-HOURS OR ANNUAL OPERATIONS 11

3/6 5800-HOURS OPERATIONS OVERALL INSPECTION AND RECONDITIONING 11

4 TIGHTENING TORQUES 12

4/1 STANDARD TIGHTENING TORQUES 12

4/2 SPECIFIC TIGHTENING TORQUES : 12

5 LUBRICATION 12

5/1 LUBRICANT 12

5/2 GREASE POINTS 13



6 OPERATING METHODS 14

6/1 MOUNTING OF CONICAL PINS OF THE CENTRAL ARTICULATION 14

6/1/1 CHECK AND ADJUSTMENT 15

6/2 BRAKE CYLINDER ADJUSTEMENT 16

6/3 AXLES DISMANTLING AND MOUNTIG METHODS 16

6/4 HYDRAULIC MOTOR AND GEAR BOX OPERATING METHODS 16

6/5 TRAMMING PUMP OPERATING METHODS 17

6/6 WHEEL CHECK 17

6/7 BRAKE TEST 17

7 PERIODIC MAINTENANCE TABLE 18



1 PRELIMINARY REMARKS

1.1 Safety

The informations contained in this manual must be studied and thoroughly assimilated before undertaking any maintenance work on the equipment

WARNING Operation, maintenance and adjustments are only allowed to persons with specific training in operation and maintenance of the equipment. Read the operating and maintenance instructions before using or servicing the equipment.

WARNING: Before starting any maintenance operation ensure that the machine is in a safe location with good safety, ventilation and lighting conditions. Ensure that lifting equipments and pedestals are compatible with elements’ weight. Follow all the safety instructions and ware safety protections as gloves, goggle, helmet, safety boots, ear protectors.

WARNING: Before any operation stabilize and fix steadily all the elements on suitable pedestals. Stop the power packs, switch the general power breaker. Place a tag or a board to warn other members of the personnel that maintenance work on the machine is in progress.

WARNING: Pressurized oil jets could cause severe injuries. Before any operation on hydraulic circuit, STOP the power packs and release remaining pressure in components by operating hydraulic control levers several times. Always release the static pressure in cylinders before disassemble them.NEVER WORK ON AN OPERATING CIRCUIT.

WARNING: While tests are in progress, do not allow any other member of the personnel to stand in the area surrounding the machine. Stay at the control station to be able to stop the movement and switch off the power pack.

WARNING: Maintenance, adjustment and repairs are restricted to qualified personnel with special training for the particular equipment. Always read the instructions carefully before starting any maintenance work.

CAUTION: Always use suitable tools and work in a clean place when dismantling and assembling hydraulic components. After removing cylinders the hydraulic inlet/outlet ports must be plugged to prevent dirt and air intrusion during operation.

WARNING: The operator must always wear required personal protection, such as safety helmet, protective overall, safety boots, hearing protectors, safety goggles etc.

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

Remember: SAFETY FIRST!Always observe the warnings accompanied by the following symbols.

WARNING

WARNING

WARNING

WARNING

WARNING



WARNING: Danger of hot surface.Hot surface can cause serious injuries.Components rod, shank or hydraulic component can be hot and beforestarting a maintenance work, please let them cool off. The operator must have adequate wears as gloves.

WARNING: Crushing hazard : do not stay in dangerous area, for instance: centralarticulation, front chassis and rear chassis.

SAFETY

Always follow the marked safety instructions, and observe caution while working

The following safety instructions are general rules.

Keeps tools and drilling equipment clean

Dot not attempt any such repairs or adjustments that you do not fully understand

ABOUT THE SAFETY OF REPAIRS

Certain workstages require the use of the feed mechanism during the repair.

- no danger is caused to anybody.

- the machine can be immediately stopped when necessary.

- The powerpack is stopped again before the repair work is continued.

Before starting any repair-work move away from the aera where you have just drilled.

Use proper tools.

Allways wear protective clothing, eye protection , earmuffs, safety footwear and other safety equipment requiered by the work.

WARNING



1.2 ABOUT THIS BOOKLET

The present manual is destined for the use of personnel in charge of carrying out, servicing andmaintenance operations on Jumbos.

It contains maintenance operations schedule and operating methods concerning the main elementsof the TRAMMING 5 RANGE.

Note that servicing and maintenance operations must be carried out by personnel with the requiredqualifications, technical knowledge, and proper training on the machine.



2 DESCRIPTION

2.1 Explanation

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

• Power full four-wheel-drive articulated carrier.

• Automotive hydrostatic transmission.

2.2 Features

• Tramming dimensions (mm) :

• Total machine weights :

AXERA 5 : 12 000 Kg.

ROBOLT 5 :14 000 Kg.

SOLO 5 : 14 000 Kg.

(AXERA 5 SHOWN)



2.3 Main components

1 : TRAMMING PUMP

2 : TRAMMING HYDRAULIC MOTOR

3 : CENTRAL GEAR BOX FRONT DRIVE LINE

4 : REAR SLIDING DRIVE LINE

5 : REAR AXLE BOLSTER PIN

6 : CENTRAL SLIDING DRIVE LINE

7 : FRONT FIXED DRIVE LINE

8 : AXLE

9 : BRAKE CYLINDERS (SPRING APPLIED, PRESSURE RELEASED)

10 : STEERING CYLINDERS

11 : CENTRAL ARTICULATION PINS

5 2 3

4 6 78

910

11

1



3 MAINTENANCE

CAUTION: The safety of users and the reliability of the tramming components depend on the maintenance operations and imply the use of genuine SANDVIK spare parts.

All defective parts must be immediately replaced.


WARNING: While tests are in progress, do not allow any other member of the personnel to stand in the area surrounding the machine. Stay at the control station to be able to stop the movement and switch off the power pack.

3.1 FIRST ENTRY INTO SERVICE

After 20 working hours or 1 week of service, check that all the screws and all the expendable pins are tighten.

3.2 OPERATIONS AT EACH SHIFT

Before starting up:

• Check the overall condition of the equipment (cylinders, hoses, tube, hydraulic unions,...).• Look for leaks.

• Tests brakes

3.3 50-HOURS OR WEEKLY OPERATIONS

• Check the overall condition of the equipment (cylinders, hoses, tube, hydraulic unions,...).• Look for leaks.

• Lubricate all the grease points.

• Check the wheels.

3.4 600-HOURS OPERATIONS

• Carry out the 50-hours operations again.

WARNING

WARNING



3.5 1800-HOURS OR ANNUAL OPERATIONS

• Check the overall condition of the equipment.• Look for leaks .

• Check the condition of the hydraulic equipments (cylinders, hoses, hydraulic unions,...).• Check the tightening torque of the central articulation’s expendable pins and axles fixing bolts.

3.6 5800-HOURS OPERATIONS OVERALL INSPECTION AND RECON-DITIONING

• Check the shape of the ball joints and the shim washers. Remove all defective parts.

• Test for correct operation.

NB : You can recover all these operations in the periodic maintenance table (last page of this manual) we invite you to use this document.



4 TIGHTENING TORQUES

4.1 Standard tightening torques

For basic genuine SANDVIK screws and nuts use the following tightening torques :

4.2 Specific tightening torques :

• Axles fixing :

• Central articulation :

5 LUBRICATION

5.1 Lubricant

Use Mobilith SHC 220, Mobilgrease HP 222 or equivalent.

metric dimension torque in Nm HEX BOLTSGRADE 8.8

torque in Nm “SIX CUT HOLLOW”

BOLTSGRADE 12.9

M6M8M10M12M14M16M18M20M22M24M27M33M36M39M42

10255085

13020028040053067010001780230030003700

164080140210330460650880113016502200385050506250

600

530



5.2 GREASE POINTS

• Grease nipples location :

1 : On the axle bolster pin (grease nipple access near power pack).

2 : On drive lines (grease U-joints and schaft sliding part too).

3 : On the both central articulations

4 : On the both steering cylinders

2

1

3

4



6 OPERATING METHODS

WARNING: Before starting any maintenance operation ensure that the machine is in a safe location with good safety, ventilation and lighting conditions. Ensure that lifting equipments and pedestals are compatible with elements’ weight. Follow all the safety instructions and ware safety protections as gloves, goggle, helmet, safety boots, ear protectors.


6.1 Mounting Of Conical Pins Of The Central Articulation

Position the shaft 1 in the bore.

Using the non-threaded conical bush 2, push the schaft down to the dimension A of 4.5 mm.

Install the threaded conical bush 3.

Install the screw and washer 4 and 5 and apply the torque progressively to the value of 530 Nm.

BE CAREFUL : Lenght of screw = 220 mm.

Install the nut 6 and apply the torque of 530 Nm.

Steer the machine several times over a tramming distance of 100 m.

Check torques of 530 Nm.

Re-check after about 300 diesel hours.

For cylinders operating methods, see SECTION 1.

WARNING

A

6 31

2

54



6.1.1 Check and adjustment

CENTRAL ARTICULATION

• Check clearance value must not be inferior 2mm (minimum) in the central articulation

2mm

2mm

(mini)

(mini)



6.2 BRAKE CYLINDER ADJUSTEMENT

1 : SPRING

2 : CAP

3 : LOCK NUT

4 : ADJUSTING NUT

P : PRESSURE PORT

B : BLEEDER PLUG

Start diesel engine, lift up the machine using stabilzers until there are no tyres in contact with the ground.

Release the brakes by pulling the unbreaking hand pump.

Make sure that the tramming charge pressure reaches a minimum of 15 bar. Read the 0-60 b gauge at the tramming compartment. The spring 1 must be no fully compressed.

Remove the cap 2 together with the light spring.

Undo the lock nut 3.

Screw in the adjusting nut 4 until feeling a light resistance when trying to rotate the wheel by hand. That indicates that the brake discs start to be in contact.

Apply the brakes.

Tighten the lock nut 3. When tightening the lock nut, make sure not to rotate the adjusting nut 4.

6.3 AXLES DISMANTLING AND MOUNTIG METHODS

AXLES

See D45 AXLE maintenance manual.

(Supplier documentation)

Weight : 400 kg

6.4 HYDRAULIC MOTOR AND GEAR BOX OPERATING METHODS

GEAR BOX

See supplier maintenance manual

HYDRAULIC MOTOR

See supplier maintenance manual

1 4 3 2

B

P



6.5 TRAMMING PUMP OPERATING METHODS

TRAMMING PUMP

See VARIABLE PUMP A4VG maintenance manual.

(Supplier documentation)

(1) : Filter element

6.6 WHEEL CHECK

6.7 BRAKE TEST

Emergency / Parking brake test :

• Raise the machine on stabilizers, no contact between tyres and ground.

• Install a 600 bar gauge at the tramming test point (1) to verify there is no problem on the tramming circuit (Caution, high pressure).

• Apply the parking brake by depressing the emergency button (2).

• Select one tramming direction and accelerate slowly => The tramming pressure must increase to 440 bar and no wheel must turn.

Service brake test :

• Raise the machine on stabilizers, no contact between tyres and ground.

• Select one tramming direction and accelerate to put the wheels in rotation. Release the accelerating pedal (3) and push on the braking pedal (4).

• => Wheel must rapidly stop turning.

In case that the brakes are faulty, do not use the machine and refit it.

• Visualy check the tyres 1, look for damages.

• Make sure the nuts 2 are correctly tighten (Wheel tightenning torque : 400 Nm).

• Make sure the lock ring 3 is correctly in place.

• Check the tyres’ pressure (10 bar for SOLIDEAL tyres or 8 bar for NOKIA tyres).

1

13

2

2 1

3

4



7 PERIODIC MAINTENANCE TABLE

For all lubrication operations, see the lubrication schedule in section 02 of this manual.

FREQUENCY (TRAMMING HOURS) When com-pleted

TRAMMING

20 orweek

200

600

1200

1800

2400

3600

5800

Yyes

Nno

All the grease points At each shift

All tightenning torques

Condition of the hydraulic equipment

Ball joints and shim washers (shape)

Tramming motor

Wheels (tightenning torque, pressure..)

Leakage At each shift

Central articulation expendable pin

Axles fixing

Brakes (park and service) At each shift

OVERALL

Overal inspection

CHECKTEST

CLEANFLUSH

LUBRICATE SERVICEREPLACE

(IF NECESSARY)

s07 tramming axera robolt solo 5 en

Documents

maintenance operation

maintenance work

maintenance instructions

construction lyon

meyzieu cedex

rangesandvik mining

periodic maintenance

safety instructions