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Rubber Tyred Gantry Crane

Kalmar E-one

2 412321-8L-2040C-ZE

Rubber Tyred Gantry Crane Kalmar E-one 2 412321-8L-2040C-ZE Maintenance Manual 19.10.2015 s/n 41360-41373 2015 Original

Maintenance Manual

Gantry Crane Kalmar E-one 2 412321-8L-2040C-ZE Maintenance Manual 19.10.2015 s/n 41360-41373 2015 Original Instructions

19.10.2015

s/n 41360-41373

2015

Original Instructions

Maintenance manual A Foreword B Safety C Preventive maintenance 0 Complete machine 1

Maintenance

manual

A

Foreword

B

Safety

C

Preventive maintenance

0

Complete machine

1

Cummins

2

Transmission

3

Driveline/axle

4

Brakes

5

Steering

6

Suspension

7

Load handling

9

Frame, body, cab and accessories

11

Common electrics

F

Technical data

G Index

1

Table of content

A Foreword

3

Maintenance manual Reading this manual Feedback

3

5

7

2

A Foreword – Maintenance manual

3

A

Foreword

Maintenance manual

General

Read the instructions in this manual carefully, and follow them strictly so that the safety and reliability of the machine will be main‐ tained at the intended level.

Contact your superior if some parts of this manual lead to questions or some important information seems to be missing.

We thank you for selecting Cargotec Finland Oy as the provider of your machine. We believe that we can fulfil your expectations with regard to the operational features and availability of maintenance services.

Contents

This maintenance manual contains the following information:

A

Foreword

General information about the purpose and contents of this maintenance manual, instructions for reading the manual, and a form for giving feedback and correcting any inaccuracies.

B

Safety

Information regarding safety.

C

Preventive maintenance

Information about preventive maintenance. Maintenance tables.

0

Complete machine

Technical description, information about the machine structure and functions, and function-specific troubleshooting instructions. Each subfunction describes the components related to the function in question. The most common components are thus mentioned in several sections, but they are usually described in connection with the first function to which the component is related. In addition to the general description, there is also a detailed description of the issues typical of the subfunction. The next subfunction using the same component has descriptions of the components relevant to the new function only. Instructions for service procedures.

1

Engine

2

Transmission

3

Driveline/Axle

4

Brakes

5

Steering

6

Suspension

 

7

Load handling

9

Frame, body, cab and accessories

11

Common electrics

F

Specifications

Technical specifications, conversion tables, unit conversion factors.

G

Terminology and index

General terms and abbreviations, their explanations, index of headings.

4

A Foreword – Maintenance manual

Division into function groups

The division into function groups is the same for all machines manu‐ factured by Cargotec Finland Oy. The groups are indicated by num‐ bers with two digits (e.g., 4.3 Power-assisted brake system). Machine-specific adaptations of the function groups are indicated by

a third or fourth digit (e.g., 4.3.9 Wheel brake or 4.3.9.1 Disc brake).

This results in certain headings (function groups) being omitted in the documentation for certain machines since the machine lacks that particular function. This means that there may be gaps in the function group numbering (e.g., 2.7 Cooling system may be inclu‐ ded for certain machines, but may be missing for other machines).

References between different manuals (operator's manual, mainte‐ nance manual, and workshop manual) are used since the different manual types have different purposes and thus different information content.

References between sections within this maintenance manual are indicated with the chapter and section number, e.g., "See Chapter

4, Brakes, Section 4.3.9., Wheel brake".

Conditions

The instructions are based on the use of generally available stand‐ ard tools. All lifting devices, e.g., slings, straps, and ratchet blocks, must meet the national standards and regulations for lifting devices.

Cargotec Finland Oy will not accept any responsibility for modifica‐ tions performed without permission from Cargotec Finland Oy, or if lifting devices, tools, or work methods other than those described in this manual are used.

Storage

Keep the manual in good condition, and store it in a place where it

is always available to the service personnel.

About the machine

The information in this manual corresponds to the basic design and appearance of the machine at the time of delivery. Due to customer adaptations, there may be variations and/or deviations.

Cargotec Finland Oy reserves the right to modify specifications and equipment without prior notice. All information and data in the man‐ ual are valid at the time of publication.

Copyright

This document may not be copied, presented, or delivered to a third party without our explicit permission, or used for purposes other than those allowed by us.

We reserve the right to alter the adjustment values, equipment, and service and repair instructions for the machine without prior notice.

Cargotec Finland Oy

A Foreword – Reading this manual

5

Reading this manual

Information on possible safety hazards

This manual includes three types of warnings containing instructions on how to avoid situations that may compromise safety.

DANGER Warns of a situation that involves immediate risk of personal injury or death if

DANGER

Warns of a situation that involves immediate risk of personal injury or death if the

Warns of a situation that involves immediate risk of personal injury or death if the safety instructions provided are not observed.

WARNING Warns of a situation that may cause personal injury, death, and/or substantial damage to

WARNING

Warns of a situation that may cause personal injury, death, and/or substantial damage to the

Warns of a situation that may cause personal injury, death, and/or substantial damage to the machine or other property if the safety instructions provided are not observed.

CAUTION Warns of a situation that may cause moderate personal injury and/or damage to the

CAUTION

Warns of a situation that may cause moderate personal injury and/or damage to the product

Warns of a situation that may cause moderate personal injury and/or damage to the product or other property if the safety instructions pro‐ vided are not observed.

Important information

The word NOTE is used to emphasise issues concerning safety or the maintenance instructions to which special attention must be paid while working on the machine.

An example of how the word NOTE appears is presented below.

NOTE

Calls the reader's attention to an instruction that, e.g., emphasises operational safety.

to an instruction that, e.g., emphasises operational safety. Fig. : The symbol indicates an optional equipment.

Fig. : The symbol indicates an optional equipment.

Optional equipment

The machine can be equipped with various accessories or optional equipment. The equipment is marked with the symbol seen on the left. The symbol is always accompanied with text representing and/ or describing the equipment.

The NOTE symbol is clearly distinguished from the text, and it is placed next to the text and picture representing the equipment.

6

A Foreword – Reading this manual

Function descriptions

The function descriptions are presented as overviews in a chart for‐ mat that describe the function and the associated components and signals.

The function descriptions describe the function in a logical order from the input signal to the output signal. Most functions require that certain preset conditions be met before the function can be activa‐ ted. In these cases, the required conditions are listed above the fig‐ ure.

The function descriptions use symbols to depict components like valves and sensors.

An example of a function description is provided on the following page.

Manual package

The following manuals are included in the machine delivery as ordered:

Operator's manual

Maintenance manual

Spare parts catalogue

Each manual can be ordered separately, in case extra copies of instruction manuals or spare parts catalogue for the machine are needed later.

Ordering the manuals

The manuals can be ordered from Cargotec Finland Oy's spare parts department.

Refer to the publication number of the manual when placing the order.

A Foreword – Feedback

7

Feedback

Form for copying

It is the goal of Cargotec Finland Oy to provide everyone working on the maintenance of Kalmar machines with access to the correct information.

Your feedback is important for us to be able to improve the informa‐ tion.

Copy this form, write down your views, and send it to us. Thank you for your participation!

To:

Cargotec Finland Oy

Product Support

P.O. Box 387

FI-33101 Tampere

FINLAND

Fax: +358 3 265 8220

From:

Company / sender:

Telephone:

E-mail:

Date:

-

-

Manual

Name / publication number:

information

Chapter / page number:

Suggestions,

 

comments,

remarks, etc.

8

A Foreword – Feedback

1

Table of content

B Safety 3 General safety instructions 3 Safety instructions 4 Service Position 4 Electric systems
B Safety
3
General safety instructions
3
Safety instructions
4
Service Position
4
Electric systems
4
Several mechanics working on the machine
7
Working on top of the machine
7
Working under the machine
8
Lifting heavy components
8
Vibration
9
Noise
9
Solvents
9
Fire and explosion risks
10
Fluid or gas under pressure
11
Coolant
12
Refrigerant
12
Air pollution
12
Tensioned springs
13
Rotating components and tools
14
Tyres
14
Regulations for safe maintenance work
15
Concerning the maintenance and repair personnel
16
Instructions for using shore supply (if equipped)
17

2

B Safety – General safety instructions

3

B

Safety

General safety instructions

General

Everyone performing maintenance and adjustment procedures on the machine must follow the safety instructions included in this man‐ ual.

Maintenance must be carried out by professional and trained per‐ sonnel only.

Training on maintenance and occupational safety issues can be ordered from our product support department if necessary.

Remember:

Follow the safety instructions included in this manual.

Obtain the training required by the job and, if necessary, ask your work instructor for guidance on the issues regarding safety at work.

Follow local laws, safety instructions, and regulations.

Do the job with equipment and tools that you have been trained to use safely and properly.

Work carefully but efficiently, and do not take any risks.

In this publication, Cargotec Finland Oy. has documented and warned about situations and risks that may occur in connection with operation as well as service and repairs of the machine under nor‐ mal conditions.

Therefore, it is very important that all persons working on the machine acquaint themselves with and act according to the informa‐ tion in the maintenance manual and operator's manual.

4

B Safety – Safety instructions

Safety instructions

General

Read the safety instructions before starting servicing or other work on the machine, and follow them strictly to keep operational safety at the intended level.

Service Position

General

The machine's service position is used during servicing, mainte‐ nance, and other procedures during which the machine must be sta‐ tionary

Service position:

The machine is parked, and the parking brake is engaged.

The spreader has been lowered fully.

The engine is off.

The main power is off.

Electric systems

DANGER

DANGER The electric systems must be serviced and repaired by trained serv‐ ice personnel.

DANGER

The electric systems must be serviced and repaired by trained serv‐ ice personnel.

The electric systems must be serviced and repaired by trained serv‐ ice personnel.

Electric systems of the machine

High-current system 400/440 VAC

Frequency 50/60 Hz

Main power supply from external power source (zero emission

RTG

power supply from external power source (zero emission RTG ), see chapter F Technical data .

), see chapter F Technical data.

Risks

When using shore supply, there are energized parts in the machine although the main switch is off.

Danger of electric shock if energized electric centre components are touched.

Danger of electric shock if cables are damaged.

Danger of electric shock if voltage is switched on unexpectedly.

Danger of electric shock if components energized by shore supply are touched.

Battery acid splashing on the skin or in the eyes.

Burns caused by short circuit when handling batteries.

B Safety – Safety instructions

5

Precautions

Before commencing work, ensure that the electric system is de-energized. The high-current system includes components that remain energized for several minutes after the engine is stopped. Wait for 10 minutes after stopping the engine before commencing work on the electric system.

Ensure that machine components are not energized by shore supply.

Inform other people of the servicing being performed. Place signs prohibiting the switching on of power in the appropriate places.

Regularly check the condition of the machine cables and the shore supply cable.

Handle the batteries carefully.

While working on the batteries, remove your watch, rings, and other metal objects that could cause a short circuit. Use insula‐ ted tools.

Working with the hydraulic system: when system is turned off and main current broken there is no residual pressure in the hydraulic system.

Zero emission RTG (option)

can be provided with

Power supply to the zero emission RTG following voltage levels:

supply to the zero emission RTG following voltage levels: • Over 1 kV (medium voltage), crane

Over 1 kV (medium voltage), crane is equipped with medium voltage transformer

Below 1 kV (low voltage)

Refer to chapter F Technical data for the power supply voltage of the crane.

Protection against direct contact of power supply

6

B Safety – Safety instructions

A
A
DANGER

DANGER

Do not open cable reel slipring housing (A) if the power supply cir‐ cuits are live.

Over 1 kV power supply: Do not open transformer housing if the power supply circuits are live.

Transformer location varies depending on crane’s equipment, see Operator’s manual.

When the crane main switch is switched off, power supply circuits from the land feeding point to the crane main switch are still live if the main power supply is not switched off from the land feeding point.

Land feeding point:

Before commencing any maintenance or repair of equipment in the power supply circuit, always ensure the main power supply is switched off from the land feeding point switchgear. The switchgear must be locked, maintenance earthed and marked with appropriate maintenance work warning sign. The safety instructions of the switchgear manufacturer must be followed to ensure the safe opera‐ tion procedures.

Crane:

Crane main switch must be opened, locked to open position and marked with maintenance work warning sign.

Protection against indirect contact of power supply

DANGER There must be an earth fault monitoring device on the land feeding point switchgear.

DANGER

There must be an earth fault monitoring device on the land feeding point switchgear. In

There must be an earth fault monitoring device on the land feeding point switchgear. In case of earth fault it will immediately open the crane main switch.

Clothing

Wear appropriate work clothing. Remove loosely hanging clothing (tie, scarf, etc.). Do not wear clothes with wide sleeves, wide trouser legs, etc.

Remove jewelry as it may get caught in moving parts.

Long hair must be tied up securely, otherwise it may easily get caught in moving parts. Be careful when performing welding and flame cutting work since hair catches fire easily.

B Safety – Safety instructions

7

Several mechanics working on the machine

DANGER

WARNING

WARNING

Be especially careful if several mechanics work on the machine at the same time. Communicate so that everyone knows where the others are and what they are doing.

everyone knows where the others are and what they are doing. Risks Falling objects, such as

Risks

Falling objects, such as tools, cause a risk of injury.

Movements performed by the operator, e.g., movement of lifting equipment, may cause severe personal injuries.

Precautions

Ensure that the spreader has been fully lowered or secured in some other manner.

Only one person at a time is allowed on the ladder.

Do not leave objects in places from which they may fall when, for example, the machine is moved.

No personnel are allowed in the operating range of the rope system and the ropes during the operation of the machine.

Be aware of the risks when several persons work around the machine.

Make your co-workers aware of what you are working with.

Working on top of the machine

NOTE

Always use trolley locking device during maintenance.

Risks

Oily platforms and ladders cause a risk of slipping and falling while moving on the machine.

The risk of falling is high, especially when moving and working out‐ side of the handrails.

Precautions

Carefully clean all platforms, walkways, and ladders to prevent the risk of slipping.

Always wear a safety harness when working outside of the handrails.

8

B Safety – Safety instructions

Working under the machine

Risks

The spreader may be lowered and cause a risk of injury.

Precautions

Ensure that the spreader has been fully lowered or secured in some other manner.

Lifting heavy components

WARNING

WARNING

WARNING

Careless handling of heavy components can lead to serious personal injury and material damage.

Use type approved lifting tools or other devices to move heavy com‐ ponents. Ensure that the device is stable and intact.

Risks

WARNING

WARNING

Careless handling of heavy components can lead to serious personal injury and material damage.

Use type approved lifting tools or other devices to move heavy com‐ ponents. Ensure that the device is stable and intact.

Unsuitable lift slings, straps, etc. may break or slip.

The centre of gravity (balance point) of the component can change during the course of the work, and the component may then make unexpected movements which may cause severe personal injuries and material damage.

A component lifted with lifting equipment can start to turn if the bal‐

ance is upset.

A component lifted using an overhead crane may start to swing

back and forth, which can cause a risk of injury.

Lift using a lifting device.

Use lifting tools or equipment, especially when such equipment is available for specific work operations.

If lifting must be performed without a lifting device:

Lift near your body.

Keep your back straight. Raise and lower with your legs and arms, do not bend your back. Do not rotate your body while lift‐ ing. Ask for assistance in advance.

Wear gloves. Gloves provide good protection against minor crushing injuries and cuts to fingers.

Always wear protective shoes.

B Safety – Safety instructions

9

Vibration

General

In case of long-term use of vibrating tools, for example, percussion drills or grinders, injuries may be sustained as vibrations are trans‐ mitted from tools to hands. This happens especially when the fin‐ gers are cold.

Precautions

Use heavy gloves to protect against cold and vibrations.

Switch between work duties to give your body time to rest.

Change your working position and grip so that your body is not stressed in only one position by the vibrations.

Noise

General

Noise louder than 85 dB (A) that lasts longer than 8 hours is consid‐ ered harmful to hearing. Tones at high frequencies are more dam‐ aging than low tones at the same sound level. Impact noise can also be hazardous, e.g., hammer blows.

Risks

Hearing damage can occur at noise levels higher than the limits. In severe cases, hearing damage can become permanent.

Precautions

Use hearing protection. Ensure that it has been tested and pro‐ tects against the noise level in question.

Solvents

General

Fluids that (as opposed to water) dissolve grease, paint, lacquer, wax, oil, adhesive, rubber, etc. are called organic solvents.

Such liquids include white (petroleum) spirits, petrol, alcohols, die‐ sel, xylene, trichloroethylene, and toluene.

Many solvents are flammable and constitute a fire hazard.

Risks

Products containing solvents produce vapours that can cause dizzi‐ ness, headaches, and nausea. They may also irritate mucous mem‐ branes in the throat and respiratory tracts.

If solvents come in direct contact with the skin, this may cause dry‐ ing and cracking. The risk of skin allergies increases. Solvents may also cause injury if they penetrate through the skin and are absor‐ bed by the blood.

If the body is continuously exposed to solvents, the nervous system may be damaged. Symptoms include sleep disorders, depression, nervousness, poor memory, or general tiredness and fatigue. Con‐ tinuous inhalation of petrol and diesel fumes is suspected to cause cancer.

10

B Safety – Safety instructions

Precautions

Avoid inhaling solvent fumes and ensure good ventilation. If necessary, wear a fresh-air mask or respiratory device with a suitable filter for toxic gases.

Never leave a solvent container open; seal the lid carefully.

Use solvents with a low content of aromatic substances. This reduces the risk of injuries.

Avoid skin contact.

Use protective gloves.

Make sure that work clothes are solvent-resistant.

Fire and explosion risks

General

Examples of explosive substances are oils, petrol, diesel fuel, organic solvents (lacquer, plastic, cleaning agents), rust proofing agents, welding gas, gas for heating (acetylene), and high concen‐ trations of dust particles from combustible materials. Rubber tyres are highly flammable and cause fires that spread explosively.

Risks

Examples of the causes of ignition include welding, cutting, smok‐ ing, sparks produced by grinding, and flammable materials coming into contact with hot machine parts.

Petrol fumes, for example, are heavier than air and can thus run down a sloping grade or down into a grease pit where, e.g., welding flames can cause an explosion. Evaporated petrol has a very pow‐ erful explosive force.

Special cases

Diesel fuel oil with added petrol has a reduced flash point. There is an explosion risk even at room temperature. The explosion risk due to warmed diesel fuel oil is greater than for petrol.

When changing oil in the engine, hydraulic system, and transmis‐ sion, keep in mind that the oil may be hot and can cause burn inju‐ ries.

Welding on or near the machine: If diesel or other oils have leaked out and have been absorbed by rags, absorbing agent, paper, or other porous material, welding sparks can cause ignition and an explosive spread of fire.

When a battery is being charged, the battery electrolyte forms hydrogen gas, which is highly explosive. The risk of explosion is especially high when a booster battery or a rapid-charge unit is used, as these increase the risk of sparks.

Today's machines contain a lot of electronic equipment. During welding, the control units and battery cables must be disconnected. Otherwise, strong welding currents can short-circuit the electronics, destroy expensive equipment, and may also cause an explosion or fire.

Welding work must never be carried out on painted surfaces (remove paint by blasting at least 200 mm around the welding or cutting point). Use gloves, respiratory protection, and protective safety glasses. Also, welding work must never take place near plas‐ tic or rubber materials without first protecting them from the heat.

B Safety – Safety instructions

11

Paints, plastics, and rubber generate various substances when heated that may be hazardous to health. Be careful with machines that have been exposed to intense heat or fire.

Precautions

Store explosive substances in approved and sealed containers.

Ensure that there are no ignition sources near flammable or explosive substances.

Ensure that ventilation is adequate or there is an air extraction unit when handling flammable substances.

At high temperatures epoxy paint releases toxic gases. During repair welding adequate ventilation has to be ensured.

Inhaling epoxy paint fumes irritates respiratory organs and mucous membranes in the nose and the throat. During painting ensure good ventilation.

Before starting welding or other thermal work in the power unit, check and / or repair all fluid and oil leaks and clean the work‐ ing area carefully.

Fluid or gas under pressure

General

Pressure lines can be damaged during work, and fluid or gas can stream out.

There may be high pressure in a line even if the pump has stopped. Therefore, gas or fluid can leak out when the connection to the hose is loosened.

Risks

There are injury risks in connection with work on:

hydraulic and brake systems

fuel system

tyre repairs

air conditioning system

Precautions

Use safety glasses and protective gloves.

Never work on a pressurized system.

Never adjust a pressure relief valve to a higher pressure than recommended by the manufacturer.

Damaged hydraulic hoses must be replaced as soon as possi‐ ble! Check connections thoroughly.

Use fluid when checking for leaks.

Never blow clothes clean with compressed air.

Discarded accumulators must first be punctured before they are deposited as waste (to avoid risk of explosion). Carefully drill a hole with 3 mm diameter after depressurizing.

Never use your hands to detect a leak. A fine high-pressure stream from a hydraulic hose can easily penetrate the skin and cause very severe injuries.

12

B Safety – Safety instructions

Coolant

General

The coolant in the machine's cooling system consists of water, anti- corrosion compound, and (when needed) antifreeze fluid, for exam‐ ple, ethylene glycol.

Coolant must not be drained into the sewer system or directly onto the ground.

Risks

The cooling system is pressurized when the engine is warm. Hot coolant can jet out and cause scalding in case of a leak or when the expansion tank cap is opened.

Inhaling ethylene glycol and anti-corrosion compound is dangerous and hazardous to health.

Precautions

Use protective gloves and safety glasses if there is a risk of splashing or spraying.

Carefully open the filler cap first to release the excess pres‐ sure. Be careful; hot steam and coolant may stream out.

If possible, avoid working on the cooling system when the cool‐ ant is hot.

Refrigerant

General

Refrigerant is used in the machine's air conditioning system.

Risks

The air conditioning system operates at high pressure. Escaping refrigerant can cause freeze burns.

Heated refrigerant (e.g., during the repair of leaks in the air condi‐ tioning system) produces gases that are very toxic if inhaled.

Precautions

The air conditioning system must be serviced by authorized and trained personnel only. Follow national legislation and local regulations!

Use protective gloves and safety glasses if there is a risk of leaks.

Make sure that there are no heat-producing sources or objects close by (cigarette glow, welding flame).

Air pollution

General

Air pollution is the impurities in the air that are regarded as hazard‐ ous to health. Certain pollution is more prominent in certain environ‐ ments.

The following air pollution hazardous to health is especially promi‐ nent in workshops:

B Safety – Safety instructions

13

Carbon monoxide (fumes): Present in exhaust fumes. Odour‐ less and therefore especially dangerous.

Nitrogen oxides (nitrous gases):Present in exhaust fumes.

Welding smoke: Especially hazardous to health when welding on oily surfaces, galvanized, or lacquered materials.

Oil mist: For example, when applying anti-corrosion agent.

Grinding dust and gases: Generated when grinding and heat‐ ing plastics, lacquer, anti-corrosion agents, lubricants, paint, etc.

Isocyanates: Present in certain paints, fillers, adhesives, and foam plastics.

Risks

Sulphuric acid mist is corrosive and injures the respiratory tracts. Sulphuric acid is generated when heating certain plastics and paints.

Isocyanates can be released in the form of steam or dust when cut‐ ting, grinding, or welding. Isocyanates may also be present in aero‐ sols. They can irritate mucous membranes, producing symptoms similar to asthma and impairing lung function. Even brief exposure to high concentrations can cause problems of persistent high sensi‐ tivity.

Precautions

Ensure adequate ventilation during welding, charging a battery, and other work where hazardous gases are generated.

Use suitable gloves and respiratory protection when there is a risk of oil mist. Ensure that the protective equipment is oil- resistant.

Apply oil-resistant protective lotion to unprotected skin.

Ensure that an eye-wash station is in the immediate vicinity when working with corrosive substances.

Avoid unnecessary operation of the machine inside the work‐ shop. Connect an air extractor to the exhaust pipe so that the exhaust fumes are removed from the workshop.

Tensioned springs

General

Examples of tensioned springs:

suspension elements in rubber suspension

return springs in the parking brake cylinder

lock rings

gas springs

Risks

If a tensioned spring is released, it is shot out by the spring force and can also take adjoining parts with it.

Small springs can cause eye injuries.

Parking brake springs are tensioned with high force and can cause very severe injuries if they are accidentally released in an uncontrol‐ led manner.

14

B Safety – Safety instructions

Gas springs are tensioned with high force and can cause very severe injuries if they are accidentally released in an uncontrolled manner.

Precautions

Use safety glasses.

Lock rings should be of a suitable type and in good condition.

Follow the instructions in this and other manuals when per‐ forming maintenance.

Always use the recommended tools.

Rotating components and tools

General

Examples of rotating components and tools:

cooling fan

drive belts

drive shafts

drills

grinders

Risks

Rotating components, for example, fans or shafts, can cause severe injuries if touched.

Drills, grinders, and other machines with rotating parts can cause severe injuries if clothes or hair get caught and are wound up in the machine.

Precautions

See Clothing on page 6

Tyres

DANGER

DANGER

DANGER

Tyres should be regarded as pressurized containers. They constitute a risk of injury if handled incorrectly.

Never repair damaged tyres, rims, or lock rings. Tyre repairs should only be performed by authorized service personnel.

Risks

Dismantling wheels: Tyres, rims, or lock rings can be thrown.

Inflating tyres: Tyres, rims, or lock rings can be thrown.

Precautions

Deflate the tyre before starting to work on the wheel.

Check that tyres, rims, and lock rings are intact. Never repair damaged tyres, rims, or lock rings.

Use a protective screen and safety glasses.

B Safety – Safety instructions

15

Regulations for safe maintenance work

General

1. Thoroughly acquaint yourself with the RTG structure and the manuals. Observe the instructions and warnings.

2. Try to determine the hazards, and avoid them. Report any faults that you have noticed to your superior or to the person in charge of repairs.

3. Fall protection: Working at heights on cranes or hoists, all per‐ sons shall wear safety harnesses that are fitted with a rope and securely attached to a structural member of the crane.

4. Always use on protective clothing, overall, helmet, gloves, safety shoes and etc.

5. Always observe sufficient caution and care when climbing into or coming down from the RTG. Always move along the paths designated as walkways. Keep the walkways clean. Remove all safety risks, such as snow and ice, and other foreign matter. Wipe away all oil leakages at once to prevent slipping.

6. Keep the RTG clean, especially the adjusting and control devi‐ ces.

7. Do not allow any unauthorized persons to operate the RTG entrusted in your use. The operator of the RTG is responsible for any damage caused by the machine.

8. Acquaint yourself in advance with the use of emergency exits.

9. Do not stand under a hanging container or load.

10. If problems arise, remember to stay calm. Think first, and then act accordingly.

16

B Safety – Safety instructions

Concerning the maintenance and repair personnel

General

1.

The service and repair personnel of the RTG is responsible for that the machine doesn’t cause damage to other persons in connection with the service or repair work.

2.

Be especially careful when you do maintenance work in abnor‐ mal conditions that require special working methods, for exam‐ ple, replacing the hoist ropes.

3.

Before starting off, make sure that nobody is standing in front or behind the RTG.

4.

Avoid sudden stops and starts.

5.

Always perform the maintenance and repair work according to the instructions given.

6.

By observing a danger spot, immediately report to the person responsible for safety.

7.

The machine must not be handed over for operation, until the observed faults and damages have been repaired.

8.

Observe the signs and instructions indicating free height. You should know the exact total height of your RTG before driving

into places with restricted free height. Be especially careful with temporary structures, hanging overhead power lines, etc. Watch out also for objects at cabin height.

9.

You may perform the service and repair work only in compli‐ ance with your actual qualification.

10.

Don’t try to guess! Maybe you make a wrong guess, causing a possible danger to yourself and the other personnel.

11.

If

necessary, consult a person being aware of how to proceed.

12.

When servicing pressurized systems, proceed very carefully. Non-discharged energy sources always are hazardous.

13.

Follow unconditionally the instructions given.

14.

it is necessary to remove protective guards during the serv‐ ice, place warning signs and take other measures to protect other persons from danger.

If

15.

When changing driving direction, stop the carrier completely with the service brake before moving the direction selector lever.

16.

Watch out for the edges of driveways where the surface may be yielding and cause the danger of overturning.

17.

Remember that the RTG is not intended for carrying persons.

18.

Always stop the engines whenever you leave the RTG even for

a

short while. Lower any load to the ground.

19.

Make a detailed report on any collisions, including the damage caused. This could prevent accidents from being repeated.

20.

Observe the weight of your RTG , and its total weight loaded. Do not drive on surfaces with insufficient load capacity.

21.

starting spray is used to aid cold-starting, strictly follow the instructions on the use of these aerosols given later in this manual.

If

22.

Follow the periodic maintenance schedule. This ensures that the controls and the whole RTG operate reliably and safely.

23.

The engines must always be stopped when service or inspec‐ tions are being carried out.

24.

The use of open flame is absolutely forbidden when checking fuel or battery electrolyte levels.

B Safety – Safety instructions

17

25. The radiator is pressurized when the coolant is hot - open the radiator cap slowly and cautiously.

26. Hot exhaust pipe cause burns, extreme carefulness required.

27. Do not open the main switch when the engines are running.

28. Only authorized electricians can do maintenance for electrical systems and open electrical boxes. Never do any maintenance work when parts are live. Special carefulness with charged components such as condensators of drive converters is required.

29. Only a person that is well acquainted with the RTG’s control and the cabin equipment is allowed to be in the cabin during service and repairs.

30. Working with the hydraulic system: always have the system turned off and main power cut off during maintenance work. Use a pressure gauge to check that there is no residual pres‐ sure in the hydraulic system before starting work on the hydraulics.

31. Driving is forbidden without fastened seat belts.

32. Never park the machine on a inclined plane.

Instructions for using shore supply (if equipped)

General

CAUTION

CAUTION

Always use shore supply when RTG is not in use. If shore supply is not used, the air conditioning devices do not operate and the electri‐ cal devices may get wet and damaged. Always close the equipment compartments' doors when using shore supply.

If use of the shore supply is neglected, it may release Cargotec Fin‐ land Oy from all warranty liabilities.

When using shore supply, the following equipment operates when the PLC main switch is off:

Sockets (direct feed)

All heaters (electrical housings, motors, generators, main die‐ sel, the radiator of the electrical compartment, the radiator in the cabin) (direct feed)

Battery charger (direct feed)

Air conditioning in the cabin and the electrical compartment (direct feed if the frequency of the machine and the shore sup‐ ply is the same)

The lights in the equipment compartments (feed through the light switches)

Winch (direct feed to the winch main switch)

When using shore supply, the following equipment operates when the PLC main switch is on:

Cabin fans (automatically turns the radiator off - control with the touch panel)

All walkway lights (control with the touch panel or the push but‐ tons of the power unit and the rear frame)

18

B Safety – Safety instructions

DANGER

DANGER

Danger when shore supply is on. High voltage 230V/ 400V is on (gantry motors, trolley motor, hoist motor).

1

Table of content

C Preventive maintenance

 

3

For the service personnel

 

3

Maintenance tables

 

5

Reading instructions for maintenance table

 

5

Initial checks

 

5

Daily checks

8

Scheduled maintenance - General

 

11

Scheduled maintenance - Engine

 

14

Scheduled maintenance - Driveline / Axle

 

20

Scheduled maintenance - Bakes

 

23

Scheduled maintenance - Steering

 

34

Scheduled maintenance - Suspension

 

35

Scheduled maintenance - Load handling

 

37

Scheduled maintenance - Frame, body, cab and accessories

50

Scheduled maintenance - Common electrics

54

Scheduled maintenance - Technical data

 

60

2

C Preventive maintenance – For the service personnel

3

C

Preventive

maintenance

General

Follow our maintenance programme carefully to ensure that the operational safety and reliability of the machine are maintained at the intended level.

The maintenance programme specifies the inspection and mainte‐ nance procedures as follows:

Daily checks

Visual/operating checks

Scheduled maintenance

IMPORTANT

Maintenance and adjustment procedures must be carried out by pro‐ fessional and trained personnel only.

To meet the terms and conditions of the warranty agreement, use only recommended fluids and original equipment and spare parts available from our spare parts department.

Following the maintenance programme defined in this maintenance manual is a prerequisite for maintaining the machine warranty.

For the service personnel

General

The maintenance instructions provide the service personnel with information about the mechanisms and maintenance items of the machine as well as guidelines for safe maintenance.

Familiarise yourself with the operation of the machine, the mainte‐ nance programme, maintenance items, and work instructions. Always follow the maintenance instructions.

For regular maintenance, use the oils, greases, and fluids specified later in this manual and the filters and other service parts available from our spare parts department.

Absolute cleanliness should be observed especially during the regu‐ lar maintenance of the hydraulic and fuel systems to ensure the reli‐ able operation of the machine.

Work premises

Perform the maintenance in clean premises to prevent impurities from entering the devices on the machine. Protect the premises against dust from the environment; for example, if sand and metal particles enter the oil and other fluid systems of the devices, severe damage will be caused to the devices.

4

C Preventive maintenance – For the service personnel

Ensure that maintenance can be performed without compromising occupational safety.

Ensure that the used oils, greases, and fluids are delivered to a haz‐ ardous waste collection point in accordance with the applicable instructions.

Reporting

Carefully document the maintenance procedures performed, writing down any defects detected and repairs made.

If you notice any defects, immediately inform your supervisor or the person responsible for the maintenance of the machine. The defects must be repaired before continuing to use the machine.

Store the reports carefully so that they are easily available when needed.

C Preventive maintenance – Maintenance tables

5

Maintenance tables

Reading instructions for maintenance table

Reading instructions for maintenance tables

IMPORTANT

IMPORTANT

Following applies when only power source for the crane is a diesel generator:

Following applies when only power source for the crane is a diesel generator:

All service intervals are based on operating hours of main diesel engine. For operating hours, see “Main diesel hours” counter on the power unit.

Following applies when the crane is powered by external power sup‐ ply (Zero emission RTG):

Following applies when the crane is powered by external power sup‐ ply (Zero emission RTG):

• Service intervals, other than for engine, are based on operating hours while the crane

Service intervals, other than for engine, are based on operating hours while the crane has been powered either by external power supply or by diesel generator. For operating hours, use the sum of “Supply hours” and “Generator hours” counters in the EE-House.

• Service intervals for engine are based on operating hours of main diesel engine. For

Service intervals for engine are based on operating hours of main diesel engine. For operating hours, see “Generator hours” counter in the EE-House.

Initial checks

Initial maintenance

Maintenance of a new machine during the first 500 hours of opera‐ tion.

For reading instructions, see section Reading instructions for main‐

tenance tables.

6

C Preventive maintenance – Maintenance tables

Maintenance item

 

Service interval / hours of operation

Reference

 

1

Engine

Checking the condition and tension of

After first 250 operating hours. Replace the belt if it has unacceptable cracks, is frayed, or has pieces of material missing.

 

drive belts of auxiliary diesel

drive belts of auxiliary diesel
 

Checking

the

radiator

condition

of

After first 250 operating hours.

 

auxiliary diesel

auxiliary diesel

3

Driveline / Axle

 

Changing oil of the wheel hubs (driven and nondriven wheels)

After first 100 operating hours.

Chapter 3, section 3.3 Driven wheel

Changing oil of driven axle assembly, wheel hub planetary gear drive, interaxle differential, wheel bearing

After first 100 operating hours.

Chapter 3, section 3.3 Driven wheel

 

NOTE

Only 16 wheel RTG

 

Changing

oil

of

non-driven

axle

After first 100 operating hours.

Chapter

3,

section

3.4

Non-driven

assembly

 

wheel

 

NOTE

Only 16 wheel RTG

 

4

Brakes

Changing oil of hydraulic power unit for

3 months after commissioning of the crane.

Appendixes, section Emergency hoist brake

the emergency hoist brake

the emergency hoist brake
 

7

Load handling

 

Checking

the

chain

tension

of

After first 300 operating hours. Tighten if needed.

Bromma spreader manual

 

spreader

   

Checking the operation of twistlocks of spreader

After first 100 operating hours. Tighten the twistlocks if needed.

Bromma spreader manual

 

Lubrication of spreader

 

Lubricate and check the various points as per the lubrication instructions after first 50 and 300 operating hours.

Bromma spreader manual

 

Changing the pressure filter(s) of

After first 500 operating hours.

Appendixes,

section

Spreader

spreader's hydraulic unit

spreader's hydraulic unit
 

hydraulic unit

 

C Preventive maintenance – Maintenance tables

7

Maintenance item

 

Service interval / hours of operation

Reference

Changing the return filter(s) of

After first 500 operating hours.

Appendixes,

section

Spreader

spreader's hydraulic unit

spreader's hydraulic unit
 

hydraulic unit

Changing the air filter(s) of spreader's

After first 500 operating hours.

Appendixes,

section

Spreader

hydraulic unit

hydraulic unit
 

hydraulic unit

Checking during operation of the hoist motor that specified technical data are met (power input, temperatures of windings, bearings, coolants, etc.)

After first 500 operating hours.

 

Checking during operation of the hoist motor that running smoothness of machine and running noise of bearings have not deteriorated

After first 500 operating hours.

 

Checking during standstill of the hoist motor that no subsidence or cracks have occurred in the foundation

After first 500 operating hours.

 

Checking the hoist motor's cables and insulating parts (as far as accessible) are in proper condition and show no signs of discolouration

After first 500 operating hours.

 

Changing oil of the trim gear

Changing oil of the trim gear
 

After first 100 operating hours.

Chapter 7, section 7.2 Lifting/lowering

Cleaning the trim gear housing

Cleaning the trim gear housing After first 100 operating hours.  

After first 100 operating hours.

 

11 Common electrics

 

Checking

the

condition

of

the

After first 200 operating hours.

Chapter 11, section 11.5 Distribution of electricity

endpoints of energy chain

endpoints of energy chain
 

Checking the strain reliefs of energy

After first 200 operating hours.

Chapter 11, section 11.5 Distribution of electricity

chain

chain

Checking the wear of energy chain

Checking the wear of energy chain After first 200 operating hours. Chapter 11, section 11.5 Distribution

After first 200 operating hours.

Chapter 11, section 11.5 Distribution of electricity

Checking

the

energy

chain

Checking the energy chain for After first 200 operating hours. Chapter 11, section 11.5 Distribution of

for

After first 200 operating hours.

Chapter 11, section 11.5 Distribution of electricity

obstructions

 

Checking the condition of roller links of

After first 200 operating hours.

Chapter 11, section 11.5 Distribution of electricity

energy chain

energy chain
 

Checking the condition of cables and

After first 200 operating hours.

Chapter 11, section 11.5 Distribution of electricity

hoses of energy chain

hoses of energy chain
 

Checking the condition of troughs of

After first 200 operating hours.

Chapter 11, section 11.5 Distribution of electricity

energy chain

energy chain
 

8

C Preventive maintenance – Maintenance tables

Maintenance item

Service interval / hours of operation

Reference

Checking the operation of moving arm

After first 200 operating hours.

Chapter 11, section 11.5 Distribution of electricity

of energy chain

of energy chain

Changing oil of the cable reel gear Zero emission RTG

After first 100 operating hours

Appendixes, Cable reel

Daily checks

Daily checks

WARNING

WARNING

Never operate a defective machine.

If any defects are found during daily inspections, report the defects immediately to your superior or those responsible for the machine's maintenance.

Daily check of the machine is extremely important to ensure efficient and safe operation.

It is recommended that the operator or the person responsible for the maintenance of the machine carry out the inspections before each shift. This way it can be ensured that work does not com‐ mence with a defective machine.

For reading instructions, see section Reading instructions for main

tenance tables.

C Preventive maintenance – Maintenance tables

9

Item

 

Inspection method

Note

Reference

 

General

 

Oil and fluid leaks

 

Visually

   

1

Engine

Oil level

 

Dipstick

 

Chapter

1,

section

1.8

 

Lubrication

 

Coolant level

 

Visually

 

Chapter

1,

section

1.7

 

Cooling system

Air filter

 

Visually

The filter must be changed if the clog warning indicator shows completely red.

Chapter

1,

section1.6

Air

 

intake/exhaust outlet

Fuel

prefilter/water

Visually

Remove water if necessary.

Chapter 1, section 1.2 Fuel

separator

system

Condition

and

tension

of

Visually

Replace

the

belt

if

it

has

 

drive belts

 

unacceptable

cracks,

is

 

frayed,

or

has

pieces

of

material missing.

 

Leakage of charge air pipe

 

Visually/audio check

 

Chapter 1, section 1.6 Air

 

intake/exhaust outlet

 

Shields and doors

 

Visually

   

Closed

and

locked

correctly

Coolant

level

of

auxiliary

Visually

   

diesel

diesel
 

Supply

and

fuel

level

of

Visually

   

auxiliary diesel

auxiliary diesel

Oil level of auxiliary diesel

Dipstick

   
 
 

Condition and tension of drive belts of auxiliary diesel

Visually

Every 250 operating hours. Replace the belt if it has unacceptable cracks, is frayed, or has pieces of material missing.

 
 
 

Radiator

condition

of

Visually

Every 250 operating hours.

 

auxiliary diesel

auxiliary diesel

3

Driveline / Axle

 

Oil leaks

 

Visually

   

10

C Preventive maintenance – Maintenance tables

Item

 

Inspection method

Note

Reference

4

Brakes

Operation of gantry brakes

Brake test immediately after moving off.

   

Checking condition of oil in the hydraulic power unit for the emergency hoist brake.

Sight glass.

Change the oil if it contains water or other impurities.

 
 
 

5

Steering

Operation of steering gear

Visually

   

Oil leaks of steering gear

Visually

   

6

Suspension

Wheel

pressure

and

Visually

Every 300 operating hours, check the tyre pressure.

 

condition, wheel attachment

NOTE

It's normal for tyre pressure dropping by 5% in a month.

7

Load handling

Oil level of skew gear

 

Sight glass

   

Oil leaks of skew gear

 

Visually

   

Noise of skew gear

 

Audio check

   

Oil level of trolley gear

 

Sight glass

   

Oil leaks of trolley gear

 

Visually

   
 

Oil

temperature

of

trolley

Visually

   

gear

Noise of trolley gear

 

Audio check

   

Oil level of hoist gear

 

Sight glass

   

Oil leaks of hoist gear

 

Visually

   

Oil temperature of hoist gear

Visually

   

Noise of hoist gear

 

Audio check

   

C Preventive maintenance – Maintenance tables

11

Item

Inspection method

Note

Reference

Ropes for possible damage and change in shape

Visually

   

Spreader and lifting devices

Visually

   

Position sensors of spreader

Visually

Clean if needed

Bromma spreader manual

Chain tension of spreader

Visually

Every 300 operating hours. Tighten if needed

Bromma spreader manual

Operation

of

twistlocks

of

Visually

Every 100 operating hours. Tighten the twistlocks if needed

Bromma spreader manual

spreader

Oil level of hydraulic system

Sight glass

   

of spreader

of spreader

Oil temperature of hydraulic

Visually

   

system of spreader

system of spreader

9 Frame, body, cab, and accessories

 

Controls,

instruments,

and

Visually

Operation check before and after starting the engine

 

indicator lights

 

Operation of flashing beacons and buzzers

Visually or by listening

   

Cleanness of cabin windows

Visually

Clean if required

 

11 Common electrics

 

Covers and doors of electric centres

Visually

   

Closed

and

locked

correctly

 

Oil level of cable reel gear

Sight glass

Zero emission RTG

Appendixes, section Cable

reel

Cleanliness of cable reel gear breather plug or vent hole

Visually

Zero emission RTG

Appendixes, section Cable

reel

Oil leaks of cable reel gear

Visually

Zero emission RTG

 

Noise of cable reel

 

Audio check

Zero emission RTG

 

Scheduled maintenance - General

General

Maintenance procedures to be performed every 500 hours of opera‐ tion: after 500 hours, 1000 hours, 1500 hours, etc.

12

C Preventive maintenance – Maintenance tables

Maintenance procedures to be performed every 1000 hours of oper‐ ation: after 1000 hours, 2000 hours, 3000 hours, etc.

Maintenance procedures to be performed every 2000 hours of oper‐ ation: after 2000 hours, 4000 hours, 6000 hours, etc.

Maintenance procedures to be performed every 4000 hours of oper‐ ation: after 4000 hours, 8000 hours, 12000 hours, etc.

The daily checks must also be performed during scheduled mainte‐ nance.

For reading instructions, see section Reading instructions for main‐

tenance tables.

Maintenance item

Service interval / hours of operation

Note

Reference

500

1000

2000

4000

Checking for oil and fluid leaks

x

         

Lubrication

   

x

 

Lubrication must

 

be

performed

regularly avoiding

use

of too much

lubricant

at

the

same

time.

(Greasing:

e.g.

Multipurpose

grease,

Beacon

EP/2).

Some

greasing

points

have

shorter

lubrication

 

intervals.

Service interval / 500 hours of operation

Maintenance item

Note

Checking for oil and fluid leaks

 

Service interval / 1000 hours of operation

Maintenance item

Note

Checking for oil and fluid leaks

 

C Preventive maintenance – Maintenance tables

13

Service interval / 2000 hours of operation

Maintenance item

Note

Checking for oil and fluid leaks

 

Lubrication

Lubrication must be performed regularly avoiding use of too much lubricant at the same time. (Greasing: e.g. Multipurpose grease, Beacon EP/2). Some greasing points have shorter lubrication intervals.

Service interval / 4000 hours of operation

Maintenance item

Note

Checking for oil and fluid leaks

 

Lubrication

Lubrication must be performed regularly avoiding use of too much lubricant at the same time. (Greasing: e.g. Multipurpose grease, Beacon EP/2). Some greasing points have shorter lubrication intervals.

14

C Preventive maintenance – Maintenance tables

Scheduled maintenance - Engine

Table

Maintenance item

 

Service interval / hours of operation

Note

Reference

 
 

500

1000

2000

4000

 

Changing oil

           

Chapter

1,

section1.8

 

x

Lubrication

Replacing the oil filter(s)

 

x

       

Chapter

1,

section1.8

 

Lubrication

Replacing the fuel filter(s)

   

x

     

Chapter 1, section 1.2 Fuel

 

system

Cleaning the fuel filter(s) (if using Spin- On Type)

 

x

     

Chapter 1, section 1.2 Fuel

system

Empty dust collector of air filter

 

x

     

Chapter

1,

section

1.6

Air

intake/exhaust outlet

 

Changing coolant filter(s), if in use

 

x

     

Chapter 1, section 1.7 Cooling

system

Cleaning breather tube

     

x

   

Chapter

1,

section

1.6

Air

 

intake/exhaust outlet

 

Checking the fan hub bearing clearance

   

x

   

Chapter

1,

section

1.6

Air

intake/exhaust outlet

 

Inspection

of

the

vibration

   

x

   

Chapter

1,

section

1.6

Air

damper mounting

intake/exhaust outlet

 

Adjusting valves and injectors

   

x

   

Chapter

1,section

1.5

Mechanical parts

 

Changing air filters (2 pcs) when red indicator flag is at the raised position

     

x

 

Chapter

1,

section

1.6

Air

intake/exhaust outlet

 

Steam cleaning of engine

       

x

   

Inspection of turbo charger

       

x

   

Inspection of idler pulley assembly of the engine

     

x

   

Inspection of water pump of the engine

     

x

   

Replacing

the

fuel

filter

x

       

Appendixes, section Auxiliary

element of auxiliary diesel

element of auxiliary diesel power unit  

power unit

 

C Preventive maintenance – Maintenance tables

15

Maintenance item

 

Service interval / hours of operation

Note

Reference

 

500

1000

2000

4000

Checking the air induction

x

       

Appendixes, section Auxiliary

system of auxiliary diesel

system of auxiliary diesel power unit

power unit

for

leaks,

damage

and

restrictions

 

Replacing the air cleaner

x

       

Appendixes, section Auxiliary

element of auxiliary diesel

element of auxiliary diesel power unit

power unit

Checking the external nuts, bolts and unions of auxiliary

 

x

     

Appendixes, section Auxiliary

power unit

diesel

for tightness

for tightness

 

Draining and cleaning the engine mounted fuel tank of

   

x

   

Appendixes, section Auxiliary

power unit

auxiliary diesel

auxiliary diesel
 

Checking the free movement of the engine and speed

   

x

   

Appendixes, section Auxiliary

power unit

controls of auxiliary diesel

controls of auxiliary diesel

Cleaning

and

checking,

or

   

x

   

Appendixes, section Auxiliary

replacing,

the

fuel

injector

power unit

nozzles of auxiliary diesel

nozzles of auxiliary diesel

Replacing the fan drive belt of

   

x

   

Appendixes, section Auxiliary

auxiliary diesel

auxiliary diesel
 

power unit

Checking the oil pressure of

   

x

   

Appendixes, section Auxiliary

auxiliary diesel

auxiliary diesel
 

power unit

Replacing the oil filter and oil

     

x

At

least once a

Appendixes, section Auxiliary

of auxiliary diesel

of auxiliary diesel year. power unit

year.

power unit

Flushing the cooling system of

     

x

At

least once a

Appendixes, section Auxiliary

auxiliary diesel

auxiliary diesel
 

year.

power unit

16

C Preventive maintenance – Maintenance tables

Service interval / 500 hours of operation

 

Maintenance item

 

Note

Changing oil

   

Replacing the oil filter(s)

   

Replacing the fuel filter element of auxiliary diesel

Replacing the fuel filter element of auxiliary diesel
   

Checking the air induction system of auxiliary diesel leaks, damage and restrictions

Checking the air induction system of auxiliary diesel leaks, damage and restrictions for  

for

 

Replacing the air cleaner element of auxiliary diesel

Replacing the air cleaner element of auxiliary diesel  
 

Service interval / 1000 hours of operation

 

Maintenance item

 

Note

Changing oil

   

Replacing the oil filter(s)

   

Replacing the fuel filter(s)

   

Cleaning the fuel filter(s) (if using Spin-On Type)

   

Empty dust collector of air filter

   

Changing coolant filter(s), if in use

   

Replacing the fuel filter element of auxiliary diesel

Replacing the fuel filter element of auxiliary diesel
   

Checking the air induction system of auxiliary diesel leaks, damage and restrictions

Checking the air induction system of auxiliary diesel leaks, damage and restrictions for  

for

 

Replacing the air cleaner element of auxiliary diesel

Replacing the air cleaner element of auxiliary diesel  
 

Checking the external nuts, bolts and unions of auxiliary

 

diesel

diesel for tightness

for tightness

C Preventive maintenance – Maintenance tables

17

Service interval / 2000 hours of operation

 

Maintenance item

 

Note

Changing oil

   

Replacing the oil filter(s)

   

Replacing the fuel filter(s)

   

Cleaning fuel filter(s) (if using Spin-On Type)

   

Empty dust collector of air filter

   

Cleaning breather tube

   

Checking the fan hub bearing clearance

   

Inspection of the vibration damper mounting

   

Changing coolant filter(s), if in use

   

Adjusting valves and injectors

   

Replacing the fuel filter element of auxiliary diesel

Replacing the fuel filter element of auxiliary diesel
   

Checking the air induction system of auxiliary diesel leaks, damage and restrictions

Checking the air induction system of auxiliary diesel leaks, damage and restrictions for  

for

 

Replacing the air cleaner element of auxiliary diesel

Replacing the air cleaner element of auxiliary diesel
   

Checking the external nuts, bolts and unions of auxiliary

 

diesel

for tightness

for tightness

 

Draining and cleaning the engine mounted fuel tank of auxiliary diesel

Draining and cleaning the engine mounted fuel tank of auxiliary diesel
 

Checking the free movement of the engine and speed controls of auxiliary diesel

Checking the free movement of the engine and speed controls of auxiliary diesel
 

Cleaning and checking, or replacing, the fuel injector nozzles of auxiliary diesel

Cleaning and checking, or replacing, the fuel injector nozzles of auxiliary diesel
 

Replacing the fan drive belt of auxiliary diesel

Replacing the fan drive belt of auxiliary diesel  
 

Checking the oil pressure of auxiliary diesel

Checking the oil pressure of auxiliary diesel
   

Replacing the air cleaner element of auxiliary diesel

Replacing the air cleaner element of auxiliary diesel
   

18

C Preventive maintenance – Maintenance tables

Service interval / 4000 hours of operation

 

Maintenance item

 

Note

Changing oil

   

Replacing the oil filter(s)

   

Replacing the fuel filter(s)

   

Cleaning fuel filter(s) (if using Spin-On Type)

   

Empty dust collector of air filter

   

Cleaning breather tube

   

Checking the fan hub bearing clearance

   

Changing air filters (2 pcs) when red indicator flag is at the raised position

 

Inspection of the vibration damper mounting

   

Changing coolant filter(s), if in use

   

Changing coolant and flushing cooling system

   

Adjusting valves and injectors

   

Steam cleaning of engine

   

Inspection of turbo charger