01 Prevmaint s281.821 v1 en 260116 248

Sandvik UJ440i
Preventive Maintenance
Doc. no. S 281.821 en Ver. 1
This document is valid for:
Serial no. / Machine no.
Sign.
Sandvik UJ440i
Copyright 2007 Sandvik SRP AB. All rights reserved. No parts of this document may be reproduced or copied in any form or by any means without written permission from Sandvik SRP AB. All data and information in this manual may be changed without further notice. Reservations for misprints. Document number: S 281.821 en Issue: 20071210 Version: 1
Sandvik SRP AB Stationsplan, SE-233 81 Svedala, Sweden Tel: +46 (0)40 409000, Fax: +46 (0)40 409260 www.sandvik.com
Table of contents
1. Preventive Maintenance
1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24 1.25 1.26 1.27 1.28 1.29 1.30 1.31 1.32 1.33 1.34 1.35 1.36 1.37 1.38 1.39 UJ440i General ................................................................................. 5 Caterpillar engine (option) .................................................... 6 Daily inspection..................................................................... 9 Daily inspection (Continued)............................................... 11 After 50-600 hours .............................................................. 13 Weekly inspection............................................................... 15 When required .................................................................... 17 After 80 hours ..................................................................... 19 After 250 hours ................................................................... 21 After 500 hours ................................................................... 23 After 750 hours ................................................................... 25 After 1 000 hours ................................................................ 27 After 1 000 hours (Continued) ............................................ 29 After 1 250 hours ................................................................ 31 After 1 500 hours ................................................................ 33 After 1 750 hours ................................................................ 35 After 2 000 hours ................................................................ 37 After 2 000 hours (Continued) ............................................ 39 After 2 250 hours ................................................................ 41 After 2 500 hours ................................................................ 43 After 2 750 hours ................................................................ 45 After 3 000 hours ................................................................ 47 After 3 000 hours (Continued) ............................................ 49 After 3 250 hours ................................................................ 51 After 3 500 hours ................................................................ 53 After 3 750 hours ................................................................ 55 After 4 000 hours ................................................................ 57 After 4 000 hours (Continued) ............................................ 59 After 8 000 hours ................................................................ 60 After 10 000 hours .............................................................. 61 After 12 000 hours .............................................................. 61 Every 6 months................................................................... 61 Yearly .................................................................................. 62 Every 3 years...................................................................... 63 Every 6 years...................................................................... 63 Every 14 400 litres of fuel ................................................... 63 Every 114 000 litres of fuel ................................................. 64 Every 170 400 litres of fuel ................................................. 64 Every 380 000 litres of fuel ................................................. 64
Sandvik SRP AB Doc. no. S 281.821 en Ver. 1
Table of contents 1.40 Completed maintenance jobs ............................................. 65
UJ440i
1. Preventive Maintenance
1.1 General
The person who carries out preventive maintenance work must have good knowledge of the mobile unit and must know when and how adjustments should be made
This instruction is only intended as a guideline of the activities to be performed. For validity of the guarantee it is essential to check the detailed instructions for the different components presented in each specific section.
WARNING!
Most of the maintenance instructions are followed by a reference to a part in another UJ440i manual. The following manuals are referred to: PD = Product Documentation OM = Operators Manual Example: The reference PD:12 stands for Part 12 NF Conveyor in the manual UJ440i Product Documentation.
NOTE!
The section headings in this manual stands for the counted time from when the mobile unit was initially started. The maintenance cycle continues after 4 000 hrs. Repeat the maintenance instructions for 250 hrs. when 4 250 hrs. has passed. For assistance, contact the nearest Sandvik company, agent, representative or directly: Sandvik SRP AB Service Dept. SE-233 81 Svedala, Sweden Telephone +46 40-40 90 00 Telefax +46 40-40 92 60
UJ440i
1. UJ440i Preventive Maintenance
1.2 Caterpillar engine (option)

Records should be kept for the following items: Fuel consumption Service hours Documents - all documents should contain: date, service hours, fuel consumption, unit number and engine serial number. For warranty, keep the following types of documents as proof of maintenance or repair: Dealer work orders and itemized bills Owners repair costs Owners receipts Maintenance log Accurate maintenance records can be used to show compliance with the required maintenance practices and maintenance intervals.
NOTE!
Other maintenance agreements for Caterpillar engines may apply. Contact Sandvik for more information.
Products that operate in severe operating conditions may require more frequent maintenance.
WARNING!
UJ440i
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UJ440i
Panel P1 See drawing 191.2575
E1-S90F
Daily inspection
UJ440i
1.3 Daily inspection

NOTE!
Listen for abnormal noises.

1. First week. Check at working rpm and warm oil. Warm up hydraulic oil above 0 C, at low temp <0 C by activating the warm up button with diesel engine at idle before starting up the process. 2. First week
Alarms
Check the alarm log list and take care of any warnings OM:11
Hydraulics
Check for leakage and damage, hoses, valves and couplings Check hydraulic oil level in tank 1
1. First week
4 Jaw crusher
PD:01 PD:01 Check bearing temperatures and drive motor load Lubrication OM:12 OM:12
5 Track unit - Trackline D6

Clear all material from around the sprocket, idler and track group PD:06 PD:06 PD:06 PD:06 Check the track tension Check for loose bolts, if necessary tighten them Check for oil and grease leaks, seal any leaks immediately PD:05 PD:05 PD:05 PD:05
1 Discharge conveyor
Check the pull cord stop Check the belt for damage Check rollers for damage Check that tail pulley is running smoothly
2 Power unit - Diesel engine (Volvo Penta TAD1252VE)

Inspect engine and engine compartment Check lubricating oil level, if necessary refill Check coolant level 1 Check the main air filter status on the display Check the fuel system primary filter (water separator), drain when necessary PD:03 PD:03 PD:03 PD:03, OM:11 PD:03
5 Track unit - Track One T0650C02 / T0650C03

Inspect the extent of track undercarriage dirtiness Inspect the general condition of the track undercarriage components Inspect the fastening elements of the frame sections and the track undercarriage fastenings Inspect the seal of gear-motor unit and the possible hydraulic connections Inspect the general state of the spring and tensioning system of the front idler unit Check for leakage on the track rollers Check for leakage on the carrier roller or wearing rails PD:07 PD:07 PD:07 PD:07 PD:07 PD:07 PD:07 PD:07 PD:07
2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)

Visual inspection of engine for leaks Check the cooling system Check coolant level Check the air filter (air cleaner) service indicator Check oil level Check battery and battery cable connections Check the primary fuel filter (water separator), drain when necessary Check/Adjust/Lubricate Power Take-Off Clutch. PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check for leakage on the track group (only on lubricated track group) Inspect the track group pre-tensioning (track sag)
6 Feeder GF1246
Listen for abnormal noises Check suspension and attachment of hydraulic hoses below the feeder. Make sure there is no wear between hoses or between hoses and chassis OM:13
1. NOTE! The first coolant change is only made after 10 000 hours or 1 year.
8 Dust filter (OPTION) 2 Power unit - Fluid coupling (21 KPTO)

Check oil level 1 Check for leaks
1. First week
Check that the suction capacity is normal PD:04 PD:04 Check visually if there is any changes of the emission from the stack If necessary, clean the shaker device
PD:10 PD:10 PD:10
2 Power unit - Power take-off gearbox (OMKA)

Check oil level 1 Filter indicator (visual) 2 Check for leaks PD:04 PD:04 PD:04
Continues
UJ440i
E1-S90F
10
12
Daily inspection (Continued)
10
UJ440i
1.4 Daily inspection (Continued)

NOTE!
Hydraulic hammer (OPTION) (Described in a separate binder)

Grease the tool shank and the tool bushings Observe hydraulic oil temperature, all lines and connections as well as impact efficiency and evenness of operation. Check visually if there is any changes of the emission from the stack Tighten loose connections Check the swivel pin clearances of the hydraulic hammer boom, if necessary replace the pins and bushings Lubricate all grease nipples Check the hoses, pipes and couplings Check the locking bolts of swivel pins Check the mounting bolts of the hydraulic hammer
10
Crusher lubrication pump (OPTION)

Check the filling level in the lubricant vessel, if necessary vent the system and/or refill it PD:13
12 NF Conveyor (OPTION)
Check the pull cord emergency switch Check the belt for damage Check that tail pulley is running smoothly PD:12 PD:12 PD:12
UJ440i
11
E1-S90F
50-600 hours inspection
12
UJ440i
1.5 After 50-600 hours

NOTE!
This maintenance interval applies specifically to the Volvo diesel engine:

Change engine oil 1 2 3 Change oil filter / bypass filer 2 3 PD:03 PD:03
1. Oil change intervals will vary depending upon the grade of the oil and the amount of sulfur in the fuel. 2. NOTE! Oil filter must be changed with every oil change. 3. At least once a year.
The oil change intervals can vary between 50600 hours depending upon the grade of the oil and the sulphur content of the fuel. Note that the oil change intervals may never exceed a period of 12 months. If change intervals longer than those provided are desired, the condition of the oil must be checked by the manufacturer of the oil by regular testing.
NOTE!
Oil filter must be changed with every oil change.
Oil grade
Sulphur content in fuel, by weight < 0.3 % 0.3 0.5 % > 0.5 % 1
150 hrs / 12 months 100 hrs / 12 months
Oil change interval, reached first in operation

VDS-3 VDS-2 and ACEA: E7 2 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 ACEA: E7, E5, E4 API: CI-4, CH-4, CG-4 600 hrs / 12 months 400 hrs / 12 months 300 hrs / 12 months 200 hrs / 12 months
200 hrs / 12 months
100 hrs / 12 months
50 hrs / 12 months
1. If the sulfur content is > 1.0% by weight, use oil with TBN > 15. 2. The engine oil must comply with both quality requirements.
NOTE!
Mineral based oil, either fully or semi-synthetic, can be used on condition that it complies with the quality requirements above. For selection of viscosity, refer to the Volvo Penta manual in PD:03. The abbreviations in the table above can also be found in the Volvo Penta manual.
UJ440i
13
E1-S90F
10
Weekly inspection
14
UJ440i
1.6 Weekly inspection

NOTE!

Inspect the seal of the front idler and tensioning system (front idler unit) Inspect the re-tensioning span of the track front idler unit (max possible tensioning span reached) PD:07 PD:07 PD:07
Safety control
Check the presence and condition of all safety guards Make a test of all emergency stops
Hydraulics
Check for leakage and damage, hoses, valves and couplings Check hydraulic oil level in tank 1
1. First week
Check the condition of and wear on the front idler and sliding bracket PD:01 PD:01
8 Dust filter (OPTION)

Check that the suction capacity is normal Check visually if there is any changes of the emission from the stack PD:10 PD:10 PD:10

Check the jacket water heater Drain water and sediment from the fuel tank PD:03 PD:03
If necessary, clean the shaker device
9 Hydraulic hammer (OPTION - Described in a separate binder)

Remove the tool retaining pin and the tool and check their condition, if necessary grind the burrs away
2 Power unit - Fluid coupling (21 KPTO)

Check oil level PD:04
Check that the tool has received sufficient grease, if necessary grease more frequently Tighten bolts and couplings Check the oil level in the oil tank, if necessary add oil

Check oil level 1 Filter indicator (visual) PD:04 PD:04
Clean off the dust from the cover of oil tank Check the tool shank and tool bushings for wear Check the hydraulic hoses, if necessary replace them Contact your local dealer for the initial 50-hour inspection
1. Check at working rpm and warm oil. Warm up hydraulic oil above 0 C, at low temp <0 C by activating the warm up button with diesel engine at idle before starting up the process.
3 Crusher drive belts

Check the protection hood Check the V-belts for wear and tension Remove debris
10
Crusher lubrication pump (OPTION)

Check the filling level in the lubricant vessel, if necessary vent the system and/or refill it Check that grease is dispensed to crusher bearings PD:13 PD:13
4 Jaw crusher
Grease all four bearings Lubrication Check tightness of all threaded fasteners Check preload in retraction springs Check wear on jaw plates and check plates Inspect dust seals Check toggle plate and toggle seats for wear or damage Inspect V-belt drive OM:12 OM:12 OM:12 OM:12 OM:12 OM:12 OM:12 OM:12
UJ440i
15
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when required
16
UJ440i
1.7 When required
Engine heater Webasto (OPTION)

Webasto fuel filter PD:20
2 Air filters
Main air filter element 1 Secondary air filter element
2
OM:09 OM:09
1. Change when the Filter guard alarm on the machine control panel display is activated. 2. Changed every 2-3 times the primary air filter is replaced

Replace battery Clean the air filter (air cleaner) element, if necessary replace it If the engine is to be stored, check the engine storage procedure first Check the fuel system, if necessary prime it Check operating conditions (Severe Service Application) PD:03 PD:03 PD:03 PD:03 PD:03
2 Power unit - Fluid coupling (KPTO)

Breather filter PD:04

Breather filter PD:04
UJ440i
17
E1-S90F
80 hours inspection
18
UJ440i
1.8 After 80 hours
Hydraulics
Change all hydraulic oil filters Change high pressure filter Change return filter cartridge Change drain filters Change breather filter element on hydraulic tank Check hydraulic oil level Check couplings and hoses PD:01 PD:01 PD:01 PD:01 PD:01 PD:01 PD:01

Renew oil Renew filter Check the tightness of all bolts, retighten if necessary PD:04 PD:04 PD:04
5 Track unit Track One T0650C02 / T0650C03

Inspect the fastening elements of frame sections and track undercarriage fastenings - grouser shoe fastening (spot-checks) PD:07

Renew oil1 Renew filters PD:03 PD:03
Check the condition of and wear on the drive gear box sprocket Check the condition of and wear on the track rollers Check the condition of and wear on the carrier roller Check the condition of and wear on track link running surfaces, bushings (other diameter) and stretching of track Check the condition of and wear on the track group grouser shoes
PD:07 PD:07 PD:07 PD:07
1. The oil change is recommended, the new engine oil should be one that is recommended by Volvo Penta. NOTE! Oil filter must be changed with every oil change.
PD:07

Renew oil Renew oil and filters (25 micron) Check the bolts on the drive pulley PD:04 PD:04 PD:04
UJ440i
19
E1-S90F
250 hours inspection
20
UJ440i
1.9 After 250 hours

Drain fuel tank (sludge collector) 1 Check the alternator belt, if necessary adjust it 1 Check batteries electrolyte level
1

Check the bolts on the drive pulley PD:03 PD:03 PD:03
n
PD:04

Renew gearbox oil1 Re-tighten all bolts, especially the sprocket bolts PD:07 PD:07 PD:07 PD:07 PD:07

Check supplemental coolant additive concentration, if necessary renew Check battery electrolyte level
2
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check all wear limits Check track group alignment and levelness Check the gearbox oil level and add if necessary
Check the electronics grounding stud, if necessary clean and/or tighten it 2 Check hoses / clamps, if necessary replace them 2 Clean the crankcase breather Clean the radiator 2 Obtain an engine oil sample 2 Drain water and sediment from the fuel tank Renew engine oil 3 4 Renew oil filter 4 Replace the primary fuel filter (water separator) 2 Replace the secondary fuel filter 2
2

Check gear box oil level. If necessary, refill.
1. First change after 200 hours.
PD:07
7 Magnet conveyor (OPTION)

Check the self-lubricating bearings, separator belts and Flexlok couplings PD:08
1. At least once a year. 2. Or for every 14 400 litres of fuel or yearly - which ever occurs first. 3. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 4. NOTE! Oil filter must be changed with every oil change.
UJ440i
21
E1-S90F
12
22
UJ440i
1.10 After 500 hours

6. NOTE! Oil filter must be changed with every oil change.
Hydraulics
Drain condensing water from hydraulic tank PD:01
Check/adjust the conveyor belt Check/adjust the belt cleaning devices Check the roller systems Check the belt scale Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06

5 Track unit Trackline D6

Re-tighten all bolts, especially the sprocket bolts Check all wear limits Check track group alignment and levelness Check the gearbox oil level and add if necessary PD:07 PD:07 PD:07 PD:07

Drain fuel tank (sludge collector)
1 1

PD:03 PD:03 PD:03 Check gear box oil level. If necessary, refill or change oil1.
1. The gear box oil must be changed at least once a year.
PD:07
Check the alternator belt, if necessary adjust it Check batteries electrolyte level 1


Check supplemental coolant additive concentration, if necessary renew Check belts, if necessary adjust and/or replace them Check the starting motor Check the turbocharger Check the water pump Check the engine protective devices 2 Check battery electrolyte level 3 Check the electronics grounding stud, if necessary clean and/or tighten it 3 Check hoses / clamps, if necessary replace them 3 Clean the crankcase breather 3 Clean the radiator 3 Obtain an engine oil sample 3 Obtain a coolant sample (level 1) Obtain a coolant sample (level 2) 4 Drain water and sediment from the fuel tank Renew engine oil 5 6 Renew oil filter
6 3
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03

Lubricate all grease ripples Tighten bolts and couplings Check the oil level in the oil tank, if necessary add oil Clean off the dust from the cover of oil tank Check that swivel pins have no excessive play in their bushes, if necessary replace pins and bushes Replace all filter elements Contact your local dealer for the 600-hour (or yearly) inspection
Check the conveyor belt Check the cleaning devices Check the roller system Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12 PD:12
Replace the primary fuel filter (water separator) Replace the secondary fuel filter 3
1. At least once a year. 2. Or every 6 months - which ever occurs first. 3. Or for every 14 400 litres of fuel or yearly - which ever occurs first. 4. After the initial 500 hours (for new systems, refilled systems and converted systems), then yearly. 5. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year.
UJ440i
23
E1-S90F
24
UJ440i
1.11 After 750 hours

1

Re-tighten all bolts, especially the sprocket bolts PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 Check all wear limits Check track group alignment and levelness Check the gearbox oil level and add if necessary PD:05 PD:05 PD:05 PD:05
Check the alternator belt, if necessary adjust it 1 Check batteries electrolyte level 1 Charge air pipes, check for leaks Change the primary fuel filter Change the secondary fuel filter Change the external primary fuel filter

Check gear box oil level. If necessary, refill or change oil1.
PD:07

Check supplemental coolant additive concentration, if necessary renew Check battery electrolyte level 2 Check the electronics grounding stud, if necessary clean and/or tighten it 2 Check hoses / clamps, if necessary replace them 2 Clean the crankcase breather Clean the radiator 2 Obtain an engine oil sample
2 2

PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
2
Check the self-lubricating bearings, separator belts and Flexlok couplings
PD:08
Drain water and sediment from the fuel tank Replace the primary fuel filter (water separator) Replace the secondary fuel filter Renew engine oil 3 4 Renew oil filter 4
2
PD:03 PD:03 PD:03 PD:03
UJ440i
25
E1-S90F
1 000 hours inspection
26
UJ440i
1.12 After 1 000 hours
Hydraulics
Obtain an engine oil sample 2 Replace the secondary fuel filter

2
PD:03 PD:03 PD:03 PD:03 PD:03
Replace the primary fuel filter (water separator) 2
Check/adjust the conveyor belt Check/adjust the belt cleaning devices Check the roller systems Check the belt scale Check the drive motor Check the drive mechanism Check the screw take-up device Check the counterweight take-up device Check/lubricate the pulleys Check the guiding boards Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06
Renew engine oil 3 4 Renew oil filter

4
1. Or every 6 months - which ever occurs first. 2. Or every 14 400 litres of fuel or yearly - which ever occurs first. 3. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 4. NOTE! Oil filter must be changed with every oil change.

Check pump chain length (19 KPT: max length 1362 mm, 21 KPT: max length 1556 mm) PD:04


Drain fuel tank (sludge collector) 1 Check the alternator belt, if necessary adjust it 1 Check batteries electrolyte level 1 Change coolant filter 2 3 PD:03 PD:03 PD:03 PD:03
Continues
1. At least once a year. 2. NOTE! Do not change the coolant filter and coolant at the same time! 3. Or every 6 months - which ever occurs first. NOTE! This maintenance cycle (every 1 000 hours or 6 months) only starts after the first coolant change after 10 000 hours or 1 year.

Check supplemental coolant additive concentration, if necessary renew Check belts, if necessary adjust and/or replace them Check the starting motor Check the turbocharger Check the water pump Check the engine protective devices Check battery electrolyte level
2 1
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check the electronics grounding stud, if necessary clean and/or tighten it 2 Check hoses / clamps, if necessary replace them 2 Clean the crankcase breather Clean the radiator
2 2
Drain water and sediment from the fuel tank Obtain a coolant sample (level 1)
UJ440i
27
E1-S90F
12
1 000 hours inspection (Continued)
28
UJ440i
1.13 After 1 000 hours (Continued)

Check the conveyor belt Check the cleaning devices Check the roller system Check the screw take-up device Check the pulleys Check the guiding boards PD:07 Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12 PD:12 PD:12 PD:12 PD:12


UJ440i
29
E1-S90F
30
UJ440i

1

Re-tighten all bolts, especially the sprocket bolts PD:03 PD:03 PD:03 Check all wear limits Check track group alignment and levelness Check the gearbox oil level and add if necessary PD:07 PD:07 PD:07 PD:07
Check the alternator belt, if necessary adjust it 1 Check batteries electrolyte level 1

2

PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 Check gear box oil level. If necessary, refill or change oil1.
PD:07
Check the electronics grounding stud, if necessary clean and/or tighten it 2 Check hoses / clamps, if necessary replace them 2 Drain water and sediment from the fuel tank Clean the crankcase breather Clean the radiator
2 2


Lubricate all grease ripples Tighten bolts and couplings Check the oil level in the oil tank, if necessary add oil Clean off the dust from the cover of oil tank Check that swivel pins have no excessive play in their bushes, if necessary replace pins and bushes Replace all filter elements Refill the tank with new clean oil Replace tank breather element
Obtain an engine oil sample 2 Replace the secondary fuel filter 2 Replace the primary fuel filter (water separator) 2 Renew engine oil 3 4 Renew oil filter
UJ440i
31
E1-S90F
12
32
UJ440i

4. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 5. NOTE! Oil filter must be changed with every oil change.
Hydraulics


Re-tighten all bolts, especially the sprocket bolts Check all wear limits Check track group alignment and levelness PD:07 PD:07 PD:07 PD:07

Drain fuel tank (sludge collector) 1 Check the alternator belt, if necessary adjust it 1 Check batteries electrolyte level 1 Charge air pipes, check for leaks Change the primary fuel filter Change the secondary fuel filter Change the external primary fuel filter PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check the gearbox oil level and add if necessary

PD:07


Check supplemental coolant additive concentration, if necessary renew Check belts, if necessary adjust and/or replace them Check the starting motor Check the turbocharger Check the water pump Check the engine protective devices 2 Check battery electrolyte level 3 Check the electronics grounding stud, if necessary clean and/or tighten it 3 Check hoses / clamps, if necessary replace them 3 Clean the crankcase breather 3 Clean the radiator 3 Drain water and sediment from the fuel tank Obtain a coolant sample (level 1) Obtain an engine oil sample 3 Renew engine oil 4 5 Renew oil filter
5 3
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check the conveyor belt Check the cleaning devices Check the roller system Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12
Replace the primary fuel filter (water separator) Replace the secondary fuel filter 3
1. At least once a year. 2. Or every 6 months - which ever occurs first. 3. Or every 14 400 litres of fuel or yearly - which ever occurs first.
UJ440i
33
E1-S90F
34
UJ440i

Drain fuel tank (sludge collector) 1 Check the alternator belt, if necessary adjust it Check batteries electrolyte level
1 1


Check supplemental coolant additive concentration, if necessary renew Check battery electrolyte level 2 Check the electronics grounding stud, if necessary clean and/or tighten it 2 Check hoses / clamps, if necessary replace them 2 Clean the crankcase breather 2 Clean the radiator
2

PD:07

Drain water and sediment from the fuel tank Obtain an engine oil sample
2 2
Replace the primary fuel filter (water separator) Replace the secondary fuel filter 2 Renew engine oil 3 4 Renew oil filter
4
PD:03 PD:03 PD:03 PD:03
1. At least once a year. 2. Or every 14 400 litres of fuel or yearly - which ever occurs first. 3. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 4. NOTE! Oil filter must be changed with every oil change.
UJ440i
35
E1-S90F
36
UJ440i
Hydraulics
Change hydraulic oil Change high pressure filter Change return filter cartridge Change drain filters Change breather filter on hydraulic tank Drain condensing water from hydraulic tank PD:01 PD:01 PD:01 PD:01 PD:01 PD:01

Drain fuel tank (sludge collector) 1 Check the alternator belt, if necessary adjust it Check batteries electrolyte level Change coolant filter 2 3
1 1
PD:03 PD:03 PD:03 PD:03
Check/adjust the conveyor belt Check/adjust the belt cleaning devices Check the roller systems Check the belt scale Check the drive motor Check the drive mechanism Check the screw take-up device Check the counterweight take-up device Check/lubricate the pulleys Check the guiding boards Check the gear Check the pull cord em. switch Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06

Check supplemental coolant additive concentration, if necessary renew Check belts, if necessary adjust and/or replace them Check the starting motor Check the turbocharger Check the water pump Check the engine protective devices 4 Check the alternator
5
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check battery electrolyte level 6 Check the electronics grounding stud, if necessary clean and/or tighten it 6 Check hoses / clamps, if necessary replace them 6 Clean the crankcase breather 6 Clean the radiator 6 Drain water and sediment from the fuel tank Obtain an engine oil sample 6 Obtain a coolant sample (level 1) Replace the primary fuel filter (water separator) 6 Replace the secondary fuel filter Renew engine oil Renew oil filter 8
78 6
1. At least once a year. 2. NOTE! Do not change the coolant filter and coolant at the same time! 3. Or every 6 months - which ever occurs first. NOTE! This maintenance cycle (every 1 000 hours or 6 months) only starts after the first coolant change after 10 000 hours or 1 year. 4. Or every 6 months - which ever occurs first. 5. Or yearly - which ever occurs first. 6. Or every 14 400 litres of fuel or yearly - which ever occurs first. 7. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 8. NOTE! Oil filter must be changed with every oil change.
Continues
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UJ440i

Renew oil and filters (25 micron) Check for leaks Check pump chain length (19 KPT: max length 1362 mm, 21 KPT: max length 1556 mm) PD:04 PD:04 PD:04
6 Feeder GF1246
Lubricate vibrator bearings OM:13


Renew oil Renew filter Check the tightness of all bolts, retighten if necessary If necessary renew seals PD:04 PD:04 PD:04 PD:04
Check the conveyor belt Check the cleaning devices Check the roller system Check the screw take-up device PD:12 PD:12 PD:12

Renew gearbox oil Re-tighten all bolts, especially the sprocket bolts Check all wear limits Check track group alignment and levelness PD:07 PD:07 PD:07 PD:07
Check the pulleys Check the guiding boards Check the pull cord emergency switch Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12

Change gear box oil1 PD:07
1. The oil needs not to be changed after 2 000 hours if it already has been changed between 500 and 1 750 hours. If so, make sure that the oil is changed within 2 000 hours (or at least a year) from the previous change.
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E1-S90F
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UJ440i

1 1

Charge air pipes, check for leaks Change the primary fuel filter Change the secondary fuel filter Change the external primary fuel filter

PD:07

Check supplemental coolant additive concentration, if necessary renew Check battery electrolyte level 2 Check the electronics grounding stud, if necessary clean and/or tighten it 2 Check hoses / clamps, if necessary replace them 2 Clean the crankcase breather 2 Clean the radiator
2

PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
2
PD:08
Drain water and sediment from the fuel tank Obtain an engine oil sample
2
Drain water and sediment from the fuel tank Replace the primary fuel filter (water separator) Replace the secondary fuel filter Renew engine oil 3 4 Renew oil filter 4
2
PD:03 PD:03 PD:03 PD:03

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Hydraulics

Re-tighten all bolts, especially the sprocket bolts Check all wear limits PD:07 PD:07 PD:07 PD:07
Check track group alignment and levelness Check the gearbox oil level and add if necessary

PD:07


1
Check the conveyor belt PD:03 PD:03 PD:03 Check the cleaning devices Check the roller system Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12 PD:12

Check supplemental coolant additive concentration, if necessary renew Check belts, if necessary adjust and/or replace them Check the starting motor Check the turbocharger Check the water pump Check the engine protective devices 2 Check battery electrolyte level
3
Check the electronics grounding stud, if necessary clean and/or tighten it 3 Check hoses / clamps, if necessary replace them 3 Clean the crankcase breather Clean the radiator 3 Drain water and sediment from the fuel tank Obtain a coolant sample (level 1) Obtain an engine oil sample 3 Replace the primary fuel filter (water separator) 3 Replace the secondary fuel filter 3 Renew engine oil Renew oil filter
5 45 3
1. At least once a year. 2. Or every 6 months - which ever occurs first. 3. Or every 14 400 litres of fuel or yearly - which ever occurs first. 4. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 5. NOTE! Oil filter must be changed with every oil change.
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E1-S90F
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UJ440i

1 1


Check supplemental coolant additive concentration, if necessary renew Check battery electrolyte level 2 Check the electronics grounding stud, if necessary clean and/or tighten it 2 Check hoses / clamps, if necessary replace them 2 Clean the crankcase breather 2 Clean the radiator 2 Drain water and sediment from the fuel tank Obtain an engine oil sample
2 2

PD:03 PD:03 PD:03
PD:07

PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 Check the self-lubricating bearings, separator belts and Flexlok couplings PD:08
Replace the primary fuel filter (water separator) Replace the secondary fuel filter 2 Renew engine oil 3 4 Renew oil filter
4
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UJ440i
Hydraulics

Check supplemental coolant additive concentration, if necessary renew PD:03 PD:03 PD:03 PD:03 PD:03
1
Check/adjust the conveyor belt Check/adjust the belt cleaning devices Check the roller systems Check the belt scale Check the drive motor Check the drive mechanism Check the screw take-up device Check the counterweight take-up device Check the pulleys Check the guiding boards Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06
Check belts, if necessary adjust and/or replace them Check the starting motor Check the turbocharger Check the water pump Check the engine protective devices
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check the crankshaft vibration damper 2 Check the electronic unit injector, if necessary adjust it 2 Check the engine mounts 2 Check the engine speed / timing sensors, if necessary clean and/or calibrate them 2 Check the engine valve lash, if necessary adjust it 2 Check the engine valve rotators 2 Check battery electrolyte level
3
Check the electronics grounding stud, if necessary clean and/or tighten it 3 Check hoses / clamps, if necessary replace them 3

Drain fuel tank (sludge collector) 1 Check the alternator belt, if necessary adjust it 1 Check batteries electrolyte level
1
Clean the crankcase breather Clean the radiator PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
3
Clean and test the after cooler core 4 Clean the engine 2 Drain water and sediment from the fuel tank Obtain a coolant sample (level 1) Obtain an engine oil sample 3 Replace the primary fuel filter (water separator) 3 Replace the secondary fuel filter
3
Charge air pipes, check for leaks Change the primary fuel filter Change the secondary fuel filter Change the external primary fuel filter Change coolant filter
23
Replace the water temperature regulator 5 Renew coolant extender (ELC) 5 Renew coolant (DEAC) Renew engine oil Renew oil filter 7
67 5
1. Or every 6 months - which ever occurs first. 2. Or every 170 400 litres of fuel - which ever occurs first. 3. Or every 14 400 litres of fuel or once a year - which ever occurs first. 4. Or every 114 000 litres of fuel - which ever occurs first. 5. Or every 3 years - which ever occurs first. 6. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 7. NOTE! Oil filter must be changed with every oil change.
Continues
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UJ440i

Check pump chain length (19 KPT: max length 1362 mm, 21 KPT: max length 1556 mm) PD:04


Check the conveyor belt Check the cleaning devices Check the roller system Check the screw take-up device Check the pulleys PD:12 PD:12 PD:12 PD:12 PD:12 PD:12 PD:12

Check the guiding boards Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings

PD:07
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UJ440i

1


2

2

PD:07
Check the electronics grounding stud, if necessary clean and/or tighten it 2 Check hoses / clamps, if necessary replace them 2 Clean the crankcase breather 2 Clean the radiator 2 Drain water and sediment from the fuel tank Obtain an engine oil sample 2 Replace the primary fuel filter (water separator) Replace the secondary fuel filter Renew engine oil 3 4 Renew oil filter 4
2

PD:03 PD:03 PD:03 PD:03
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52
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Hydraulics

Renew oil PD:04 PD:04 PD:04 Renew filter
Check/adjust the conveyor belt Check the belt cleaning devices Check the roller systems Check the belt scale Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06
Check the tightness of all bolts, retighten if necessary


PD:07

1 1
PD:03 PD:03 PD:03
Check the alternator belt, if necessary adjust it Check batteries electrolyte level
1


Check supplemental coolant additive concentration, if necessary renew Check belts, if necessary adjust and/or replace them Check the starting motor Check the turbocharger Check the water pump Check the engine protective devices 2 Check battery electrolyte level
3
Check the conveyor belt Check the cleaning devices Check the roller system Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12 PD:12
Check the electronics grounding stud, if necessary clean and/or tighten it 3 Check hoses / clamps, if necessary replace them 3 Clean the crankcase breather Clean the radiator 3 Drain water and sediment from the fuel tank Obtain a coolant sample (level 1) Obtain an engine oil sample 3 Replace the primary fuel filter (water separator) 3 Replace the secondary fuel filter 3 Renew engine oil Renew oil filter
5 45 3
1. At least once a year. 2. Or every 6 months - which ever occurs first. 3. Or every 14 400 litres of fuel or yearly - which ever occurs first. 4. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 5. NOTE! Oil filter must be changed with every oil change.
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1

Check the alternator belt, if necessary adjust it 1 Check batteries electrolyte level 1 Charge air pipes, check for leaks Change the primary fuel filter Change the secondary fuel filter Change the external primary fuel filter

PD:07

Check supplemental coolant additive concentration, if necessary renew Check battery electrolyte level 2 Check the electronics grounding stud, if necessary clean and/or tighten it 2 Check hoses / clamps, if necessary replace them 2 Clean the crankcase breather Clean the radiator 2 Drain water and sediment from the fuel tank Obtain an engine oil sample 2 Replace the primary fuel filter (water separator) Replace the secondary fuel filter Renew engine oil 3 4 Renew oil filter 4
2 2 2

PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 Check the self-lubricating bearings, separator belts and Flexlok couplings PD:08
1. At least once a year 2. Or every 14 400 litres of fuel or yearly - which ever occurs first. 3. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 4. NOTE! Oil filter must be changed with every oil change.
UJ440i
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E1-S90F
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UJ440i
Hydraulics
Change hydraulic oil Change high pressure filter Change return filter cartridge Change drain filters Change breather filter on hydraulic tank Drain condensing water from hydraulic tank PD:01 PD:01 PD:01 PD:01 PD:01 PD:01

Check supplemental coolant additive concentration, if necessary renew Check belts, if necessary adjust and/or replace them Check the starting motor Check the turbocharger Check the water pump Check the engine protective devices
1
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check/adjust the conveyor belt Check/adjust the belt cleaning devices Check the roller systems Check the belt scale Check the drive motor Check the drive mechanism Check the screw take-up device Check the counterweight take-up device Check the pulleys Check the guiding boards Check the gear Check the pull cord em. switch Check the safety switch Check the rotation detector Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Impact bars - Skirt boards - Belt scrapers - Drive gear - Idlers PD:06 PD:06 PD:06 PD:16 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06 PD:06
Check the alternator 2 Check battery electrolyte level 3 Check the electronics grounding stud, if necessary clean and/or tighten it 3 Check hoses / clamps, if necessary replace them 3 Clean the crankcase breather 3 Clean the radiator 3 Drain water and sediment from the fuel tank Obtain a coolant sample (level 1) Obtain an engine oil sample 3 Replace the primary fuel filter (water separator) Replace the secondary fuel filter Renew engine oil 4 5 Renew oil filter 5
3 3
PD:03 PD:03 PD:03 PD:03
1. Or every 6 months - which ever occurs first. 2. Or yearly - which ever occurs first. 3. Or every 14 400 litres of fuel or yearly - which ever occurs first. 4. If the engine oil is being analyzed, using Caterpillars SOS oil analys program, the oil change interval may be increased to 500 hours for the Deep oil pan (used for motors with serial numbers higher than LGK05295). NOTE! Oil must be changed at least once a year. 5. NOTE! Oil filter must be changed with every oil change.

Drain fuel tank (sludge collector) 1 Check the alternator belt, if necessary adjust it 1 Check batteries electrolyte level 1 Change coolant filter
23

PD:03 PD:03 PD:03 PD:03 Renew oil and filters (25 micron) Check pump chain length (19 KPT: max length 1362 mm, 21 KPT: max length 1556 mm) PD:04 PD:04

Renew oil Renew filter Check the tightness of all bolts, retighten if necessary If necessary renew seals PD:04 PD:04 PD:04 PD:04
Continues
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E1-S90F
11
12
NOTE!
The maintenance cycle continues after 4 000 hrs. Go back to Section 1.9 and repeat the maintenance instructions for 250 hrs. when 4 250 hrs. has passed.
58
UJ440i

Renew gearbox oil Re-tighten all bolts, especially the sprocket bolts Check all wear limits Check track group alignment and levelness Check the gearbox oil level and add if necessary PD:07 PD:07 PD:07 PD:07 PD:07

Change gear box oil1 PD:07
1. The oil needs not to be changed after 4 000 hours if it already has been changed between 2 2500 and 3 750 hours. If so, make sure that the oil is changed within 2 000 hours (or at least a year) from the previous change.
6 Feeder GF1246
Lubricate vibrator bearings OM:13

l
PD:08
11 Screen (OPTION)
Lubricate the vibrator bearings PD:12
Check the conveyor belt Check the cleaning devices Check the roller system Check the screw take-up device Check the pulleys Check the guiding boards Check the pull cord emergency switch Check the rotation detector Checks/adjustments/replacements/lubrication according to Service Diagram (drawing): - Tail pulley - Wear plates - Skirt boards - Belt scrapers - Drive gear - Idlers - Bearing housings PD:12 PD:12 PD:12 PD:12 PD:12 PD:12 PD:12 PD:12 PD:12
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NOTE!
These maintenance intervals applies both to the Volvo and the Caterpillar diesel engines: After 10 000 hours Every 6 months Yearly
NOTE!
These maintenance intervals applies specifically to the Caterpillar diesel engine: After 8 000 hours After 12 000 hours Every 3 years Every 6 years Every 14 400 litres of fuel Every 28 500 litres of fuel Every 114 000 litres of fuel Every 170 400 litres of fuel Every 380 000 litres of fuel.s

NOTE!
This maintenance interval applies specifically to the Caterpillar diesel engine.

Check the driven equipment 1
1. Or every 3 years - which ever occurs first.
PD:03
60
UJ440i

NOTE!
This maintenance interval applies both to the Volvo and the Caterpillar diesel engines.
Change coolant for the first time 1 2 2 PD:03
Date for the first coolant change
Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)

Consider an overhaul 3 PD:03
1. NOTE! Do not change coolant and the coolant filter at the same time! 2. Or after 1 year - which ever occurs first. NOTE! The normal maintenance cycle for coolant change (every 1 000 hours or 6 months) only starts after the first coolant change. 3. Or every 380 000 litres of fuel - which ever occurs first.

NOTE!

Renew coolant (ELC) 1
1. Or every 6 years - which ever occurs first.
PD:03
1.32 Every 6 months

NOTE!
Change coolant filter 1 2 PD:03

Check the engine protective devices 3 PD:03
1. NOTE! Do not change the coolant filter and coolant at the same time! 2. Or every 1 000 hours - which ever occurs first. NOTE! This maintenance cycle (every 1 000 hours or 6 months) only starts after the first coolant change after 10 000 hours or 1 year. 3. Or every 500 hours - which ever occurs first.
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1.33 Yearly
NOTE!
Change coolant filter 1 2 Change air filter element Clean / paint engine Change air filter (tank ventilation) Drain fuel prefilter from water or impurities 3 Change engine oil 4 Change oil filter / bypass filer
4
Date for the first coolant change

PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03, OM:11 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Check the main air filter status on the display 5 Drain fuel tank (sludge collector) 6 Check the alternator belt, if necessary adjust it 6 Check batteries electrolyte level 6 Charge air pipes, check for leaks Change fuel pre-filter Change fuel filter 7
7 7

Check the alternator 8 Check battery electrolyte level 9 Check the electronics grounding stud, if necessary clean and/or tighten it 9 Check hoses / clamps, if necessary replace them 9 Clean the crankcase breather 9 Clean the radiator 9 Obtain an engine oil sample
9
PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03 PD:03
Obtain a coolant sample (level 2) 10 Replace the primary fuel filter (water separator) 9 Replace the fuel system secondary filter element Renew engine oil
11 9
Renew oil filter cartridge 11
1. NOTE! Do not change the coolant filter and coolant at the same time! 2. Or every 1 000 hours - which ever occurs first. NOTE! This maintenance cycle (every 1 000 hours or 6 months) only starts after the first coolant change after 10 000 hours or 1 year. 3. At least once a year, but weekly is preferred. 4. At least once a year, but shorter time intervals (50-600 hours) are preferred. Oil change intervals will vary depending upon the grade of the oil and the amount of sulfur in the fuel. NOTE! Oil filter must be changed with every oil change. 5. At least once a year, but daily is preferred. 6. At least once a year, but every 250 hours is preferred. 7. At least once a year, but every 750 hours is preferred. 8. Or every 2 000 hours - which ever occurs first. 9. Or every 250 hours or every 14 400 litres of fuel - which ever occurs first. 10. NOTE! A new, refilled or converted system requires maintenance after the initial 500 hours, then yearly. 11. Or every 250 hours (for mobile units with a standard oil pan) / 500 hours (for mobile units with a deep oil pan) or every 28 500 litres of fuel - which ever occurs first.
62
UJ440i
1.34 Every 3 years

NOTE!

Renew coolant (DEAC) 1 Renew coolant extender (ELC) 1 Replace the water temperature regulator Check the driven equipment
2 1
PD:03 PD:03 PD:03 PD:03
1. Or every 3 000 hours - which ever occurs first. 2. Or every 8 000 hours - which ever occurs first.
1.35 Every 6 years

NOTE!

Renew coolant (ELC) 1
1. Or every 12 000 hours - which ever occurs first.
PD:03
1.36 Every 14 400 litres of fuel

NOTE!

Clean and test the aftercooler core 1
1. Or every 250 hours or yearly - which ever occurs first.
PD:03
UJ440i
63

NOTE!

Clean and test the aftercooler core 1
PD:04

NOTE!

Check the crankshaft vibration damper 1 Check the electronic unit injector, if necessary adjust it 1 Check the engine mounts 1 Check the engine speed / timing sensors, if necessary clean and/or calibrate them 1 Check the engine valve lash, if necessary adjust it 4 Check the engine valve rotators Clean the engine
1 1
PD:04 PD:04 PD:04 PD:04 PD:04 PD:04 PD:04

NOTE!

Consider an overhaul 1
PD:04
64
UJ440i
1.40 Completed maintenance jobs

AFTER 80 HOURS TO 4 000 HOURS
Working hours 80 250 500 750 1 000 1 250 1 500 1 750 2 000 2 250 2 500 2 750 3 000 3 250 3 500 3 750 4 000 Date Signature / Stamp Date Signature / Stamp Date Signature / Stamp
The maintenance cycle continues after 4 000 hrs. Go back to Section 1.9 and repeat the maintenance instructions for 250 hrs when 4 250 hrs has passed.
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AFTER 8 000, 10 000 AND 12 000 HOURS

Working hours 8 0001 10 0002 12 0001
1. Applies only to the Caterpillar diesel engine. 2. Applies both to the Volvo and the Caterpillar diesel engines.
Date
Signature / Stamp
Date
Signature / Stamp
Date
Signature / Stamp
NOTE! NOTE!
The after 10 000 hours maintenance interval applies both to the Volvo and the Caterpillar diesel engines. The after 8 000 hours and the after 12 000 hours maintenance intervals applies specifically to the Caterpillar diesel engine.
EVERY 6 MONTHS
Time interval 6 months 12 months 18 months 24 months 30 months 36 months 42 months 48 months 54 months 60 months Date Signature / Stamp Date Signature / Stamp Date Signature / Stamp
NOTE!
The every 6 months maintenance interval applies both to the Volvo and the Caterpillar diesel engines. The maintenance cycle continues after 60 months. Go back to Section 1.32 and repeat the maintenance instructions for every 6 months when 60 months. has passed.
66
UJ440i

YEARLY
Time interval 1 year 2 years 3 years 4 years 5 years Date Signature / Stamp Date Signature / Stamp Date Signature / Stamp
NOTE!
The yearly maintenance interval applies both to the Volvo and the Caterpillar diesel engines. The maintenance cycle continues after 5 years. Go back to Section 1.33 and repeat the maintenance instructions for every year when 5 years has passed.
EVERY 3 YEARS
Time interval 3 years 6 years Date Signature / Stamp Date Signature / Stamp Date Signature / Stamp
NOTE!
The every 3 years maintenance interval applies specifically to the Caterpillar diesel engine. The maintenance cycle continues after 6 years. Go back to Section 1.34 and repeat the maintenance instructions for every 3 years when 6 years has passed.
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EVERY 6 YEARS
Time interval 6 years 12 years Date Signature / Stamp Date Signature / Stamp Date Signature / Stamp
NOTE!
The every 6 years maintenance interval applies specifically to the Caterpillar diesel engine. The maintenance cycle continues after 12 years. Go back to Section 1.35 and repeat the maintenance instructions for every 6 years when 12 years has passed.
EVERY 14 400 LITRES OF FUEL

Fuel interval 14 400 litres 28 800 litres 43 200 litres 57 600 litres 72 000 litres 86 400 litres 100 800 litres 115 200 litres 129 600 litres 144 000 litres Date Signature / Stamp Date Signature / Stamp Date Signature / Stamp
NOTE!
The every 14 400 litres of fuel maintenance interval applies specifically to the Caterpillar diesel engine. The maintenance cycle continues after 144 000 litres of fuel. Go back to Section 1.36 and repeat the maintenance instructions for every 14 400 litres of fuel when 144 000 litres of fuel has been used.
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UJ440i

Fuel interval 114 000 litres 228 000 litres Date Signature / Stamp Date Signature / Stamp Date Signature / Stamp
NOTE!

NOTE!

NOTE!
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UJ440i

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Sandvik UJ440i

This document is valid for:

Serial no. / Machine no.

Table of contents 1.40 Completed maintenance jobs ............................................. 65

Sandvik SRP AB Doc. no. S 281.821 en Ver. 1

Sandvik SRP AB Doc. no. S 281.821 en Ver. 1

1. UJ440i Preventive Maintenance

1.2 Caterpillar engine (option)

Sandvik SRP AB Doc. no. S 281.821 en Ver. 1

1. UJ440i Preventive Maintenance

This page is intentionally left blank

Sandvik SRP AB Doc. no. S 281.821 en Ver. 1

1. UJ440i Preventive Maintenance

Panel P1 See drawing 191.2575

Sandvik SRP AB Doc. no. S 281.821 en Ver. 1

1. UJ440i Preventive Maintenance

1.3 Daily inspection

Listen for abnormal noises.

5 Track unit - Trackline D6

2 Power unit - Diesel engine (Volvo Penta TAD1252VE)

5 Track unit - Track One T0650C02 / T0650C03

2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)

8 Dust filter (OPTION) 2 Power unit - Fluid coupling (21 KPTO)

PD:10 PD:10 PD:10

2 Power unit - Power take-off gearbox (OMKA)

Sandvik SRP AB Doc. no. S 281.821 en Ver. 1

1. UJ440i Preventive Maintenance

Panel P1 See drawing 191.2575

Daily inspection (Continued)

Sandvik SRP AB Doc. no. S 281.821 en Ver. 1

1. UJ440i Preventive Maintenance

1.4 Daily inspection (Continued)

Listen for abnormal noises.

Hydraulic hammer (OPTION) (Described in a separate binder)

Crusher lubrication pump (OPTION)

Sandvik SRP AB Doc. no. S 281.821 en Ver. 1

1. UJ440i Preventive Maintenance

Panel P1 See drawing 191.2575

50-600 hours inspection

Sandvik SRP AB Doc. no. S 281.821 en Ver. 1

1. UJ440i Preventive Maintenance

1.5 After 50-600 hours

This maintenance interval applies specifically to the Volvo diesel engine:

Oil filter must be changed with every oil change.

Oil change interval, reached first in operation

200 hrs / 12 months

100 hrs / 12 months

Sandvik SRP AB Doc. no. S 281.821 en Ver. 1

1. UJ440i Preventive Maintenance

Panel P1 See drawing 191.2575

Sandvik SRP AB Doc. no. S 281.821 en Ver. 1

1. UJ440i Preventive Maintenance

1.6 Weekly inspection

Listen for abnormal noises.

8 Dust filter (OPTION)

2 Power unit - Diesel engine (Caterpillar C13 ACERT Ind-C)

If necessary, clean the shaker device

9 Hydraulic hammer (OPTION - Described in a separate binder)

2 Power unit - Fluid coupling (21 KPTO)

2 Power unit - Power take-off gearbox (OMKA)

3 Crusher drive belts

Crusher lubrication pump (OPTION)