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    5 SM 2200 Maintenance

    Uploaded by

    Plr. Baswapur
    The document provides maintenance tasks and safety checks for a machine. It includes daily, weekly, and scheduled maintenance at 250, 500, and 1000 hour intervals. Key tasks include greasing points, checking fluid levels, cleaning components, and inspecting for leaks or wear. The document also outlines safety devices that must be checked, such as emergency stop buttons and alarms.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    5 SM 2200 Maintenance

    Uploaded by

    Plr. Baswapur
    274 views48 pages
    The document provides maintenance tasks and safety checks for a machine. It includes daily, weekly, and scheduled maintenance at 250, 500, and 1000 hour intervals. Key tasks include greasing points, checking fluid levels, cleaning components, and inspecting for leaks or wear. The document also outlines safety devices that must be checked, such as emergency stop buttons and alarms.

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    © © All Rights Reserved

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    PDF, TXT or read online from Scribd

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    The document provides maintenance tasks and safety checks for a machine. It includes daily, weekly, and scheduled maintenance at 250, 500, and 1000 hour intervals. Key tasks include greasing points, checking fluid levels, cleaning components, and inspecting for leaks or wear. The document also outlines safety devices that must be checked, such as emergency stop buttons and alarms.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    274 views48 pages

    5 SM 2200 Maintenance

    Uploaded by

    Plr. Baswapur
    The document provides maintenance tasks and safety checks for a machine. It includes daily, weekly, and scheduled maintenance at 250, 500, and 1000 hour intervals. Key tasks include greasing points, checking fluid levels, cleaning components, and inspecting for leaks or wear. The document also outlines safety devices that must be checked, such as emergency stop buttons and alarms.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 48

    4/22/2013 1

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    Daily Maintenance Task
    Greasing all Points - Mainly

    Bearing Seal Belt Tensioner

    Steering Front/Rear
    Bearing

    Guide Columns
    Scrapper door
    Brgs.
    Column
    suspension
    Daily Maintenance Task
    Ensure all Anti Slip Surfaces Ladders are kept Clean and free from
    grease/oil and dirt.
    Daily Maintenance Task
    Water System
    • Check Water Tank Level
    • Check Water Filter Mesh
    • Check Nozzles
    Daily Maintenance Task
    Engine Check
    Check Engine oil level.
    Check Fuel Level.
    Check Engine Coolant level.
    Check Air Filters / Dirt indicators.
    Check Engine Air intake hoses for damage/squeezing.
    Air Filter dirt indicator

    Fuel Level
    1500L (max)
    Coolant Level Engine Oil Level
    Daily Maintenance Task
    Hydraulic System Check
    Check for Hydraulic oil leakages from components/hoses etc.
    Check Hydraulic/PTO Gear Box Oil Level
    Check Hydraulic Filters Dirt Indicators
    Check Hydraulic Hoses leakages/abrasion
    Check Hydraulic/PTO Gear Box Cooler Fins Leakages
    Daily Maintenance Task
    Milling Drum Unit
    Check / Change
    Cutting Tools Visual Check for Leakages – Gear Box &
    Free Bearing End
    Daily Maintenance Task
    Advance Drive System

    Check Track Hoses

    Clean Undercarriage

    Check Track Rollers for leakages


    Weekly Maintenance
    DAILY MAINTENANCE +
    Clean Cooler Fins.
    Clean out advance drive motor
    protective cover.
    Check all bolts for tightness.
    Drum mtg. Bolts, Overlay, Track pads,
    Engine mtg. PTO G.box mtg.

    Inspect Electrical ‘X1’ cabinet use


    blower to clean.
    Milling Drum Maintenance.
    250 Hrs Schedule Maintenance
    1. Engine Maintenance
    Change Engine oil with Filters
    Change Fuel Filters and water Separator
    Inspect Air Filter Elements in Dark Room

    Check Coolant
    Check coolant
    additive
    concentration with
    test strip.
    Nitrite concentration
    1600 – 2000 ppm
    250 Hrs Schedule Maintenance
    contd.
    Check Battery acid level,
    clean cover breather holes
    and grease terminals.

    Clutch Greasing

    Check all Drive Belts


    500 Hrs Schedule Maintenance
    250 Hrs Engine maintenance

    + Replace Hyd. Filters

    Milling Drum Gbox OilPTO Gbox Oil Track Gbox Oil


    Free Brg. Oil
    500 Hrs Schedule Maintenance
    … contd.
    Replace Water Pump Lube Oils

    5 Bar ?
    1000 Hrs Maintenance
    1. 250 Hrs Engine Maintenance.
    2. 500 Hrs G.Box Maintenance.
    3. Replace Hyd oil + Filters
    Machine monitoring System
    = General Fault !!! In case of fault, RED pilot light will glow, warning
    Horn will sound and symbol will appear in CGC.

    On pressing key text message


    will appear. Fault message can be
    acknowledged by pressing
    The error message will disappear and warning sound will go off.

    = Diesel Engine fault!!RED warning light indicates fault has been


    recognized by engine monitoring system.

    YELLOW light blinking indicates error code. Engine operating manual to be


    referred to analyse diagnosis code.
    STOP Engine
    FAULT ! Stop, check and Rectify

    = Diesel engine fault indication – SPN/FMI read flash code

    = Engine Oil pressure Oil

    = Engine coolant Level Low

    = Engine coolant Temperature High.

    = Engine Fault
    Engine Troubleshooting

    •Follow Fault Messages from CGC.


    •Follow Flash Code message from diagnostic lamp example flash code 27 = 2
    short flashes followed by hesitation followed by 7 short flashes
    •Check external wiring connection of engine/sensors/ECM.

    • CONTACT : CATERPILLAR SERVICE/WIRTGEN


    FAULT MESSAGES ON CGC DISPLAY
    = Machine general fault indication on control panel. Also Service Due
    Indication.

    = Milling drum open – Drum will not start.

    = Maximum height limit switch activated.

    = Not enough water in tank-water pumps will not work.

    = Battery Voltage < 23.5V – Check battery.

    = Air intake temperature high.

    = Air intake filter contaminated.


    Stop ! Check ! Rectify ! and
    Acknowledge

    = Emergency Stop activated.

    = Engine / general Can Bus fault-’subscriber missing’

    = Hydraulic Oil Temperature High

    = Cooling Fan Error

    = Hydraulic Filter Contamination.

    = Engine Service Due

    = Machine maintenance Due


    SAFETY DEVICES – CHECKING - 1
    EMERGENCY STOP BUTTONS
    “Press when Engine is at idling speed”
    - Engine must stop-

    Caution :
    Ensure engine is stopped only during emergency
    and for test purposes and NOT to generally stop
    the engine.
    SAFETY DEVICES – CHECKING - 2

    ENGINE STOP BUTTON

    When engine is idling - Press the Button


    longer than 0.5 seconds.

    - Engine must Stop


    SAFETY DEVICES – CHECKING - 3

    REVERSING HORN

    Horn will sound at intervals as soon as the


    machine moves in Reverse.
    SAFETY DEVICES – CHECKING - 4

    WARNING HORN
    Horn ‘A’ must sound when pressing the
    button in the Main Control Panel

    Horn ‘B’ must sound when pressing the


    button on side Side Control Panel.
    SAFETY DEVICES – CHECKING - 5

    SAFETY RAILS

    Do not operate the machine without the


    Safety Rails. This safety device must be
    correctly applied at all times.
    SAFETY DEVICES – CHECKING - 6

    SAFETY LATCH SCRAPER

    Raise the Scraper until the safety latch


    engages.
    Ensure that the bolt securely engages in
    the safety latch when scraper is raised.
    SAFETY DEVICES – CHECKING - 7
    LIMIT SWITCH SCRAPER

    Raise the Scraper until the Limit Switch is


    Activated within a movement of 150mm.
    SAFETY DEVICES – CHECKING - 8

    SIDE PLATE

    Raise the Side Plate. After releasing the


    switch the side plate will automatically
    lower itself.
    SAFETY DEVICES – CHECKING - 9

    Check Anti Slip Surface

    Check anti – slip surface


    Clean or Change when necessary.
    Safety - Important

    Use High Pressure Cleaner only for machine cleaning purpose. DONOT
    point jet cleaner towards sensitive Engine components, cables, electrical
    or electronic components.
    CAUTION: Do not point jet cleaner against eyes !!!
    Clutch Assembly
    Clutch Repair
    Without
    tension = Pressurise 50 bar via
    148mm Hyd hand pump. Max
    minus 10% allowed 15mm
    Replace disks
    P T O / Splitter G. Box
    Undercarriage

    Leaking roller - Replace

    Chain Wear

    Permissible sweating of Seal


    Under Carriage

    Idler Roller

    Sprocket Worn

    Chain and Sprocket to be replaced as a Set.!


    Track Chain Wear
    Milling drum

    Maintain Ejector Blocks – replace when necessary –


    Reduces load on engine and Traction. Replace Tool
    holders when excessive play between Tool Shank and
    Holder Bore.
    Drum maintenance is dependent on Silica content of the milled material and
    operating practises e.g. depth and speed of machine while milling. Hard facing
    and Holder root weld should be planned at regular intervals
    Milling drum
    Inspect all Tool Holders welding, replace
    worn tool holders wherever bores are oblong
    resulting in lose of cutting tools. This is
    dependent on experience with different
    material characteristics.
    Milling Drum G.Box

    Follow scheduled maintenance, analyzing the oil carefully after every


    maintenance for metal particles. G.Box is not to be opened without prior
    consent of Wirtgen Service.
    Guide / Steering Columns

    Check Guide column Key way/ spline key


    Gap Max 5mm. Between key and keyway.

    Regular/sufficient guide column greasing and


    avoid uneven raising of machine in undulated
    terrain.
    Guide / Steering Columns
    Advance drive G.Box

    G.Box without Brake G.Box with Brake

    Carry out timely Schedule oil maintenance and requires no special


    maintenance. Inspect oil after every change for wear. If necessary conduct
    SOS every oil change.
    List of Lubricants
    Schedule
    No Location Grade Quantity
    (Hrs)

    1 Milling drum Gear box PG220 39 L 500

    Milling drum Gear box


    2 (Support) PG220 1.2 L 500

    3 Belt tensioner 85W90 5L 250

    4 Fuel Tank HSD 1500 When Reqd

    5 Eng Oil 15W40 CI4 70 L 250

    6 Coolant CAT ELC 170 L 3000


    List of Lubricants
    Schedule
    No Location Grade Quantity
    (Hrs)
    7 Hyd oil HVLP 68 500 L 1000
    8 Splitter Gear BOX 85W90 14 L 500
    9 Adv Drv GB –F 85W90 4.6 X 2 250
    10 Adv Drv GB –R 85W90 5,2 X 2 250
    11 Water tank Pottable 5000 When Reqd
    12 Water filling pump 85W90 0.5 L 500
    13 Sprinkler Pump 15W40 0.7 L 250
    14 Grease EP3 - -
    E.O.D

    48

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