Original instructions

Maintenance manual
TRAMMING
311 RANGE
311 RANGE TRAMMING SERVICE MANUAL

WARNING

IGNORING INSTRUCTION HAZARD

To avoid death or injury you MUST read, understand and follow Operator’s
and Maitenance Manuals before installing, inspecting, operating, servicing,
testing, cleaning, transporting, storing, dismanthling or disposing of the
product or a part or accessory of the product.

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SERVICE MANUAL 311 RANGE TRAMMING

CONTENTS

1. PRELIMINARY REMARKS ............................................................................ 5

1.1. Safety ......................................................................................... 5

1.2. About this booklet............................................................................. 7

2. DESCRIPTION ............................................................................................... 8

2.1. Explanation........................................................................................ 8

2.2. Features ......................................................................................... 8

2.3. Main components.............................................................................. 9

3. PERIODIC MAINTENANCE ......................................................................... 10

3.1. First entry into service.................................................................... 10

3.2. Operations at each shift ................................................................. 10

3.3. 50 hours or weekly operations ...................................................... 11

3.4. 100 hours operations...................................................................... 11

3.5. 200 hours operations...................................................................... 11

3.6. 800 hours operations...................................................................... 11

3.7. 1000 hours operations.................................................................... 11

3.8. 5800 hours operations overall inspection and reconditioning... 11

4. TIGHTENING TORQUES ............................................................................. 12

4.1. Standard tightening torques .......................................................... 12

4.2. Specific tightening torques............................................................ 12

5. LUBRICATION ............................................................................................. 13

5.1. Greasing points............................................................................... 13

5.1.1. Grease nipples location ....................................................................................... 13
5.1.2. Central greasing system (optional) ...................................................................... 14

5.2. Axles ....................................................................................... 15

5.3. Axle DANA 112 oil change ............................................................. 16

5.4. Axle DANA 123 oil change ............................................................. 16

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6. OPERATING METHODS .............................................................................. 17

6.1. Central articulation’s expandable pins mounting........................ 17

6.2. Central articulation’s play checking.............................................. 18

6.3. Axle bolster’s play checking.......................................................... 18

6.4. Steering cylinders ........................................................................... 18

6.5. 112 Axle brake cylinders adjustement .......................................... 19

6.6. 123 Axle brake cylinders adjustement .......................................... 20

6.7. 112 axles dismantling and mountig methods .............................. 21

6.8. 123 axles dismantling and mountig methods .............................. 21

6.9. Hydraulic motor and gear box operating methods...................... 21

6.10. Tramming pump operating methods............................................. 21

6.11. Wheels checking ............................................................................. 22

6.12. Emergency/park and service brakes tests ................................... 23

7. PERIODIC MAINTENANCE TABLE ............................................................ 27

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SERVICE MANUAL 311 RANGE TRAMMING
1. PRELIMINARY REMARKS
1.1. Safety
The informations contained in this manual must be studied and thoroughly assimilated before
undertaking any maintenance work on the equipment.

Remember: SAFETY FIRST!

Always observe the warnings accompanied by the following symbols.

The following safety instructions are general rules.

WARNING

Operation, maintenance and adjustments are only allowed to persons with

specific training in operation and maintenance of the equipment.

Before starting any maintenance operation ensure that the machine is in a

safe location with good safety, ventilation and lighting conditions.

Read the operating and maintenance instructions before using or servicing

the equipment.

Follow all the safety instructions.

Do not attempt any repairs or adjustments that you do not fully understand.

The operator and the maintenance people must always wear required
personal protection, such as safety helmet, protective overall and gloves,
safety boots, hearing protectors, safety goggles and other safety equipment
requiered by the work.

Danger of hot surface.

Hot surface can cause serious injuries.
Diesel engine, exhaust purifier, coolant tank, rod, shank or hydraulic
components can be hot, thus before starting any maintenance work, always
let them cool off.

Ensure that lifting equipments and pedestals are compatible with elements’
weigh.

Before any operation stabilize and fix steadily all the elements on suitable
pedestals.

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311 RANGE TRAMMING SERVICE MANUAL

Crushing hazard : do not stay in dangerous area, for instance: central

articulation, front chassis and rear chassis.

Danger of high pressure oil jets.

High pressure oil jets can cause serious personal injuries.

Before any operation on hydraulic circuit, STOP the power pack and release
remaining pressure in components by operating hydraulic control levers
several times.
Always release the static pressure in cylinders before disassemble them.

Never work on an operating circuit.

While tests are in progress, do not allow any other member of the personnel
to stand in the area surrounding the machine. Stay at control station in order
to be able to stop immediatly movements, power pack and/or diesel engine
by pressing an emergency stop push button.

Stop again power pack and/or diesel engine, if continuing maintenance or

repair work is needed.

Place a tag or a board to warn other members of the personnel that

maintenance work on the equipment is in progress.

Always use suitable tools and work in a clean place.

Keeps tools and equipment clean.

When dismantling hydraulic components, the hydraulic inlet/outlet ports

must be plugged to prevent dirt and air intrusion during operation.

Always have a fire extinguisher at hand and lurn of to use it.

Please notice that the hydraulic oil, fuel, and battery liquid can cause
pollution. Please refer to your own environmental standars for the liquide
processing.

Before operating maintenance always plan your work in order to use

adequate and in good shape receptacles.

Do not use the diesel engine if it is not needed because of exhaust gas, think
about the people and the environment.

For decommissioning, scrapping and disposal of machine’s components

(diesel engine, tyres, batteries, etc...), you must always observe the law in
force in your country.

In case of no law or if you think it’s not suficient, you can contact the
conponent supplier.

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SERVICE MANUAL 311 RANGE TRAMMING
1.2. About this booklet
The present manual is destined for the use of personnel in charge of carrying out, servicing and
maintenance operations on Jumbos.
It contains maintenance operations schedule and operating methods concerning the main
elements of the 311 range tramming.
Note that servicing and maintenance operations must be carried out by personnel with the
required qualifications, technical knowledge, and proper training on the machine.

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311 RANGE TRAMMING SERVICE MANUAL

2. DESCRIPTION
2.1. Explanation

311 RANGE single boom electro hydraulic jumbos features:

• Power full four-wheel-drive articulated carrier.
• Automotive hydrostatic transmission.

2.2. Features

• Tramming dimensions (mm) :

SANDVIK
DD311

3100
320

3000 2810
6735 1875

• Total machine weights :

DD311: 12 000 Kg.

DS311 : 14 000 Kg.
DL331 : 14 000 Kg.

• Axles

Type Front axle Rear axle

311 range with electric drilling Front axle Dana 112/352 Rear axle Dana 112/353

311-D range (with diesel drilling) Front axle Dana 112/352 Rear axle Dana 112/353

311 range with electric and diesel

Front axle Dana 112/352 Rear axle Dana 123/136
drilling

DL311/321 carriers Front axle Dana 123/118 Rear axle Dana 112/353

DL331 range with electric drilling Front axle Dana 112/352 Rear axle Dana 112/353

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SERVICE MANUAL 311 RANGE TRAMMING
2.3. Main components

3
2

4 6 7

8 8
10

9 9

11

1 : TRAMMING PUMP (MOUNTED ON DIESEL ENGINE)

2 : TRAMMING HYDRAULIC MOTOR
3 : CENTRAL GEAR BOX FRONT DRIVE LINE
4 : REAR SLIDING DRIVE LINE
5 : REAR AXLE BOLSTER PIN
6 : CENTRAL SLIDING DRIVE LINE
7 : FRONT FIXED DRIVE LINE
8 : AXLE
9 : BRAKE CYLINDERS (SPRING APPLIED, PRESSURE RELEASED)
10 : STEERING CYLINDERS
11 : CENTRAL ARTICULATION PINS

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311 RANGE TRAMMING SERVICE MANUAL

3. PERIODIC MAINTENANCE

WARNING
The safety of users and the reliability of the tramming components depend
on the maintenance operations and imply the use of genuine SANDVIK spare
parts.
All defective parts must be immediately replaced.

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

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

All indicated periodicities are diesel engine (or tramming) hours.

3.1. First entry into service

• After the first 20 working hours or 1 week of service, check the tightness of wheels nuts, axles
fixing bolts, transmission’s bolts and nuts and central articulation’s expendable pins.
• Apply also the 50 hours or weekly periodic maintenance operations.

3.2. Operations at each shift

Before starting up:
• Check the overall condition of the equipment (tyres, cylinders, hoses and fittings,...).
• Look for leaks.
• Look for missing nuts and bolts.
• Emergency/park and service brakes tests.

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3.3. 50 hours or weekly operations
• Check the overall condition of the equipment (tyres, cylinders, hoses and fittings,...).
• Look for leaks.
• Look for missing nuts and bolts.
• Emergency / park and service brakes tests.
• Lubricate all the grease points.
• Check the tyres pressure.

3.4. 100 hours operations

• Change & replace axles oil (Differential, Planetary & Reduction).

3.5. 200 hours operations

• Check the overall condition of the equipment (tyres, cylinders, hoses and fittings,...).
• Look for leaks.
• Look for missing nuts and bolts.
• Emergency / park and service brakes tests.
• Lubricate all the grease points.
• Check the tyres’ pressure.
• Check the tightness of wheels nuts, axles fixing bolts, transmission’s bolts and nuts and central
articulation’s expendable pins.
• Check levels axles oil (Differential, Planetary & Reduction).

3.6. 800 hours operations

• Change & replace axles oil (Differential, Planetary & Reduction).

3.7. 1000 hours operations

• Check the overall condition of the equipment (tyres, cylinders, hoses and fittings,...).
• Look for leaks.
• Look for missing nuts and bolts.
• Emergency / park and service brakes tests.
• Lubricate all the grease points.
• Check the tyres pressure.
• Check the tightness of wheels nuts, axles fixing bolts, transmission’s bolts and nuts and central
articulation’s expendable pins.
• Check the central articulation’s play.
• Check the axle bolster oscillation play. If any play appears, replace the axle bolster’s bushings.

3.8. 5800 hours operations overall inspection and reconditioning

• Check the shape of the ball joints and the shim washers. Remove all defective parts.
• Test for correct operation.

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

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311 RANGE TRAMMING SERVICE MANUAL

4. TIGHTENING TORQUES
4.1. Standard tightening torques
For basic genuine SANDVIK screws and nuts use the following tightening torques.

Metric dimension Torque in Nm Torque in Nm

HEX BOLTS ALLEN BOLTS
GRADE 8.8 GRADE 12.9

M6 10 16
M8 25 40
M10 50 80
M12 85 140
M14 130 210
M16 200 330
M18 280 460
M20 400 650
M22 530 880
M24 670 1130
M27 1000 1650
M33 1780 2200
M36 2300 3850
M39 3000 5050
M42 3700 6250

4.2. Specific tightening torques

• Axles fixing:

950

• Central articulation:

530

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5. LUBRICATION
5.1. Greasing points
Use Mobilith SHC 220, Mobilgrease HP 222 or equivalent.
5.1.1 Grease nipples location

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

2 : On drive lines (grease U-joints and schaft sliding part too).
3 : On both central articulation yokes.
4 : On all steering cylinders yokes.

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5.1.2 Central greasing system (optional)

If available, use the central greasing system to grease the tramming components.

3
4

77019301_@
2
1

10 11 12 13 14 15 16
2 6
1

3 7 20

10
4

8 5
5 11 12
CENTRAL GREASING 9

6 SYSTEM (optional) 19 17
18
7 11 12 22
14
77019301_@
13
8
17 18 19 20 21 22 23 24 25
15 16 21
9
77019301_@ 23

77019300_A

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5.2. Axles

Type Front axle Rear axle

311 range with electric drilling Front axle DANA 112/352 Rear axle DANA 112/353

311-D range (with diesel drilling) Front axle DANA 112/352 Rear axle Dana 112/353

311 range with electric and diesel

Front axle DANA 112/352 Rear axle DANA 123/136
drilling

DL311/321 carriers Front axle DANA 123/118 Rear axle DANA 112/353

DL331 range with electric drilling Front axle DANA 112/352 Rear axle DANA 112/353

AXLE TYPE CAPACITY OIL TYPE

(supplied fron factory)
Planetary gear 2x1.4L
Front axle DANA 112/352 Type SAE 85W90
Central housing 7L
Planetary gear 2x2L
Front axle DANA 123/118 Type SAE 85W90
Central housing 11.6L
Planetary gear 2X1.4L
Rear axle DANA 112/353 Type SAE 85W90
Central housing 7.2L
Planetary gear 2x2.2L
Rear axle DANA 123/136 Type SAE 85W90
Central housing 13L

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5.3. Axle DANA 112 oil change

1 2 3

2 2

1 Oil filling plug

2 Oil draining plug

3 Check level plug

1 3
2

5.4. Axle DANA 123 oil change

2 1 3

1 Oil filling plug

2 Oil draining plug

1 3 3 Check level plug

2

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SERVICE MANUAL 311 RANGE TRAMMING
6. OPERATING METHODS

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

Maintenance, adjustment and repairs are restricted to qualified personnel

with special training for the particular equipment. Always read the
instructions carefully before starting any maintenance work.

6.1. Central articulation’s expandable pins mounting

4 5
2
A

1
6 3

• Position the shaft 1 in the bore.

• Using the non-threaded conical bush 2, push the schaft down to the dimension A of 4.5 mm.
• Install the threaded conical bush 3.
• Install the screw and washer 4 and 5 and apply the torque progressively to the value of 530
Nm.
• BE CAREFUL : Lenght of screw = 220 mm.
• Install the nut 6 and apply the torque of 530 Nm.
• Steer the machine several times over a tramming distance of 100 m.
• Check torques of 530 Nm.
• Re-check after about 200 diesel hours.

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6.2. Central articulation’s play checking

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

2mm
(mini)

2mm
(mini)

6.3. Axle bolster’s play checking

Check the axle bolster’s oscillation bushings by lifting up the axle bolster. With small movements,
check the play that has possibly developed in the oscillation bushings. If any play appears,
replace the bushings.

6.4. Steering cylinders

For cylinders operating methods, see cylinders manuals in SECTION 1.

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6.5. 112 Axle brake cylinders adjustement

Spring
O-ring

Filling plug

P 30-45 N.m

Loctite 270
5-7 N.m

Shim
Intermediate 200 N.m
disk
283 N.m
Loctite 270
10-15 N.m

Arm

Check level plug

• Check integrity and position of the cylinder’s O-ring.

• Position disk spring and engage the cover.
• Check the sense of direction disk spring and relative centring.
• Lock the cover and tighten at 30-45 Nm.
• Apply minimum 15 to 30 bar (217 to 435 psi) hydraulic pressure to pressure port to compress
the spring.
• Insert the intermediate disk.
• Apply Loctite 270 and tighten all screws (3 at 120°) with spring at 10-15 Nm.
• Apply Loctite 270 and tighten all screws (3 at 120°) at 5-7 Nm.
• Check integrity and position of the arm’s O’ring, insall the complete arm.
• Tighten screws at 283 Nm and nuts at 200 Nm.

NOTE: Brake cylinders sould be filled with mineral brake fluid.

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6.6. 123 Axle brake cylinders adjustement

Spring
Filling plug
O-ring

30-35 N.m

Intermediate
disk

Loctite 242
10-15 N.m

Shim

Loctite 270
Arm 5-7 N.m
Check level plug

200-221 N.m

Check level plug

• Check integrity and position of the cylinder’s O-ring.

• Position disk spring and engage the cover.
• Check the sense of direction disk spring and relative centring.
• Lock the cover and tighten at 30-35 Nm.
• Apply minimum 21 to 35 bar hydraulic pressure to pressure port to compress the spring.
• Insert the intermediate disk.
• Apply Loctite 242 and tighten all screws (3 at 120°) with spring at 10-15 Nm.
• Apply Loctite 270 and tighten all screws (3 at 120°) at 5-7 Nm.
• Check integrity and position of the arm’s O’ring, insall the complete arm.
• Tighten screws and nuts at 200-221 Nm.

NOTE: Brake cylinders sould be filled with mineral brake fluid.

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6.7. 112 axles dismantling and mountig methods

AXLES
See 112 AXLE supplier’s maintenance
manual.

Weight : Front axle DANA 112/352: 359 kg

Weight : Rear axle DANA 112/353: 365 kg

6.8. 123 axles dismantling and mountig methods

AXLES
See 123 AXLE supplier’s maintenance
manual.

Weight : Front axle DANA 123/118: 520 kg

6.9. Hydraulic motor and gear box operating methods

GEAR BOX
See supplier’s maintenance manual.

HYDRAULIC MOTOR
See supplier’s maintenance manual.

6.10. Tramming pump operating methods

1 TRAMMING PUMP
See VARIABLE PUMP A4VG supplier’s
maintenance manual.

(1) : Filter element

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311 RANGE TRAMMING SERVICE MANUAL

6.11. Wheels checking

3 1
• Visualy check the tyres 1, look for
damages.
• Make sure the nuts 2 are correctly tighten
(Wheel tightenning torque : 630 Nm).
• Make sure the lock ring 3 is correctly in
2 place.
• Check the tyres’ pressure (10 bar for
SOLIDEAL/HAULER tyres).

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6.12. Emergency/park and service brakes tests
BRAKES TESTS

3 1
2

6 7

1. Emergency/park brake push button. 4. Accelerator pedal.

2. Driving direction/speed selector joystick 5. Service brake pedal.
and horn. 6. Tramming pressure gauge.
3. Emergency/park brake test selector 7. Front and rear service brake pressure
switch. gauges

WARNING
MOBILE MACHINERY HAZARD!

Moving machine and its moving parts could cause death or severe injury.

Ensure there is nobody in the hazard zone during operation.

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DS311 (Safety telescopic canopy version)

5m
5m
5m 5m

DS311-C (Cabin version)

5m
5m
5m 5m

DANGER

Do not allow personnel to stand in the hazard zone indicated above during
tramming.

DANGEROUS ZONES:
• 5m zones toward the front end of the turret and 5m zones backward the
rear end of the machine
• 5m zones from right and left sides of the machine.

Never allow riders on any part of the machine.

Always sound the horn before starting the engine and moving the machine.

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1. EMERGENCY / PARK BRAKE TEST

WARNING
WHENEVER AN OPERATOR TAKES CHARGE OF THE MACHINE, HE MUST
PERFORM THIS TEST BEFORE ANY OTHER OPERATION.

Operator must be seated with the safety belt fastened all the time during the test.
Test must be done with machine’s wheels on ground.
• Apply the park brake by pushing the emergency/park brake push button (1).
• Select the faster speed with Joystick (2).
• Select a safe tramming direction (2), put and keep the brake test switch (3) in TEST
position and accelerate (4) slowly => The tramming pressure must reach 270 bar (at
tramming pressure gauge 6) AND THE MACHINE MUST NOT MOVE.

NOTE: The test must be done for the two tramming directions.

DANGER
IF THE MACHINE MOVES, DO NOT USE THE MACHINE AND INFORM A
RESPONSIBLE PERSON IMMEDIATELY.

2. SERVICE BRAKE CIRCUIT TESTS:

Operator must be seated with the safety belt fastened all the time during the test.

TEST 1:
Check the service brake pressures by pushing the service brake pedal (5) and by reading the
front and rear service brake pressure gauges (7). The pressures gauges must indicate 80 bar
minimum.

TEST 2:
Sandvik recommends to perform this test at least once a week and at every maintenance
operation.
• The machine on stabilizers, no contact between tyres and ground.
• Select a safe tramming direction (2) and accelerate (4) to put wheels in rotation.
• Release the accelerating pedal (4) and push on the service brake pedal (5) => WHEELS
MUST IMMEDIATELY STOP TURNING.

NOTE: The test must be done for the two tramming directions.

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DANGER

IF THE SERVICE BRAKE IS FAULTY, DO NOT USE THE MACHINE AND

INFORM A RESPONSIBLE PERSON IMMEDIATELY.

TEST 3:
Sandvik recommends to test the service brake additionally by dynamic way.

WARNING
This test must only be made by service team on one test track after periodic
maintenance operations or when the brakes are replaced.

This test requires 50 meters long and straight test track. The test track must be also flat and
horizontal, do not arrange the dynamic test on inclined test track.

The test procedure is as follows:

• Select the faster speed with joystick (2).
• Select a safe driving direction (2).
• Accelerate (4) the machine 10 - 20 meters, release the accelator pedal (4) and push on the
service brake pedal (5) => THE MACHINE MUST STOP IMMEDIATELY.
• If the machine doesn’t stop, push the control button (1) of the emergency brakes.

NOTE: The test must be done for the two tramming directions.

DANGER

IF THE SERVICE BRAKE IS FAULTY, DO NOT USE THE MACHINE AND

INFORM A RESPONSIBLE PERSON IMMEDIATELY.

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7. PERIODIC MAINTENANCE TABLE

Serial number: Diesel engine/tramming Name:

hours:
Date: Signature:

CHECK / CLEAN AND CHANGE /

LUBRICATE
TEST FLUSH REPLACE
Frequency in diesel engine/tramming hours Completed
?
311 RANGE
TRAMMING
At each shift
First 20h or

1000h

5800h
week

100h

200h

800h

YES
50h

NO
Lubricate all the grease
points.
Check the overall condition
of the equipment (tyres,
cylinders, hoses and
fittings,...).
Look for leaks and missing
nuts and bolts.
Emergency / park and
service brakes tests.
Check the tyres pressure.

Check the tightness of

wheels nuts, axles fixing
bolts, transmission’s bolts
and nuts and central
articulation’s expendable
pins.
Check the central
articulation’s play.
Axles oil (Differential,
Planetary & reduction),
checking and replacement.

Check the axle bolster

oscillation play. If any play
appears, replace the axle
bolster’s bushings.
OVERALL
Overal inspection.

NOTE: For all lubrication operations (oil and filters replacements), see the lubrication
schedule in section 2 of this manual.

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