Crab - 2100E - Maintenance Manual [PDF]

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MAINTENANCE MANUAL Always keep this manual on board the vehicle



Cod. 12585 REV. 00 Updated to 15/06/2010



CRAB 2100 E



All reproduction rights reserved. All reproductions or translations, even partial, are forbidden unless written authorisation is given by ZEPHIR S.p.A.



“Original instructions” “Translation of the original instructions” The data in this publication are purely indicative. The manufacturing company reserves the right to alter and make improvements without prior notice and without the obligation of updating this manual. The manufacturing company is not liable for any translation errors of the original text.



CRAB 3100 E MAINTENANCE MANUAL



Both workers and the personnel in charge of maintenance must read this manual through carefully and all the other manuals that come with the vehicle before using or servicing it. This manual must be kept on board the vehicle so it can be consulted at any time and must always go with the machine. For the natural and constant evolution and improvement of the product the manufacturing company reserves the right to update the contents of this publication without giving prior notice. The manufacturing company shall not be held liable for any inaccuracies or negative consequences deriving from such inaccuracies except in cases of company negligence.



ZEPHIR S.p.A. Via S. Allende, 85 41122 MODENA (MO) Italy Tel. +39 059 252554 - Fax +39 059 253759 Customer service +39 059 252365 [email protected] http://www.zephir.eu e.mail: [email protected]



TABLE OF CONTENTS 1. 2. 3. 4. •



INTRODUCTION......................................................... 1 TECHNICAL DATA..................................................... 7 SCHEDULED MAINTENANCE................................ 11 SCRAPPING OF THE MACHINE............................. 27 CONTENTS IN ALPHABETICAL ORDER............... 31



1 - INTRODUCTION



1 INTRODUCTION............................................................................................... 1 1.0 FOREWORD..................................................................................................... 3 1.1 SAFETY RECOMMENDATIONS...................................................................... 4



INTRODUCTION



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MAINTENANCE MANUAL



1 - INTRODUCTION 1.0 FOREWORD This manual contains information necessary for the routine maintenance of ZEPHIR machines. The purpose of this chapter is to explain to the personnel in charge of the routine maintenance of the product the procedures to attain the end result: re-establish and guarantee functionality of the ZEPHIR machine over time. Maintenance frequencies given in this chapter refer to normal working conditions. Frequency could vary during running-in or under certain conditions. The main purpose of this chapter is to select all jobs that are done at the same times, facilitating procedures and reducing machine downtimes. Lubrication is of paramount importance in preventive maintenance and the useful life of the machine depends on it. This is why it is absolutely essential to abide by the indications given in this manual for using the lubricant and for the frequencies.



ATTENTION: The jobs described here in detail are considered routine maintenance jobs. Because extreme precision is required with disassembling and final reassembling of the product, its successful outcome, likewise guaranteeing it returns to being fully operational again, is left to the responsibility of those who actually work on it.



ATTENTION: Do not perform any jobs, alterations or repairs of any kind other than those indicated in this manual. Only trained technical personnel or authorised by the manufacturer have the necessary knowledge of the machine and the experience to carry out all jobs with the right technique.



ATTENTION: Always use original spare parts. Contact the ZEPHIR Assistance Service for all extraordinary maintenance.



CAUTION: Avoid environmental pollution. Lubricants, fluids, coolants and the filtering elements used are classified as polluting and harmful waste according to national and international laws and regulations. Storage and disposal shall be seen to in specific structures.



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1 - INTRODUCTION 1.1 SAFETY RECOMMENDATIONS Before ever using or doing any job on the machine, always follow the instructions listed hereunder: - Read carefully all the rules in this manual. - Read carefully and comply with all the provisions contained in the specific manuals of the main components (batteries, etc…) that are to be considered an integral part of the documentation. - Read and observe all the labels and instructions specifically concerning safety affixed on the machine. - Do not allow unauthorised persons do anything on the machine and, however, never without due authorisation. Observe the procedures described in this manual. - When servicing the machine it is good practice to keep the parking brake on at all times. - If guards or casings are removed from moving parts of the machine it is compulsory to put them back in place before starting the machine. If it is necessary to start the machine without the guards, please be very careful not to put your hands or tools in the moving parts. Do not wear clothes that are open and/or hanging that could get caught in the moving parts. - Do not lubricate or repair the machine while the engine is running except in those cases specifically mentioned in the manual. - Always stop the machine following the procedures described in the manual. - Discharge the hydraulic and pneumatic pressure from all circuits before servicing the machine. - Do not work above or under the machine if it is being supported only by hydraulic or pneumatic lifting devices without safety locking valves. - Before starting any maintenance work make sure that the control locking lever is in the locked position and the ignition key taken out. - Do not use petrol, solvents or other flammable liquids to clean parts – use non flammable and non toxic type-approved off-the-shelf solvents. - Never, under any circumstances, use your hands to look for pressure leaks in the hydraulic circuit. Pressurised fluid can puncture the skin and cause lesions. - Before starting the engine warn everyone in the vicinity and anyone who could come near the machine.



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1 - INTRODUCTION - Keep face and hands as far away as possible from loose fittings if you are checking the efficiency of the hydraulic system. Wear protective glasses with side protection. - Never use matches, cigarette lighters, torches or naked flames to illuminate dark areas when servicing. - Whenever possible and depending on the type of maintenance work to be done, disconnect the battery and put a sign in the driver’s cab explaining that the machine is being serviced. - In the case of towing, use only the specific anchorage points. Pay great attention when hooking up. - Use a trolley or a trailer to transfer a broken down machine. If it is going to be towed, use the signs as established by law and follow the indications given in this manual. - Use a crane or pulley of a suitable capacity to lift and transport heavy parts. Strap the material perfectly. Use the eyebolts if any. Always make sure there is no one in the vicinity.



ATTENTION: If the machine has broken down it can only be towed for short distances, maximum 1 km, without exceeding a speed of 2-3 km/h. For greater distances the drive shafts have to be disconnected. Before starting to tow, make sure the brakes are released and observe the indications in paragraph referring to TOWING OR RECOVERING THE MACHINE in the USER AND OPERATING MANUAL). - When using compressed air to clean parts, protect your eyes with glasses with side protection, limit pressure to a maximum of 2 bar complying with the existing accident prevention standards. - For maintenance jobs or repairs that need the engine to be running, ask for a worker to stay in the driver’s seat and keep the commands under visual control all the time. Put the gear in neutral, lock the brakes and keep hands at safe distance from moving parts. - Put all the rags soaked in grease, oil or flammable liquids in a closed metal container as they could be a possible fire risk. - Always make sure the brake tank is filled to the level prescribed. - Always lock all the wheels with locking devices when bleeding the braking system or removing pipes. - When using lights (whether they are the machines or auxiliary ones), arrange them so as not to dazzle the people while they are working. - Do not connect wet electrical sockets or plugs. MAINTENANCE MANUAL



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1 - INTRODUCTION - When maintenance or repairs are finished, never leave tools, rags or other material inside compartments housing moving parts or compartments inside which air flows for suction and cooling. - Always block cowlings and trap-doors with the stop rods before embarking on any maintenance work.



DANGER: Disregard for the safety standards and correct maintenance procedures can cause damage or defects to the machine and possibly even physical harm or death to the worker or people in the vicinity. ATTENTION: Strict compliance with the maintenance rules will guarantee good preservation of the machine, ensure good operation and avoid the need for costly repairs. ATTENTION: Before starting any maintenance work, repairs or checks, move the gear lever into “NEUTRAL”, stop the engine and engage the handbrake. If the engine has to be started on closed premises, make sure ventilation is adequate. Never use petrol, solvents or other flammable liquids for cleaning.



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2 TECHNICAL DATA........................................................................................... 7 2.1 DIMENSIONS.................................................................................................... 9 2.2 TECHNICAL FEATURES................................................................................ 10



TECHNICAL DATA



2



2 - TECHNICAL DATA



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MAINTENANCE MANUAL



2 - TECHNICAL DATA 2.1 DIMENSIONS CRAB 2100 E (Short version)



CRAB 2100 E (Standard version)



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2 - TECHNICAL DATA 2.2 TECHNICAL FEATURES ENGINE Max power........................................................................................................................20 kW Voltage................................................................................................................................80 V Current..............................................................................................................................290 A Speed........................................................................................................................ 1900 Rpm ELECTRICAL SYSTEM Main system voltage (traction)............................................................................................80 V Batteries........................................................................................................... 1x1000 Ah 80 V Integrated battery charger on board for supplying power.............................................. 380 Vac BRAKES Service and emergency Disc type, operated with a double pump on separate circuits, with 3 pressure accumulators with a capacity of 0.35 l calibrated at 60 bar. Parking Disc type with mechanical control by means of either a hydraulic or pneumatic cylinder. ELECTRIC PUMP HYDRAULIC SYSEM Voltage................................................................................................................................80 V Power.................................................................................................................................1 kW Current................................................................................................................................15 A Speed..........................................................................................................................2200 rpm Displacement.................................................................................................................. 3.2 cc/r



NOTE: To be more precise and correct and for all additional information please consult the motor Manual which is given with the machine.



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3 SCHEDULED MAINTENANCE...................................................................... 11 3.1 BATTERIES (CHARGING, USING AND SERVICING)................................... 13 3.1.1 Precautions......................................................................................... 13 3.1.2 Charging............................................................................................. 13 3.1.3 Topping up.......................................................................................... 13 3.1.4 Discharging......................................................................................... 14 3.1.5 Cleaning.............................................................................................. 14 3.1.6 Automatic topping up system.............................................................. 14 3.2 RAILWAY AXLES (MAINTENANCE AND LUBRIFICATION)......................... 15 3.2.1 Frequency........................................................................................... 15 3.2.2 Lubrication.......................................................................................... 16 3.2.3 Periodical maintenance schedule....................................................... 18 3.3 ADJUSTING THE DRUM BRAKES................................................................ 18 3.4 ADJUSTING THE PARKING BRAKE.............................................................. 19 3.5 GENERAL INFORMATION ABOUT OIL......................................................... 20 3.5.1 Draining the oil.................................................................................... 20 3.5.2 Filling with oil....................................................................................... 20 3.5.3 Servicing the filter............................................................................... 21 3.6 ELECTRIC MOTOR MAINTENANCE............................................................. 22 3.7 FRONT REDUCTION GEAR MAINTENANCE............................................... 23 3.8 OIL TABLE...................................................................................................... 23 3.9 GENERAL GREASING................................................................................... 23 3.10 PERIODICAL MAINTENANCE TABLE........................................................... 23 3.11 TIGHTENING TORQUE TABLE...................................................................... 25



SCHEDULED MAINTENANCE



3



3 - SCHEDULED MAINTENANCE



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3 - SCHEDULED MAINTENANCE 3.1 BATTERIES (CHARGING, USING AND SERVICING) 3.1.1 Precautions It is mandatory to read and comply with the instructions given below to avoid injuries to people or damage to parts of the machine. - Charge the battery on ventilated premises; lift the cover or remove the battery from the bogie. - Do not go near the battery with naked flames: risk of explosion due to the formation of explosive gases. - Do not make any temporary or abnormal electrical connections. - The terminals must be tightened well and free from encrustations. The insulating part of the cables must be in good condition. - Keep the battery clean, dry and free from corroding products using antistatic cloths. - Do not put any metal tool or other metal objects on the battery. - Keep a check on the electrolyte temperature when charging the battery: it must not exceed 45°C max. - Make sure the level of the electrolyte goes above the splash guard by about 5-7 mm. - If there is an automatic topping up system you must follow the instructions for use carefully that you will find in this battery handbook. - Avoid contact of the acid with the skin. 3.1.2 Charging The battery needs to be charged before the voltage drops below 1.7 V per element and the electrolyte density drops to 1,140 Kg/l (25°C). Before you start charging the battery, make certain its temperature is below 30°C and that the level of the electrolyte in the elements is not under the splash guard line (only in this case top up to the splash guard line with distilled water). When charging is finished, check that all the elements have reached a density of between 1270-1290 Kg/l at 25°C and that the voltage per element is about 2.7V; if you charge excessively the battery will be ruined. Battery temperature must never exceed 45°C; if ever it is, reduce the charge current value immediately. 3.1.3 Topping up Topping up is to be done after charging and the level of the electrolyte must be about 5-7mm above the surface of the splash guard. If you top up too much the electrolyte will overflow during service with the risk of corroding the casing, of losing electrical insulation and reducing battery capacity. For normal uses, the consumption of water is such that topping up can be done weekly.



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3 - SCHEDULED MAINTENANCE 3.1.4 Discharging Discharging the battery must stop when about 80% of its nominal capacity has already been used. An excessive discharge could cause the battery to deteriorate irreversibly and as a result the warranty terms would be invalidated. 3.1.5 Cleaning Keep caps and connections covered and dry. Do not grease the connections - use pure Vaseline or a neutral grease only on the positive terminals. Keeping it clean will preserve electrical insulation, ensure good operation and a long life for the battery.



Battery compartment (open)



Electrical connection



3.1.6 Automatic topping up system System description One very important advantage of this system is that it requires no complex equipment for supplying water. Another important and specific characteristic of the system is that the gases (a mixture of hydrogen and oxygen) generated inside the elements can be discharged spontaneously through the self-levelling plugs. This method minimises the danger of accidental explosions. The system consists of: - A tank of distilled water - Self-levelling float plugs with level indicator - Flow meter - Pipe for the connection between the plugs and the tank - Dual valve quick coupling for tank-battery connection - A separate circuit, if necessary, with microporous terminals on it to recover the gases.



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3 - SCHEDULED MAINTENANCE Use The distilled water tank must be placed about 2 metres up from the top of the self-levelling plugs. As the batteries do not use a lot of water when in normal use, it is not usually necessary to top up after each discharge and charge cycle. Topping up frequency depends on various factors such as the type of service, ambient temperature, conditions and type of battery, charging system. The need to top up is verified at the end of the work shift (discharge phase) before connecting the battery to the rectifier, seeing at what point the level indicators are. If the electrolyte level requires the addition of water, connect the battery to the rectifier and top up only after charging has finished and as quickly as possible (e.g. do not top up on Monday morning if the charging phase finished at the end of the previous week). Topping up is to be considered done when all the level indicators are in the top position and the flowmeter is still. Operation When the tank is connected to the battery to be topped up the water it contains, which is higher than the self-levelling plugs, feeds each element by gravity. The level of electrolyte in each single element rises up to a level set by the size of the float. When the optimum level is reached, the upward thrust of the float stops the water flowing into the element. The plugs are connected in series to the battery and each one works separately from the others.



3.2 RAILWAY AXLES (MAINTENANCE AND LUBRICATION) 3.2.1 Frequency Lubrication and maintenance is to be done at the frequencies prescribed and with all due care because functionality, efficiency and duration of the transmission greatly depend on it. The frequency indicated for each operation is influenced by the conditions in which the machine works: if the environment is very dusty or damp or there are great and sudden differences in temperature, the intervals will be shorter and even halved in the worst possible conditions. This manual describes use when there is an ambient temperature of between -20° and +50° C; in the case of different conditions please contact the manufacturer.



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3 - SCHEDULED MAINTENANCE 3.2.2 Lubrication CAUTION: Completely clean conditions are essential for all checks or when changing lubricants to prevent foreign bodies accidentally getting inside the parts to lubricate. Before undoing the oil plugs or connecting the pump to the pressure greasers, thoroughly clean the adjacent areas using a mild degreasing solvent if necessary. It is good practice not to mix lubricants of different brands (even if their characteristics are the same) so we suggest making your initial choice based on factors such as availability, price or because it’s a brand you prefer and then use it all the time. Filling the axle All the moving parts of this series of axles are lubricated by the oil in the differential box; below are the steps to follow: - Put the machine on as horizontal a surface as possible. - Unscrew the oil filling up/level plug (see the following figure). - With the aid of a funnel, pour the lubricant oil into the box up to the bottom edge of the filling up/level plug hole . - Screw the oil filling up/level plug back down .



VENT PIPE OIL FILLING PLUG OIL LEVEL PLUG DRAINAGE PLUG



ID PLATE GREASER



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MAINTENANCE MANUAL



3 - SCHEDULED MAINTENANCE



VENT PIPE OIL FILLING PLUG OIL LEVEL PLUG DRAINAGE PLUG



ID PLATE GREASER



Filling the reduction gear - Put the machine on as horizontal a surface as possible - Unscrew the oil filling up/level plug (see the following figure). - With the aid of a funnel, pour the lubricant oil into the box up to the bottom edge of the filling up/level plug hole . - Screw the oil filling up/level plug back down . Differential oil The first oil change in the differential box is between the first 50 and 100 hours of working. Then check the level of the differential oil every 500 hours of working and change it every 1,500 hours of working.



VENT PIPE OIL FILLING PLUG OIL LEVEL PLUG DRAINAGE PLUG



ID PLATE GREASER



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NOTE: use oil type MIL – L 2105 SAE 80/90 EP (DIN 5 15 17 / DIN 5 15 12)



3.2.3 Periodical maintenance schedule Check tightness of the nuts between the first 50 and 100 hours of working. Then check nut tightness and handbrake adjustment every 500 hours of working and bearing play and wear every 1,500 hours.



3.3 ADJUSTING THE BRAKES The shoes are adjusted and tested by Zephir qualified workers during assembly; braking is tested on a flat surface. ATTENTION!! The brakes are not run-in when the machine is new and a short time of use might be necessary before maximum braking performance is reached so please be extremely careful. Check the thickness of the brake shoes and if the braking material has a very low residual thickness replace them. If ever pedal travel is high it can be adjusted in the following way: - Remove the plastic guard (1) at the bottom of the block; - Remove the cap (2) by the shoe to measure the distance between the shoe and the drum. - To move the shoe up to the drum, turn the ratchet (3) downwards with a screwdriver. - Check that the wheel turns freely when you have finished adjusting.



2



3



1



4



ATTENTION!! Play between the shoes and the drums must be between 0.15-0.20 mm (4).



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ATTENTION! This must be done by qualified maintenance personnel or by the manufacturer’s personnel.



3.4 ADJUSTING THE PARKING BRAKE Adjust the parking brake by means of the cable (adjusting) device indicated by the arrow in the following diagram:



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3 - SCHEDULED MAINTENANCE 3.5 GENERAL INFORMATION ABOUT OIL Maintenance to be done every 1,500 hours 3.5.1 Draining the oil: - Open the cock as shown in the photo and drain all the oil from the tank.



Drainage cock



3.5.2 Filling with oil: - Put oil in the tank up to the maximum level, screw the filling up plug shown in the following figure. - Start the engine; after a few minutes start the jacks to fill the cylinders and pipes with oil. Add oil to the tank several times always with the engine off. - With all the jacks in their maximum extended position and the machine on a flat surface, check the level through the peep hole shown in the following figure.



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3 - SCHEDULED MAINTENANCE 3.5.3 Servicing the filter PRESSURE SWITCH ON THE HYDRAULIC OIL FILTER If the internal element of the filter does not let enough oil through (hot oil), an electric signal in output from the pressure switch (appropriately calibrated) situated directly on the body of the filter, turns a red warning light on on the instrument panel. Change the filtering element to ensure that the impurities in the oil, not trapped by the filter, cannot damage hydraulic components and elements like pumps, solenoid valves, cylinders, etc… Attention! remember to close the cock as shown in the photo before changing the filter. NOTE: it is normal for the warning light to turn on for a few minutes when the oil is cold. If you are working in particularly difficult conditions it is advisable to service the oil filter more often.



Oil filter Cock



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3 - SCHEDULED MAINTENANCE 3.6 ELECTRIC MOTOR MAINTENANCE COMPONENT BEARINGS INSULATION



SCREWS



WINDINGS



JOB Check the temperature and see if there are any vibrations and noise. Check the insulation value with Megger especially in damp environments; it must never be less than 2 MΩ Check there are no loose screws. Make sure that all the contacts of the electrical connections are perfect otherwise there could be localised overheating. A general clean. Check that insulation to ground is the same as or higher than 2 MΩ



INTERVAL Every 1500 hours Every 1500 hours Every 1500 hours Every 1500 hours



Every 3000 hours



3.7 FRONT REDUCTION GEAR MAINTENANCE Bolt tightness must be checked every 50 hours of working. Lubrication After filling up check the actual level of the oil carefully.



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3 - SCHEDULED MAINTENANCE Correct lubrication ensures good operation and a long life of the unit generally; it is therefore important to choose the right oil with the right additives to ensure problem-free work and a long life of the unit generally and of the planetary reduction gear. It is advisable to use oils for gears with Ep additives, minimum viscosity index 80 W 90. You can determine the oil level as follows: Assembly with horizontal output shaft: - Filling up to the centre line of the reduction gear (see the following figure). Constant working temperature must not exceed 90°C. The first oil change must be done after 50-100 hours of working and then every 1500 hours of working or at least every 12 months.



3.8 OIL TABLE PARTS



OIL TYPE



Q [Kg]



HYDRAULIC CIRCUIT



MIL - H 24459



30



RAILWAY AXLES



80 W 90 MIL - L - 2105 C



18



3.9 GENERAL GREASING Grease the drive shafts and the link hinging pins weekly.



3.10 PERIODICAL MAINTENANCE TABLE ATTENTION! The following tables refer generally to the machine; for the maintenance and frequencies of the single components (engine, transmission, etc.) please see the instructions in the relevant manuals supplied with the documentation. It is very important to check tightness of the screws of the main components after the first 10 hours of working; this must then be repeated every 500 hours of working. The first complete control coupon must be done within the first 50 hours of working.



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3 - SCHEDULED MAINTENANCE



PERIODICAL MAINTENANCE TABLE



EVERY 1000 HOURS



EVERY 500 HOURS



Every 50 hours (WEEKLY)



FIRST CONTROL COUPON (within the first 50 hours)



COMPONENT



24



JOB



Railway axles



Check tightness of the nuts



All the main components



Check tightness of the screws



Accumulators



Check the precharge



Hydraulic circuit



Check the level



Hydraulic circuit filter



Check the filter



Links/articulated joints



Grease the pins



Differential



Change the oil



Front reduction gear



Change the oil



Links/articulated joints



Grease the pins



Drive shafts



Lubricate the joints



All the main components



Check tightness of the screws



Hydraulic circuit



Check the level



Railway axles



Check tightness of the nuts



Hydraulic circuit filter



Check filter cleanliness



Hand brake



Adjust the brake



Brakes



Check thickness of the pads



Differential



Check the level of the oil



Accumulators



Check precharge pressure



MAINTENANCE MANUAL



3 - SCHEDULED MAINTENANCE



EVERY 3000 HOURS



EVERY 1500 HOURS



Check the bearings Electric motor



Check insulation Check tightness of the screws



Front reduction gear



Change the oil



Accumulators



Check precharge pressure



Hydraulic circuit



Change the oil in the circuit



Railway axles



Check play and bearing wear



U BOLTS



WHEELS



3.11 TIGHTENING TORQUE TABLE Column diameter



Tightening torque



14



200 Nm



16



240 Nm



18



300 Nm



20



350 Nm



22



450 Nm



Screw diameter



Tightening torque



14



120 Nm



16



200 Nm



18



320 Nm



20



400 Nm



22



600 Nm



27



750 Nm



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3 - SCHEDULED MAINTENANCE



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4 SCRAPPING AND DISPOSAL OF THE MACHINE...................................... 27 4.1 SCRAPPING AND DISPOSAL OF THE MACHINE....................................... 29



SCRAPPING OF THE MACHINE



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4 - SCRAPPING OF THE MACHINE



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4 - SCRAPPING OF THE MACHINE 4.1 SCRAPPING AND DISPOSAL OF THE MACHINE The toxic, harmful and dangerous substances and materials used in the machine must be disposed of with the following criteria: Batteries Batteries must be given to a company specialized in this sector and duly listed in the relative national register. Attention: do not leave the batteries lying around in the environment. They contain acids that are extremely harmful for man’s health and for the environment. Oils Oils (hydraulic and axles/reduction gears) must be given to a company specialized in disposing of waste oils and duly listed in the relative national register. Attention: do not drain waste oil into the environment. Danger of causing serious environmental pollution.



Plastic materials Plastic and/or synthetic materials (tyres, hoses, claddings of the cab and of the engine cowling, etc.) must be given to a company specialized in this sector and duly listed in the relative national register. Attention: do not leave plastic and/or synthetic material lying around in the environment. Danger of causing serious environmental pollution. Recyclable materials Recyclable materials (the windows of the cab and metal parts in general) must be given to a company specialized in demolishing and recycling such materials and duly listed in the relative national register. Attention: do not leave metal parts (frame, tank, cab, etc.) in the environment. Danger of causing serious environmental pollution.



Attention! When it is time to demolish the machine make sure its ID plate and the CE mark are both destroyed.



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4 - SCRAPPING OF THE MACHINE



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CONTENTS IN ALPHABETICAL ORDER



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A Adjusting the brakes...............................................................................................................18 Adjusting the parking brake....................................................................................................19 Automatic topping up system.................................................................................................14



B Batteries (charging, using and servicing)...............................................................................13



C Charging batteries..................................................................................................................13 Cleaning batteries..................................................................................................................14



D Differential oil..........................................................................................................................17 Dimensions...............................................................................................................................9 Discharging batteries..............................................................................................................14 Disposal of the machine.........................................................................................................29 Draining the oil.......................................................................................................................20



E Electric motor maintenance....................................................................................................22



F Filling the axle........................................................................................................................16 Filling the reduction gear........................................................................................................17 Filling with oil..........................................................................................................................20 Foreword..................................................................................................................................3 Front reduction gear maintenance.........................................................................................22



G General greasing....................................................................................................................23 General information about oil.................................................................................................20



I Introduction...............................................................................................................................1



O Oil table..................................................................................................................................23



P Periodial maintenance table...................................................................................................23



R Railway axles (maintenance and lubrication).........................................................................15



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S Safety recommendations..........................................................................................................4 Scheduled maintenance......................................................................................................... 11 Scrapping of the machine.......................................................................................................27 Servicing the filter...................................................................................................................21



T Technical data..........................................................................................................................7 Technical features..................................................................................................................10 Tightening torque table...........................................................................................................25 Topping up batteries...............................................................................................................13



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ZEPHIR SpA Via S. Allende, 85 41122 MODENA (MO) Italy Tel. +39 059 252554 - Fax +39 059 253759 Customer service +39 059 252365 http://www.zephir.eu e.mail: [email protected]