Section 3.1. Machine Maintenance - Machine Maintenance Information

Transcription

1 Section 3.1 Machine Maintenance - Maintenance Charts & Diagrams: Special Component Break-In Chart Preventive Maintenance Schedule Chart Lubricant & Fill Capacities Chart Engine Oil Information Lubrication Points Diagram: 800C C Clam Bunk and Grapple Leveling Frame Important Preventive Maintenance Information: Daily Walk-Around Inspection After 50 Hours Of Operation After 100 Hours Of Operation After 250 Hours Of Operation After 500 Hours Of Operation After 1000 Hours Of Operation After 1500 Hours of Operation Other Important Maintenance Information: Tire & Track Chain Maintenance Form T

2 2 Daily Daily Special Component Break-In Schedule Torque Tapered Hub Retaining Bolts Check Ale Differential Oil Level Check Bogie Drive Housing Oil Level Check Bogie Planetary Oil Level Check Transfer Case Gearbo Oil Level Check Pump Drive Gearbo Oil Level Change Lower Fuel Pump Suction Filter Torque Wheel Lug Nuts Torque Swing Motor Mounting Bolts Torque Swing Bearing Mounting Bolts Torque Frame Articulation Bearing Mounting Bolts Torque Ale Mounting Bolts Torque Ale Bo Spreader Bolts Torque Driveshaft Carrier Bearing Support Bolts Torque Driveshaft U-Joint Bolts Change Swing Gear Bo Oil Change Pump Drive Gearbo Oil Change Transfer Case Oil Change Differential Oil Drain Sediment and Check Ale Bogie Housing Oil *** Change Planetary Oil Change Hydraulic Oil Filters Preventive Maintenance Chart Inspect Machine for Loose or Missing Fasteners Inspect for Damaged Hydraulic Hoses Clean Flammable Debris and Fluid From All Surfaces Lubricate All Cylinder & Pins Joints, & Articulation Pivot Pins Lubricate Swing Bearing Inner Ring Gear Teeth Check Engine Oil Level Drain Water/Sediment at Primary Fuel Filter Check Engine Coolant Level Inspect and Clean Radiator / Oil Cooler / A/C Condensor Fins Check Fuel Level and DEF/AdBlue Level Inspect Fire Etinguisher Check Air Cleaner Restriction Indicator * Check Hydraulic Oil Level Check Instrument Panel Gauges Test Arming \ Door Switch Interrupt Lubricate Swing Bearing Race Lubricate Articulation Bearing Race** Check Pump Drive Transmission Oil Level Check Lohmann Swing Gearbo Oil Level Torque Tapered Hub Retaining Bolts Run Air Conditioner Check Cab Emergency Escape Hatches Form T005

3 2 Daily Preventive Maintenance Chart Cont... Check Ale Differential Oil Level ** Check Bogie Drive Housing Oil Level Check Bogie Planetary Oil Level Check Transfer Case Gearbo Oil Level ** Lubricate Drive Shaft U-Joints & Carrier Bearings (Alithicon M-888) ** Lubricate Ale Drive Shaft Yoke Bearings (Alithicon M-888) ** Lubricate Ale Articulation Bearings ** Torque Swing Motor Mounting Bolts Torque Swing Bearing Mounting Bolts Torque Articulation Bearing Mounting Bolts Torque Ale Mounting Bolts Torque Ale Bo Spreader Bolts Torque Wheel Lug Nuts Torque Driveshaft U-Joint Bolts Check Air Conditioner Refrigerant Change Lower Fuel Pump Suction Filter Inspect Engine Fan & Belts Inspect, Secure & Clean Batterys Change Engine Oil & Filter (Reference Engine Manual) Change Engine Fuel Filters (Reference Engine Manual) Check Engine Coolant Antifreeze Concentration Check Radiator Hoses Change Air Cleaner Filters * Change Hydraulic Oil Filters Change Lohmann Swing Gearbo Oil Change Pump Drive Transmission Oil Have Fire Suppression System Inspected by a Professional Replace Fire Suppression System Controller Battery Flush & Refill Engine Cooling System Clean Hydraulic Tank & Change Hydraulic Oil Check Engine Valve Lash (Reference Engine Manual) Check Ale Brake Discs Change Ale Differential Oil Change Ale Bogie Housing Oil *** Change Ale Planetary Oil Change Ale Gearbo Oil * Under etremely dusty conditions, the air cleaner filters may require cleaning or changing more frequently. ** Under etremely wet and muddy conditions, the ale articulation bearings and drivetrain components will require daily inspection and lubrication. *** Drain 2-3 quarts ( Liters) inspect for contamination on all four corners of the bogie, & clean magnetic plugs. If oil has no ecessive contamination refill with clean oil. If contamination is present oil will need to be fully drained and source of contamination will need to be found. Use a good quality lithium based driveline grease when lubricating any drive shaft U-Joints or Carrier Bearings. Alithicon M-888 PN# 24140, is recommended by the manufacturer. Use a good quality grease containing at least 5-6% Molybdenum Disulfide by volume at all lubrication points unless otherwise specified. Lubriplate #176, PN# 18431, is recommended by the manufacturer. Form T

4 Lubricant Specification & Fill Capacities Chart Volvo Tier 4 TAD873VE 7.7L 320 HP (235kW) Cummins QSC 8.3L * 300 HP (224 kw) Cooling System Fuel Tank (leveling) (leveling) Lohmann Swing Gearbo* Dual Pump - Funk Transmission* Transfer Case* (N.A.F Tim 15) Transfer Case* (N.A.F Tim 16) Ale Differential* TIM 12 TIM 08 & 17 TIM 23 Bogie Housing* TIM 08, 17, 23 Wheel Planetary* TIM 12 TIM 08,17, US Quarts 27 Liters (with filter) 25 US Quarts 24 Liters (with filter) 11.5 US gal 35.2 Liters 101 US gal 382 L 115 US gal 437 L 107 US gal 405 L 123 US gal 465 L 4.5 US Quarts 4,3 Liters 2.5 US Quarts 2.4 Liters 4.8 US Quarts 4.5 Liters 5.1 US Quarts 4.8 Liters 9 qt (8.5 L) 26.4 qt (25 L) 14.8 qt (14 L) 17.4 qt (16.5 L) 20 qt (21 L) 4 35 qt (37 L) qt (11 L) qt (5 L) 8 SAE 15W-40 multi viscosity engine oil. When temps below -13 F (-25 C) it s recommend to use SAE 5W-30. American Petroleum Institute performance classification API CH-4, API CH-4/SJ, API CI-4/SK or ACEA E-5, E-7 SAE 15W-40 multi viscosity engine oil. When temps below -13 F (-25 C) it s recommend to use SAE 5W-30. American Petroleum Institute performance classification API CH-4, API CH-4/SJ, API CI-4/SK or ACEA E-5, E-7 Use a miture of 50% Ethylene Glycol or Propylene Glycol antifreeze mied with 50% distilled water. (Supplemental Coolant Additives are recommended, see engine manual for more information) ASTM No. 2D (ASTM D975 or EN 590) fuel is recommended. For operating temperatures below 32 F (0 C) a use of No.1D and No.2D blend may be used. SAE 75W-90 synthetic or DIN CLP or CLP HC - ISO 220 (see recommended oils chart on net page) SAE 75W-90 synthetic oil that meets MIL-PRF-2105E specifications. SAE 75W-90 synthetic oil that meets MIL-PRF-2105E specifications. SAE 75W-90 synthetic oil that meets MIL-PRF-2105E specifications. SAE 75W-90 synthetic oil that meets MIL-PRF-2105E specifications. SAE 75W-90 synthetic oil that meets MIL-PRF-2105E specifications. SAE 75W-90 synthetic oil that meets MIL-PRF-2105E specifications Form T005

5 Lubricant Specification & Fill Capacities Chart Cont... Hydraulic Oil Tank General Greasing Greasing of Driveshaft components 55 US Gallons 208 Liters High quality hydraulic oil with anti-wear Additives added. See Hydraulic Oil Performance Specifications Section 3.2 High quality grease containing at least 5-6% Molybdenum Disulfide by volume at All lubrication points. TimberPro recommends Lubriplate #176 PN# Use a good quality lithium based driveline grease. TimberPro recommends Alithicon M-888 PN# Recommended Lube Oil for Lohmann Swing Gearbo Company Oil Brand ADDINOL ECO GEAR 220 M, ECO GEAR 220 S Agip BLASIA 220 CLP American Agip Blasia 220, Industrial Gear Lubricant 5 EP ARAL Degol BG 220 Plus, Degol PAS 220, Degol ESG 220 BECHEM ECOGEAR 220 M, ECOGEAR 220 S JAX-Behnke Lubricants HP INDUSTRIAL GEAR OIL 220, SYNAX-EP INDUSTRIAL GEAR OIL 220 BEL-RAY SYNTHETIC GEAR OIL 6690 BENZ OIL, Inc. GEAROL 220, SYN-TECH PAO 220 BP Energol GR-XF 220, Enersyn HTX 220, Energol PM 220, Energol GR-XP 220 Castrol Alpha SP 220, Alphasyn T 220, Tribol 1100/220, Tribol 1510/220, OPTIGEAR BM 220, OPTIGEAR SYNTHETIC A 220 Chevron Teaco TEXACO PINNACLE EP 220, TEXACO MEROPA 220, Chevron, Gear Compound EP 220, Chevron Tegra Synthetic Gear Lub 220, Chevron Ultra Gear Lub 220 ESSO SPARTAN EP 220 Etna Products, Inc. ECOGEAR 220 M, ECOGEAR 220 S, BERUGEAR GS 220 BM FUCHS RENOLIN CLP 220 PLUS, RENOLIN UNISYN CLP 220 Imperial Oil Mobilgear SHC 220 KLÜBER Klüberoil GEM N Kuwait Q8 Goya NT 220, Q8 El Greco 220 Lubrication Engineers, Inc. ALMASOL 5 EP Mobil Mobilgear XMP 220, Mobilgear SHC XMP 220 MOTOREX GEAR COMPOUND 220 PLUS, GEAR SINTEC CLP 220 Petro-Canada Lubricants ULTIMA EP 220, ULTIMA SYNTHETIC EP 220 Shell Omala Oil F 220, Omala Oil HD 220 Teas Refinery Corp. INDUSTRIAL GEAR LUB 5 EP Total CARTER EP 220, CARTER SH 220 Form T

6 Engine Oil Information Engine Oil Performance The use of quality engine lubricating oils combined with appropriate oil drain and filter intervals are critical factors in maintaining engine performance and durability. The engine manufacturer recommends the use of high quality SAE 15W-40 multi viscosity heavy duty engine oils, which meet the American Petroleum Institute performance classification API CH-4, API CH-4/SJ, API CI-4/SK or European ACEA E-5, E-7 classification. A sulfate ash limit of 0.5 mass percent or less is suggested for optimum valve and piston deposit and oil consumption control. Engine Oil Viscosity Selection Operating Temperature Range of Engine Oil F C ENGINE OIL SELECTION GUIDE 5W-30 (Arctic Conditions) 10W-30 (Winter Conditions) Engine Oil Viscosity CAUTION 15W-40 (ALL Seasons) LIMITED USE OF LOW VISCOSITY OILS, SUCH AS 10W-30, MAY BE USED TO AID IN STARTING THE ENGINE AND PROVIDING SUFFICIENT OIL FLOW AT AMBIENT TEMPERATURES BELOW 23 F (-5 C). HOWEVER, CONTINUOUS USE OF LOW VISCOSITY LUBRICATING OILS CAN DECREASE ENGINE LIFE DUE TO WEAR PN# The use of multi-viscosity lubricating oils has been found to improve oil consumption control and improve engine cranking in cold temperatures while maintaining lubrication at high temperatures. While SAE 15W-40 oil is recommended for most climates, refer to the Engine Oil Selection Guide below for oil viscosity recommendations for etreme conditions. New Engine Break-In Oils Consult your Engine Maintence Manual for recommended procedure when breaking in a new or rebuilt engine Form T005

7 Lubrication Points Diagram - TF 830, 840 Machines 1) Main Boom Cylinder Base End Pivot 2) Main Boom Pivot 3) Main Boom Cylinder Rod End Pivot 4) Stick Boom Cylinder Base End Pivot 5) Stick Boom Pivot 6) Stick Cylinder Rod End Pivot and Link 7) Stick Boom Links 8) Loader Grapple Pivot 9) Floating Bunk Pivot 10) Steering Cylinder Base End 11) Steering Cylinder Rod End 12) Frame Articulation Pivot 13) Frame Articulation Bearing 14) Swing Bearing Ring Gear 15) Swing Bearing Race 16) Loader Grapple 18) Ale Drive Shaft Yoke Bearings 18) Drive Shaft U-Joints & Carrier Bearings ** 17) Ale Bogie Articulation Bearings ** DO NOT over-grease the swing bearing or articulation bearing race. If the bearing lip seal is pushed out it will allow dirt and other contaminates into the bearing. Use a good quality lithium based driveline grease when lubricating any drive shaft U-Joints or Carrier Bearings. Alithicon M-888 PN# 24140, is recommended by the manufacturer. Use a good quality grease containing at least 5-6% Molybdenum Disulfide by volume at all lubrication points unless otherwise specified. Lubriplate #176, PN# 18431, is recommended by the manufacturer ** Under etremely wet and muddy conditions, the ale articulation bearings and drive shaft components will require daily lubrication. Form T

8 Lubrication Points Diagram - TB 630 Machines 1) Main Boom Cylinder Base End Pivot 2) Main Boom Pivot 3) Main Boom Cylinder Rod End Pivot 4) Stick Boom Cylinder Base End Pivot 5) Stick Boom Pivot 6) Stick Boom Cylinder Rod End Pivot 7) Tool Cylinder Base Pivot 8) Tool Cylinder Rod & Upper 4-Bar Pivots 9) Lower 4-Bar Pivots 10) Attachment 11) Attachment Pivot 12) Ale Lock Cylinder Pivots 13) Steering Cylinder Base End 14) Frame Articulation Pivot 15) Steering Cylinder Rod End 16) Swing Bearing Ring Gear 17) Swing Bearing Race 18) Drive Shaft U-Joints & Carrier Bearings ** 19) Ale Drive Shaft Yoke Bearings ** 20) Ale Articulation Bearings ** DO NOT over-grease the swing bearing race. If the bearing lip seal is pushed out it will allow dirt and other contaminates into the bearing. Use a good quality lithium based driveline grease when lubricating any drive shaft U-Joints or Carrier Bearings. Alithicon M-888 PN# 24140, is recommended by the manufacturer. Use a good quality grease containing at least 5-6% Molybdenum Disulfide by volume at all lubrication points unless otherwise specified. Lubriplate #176, PN# 18431, is recommended by the manufacturer ** Under etremely wet and muddy conditions, the ale articulation bearings and drive shaft components will require daily lubrication Form T005

9 Lubrication Points Diagram - Clambunk and Hultdins Grapple attachment 1) Clam Bunk Arm Pivot 2) Clambunk Cylinder Base End 3) Clambunk Cylinder Rod End 4) Clambunk Tilt Pivot 5) Clambunk Bearing Race 1) Rods (4 pcs) 2) Grapple Arms (4 pcs) 3) Cylinder Ends (2 pcs) Please consult Hultdins Maintenance Manual for more information. Use a good quality lithium based driveline grease when lubricating any drive shaft U-Joints or Carrier Bearings. Alithicon M-888 PN# 24140, is recommended by the manufacturer. Use a good quality grease containing at least 5-6% Molybdenum Disulfide by volume at all lubrication points unless otherwise specified. Lubriplate #176, PN# 18431, is recommended by the manufacturer ** Under etremely wet and muddy conditions, the ale articulation bearings and drive shaft components will require daily lubrication. Form T

10 Lubrication Points Diagram - (Optional) Leveling Frame 1) Lower Turntable Pivot 2) Level Cylinder Rod End 3) Level Cylinder Base End 4) Driveline Components Use a good quality lithium based driveline grease when lubricating any drive shaft U-Joints or Carrier Bearings. Alithicon M-888 PN# 24140, is recommended by the manufacturer. Use a good quality grease containing at least 5-6% Molybdenum Disulfide by volume at all lubrication points unless otherwise specified. Lubriplate #176, PN# 18431, is recommended by the manufacturer ** Under etremely wet and muddy conditions, the ale articulation bearings and drive shaft components will require daily lubrication Form T005

11 Daily Walk-Around Inspection It is etremely important to perform a daily walk-around inspection of the machine before beginning to work. All preventive maintenance, especially a simple daily inspection, will ensure trouble-free operation and a long epected service life for your equipment. Check Engine Oil Level VOLVO The daily walk-around inspection can be divided into three groups; Visual Inspection, Lubrication and Component/System Checks. Visual Inspection: Check For Loose Or Missing Fasteners Check for Damaged Hydraulic Hoses Clean Flammable Debris and Fluids From All Surfaces Clean windows (use warm soapy water) Check condition and proper operation of rubber debris boom covers. Figure 1: Engine Oil Level Ad Blue / DEF Tank Only use warm soapy water, followed by a water rinse or an approved LEXAN cleaner followed by a clean water rince to clean LEXAN windows. Non-approved cleaners wil void warranty and can damage the windows. Lubrication: Form T005 All Cylinder & Pin Joints Swing Bearing Ring Gear Any Optional Attachments Component/System Checks: Check Engine Oil Level (See figure 1) Drain Water/Sediment At Primary Fuel Filter Check Engine Coolant Level Check & Clean - Radiator, Oil Cooler, & Condenser Fins Check Fuel Level Check Fire Etinguisher Check Air Cleaner Restriction Indicator Check Hydraulic Oil Level (See Section 3.2) Check Instrument Panel Gauges Test Arming \ Door Switch Interrupt Check AdBlue / DEF Solution (Volvo) Figure 2: Door Switch Test Hydraulic Interrupt Operation Do not bypass, remove or tamper with the Arming / Door Switch interrupt system. Serious personal injury could occur while operating the machine with the cab door open. All machines are equipped with a Arming / Door Switch interrupt system that only allows operation of the machine when the cab door is closed and the arming switch is depressed. A normally-open electrical switch is located at the base of the cab door. See Figure 2. When the cab door is open, operation of all machine controls is blocked by the IQAN control system. Proper operation of the interrupt system must be checked daily.

12 Every 50 Hours Of Operation The following items, that are required after every 50 hours of operation, are either safety related or are critical to the operation of the machine and deserve special attention. Torque Tapered Hub Retaining Bolts and Leveling Pin Nuts Tapered hub pin retainers are used at the pivot between the lower leveling frame and upper turntable bearing plate. See Figure 3. Tapered hub retaining bolts must be torqued and kept tight. It is also important to inspect and tighten the 2 retaining nut on the opposite end of the leveling pin. Damage can occur if nut is loose. Check Operator s Cab Emergency Escape Hatches Keep the operator s cab emergency escape hatches easily removable. Serious personal injury or death could result if these escape hatches cannot be removed in an emergency. The operator s cab emergency escape hatches should be checked for proper operation at least once a week. See Figure Figure 3: Tapered Hub (Optional Leveling) T00006 Figure 4: Cab Front Window and Top Emergency Escape Hatch The escape hatches can be checked by loosening the star knobs and pushing or pulling on the escape hatch. The hatch should not stick. If the hatch sticks, it must be removed completely and an antiseize or never-seize compound applied to the mating surface and studs before re-installation Form T005

13 Grease Swing Bearing Check Pump Drive Gearbo Oil CHECK Grease FILL Figure 5: Grease Swing Bearing It is important to grease the swing bearing every 50 hours of operation. The grease fittings are located in four places on the outside of the swing bearing. Be carefull not over grease the bearing or damage to the dust seal can occur. See Figures 5 Check Swing Motor Gearbo Oil Figure 6: Gearbo Oil Fill & Check (Typical) The Pump Drive gearbo oil level is checked with a sight gauge. See Figures 6. The FILL port is located at the side of the housing. If required, add SAE 75W-90 synthetic transmission oil meeting MIL-PRF-2105E specifications until the oil level reaches the top mark on the dipstick Check Front Ale Differential Oil CHECK Figure 6: Swing Gearbo Oil Fill & Check (Typical) The Swing Motor gearbo oil level is checked with a dipstick. See Figures 6. The FILL port is the dipstick hole located at the top of the housing. If required, add SAE 75W-90 synthetic transmission oil meeting MIL-PRF-2105E specifications until the oil level reaches the top mark on the dipstick Figure 7: Front Ale Differential Dipstick Location (Non Leveling Machines) The front ale is equipped with a dipstick to check the differential oil level. The dipstick on TF 800, TB 600 non-leveling machine can be found behind the Left access cover on the front frame. See Figure 7. Form T

14 Figure 8: Front Ale Differential Dipstick Location (TB 630 Leveling Machines) The differential oil level dipstick on TB 600 leveling machines is located directly behind the fuel pump on the left side of the frame. See Figure 8. If required, add SAE 75W-90 synthetic transmission oil meeting MIL-PRF-2105E specifications until the oil level reaches the top mark on the dipstick. Check Rear Ale Differential Oil Figure 10: Rear Ale Differential Dipstick Location (TB 630 Machines - As Seen From Below)) The rear ale on TB 600 machines is designed to oscillate side-to-side so a dipstick cannot be used. Instead, an oil LEVEL port is located in the ale beam. See Figure 10. If required, add SAE 75W-90 synthetic transmission oil meeting MIL-PRF-2105E specifications until the oil level reaches the top mark on the dipstick or the oil LEVEL port. Check Tandem Bogie Drive Oil LEVEL T00004 Figure 9: Rear Ale Differential Dipstick Location (TF 830 Machines) The rear ale on TF 810, 830, 840 machine is equipped with a dipstick to check the differential oil level. The dipstick can be found under the rear ale bo top cover. See Figure 9. Figure 11: Bogie Drive Housing LEVEL Port The tandem bogie drive housing (ale beam) oil LEVEL port is located on the interior side of the housing. See Figure 10. The FILL port is located on the eterior side of the housing near the top. If required, add SAE 75W-90 synthetic transmission oil meeting MIL-PRF-2105E specifications until the oil level reaches the bottom of the LEVEL port Form T005

15 Check Bogie Planetary Oil LEVEL After Every 100 Hours Of Operation All preventive maintenance is very important. However, the following items, required after every 100 hours of operation, are either safety related or are critical to the operation of the machine and deserve special attention. Lubricate Drive Shaft U-Joints & Carrier Bearings If required, add SAE 75W-90 synthetic transmission oil meeting MIL-PRF-2105E specifications until the oil level reaches the bottom of the LEVEL. See Figure 12. Check Gearbo Oil Level DRAIN Figure 12: Bogie Planetary Oil LEVEL & DRAIN Ports The drive shaft u-joints and carrier bearings should be lubricated daily if the machine is working in very damp conditions or the drive shaft is submerged in water or mud during operation. Greasing daily will help keep water out of these joints. Each U-joint in the driveline assembly is equipped with a grease point. Most grease fittings can be reached easily from either the upper or lower access areas. In some installations a small greaseline must be used to allow remote access to the fitting. FILL CHECK When required, a pillow block style carrier bearing is used to support longer driveshafts. These carrier bearings are also equipped with grease points. Carrier bearings will usually have a remote grease point to allow easy greasing. Use a good quality lithium based driveline grease such as Alithicon M-888. See pages and for drive shaft diagram Figure 13: Gearbo Oil Fill & Check (TB 600) The gearbo oil level is checked with a dipstick. See Figures 13. The FILL port is located at the top of the housing. If required, add SAE 75W-90 synthetic transmission oil meeting MIL-PRF-2105E specifications until the oil level reaches the top mark on the dipstick. Form T

16 After Every 250 Hours Of Operation Lubricate Single Ale Articulation Bearings Lubricate Ale Input Yoke Bearings Each ale is equipped with a grease point for the input yoke bearing. Use a good quality lithium based driveline grease such as Alithicon M-888. See Figure 14. The ale drive shaft yoke bearings should be lubricated daily if the machine is working in very damp conditions or the drive shaft is submerged in water or mud during operation. Greasing daily will help keep water out of these areas Figure 15: Ale Articulation Bearing Grease Points Grease fittings for the single ale articulation bearings are located remotely. See Figure 15. Torque Articulation Joint Bolts (630) T00003 Figure 14: Ale Articulation Bearing Grease Points Figure 16: Torque Articulation Mounting Bolts DO NOT over-grease the ale articulation or yoke bearing. If the bearing lip seal is pushed out it will allow dirt and other contaminates into the bearing. Torque the 1 Articulation Joint Bearing mounting bolts(44) to 1000 ft.lbs. (1330 Nm). See Figure 16. Maintain correct torque on all bolts. Failure to do so may result in severe structural damage to the machine Form T005

17 Articulation Joint Bolts (830) Ale Bo Mounting Bolts (Tandem Ael) Torque the 1 Articulation Joint mounting bolts(18) to 1000 ft.lbs. (1330 Nm). See Figure 17. Ale Mounting Bolts (Single Ael) Figure 17: Torque Articulation Bearing Mounting Bolts Figure 19: Ale Bo Mounting Bolts (TF 830 rear ale bo shown) T00002 Torque ale bo mounting bolts (4 per ale bo) to 1200 ft.lbs.(1600 Nm). See Figure 19. Ale Bo Spreader Bolts (Tandem Ael) Figure 18: Torque Single Ael Mounting Bolts Torque ale bo spreader bolts (8 per ale) to 600 ft.lbs.(800 Nm). See Figure 18. Figure 20: Ale Bo Spreader Bolt (TF 830 rear ale bo shown) Torque ale bo spreader bolts (2 per ale bo) to 1100 ft.lbs.(1490 Nm). See Figure 20. Form T

18 Swing Bearing Mounting Bolts Swing Bearing Mounting Bolts Torque to 1000 ft.lbs (1356 Nm) or you can torque the 1 swing bearing mounting bolts (22) to 200 ft.lbs. (271 Nm) then mark one flat on the head of the bolt. Turn the bolt an addtional 135 to 150 degrees (1 1/2 to 2 faces). See Figure 21. Wheel Lug Nuts Torque all wheel lug nuts to 600 ft.lbs. (800 Nm) See Figure 24. Figure 21: Torque Swing Bearing Mounting Bolts Swing Motor Mounting Bolts Torque the swing bearing mounting bolts to 235ft. lbs. (319 Nm). See Figure 22. Figure 22: Swing Motor Bolts (Typical) Driveshaft U-Joint Bolts Torque all Driveshaft U-Joint bolts to 70 ft.lbs. (95 Nm) See Figure T00001 Figure 24: Wheel Lug Nuts (Typical) The wheel mounting studs on the N.A.F. bogie ale serve two purposes; (1) retain the wheel/tire to the ale, and (2) retain the planetary wheel drive to the ale hub casting. If the wheel/tire assembly is allowed to work loose a failure of the wheel planetary and ale hub will occur. It is very important that the wheel lug nuts be kept tight. The machine operator should be aware of the importance of the wheel lug nuts being kept tight. Change Lower Fuel Lift Pump Suction Filter Change lower fuel lift pump suction filter located in the front frame. See Figure 25. Figure 23: Driveshaft Bolts (Typical) T00007 Figure 25: Lower Fuel Filter Form T005

19 Every 500 Hours Of Operation The following items, that are required after every 500 hours of operation, are either safety related or are critical to the operation of the machine and deserve special attention Figure 28: Oil Filter (Cummins) Figure 26: Engine Water Filter (Cummins Only) Change Water Filter (Cummins Only) OIL The engine coolant water filter needs to be changed every 500 hours. The engine coolant filter is located directly behind the engine. See Figure 26. FUEL Figure 29: Oil and Fuel Filters (Volvo) Engine Fuel Filters, The engine fuel filters need to changed every 500 hours. If fuel quality is an issue then they may need to be changed more often. See figure 29 and 29-1 for location of engine fuel filter locations. Please consult your engine manufactures manual for more information on proper engine maintenance and fuel requirements. Figure 27: Engine Oil Drain VOLVO Cummins Engine Oil, FUEL The engine oil and filter need to changed every 500 hours. If the conditions are etremely wet or etremely dusty the engine oil may need to be changed more often. See figure 27 for location of engine oil drain and image 28 and 29 for filter locations. Please consult your engine manufactures manual for more information on proper engine maintenance and oil requirements. FUEL 0905 Figure 29-1: Fuel Filters Form T

20 Every 1000 Hours Of Operation. The following items, that are required after every 1000 hours of operation, are either safety related or are critical to the operation of the machine and deserve special attention. Swing Motor Gearbo Flush The Swing Motor Gearbo oil will need to be drained and refilled. The drain can be accessed through a hole in the bottom of the upper plate. Remove the plug from the drain hose. To fill remve the dipstick and fill though the dipstick hole. See figure 31. Take special note of the oil being drained from the gearbo for signs of contamination. DIPSTICK Figure 30: Gearbo Drain The Pump Drive Gearbo oil will need to be drained and re-filled. To help speed up the process removing the top gearbo fill plug will speed in draining the oil. It will also help to run the machine and warming the oil before draining. See figure 30. Figure 31: Swing Gearbo Drain Take special note of the oil being drained from the gearbo for signs of contamination. If the machine has the Optional Gearbo cooler system make sure and run the gearbo cooler pump to to flush out any old gearbo oil. Also run the pump again after re-filling the gearbo and re-check the oil level Form T005

21 Every 1000 Hours or One Year Lubricate Bogie Ale Articulation Bearings Use a Good Quality grease containing at least 5-6% Molybdenum by volume. Lubriplate #176 is recommended. See figure 32 below for instructions. Bogie Ale Articulation Bearings 1000 hour Lubrication Procedure Figure 32: Gearbo Oil Cooler Loop Return Every 1500 Hours or One Year (Volvo Tier4) The Volvo TAD873VE engine will need the crankcase ventilation filter replaced after 1500 hours or one year. The crankcase filter is located on the front of the engine near the fuel and oil filters. See image Form T Figure 33: Crankcase Vent Filter (Volvo)

22 Tire & Track Chains Maintenance Tires There are several different types of tires and tire combinations for use on TF 830 and TB 630 machines. Tire pressures should be checked every 250 hours with a tire pressure gauge. The operator s daily walk around inspection should include an inspection the tires for cuts or other damage. Any debris between the rim and the tire should be removed to prevent damage. In addition, a rebound check with a hammer should be done to ensure that the tire is aired-up properly prior to the start of the working shift. Low tire pressure can cause the following; 1) Tire slippage on the rims. 2) Flat tires. 3) Damaged tires (side wall failures). 4) Tracks not staying on the tires. Track Chains There are a variety of track chains that are available and approved for use with the TF 830 and TB 630 machines. These track chains help with traction and provide ecellent flotation in soft ground. Track chains must be matched to the specific make, and size of tire used. For eample; A track chain designed for the Firestone 700/ tire will not fit a Nokia tire of the same size. Using the wrong tracks with the wrong tires can cause such problems as: 1) Tracks not staying on the tires. 2) Damage or high wear to the tires. 3) Accelerated wear to the track chains. Follow the track chain manufactures instructions when installing and tensioning track chains. Never Over-Tighten track chains. Over-tightening of track chains can cause such problems as: 1) Major Damage to Bogie Ales. 2) Damage or high wear to the tires. 3) Accelerated wear to the track chains. 28L 26 Firestone...35 psi 28L 26 Firestone...55psi with Calcium Cloride Firestone...35 psi 700 Nokian...90 psi 750 Nokian...90 psi 780 Nokian psi Form T005