section 3 - timberpro inctimberpro.com/operator/830bops/005.pdf · flush & refill engine...

Machine Maintenance Information3.1.1Form T005

Section 3.1

Machine Maintenance - Machine Maintenance Information

Maintenance Charts & Diagrams: Special Component Break-In Chart ............................................ 3.1.2 Preventive Maintenance Schedule Chart ............................................ 3.1.2 Lubricant & Fill Capacities Chart ...... 3.1.4 Engine Oil Information ...................... 3.1.6 Lubrication Points Diagram: TF 800 ......................................... 3.1.7 TB 600 ......................................... 3.1.8 Clam Bunk and Grapple .............. 3.1.9 Leveling Frame ............................ 3.1.10

Important Preventive Maintenance Information: Daily Walk-Around Inspection ........... 3.1.11 After 50 Hours Of Operation ............. 3.1.12 After 100 Hours Of Operation ........... 3.1.15 After 250 Hours Of Operation ........... 3.1.16 After 500 Hours Of Operation ........... 3.1.19 After 1000 Hours Of Operation ......... 3.1.19

Other Important Maintenance Information: Tire & Track Chain Maintenance ...... 3.1.20

Machine Maintenance Information 3.1.2 Form T005

Inspect Machine for Loose or Missing Fasteners xInspect for Damaged Hydraulic Hoses xClean Flammable Debris and Fluid From All Surfaces x Lubricate All Cylinder & Pins Joints, & Articulation Pivot Pins xLubricate Swing Bearing Inner Ring Gear Teeth xCheck Engine Oil Level xDrain Water/Sediment at Primary Fuel Filter xCheck Engine Coolant Level xInspect and Clean Radiator / Oil Cooler / A/C Condensor Fins x Check Fuel Level x Inspect Fire Extinguisher xCheck Air Cleaner Restriction Indicator * x Check Hydraulic Oil Level xCheck Instrument Panel Gauges xTest Arming \ Door Switch Interrupt x Lubricate Swing Bearing Race x Lubricate Articulation Bearing Race** xCheck Pump Drive Transmission Oil Level xCheck Lohmann Swing Gearbox Oil Level xTorque Tapered Hub Retaining Bolts xRun Air Conditioner xCheck Cab Emergency Escape Hatches x

2 Dai

ly

50

100

250

500

1000

20

00

Torque Tapered Hub Retaining Bolts x Check Axle Differential Oil Level xCheck Bogie Drive Housing Oil Level xCheck Bogie Planetary Oil Level xCheck Transfer Case Gearbox Oil Level x Check Pump Drive Gearbox Oil Level xChange Lower Fuel Pump Suction Filter x Torque Wheel Lug Nuts xTorque Swing Motor Mounting Bolts xTorque Swing Bearing Mounting Bolts xTorque Frame Articulation Bearing Mounting Bolts xTorque Axle Mounting Bolts x Torque Axle Box Spreader Bolts xTorque Driveshaft Carrier Bearing Support Bolts xTorque Driveshaft U-Joint Bolts xChange Swing Gear Box Oil xChange Pump Drive Gearbox Oil xChange Transfer Case Oil xChange Differential Oil xDrain Sediment and Check Axle Bogie Housing Oil *** xChange Planetary Oil x Change Hydraulic Oil Filters x

Special Component Break-In Schedule

Preventive Maintenance Chart 2 Dai

ly

50

100

250

500

1000

20

00


Check Axle Differential Oil Level ** xCheck Bogie Drive Housing Oil Level xCheck Bogie Planetary Oil Level xCheck Transfer Case Gearbox Oil Level ** xLubricate Drive Shaft U-Joints & Carrier Bearings (Alithicon M-888) ** xLubricate Axle Drive Shaft Yoke Bearings (Alithicon M-888) ** xLubricate Axle Articulation Bearings ** xTorque Swing Motor Mounting Bolts xTorque Swing Bearing Mounting Bolts x Torque Articulation Bearing Mounting Bolts xTorque Axle Mounting Bolts xTorque Axle Box Spreader Bolts xTorque Wheel Lug Nuts xTorque Driveshaft U-Joint Bolts xCheck Air Conditioner Refrigerant x Change Lower Fuel Pump Suction Filter x Inspect Engine Fan & Belts x Inspect, Secure & Clean Batterys xChange Engine Oil & Filter (Reference Engine Manual) xChange Engine Fuel Filters (Reference Engine Manual) xCheck Engine Coolant Antifreeze Concentration xCheck Radiator Hoses xChange Air Cleaner Filters * xChange Hydraulic Oil Filters x Change Lohmann Swing Gearbox Oil x Change Pump Drive Transmission Oil xHave Fire Suppression System Inspected by a Professional xReplace Fire Suppression System Controller Battery xFlush & Refill Engine Cooling System xClean Hydraulic Tank & Change Hydraulic Oil x Check Engine Valve Lash (Reference Engine Manual) xCheck Axle Brake Discs xChange Axle Differential Oil xChange Axle Bogie Housing Oil *** xChange Axle Planetary Oil xChange Axle Gearbox Oil x

2 Dai

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50

100

250

500

1000

20

00Preventive Maintenance Chart Cont....

* Under extremely dusty conditions, the air cleaner filters may require cleaning or changing more frequently. ** Under extremely wet and muddy conditions, the axle articulation bearings and drivetrain components will require daily inspection and lubrication. *** Drain 2-3 quarts (1.9-2.8 Liters) inspect for contamination on all four corners of the bogie, & clean magnetic plugs. If oil has no excessive 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 oth-erwise specified. Lubriplate #176, PN# 18431, is recommended by the manufacturer.


Cummins QSB6.7 *260 HP (194 kW)

Cummins QSC8.3 *300 HP (224 kW)

Cooling System

Fuel Tank - 830 830 (leveling) - 630 630 (leveling)

Lohmann Swing Gearbox*

Dual Pump - FunkTransmission*

Transfer Case*(N.A.F Tim 15)

Transfer Case*(N.A.F Tim 16)

Axle Differential*TIM 20TIM 12TIM 08 & 13TIM 21, 22, 23

Bogie Housing*TIM 20TIM 08, 13, 21, 22 & 23

Wheel Planetary* TIM 12TIM 08,13, 20, 21, 22 & 23

Cummins recommends the use of High-Quality SAE 15W-40 multi viscosity engine oil. American Petroleum Institute performance classification API CH-4, API CH-4/SJ, API CI-4/SK or ACEA E-5, E-7

Cummins recommends the use of High-Quality SAE 15W-40 multi viscosity engine oil. American Petroleum Institute performance classification API CH-4, API CH-4/SJ, API CI-4/SK or ACEA E-5, E-7

Use a mixture of 50% Ethylene Glycol or Propylene Glycol antifreeze mixed 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 recommend-ed. For operating temperatures below 32° F (0° C) a use of No.1D and No.2D blend may be used.

DIN 51502 - CLP or CLP HC - ISO 220 (see recommended oils chart on next page)

SAE 75W-90 synthetic oil that meetsMIL-PRF-2105E specifications.






21 US Quarts 20 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 L107 US gal 405 L123 US gal 465 L

4.5 US Quarts 4,3 Liters

2.5 US Quarts 2.4 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) x4

35 qt (37 L) x4

11.6 qt (11 L) x8

5.4 qt (5 L) x8

Lubricant Specification & Fill Capacities Chart


Hydraulic Oil Tank

General Greasing

Greasing of Drive-shaft components

High quality hydraulic oil with anti-wearAdditives added. See “Hydraulic OilPerformance Specifications” Section 3.2

High quality grease containing at least5-6% Molybdenum Disulfide by volume atAll lubrication points.TimberPro recommends Lubriplate #176 PN# 18431.

Use a good quality lithium based driveline grease. TimberPro recommends Alithicon M-888 PN# 24140.

60 US Gallons227 Liters

Lubricant Specification & Fill Capacities Chart Cont...

Company Oil BrandADDINOL ECO GEAR 220 M, ECO GEAR 220 SAgip BLASIA 220 CLPAmerican Agip Blasia 220, Industrial Gear Lubricant 5 EPARAL Degol BG 220 Plus, Degol PAS 220, Degol ESG 220BECHEM ECOGEAR 220 M, ECOGEAR 220 SJAX-Behnke Lubricants HP INDUSTRIAL GEAR OIL 220, SYNAX-EP INDUSTRIAL

GEAR OIL 220BEL-RAY SYNTHETIC GEAR OIL 6690BENZ OIL, Inc. GEAROL 220, SYN-TECH PAO 220BP Energol GR-XF 220, Enersyn HTX 220, Energol PM 220, Ener-

gol GR-XP 220Castrol Alpha SP 220, Alphasyn T 220, Tribol 1100/220, Tribol

1510/220, OPTIGEAR BM 220, OPTIGEAR SYNTHETIC A 220Chevron Texaco TEXACO PINNACLE EP 220, TEXACO MEROPA 220, Chev-

ron, Gear Compound EP 220, Chevron Tegra Synthetic Gear Lub 220, Chevron Ultra Gear Lub 220

ESSO SPARTAN EP 220Etna Products, Inc. ECOGEAR 220 M, ECOGEAR 220 S, BERUGEAR GS 220 BMFUCHS RENOLIN CLP 220 PLUS, RENOLIN UNISYN CLP 220Imperial Oil Mobilgear SHC 220KLÜBER Klüberoil GEM 1 – 220 NKuwait Q8 Goya NT 220, Q8 El Greco 220Lubrication Engineers, Inc. ALMASOL 5 EPMobil Mobilgear XMP 220, Mobilgear SHC XMP 220MOTOREX GEAR COMPOUND 220 PLUS, GEAR SINTEC CLP 220Petro-Canada Lubricants ULTIMA EP 220, ULTIMA SYNTHETIC EP 220Shell Omala Oil F 220, Omala Oil HD 220Texas Refinery Corp. INDUSTRIAL GEAR LUB 5 EPTotal CARTER EP 220, CARTER SH 220

Recommended Lube Oil for Lohmann Swing Gearbox


PN# 18071

ENGINE OIL SELECTION GUIDE

Engine Oil Viscosity

Ope

ratin

g Te

mpe

ratu

reR

ange

of E

ngin

e O

il

F C

140 60122 50104 40

86 3068 2050 1032 014 -10-4 -20

-22 -30-40 -40

15W

-40

(ALL

Sea

sons

)

10W

-30

(Win

ter

Con

ditio

ns)

5W-3

0(A

rctic

Con

ditio

ns)

CAUTIONLIMITED USE OF LOW VISCOSITY OILS, SUCH AS 10W-30, MAY BE USED TO AID IN STARTING THE ENGINE AND PROVIDINGSUFFICIENT OIL FLOW AT AMBIENT TEMPERATURES BELOW 23 F (-5 C). HOWEVER, CONTINUOUS USE OF LOW VISCOSITYLUBRICATING OILS CAN DECREASE ENGINE LIFE DUE TO WEAR

Engine Oil Information Engine Oil PerformanceThe 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 SelectionThe 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 extreme conditions.

New Engine “Break-In” OilsConsult your Engine Maintence Manual for recommended procedure when breaking in a new or rebuilt engine.


TF 830

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 recommend-ed by the manufacturer

** Under extremely wet and muddy conditions, the axle articulation bearings and drive shaft components will require daily lubrication.

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 End11) Steering Cylinder Rod End12) Frame Articulation Pivot13) Frame Articulation Bearing14) Swing Bearing Ring Gear15) Swing Bearing Race16) Loader Grapple18) Axle Drive Shaft Yoke Bearings 18) Drive Shaft U-Joints & Carrier Bearings ** 17) Axle 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.


Wheel removed forclarity



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 Pivot12) Axle Lock Cylinder Pivots13) Steering Cylinder Base End14) Frame Articulation Pivot 15) Steering Cylinder Rod End16) Swing Bearing Ring Gear17) Swing Bearing Race18) Drive Shaft U-Joints & Carrier Bearings **19) Axle Drive Shaft Yoke Bearings **20) Axle 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.


1) Clam Bunk Arm Pivot 2) Clambunk Cylinder Base End 3) Clambunk Cylinder Rod End 4) Clambunk Tilt Pivot 5) Clambunk Bearing Race



Lubrication Points Diagram - Clambunk and Hultdins Grapple attachment

1) Rods (4 pcs) 2) Grapple Arms (4 pcs) 3) Cylinder Ends (2 pcs) Please consult Hultdins Maintenance Manual for more information.


1) Lower Turntable Pivot 2) Level Cylinder Rod End

3) Level Cylinder Base End 4) Driveline Components



Lubrication Points Diagram - (Optional) Leveling Frame


Daily Walk-Around InspectionIt is extremely 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 expected service life for your equipment.

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)

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:

All Cylinder & Pin Joints, & Articulation Pivot Pins Swing Bearing Ring Gear Any Optional Attachments

Component/System Checks: Check Engine Oil Level Drain Water/Sediment At Primary Fuel Filter (see engine maintence manual for correct procedure) Check Engine Coolant Level Check & Clean - Radiator, Oil Cooler, & Condenser Fins Check Fuel Level Check Fire Extinguisher Check Air Cleaner Restriction Indicator Check Hydraulic Oil Level Check Instrument Panel Gauges Test Arming \ Door Switch Interrupt

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 1. 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.

Figure 1: Door Switch

00038


Every 50 Hours Of OperationThe 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 NutsTapered hub pin retainers are used at the pivot between the lower leveling frame and upper turntable bearing plate. See Figure 2. 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 3.

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 “anti-seize” or “never-seize” compound applied to the mating surface and studs before re-installation.

Figure 2: Tapered Hub (Optional Leveling)00495

Figure 3: Cab Front Window and Top Emergency Escape Hatch

T00006


Check Pump Drive Gearbox Oil

The Pump Drive gearbox oil level is checked with a sight gauge. See Figures 5. 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 Axle Differential Oil

The front axle 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 6.

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 4

Check Swing Motor Gearbox Oil

The Swing Motor gearbox oil level is checked with a dipstick. See Figures 5. 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 4: Grease Swing Bearing

Figure 5: Swing Gearbox Oil Fill & Check (Typical)

00611

Grease

CHECK

Figure 5: Gearbox Oil Fill & Check (Typical)

CHECK

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Figure 6: Front Axle Differential Dipstick Location (Non Leveling Machines)

00607


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 7.


Check Rear Axle Differential Oil

The rear axle 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 axle box top cover. See Figure 8.

The rear axle 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 axle beam. See Figure 9.

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

The tandem bogie drive housing (axle beam) oil LEVEL port is located on the interior side of the housing. See Figure 10. The FILL port is located on the exterior 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.

Figure 8: Rear Axle Differential Dipstick Location (TF 830 Machines)

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Figure 7: Front Axle Differential Dipstick Location (TB 630 Leveling Machines)

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Figure 9: Rear Axle Differential Dipstick Location (TB 630 Machines - As Seen From Below))

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Figure 10: Bogie Drive Housing LEVEL Port

00431

LEVEL


Check Bogie Planetary Oil

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 11.

Check Gearbox Oil Level

The gearbox oil level is checked with a dipstick. See Figures 12. The FILL port is located at the top of the housing.


After Every 100 Hours Of OperationAll 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

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.

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 3.1.6 and 3.1.7 for drive shaft diagram.

Figure 12: Gearbox Oil Fill & Check (TB 600)

FILL

CHECK

00579

Figure 11: Bogie Planetary Oil LEVEL & DRAIN Ports

LEVEL

DRAIN00251


After Every 250 Hours Of Operation Lubricate Axle Input Yoke Bearings Each axle 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 15.

The axle 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.

DO NOT over-grease the axle articulation or yoke bearing. If the bearing lip seal is pushed out it will allow dirt and other contaminates into the bearing.

Lubricate Single Axle Articulation Bearings

Grease fittings for the single axle articulation bearings are located remotely. See Figure 16.

Torque Articulation Joint Bolts (630)

Torque the 1” Articulation Joint Bearing mounting bolts(44) to 1000 ft.lbs. (1330 Nm). See Figure 17.

Maintain correct torque on all bolts. Failure to do so may result in severe structural damage to the machine.

Figure 17: Torque Articulation Mounting Bolts

Figure 16: Axle Articulation Bearing Grease Points

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Figure 15: Axle Articulation Bearing Grease Points

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00606


Articulation Joint Bolts (830)

Torque the 1” Articulation Joint mounting bolts(18) to 1000 ft.lbs. (1330 Nm). See Figure 18.

Axle Mounting Bolts (Single Axel)

Torque axle box spreader bolts (8 per axle) to 600 ft.lbs.(800 Nm). See Figure 19.

Axle Box Mounting Bolts (Tandem Axel)

Torque axle box mounting bolts (4 per axle box) to 1200 ft.lbs.(1600 Nm). See Figure 20.

Axle Box Spreader Bolts (Tandem Axel)

Torque axle box spreader bolts (2 per axle box) to 1100 ft.lbs.(1490 Nm). See Figure 21.

Figure 20: Axle Box Mounting Bolts (TF 830 rear axle box shown)

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Figure 19: Torque Single Axel Mounting Bolts

Figure 17: Torque Articulation Bearing Mounting Bolts

Figure 21: Axle Box Spreader Bolt (TF 830 rear axle box shown)

0048800613

00605


Swing Bearing Mounting BoltsSwing 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 22.

Swing Motor Mounting BoltsTorque the swing bearing mounting bolts to 240ft.lbs. (326 Nm). See Figure 23.

Driveshaft U-Joint BoltsTorque all Driveshaft U-Joint bolts to 70 ft.lbs. (95 Nm) See Figure 24.

Wheel Lug NutsTorque all wheel lug nuts to 600 ft.lbs. (800 Nm) See Figure 25.

The wheel mounting studs on the N.A.F. bogie axle serve two purposes; (1) retain the wheel/tire to the axle, and (2) retain the planetary wheel drive to the axle hub casting. If the wheel/tire assembly is allowed to work loose a failure of the wheel planetary and axle 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 FilterChange lower fuel lift pump suction filter located in the front frame. See Figure 26.

Figure 22: Torque Swing Bearing Mounting Bolts

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Figure 23: Swing Motor Bolts (Typical)

T00001

Figure 24: Driveshaft Bolts (Typical)00216

00216

Figure 25: Wheel Lug Nuts (Typical)

Figure 26: Lower Fuel Filter

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Every 500 Hours Of OperationThe 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.

Change Water Filter

The engine coolant water filter needs to be changed every 500 hours. The engine coolant filter is located directly behind the engine. There is two shut off valves located on each side of the filter mount that can be closed to help reduce the amount of coolant lost during filter replacement. See Figure 27.

Engine Oil,

The engine oil and filter need to changed every 500 hours. If the conditions are extremely wet or extremely dusty the engine oil may need to be changed more often. See figure 28 item number 1 for location of engine oil drain. The engine oil drain can be accessed through a panel located under the engine. There is a locking ball valve located on the engine oil pan

with a #8 male ORS hydraulic fitting if a hose needs to be added to help control the oil flow. The engines oil filter is remotely mounted in the front of the machine above the two batteries. Please consult your engine manufactures manual for more information on proper engine maintenance.

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.

The Pump Drive Gearbox oil and cooler loop will be completely drained using this method. The cooler loop will need to be re-filled before the machine can be ran. The gearbox & cooler drain can be accessed through the removable access panel located under the engine.

Take special note of the oil being drained from the gearbox for signs of contamination.

To help speed up the process removing the top cooler loop return line can also help speed up the draining process. See figure 30.

Figure 29: Gearbox fill and level sight glass

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Figure 27: Engine Water Filter

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Figure 28: Engine Oil Drain

00236

CHECK

FILLFILL SWITCH


Once oil has been drained, re-connect lower loop line to the check valve, re-install drain plug, but leave the top cooler return line unhooked. Now fill the gear box using the fill plug shown in figure 29.

Figure 30: Gearbox Oil Cooler Loop Return

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After your done filling the gearbox next you will need to run the hydraulic oil fill pump. Turn key switch to the “on” position, “DO NOT START THE ENGINE” Push fill pump switch (figure 29) to activate cooler loop pump and run until clear oil is being pushed out the top cooler

loop return line. Once a clear stream of gear oil is visible coming out the return line you can finish re-installing the top cooler loop line and then add oil to the gearbox until the correct oil level is again achieved. Once the oil has again been re-filled to the proper operating level, it is a good idea to re-check the oil level after the machine has been been ran for a few minutes.

Swing Motor Gearbox Flush

The Swing Motor Gearbox oil will need to be drained and refilled. The drain can be accessed throug be filled using one of the fill plugs located on the side of the gearbox. The level sight glass is located on the bottom of the gearbox and can be viewed from lower rear side of the gearbox. See Figure 18, number 3. Take special note of the oil being drained from the gearbox for signs of contamination.

Every 1000 Hours or One Year

Lubricate Bogie Axle Articulation Bearings

Use a Good Quality grease containing at least 5-6% Molybdenum by volume. Lubriplate #176 is recommended. See below for instructions.

Figure 31: Gearbox Oil Cooler Loop Return

Bogie Axle Articulation Bearings 1000 hour Lubrication Procedure


Tire & Track Chains MaintenanceTiresThere 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 ChainsThere 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 excellent flotation in soft ground.

Track chains must be matched to the specific make, and size of tire used.

For example; A track chain designed for the Firestone 700/50-26.5 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 Axles. 2) Damage or high wear to the tires. 3) Accelerated wear to the track chains.

28L x 26 Firestone...................35 psi

28L x 26 Firestone....................55psi with Calcium Cloride

54 x 37 Firestone.....................35 psi

700 Nokian...............................90 psi

750 Nokian...............................90 psi

700 Primex...............................90 psi

750 Primex...............................90 psi

section 3 - timberpro inctimberpro.com/operator/830bops/005.pdf · flush & refill engine...

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