124 Interlock Yarder
Operation Manual
1 Preface ...... 2 2 Safety Precautions ...... 3 3 General Description ...... 10 4 Operation ...... 12 5 Joystick Control Functions ...... 15 6 Control Panel Switches ...... 17 7 Control Panel Indicators ...... 20 8 Additional Cab Controls ...... 22 9 Control Stand ...... 24 10 Emergency Escape ...... 25 11 Self-Propelled Travelling ...... 27 12 Transport and Servicing ...... 28 13 Winch Operation ...... 35 14 Guylines ...... 38 15 Lubrication and Maintenance ...... 42 16 Horn (Whistle) ...... 53 17 Machine Rigging ...... 56 18 Trouble Shooting...... 60 19 Onboard Diagnostics - DDEC V ...... 63 20 Transmission Codes ...... 66 21 Lexan & Marguard Windows ...... 71 22 Quick Reference Parts List ...... 73
1 Preface
The operating and maintenance manual is designed to familiarize the operator of this machine with all the necessary information so that they may take full advantage of the capabilities built into the machine. If the machine is operated and maintained properly, it will yield profitable results. For this reason, it is imperative that the basic needs of the machine be satisfied. When the machine is lubricated with the recommended lubricants at the recommended intervals, abnormal part wear and failures will be avoided. Using the correct hydraulic oil for the prevailing temperatures and conditions, and careful maintenance of the hydraulic oil filters will help ensure a trouble free and dependable hydraulic system.
When ordering parts, please include the serial number of the machine. Also serviceable parts will be covered in the parts manual with the exception of the engine and the transmission, which will have their own Parts & Service manuals.
Note: Madill Equipment reserves the right to make technical changes on the machine without notice or incurring any liability where it simplifies or improves efficiency and productivity.
124 Operator's Manual 097214A Page 2 of 74 2 Safety Precautions
The following are some safety tips that you should follow when operating the 124 interlock yarder for the protection of the people who work around you and for your own protection. 2.1 Before you start Know your machine. Inspect it thoroughly. Keep it clean. Wear close fitting clothing and protective items. Make sure protective guards are in place. Check height, weight and width restrictions for your work area. Be sure you know about any hazards. Make sure you agree with your signal person on hand signals. NOTE: This machine is designed to operate on prepared landings with slopes not more than 20%. 2.2 Safety Warning Labels and Decals The Madill Yarder is delivered equipped with numerous safety and warning labels and decals, to better inform operators of the potential safety hazards. It is very important that these labels be read and understood, and that they are in place and legible at all times. If you notice that any of these are missing or unreadable due to painting, tearing, abuse, or any other cause, report it immediately to your supervisor. Attempting to operate your yarder with warning labels missing or unreadable may be a violation of WCB, or local regulations. 2.3 Starting Up Make sure all controls are in proper position for starting and that the transmission is in neutral. Check for warning tags. Start the machine only from the operator’s cab and do not leave the cab while the engine is running. Warm the machine up gradually. Practice with the function controls. Report any unusual noises or conditions for immediate repair. Stop accidents before they stop you! NOTE: Allow air pressure to reach 120 Psi before operating the winch. 2.4 While Operating PAY ATTENTION! Know the working range of your machine. Know where any obstructions might be. Do not move the machine unnecessarily fast. Be sure everyone is in the clear before moving any part of the machine. Never swing or position any attachment or load over ground crew or truck cab. Never allow anyone to ride on any attachment or load. Never attempt to operate the machine from any position outside the operator’s cab. Never operate in a location where the machine or load may contact electric power lines. ALWAYS operate with seat belt fastened. 2.5 While Travelling Make sure that no one is endangered before you make your move. Never get on or off the machine while it is in motion. Lock the swing brake when you travel. Cross
124 Operator's Manual 097214A Page 3 of 74 obstacles at an angle and at low speed. Watch to see that your boom clears all obstacles. Shift the transmission and yarding control to neutral. This machine is designed to operate on prepared landings with slopes not more than 20%. 2.6 Before Performing Service Slack yarder working lines, shut off engine and remove keys from ignition. Attach a “DO NOT OPERATE” tag in an obvious place in operator’s cab. Ensure that the battery lockout master switch located inside the front left access door is locked out.
2.7 Overloading Overloading is hazardous. Make certain you are within the safe load and work radius limits of your machine for prevailing conditions. Uneven or sloping terrain will reduce the load and working radius of your machine. Overloading the machine can result in rollover which may cause serious injury or death, damage or an increased rate of wear that will not be covered by warranty. 2.8 Fire prevention Due to the operating conditions found in mechanized logging there are significant fire hazards that can arise over time if the equipment is not kept clean and well maintained on a continual basis. In order to minimize the fire hazards present on the machine it is important to reduce or eliminate both potential sources of fuel for a fire and potential sources of ignition. Sources of fuel can accumulate due to normal operation, service or component failure. These include such materials as needles, leaves, bark, wood chips, sawdust, hydraulic oil, grease and fuel. Sources of ignition include overheating engine and hydraulic components, exhaust components, and sparks due to damage to the electrical system. The following precautions must be taken for the safe operation of the machine: • Accumulation of needles, leaves, bark, wood chips, sawdust or other debris must be removed daily. • Hydraulic leaks, accumulations of grease, fuel or oil must be repaired and cleaned up immediately. • Electrical wires, battery cables, hydraulic hoses and fuel lines must be inspected daily and replaced immediately if damaged or worn. • The radiator and engine cooling system should be cleaned and serviced daily to maintain moderate engine temperatures. • Ensure a fire extinguisher and other required firefighting equipment is on the machine and properly maintained. • When welding on the machine, ensure that the area to be welded has been thoroughly cleaned of any flammable materials and that a fire extinguisher is within close reach.
124 Operator's Manual 097214A Page 4 of 74 • Refuel the machine only after the engine has been stopped and allowed to cool down. For machines with an automatic fire suppression system the following precautions are required to ensure maximum effectiveness: • The house must be kept down with all access doors closed while the machine is running except when required for service, maintenance and inspections. • If a fire is detected before the system has discharged, activate the system manually. • DO NOT wait for the system to automatically activate. • In the event of a fire while the house is open, immediately close the house after ensuring that all personnel are clear of the area. Once closed, manually activate fire suppression system. 2.9 Safe Winch Operation Do not use the machine for operations other than it was intended. This machine is designed as a log yarder, to be operated within the parameters specified in this manual. Any other use must be approved by the manufacturer. Do not operate the machine if inspection reveals any structural damage to the boom, gantry legs or their anchor points. Inspect these parts on a regular basis, at the monthly greasing intervals or more frequently. Do not leave the machine with a load suspended in the air. Exception: The unloaded grapple or carriage may be “parked” in the air overnight with the winch spring-brakes (“maxies”) set, but only if it can be determined that this will not create a hazard for anyone in, or passing by the area. Always slack the yarding lines before swinging the boom more than 90° to the yarding road. If the boom is more than 90° to the yarding road, power it back into lead using the swing drive. These precautions prevent pulling the boom hard against the stops which can result in boom or gantry damage. 2.10 Welding Precautions When welding, the following must be done to avoid damage to the machine electrical systems. 1. Both the positive (+) and the negative (-) battery leads must be disconnected before welding. 2. Ground cable must be in close proximity to welding location. Locate ground near electrode so that no current will flow through bearings, bushings or pinned connections. 3. Welding on engine or engine mounted components is NEVER recommended. 4. Disconnect all engine control module (ECM) plugs (located on engine)
124 Operator's Manual 097214A Page 5 of 74 5. Disconnect all transmission electronic control unit (ECU) and vehicle interface module (VIM) plugs (located in control stand) 6. Disconnect the plug connected to the regen circuit pneumatic amplifier (located in control stand)
2.11 Guards All guards serve a needed safety function; they must be replaced upon completion of any service work done on the machine, or if damaged in operation.
124 Operator's Manual 097214A Page 6 of 74 When the engine is running and the transmission is in gear, all gears on the winch are turning, along with the clutches attached to them. When the transmission is in neutral and the engine is running, the gear train may still turn with substantial torque due to transmission drag. Therefore, NEVER enter the house guards while the engine is running. 2.12 Handrails Handrails must be included in regularly scheduled safety inspections. Ensure that the handrails are not broken or severely bent, paying close attention to the welds at the base of all the supports. Any handrails that are damaged should be repaired or replaced immediately. Ensure that all handrails are securely fastened to the machine especially after transport. 2.13 Horn (Whistle) The function of the horn must be tested daily and subsequently at the start of each shift. Do not operate the machine with a malfunctioning horn. Instructions for adjusting the horn can be found in section 16. 2.14 Cables (Lines) Replace worn or damaged cables. Do not operate the machine with worn, broken, or frayed cable. Install new cables when the old ones give any indication that they may fail. Inspect cables and clamps frequently. Use only cables conforming to the requirements shown on the specification plate affixed to the yarder. Boom hoist lines and pendant straps must be replaced according to the requirements of this manual. Do not use larger running lines than are specified by the manufacturer. Keep hands and body clear of moving cables. Never guide cables onto drums without using a proper spooling tool. Do not allow the crew to stand directly under the carriage, whether loaded or unloaded, or in the bight of lines. Do not swing over personnel on the ground. 2.15 Guylines Anchor the guylines behind the machine to oppose the pull of the yarding lines. Position them as shown in section 14. Keep the guylines in proper adjustment. Check daily and also inspect the stumps and rigging hardware to make sure the anchor is solid. DO NOT operate the machine unless you are satisfied that all controls and components are functioning properly. DO NOT tighten guylines by walking the machine away from the anchors. Before yarding, ensure that the guyline and boom topping drum pawls are firmly engaged into the ratchet. If this is not done, an excessive load will be placed on the drive chain and failure will result. This is not covered by warranty.
124 Operator's Manual 097214A Page 7 of 74 2.16 Brakes Keep brakes and clutches properly adjusted. Adjust brakes and clutches immediately when any indication of slipping is noted. Serious injury to ground personnel or damage to property and equipment could result if adjustments are neglected. The main, slackpuller and haulback band brakes are not to be used under continuous, prolonged slipping during the inhaul and outhaul cycle. Overheating and loss of braking will result. Do not hold the carriage or grapple stalled on the torque converter. Use the brakes. 2.17 Fall Restraint Anchors
- Fall restraint anchors are provided at the locations shown to allow access to the upper porting of the gantry.
124 Operator's Manual 097214A Page 8 of 74 - This configuration is intended to be used with a 2 lanyard fall restraint harness to allow the worker to be connected at all times. Consult local safety regulations and harness suppliers for the correct harness to be used. - The attachment points are not to be used for general lifting. - If there are any portions of the gantry that cannot be reached when a fall restraint harness is being correctly used, then the gantry must be lowered for service. - Inspect the ladder and other hand and foot holds are secure and unobstructed before using.
124 Operator's Manual 097214A Page 9 of 74 3 General Description
3.1 Power Unit The Madill 124 Interlock Yarder is powered by a Detroit Diesel Series 60 14.0L, 450 H.P. diesel engine. The engine is direct coupled to an Allison 4500OFS series Powershift transmission, providing power to the yarding winch. 3.2 Undercarriage The crawler type undercarriage features two speed hydraulic drive motors coded to 3 stage planetary gearboxes. Track rollers are lifetime lubricated. Track tension is maintained by a combination of spring tensioner and grease adjuster. 3.3 Frame The frame is formed of a single, integral welded unit. These frames are bored on a numerical controlled machining center to provide accurately positioned shafts and to ensure parallelism. Coupling this with our precision gearing means that it is unnecessary to adjust for gear mesh resulting in a quiet, smooth running winch. 3.4 Operator’s Cab Forward positioning of the cab provides the operator with excellent visibility while steel tube and plate construction provide safety. The protective guarding of the operators cab in combination with the boom mounted cab guard, are designed and manufactured to meet the operator protection requirements of the following Workers’ compensation Board of British Columbia (Canada) Standards.
WCB Standard: G601 Log Loader and Log Yarder Backstops WCB Standard: G602 Log Loader and Log Yarder Raised Cabs WCB Standard: G603 Log Loader and Log Yarder Window Guards WCB Standard: G608 Mobile Equipment Roof Structures – Heavy Duty
The operators cab is also fitted with an emergency exit, the maintenance and operation is detailed in section 9.1. The cab can also be hydraulically tilted forward to reduce the machine height for transport and allow access for service. 3.5 Machine Deck A clean and simple machine main deck features complete guard frame rails and an integrated fuel tank. Stairs to access the operators cab and upper deck are mounted to the right hand side of the machine. Access to the winch is through the two doors located on the left hand side of the machine, the cab riser access door and the removable access stairs; in addition the cab and engine house can be tilted.
124 Operator's Manual 097214A Page 10 of 74 3.6 Engine House One piece engine house is hydraulically tilted for “walk through” access. Large grates provide ventilation. 3.7 Hydraulic System The pressure compensated piston pump powers travel, swing, boom hoist and guyline functions. A load sensing valve system allows simultaneous operation of all hydraulic functions. Each function can be tuned for optimization. Hydraulic controls and yarding clutches are powered by a separate pilot pump. 3.8 Pneumatic System Pneumatic yarding controls are power by an engine mounted air compressor filling twin storage tanks. Compressed air is used to actuate the yarders slip clutches (brakes) as well as guyline dogs and the horn. 3.9 Boom and Gantry The 40 ft. gantry and 60 ft. boom are fabricated steel construction. The haulback sheave is 60 ft. off the ground. The gantry head is provided with a guyline fairlead, which is fitted with sheaves for three guylines as standard. 3.10 Drums Drums are fabricated. Main & haulback are pressed on the shafts. The drums have precast line grooves to aid in spooling the 7/8" diameter working lines. Straw drum floats on ball bearings. Three hydraulic guyline drums are provided on each machine and must be used for all yarding conditions. NOTE: The main, slackpuller and haulback drums are grooved to accept only 7/8 " diameter line (regular or swaged). Use of any other size will result in unacceptable line spooling and line damage.
124 Operator's Manual 097214A Page 11 of 74 4 Operation
4.1 General Notes On Operation When checking for leaks in the hydraulic system, use a piece of cardboard or wood. A small stream of high pressure oil can penetrate the skin and cause serious injury. DO NOT USE YOUR HAND OR FINGERS TO SEARCH FOR LEAKS. If you are struck by pressurized hydraulic fluid, see a doctor at once. When a machine is first delivered, it is important to go through a series of inspections and checks before placing the machine in service. Each machine has been thoroughly inspected. A comprehensive post-delivery inspection by the distributor will detect any problems developed in transit, so they may be corrected before the machine reaches its ultimate user. Checking the positions of the shipping blocks supporting the machine can indicate what type of damage may have occurred during shipping. All blocking should be tightly in place and all cables should be properly tensioned. Loose cables and blocks mean the machine has probably been jarred and moved around, and subjected to unusual vibration. This could mean loose parts and bolts. Inspect the machine surface for damage. Walk around the machine and perform a visual inspection, checking for oil leaks. Before the machine is run, the oil level in the engine should be checked to ensure proper level. Also check the coolant level and concentration in the radiator. Hydraulic fluid in the reservoir should be in the proper range pointed out on the sight glass; do not overfill this, room must be allowed for fluid expansion due to heat. Check the oil level in all gearboxes and the chain case, add if too low, drain if over filled. Consult the lubrication instructions for correct service procedures. Lubricate all fittings to be sure they will accept grease. Re-torque bolts if necessary. Read the procedure for machine start-up before running the engine on assembled machine. Start and run the engine until it warms up. Cycle the various functions and examine the machine for hydraulic oil leaks. Normally the first hours of operation are the most crucial to the machine because this is when the parts are breaking in. It is at this time that bolts loosen due to wearing-in process and metal contact is greatest in the hydraulic system. Bolts should be re-torqued at several intervals in the first 80 hours of operation. 4.2 Travel Restrictions & Precautions 1. Switch travel speed selector to low when travelling down grades or when loading/unloading machine. 2. ** Important** re-torque the track pad bolts after their first 40 hours of operation. 3. Keep the driving sprockets to the rear while travelling.
124 Operator's Manual 097214A Page 12 of 74 4.3 Travel Brake Function The multi-disc spring applied, hydraulically released travel brakes are automatically released when any travel control is engaged. Loss of system pressure will cause the brake to apply automatically. 4.4 Rollers & Rails Rollers and rails, and related component life can be increased by the following preventative maintenance steps: 1. Make daily visual inspections of your equipment. Check for loose bolts, leaking seals and abnormal wear. 2. Check track tension regularly and perform a regular inspection of the rollers. 3. Consider a program of switching rollers to equalize wear. It takes time, but the dollars saved in equalizing wear usually justifies the effort. The front and rear rollers take approximately 80% of the wear on track machines. The wear drops off to a minimum on center rollers. We suggest a good regular inspection of the rollers. 4.5 Air Conditioning Unit The air conditioning unit in your Madill equipment must be cycled on a bi-weekly basis to ensure that the compressor seals remain lubricated. Refrigerant may leak from the compressor if the unit is not run regularly, particularly over the fall and winter months. The air conditioner warranty does not cover claims for refrigerant loss that are compressor seal related if the unit has not been run on a regular basis. 4.6 Inspection A proper pre-start visual inspection each day of operation will help spot problems or potential problems in their early stages and save on expensive repairs and down time. This daily inspection should be done in conjunction with any and all necessary daily lubrication requirements. All lubrication procedures along with their locations are explained in the lubrication section of this manual. Open the doors of the machine and look over the wiring, hoses, clamps and piping. Check the fluid levels of the engine and radiator. Check the oil level in the hydraulic oil reservoir. Inspect the side frames for oil on the rollers and the drive gear boxes. The regular inspection of this machine is the first step in a good maintenance program. Following our recommended procedures will assure you efficient and profitable operation.
124 Operator's Manual 097214A Page 13 of 74 4.7 Yarder Dimensions
124 Operator's Manual 097214A Page 14 of 74 5 Joystick Control Functions
5.1 Left Hand Joystick
124 Operator's Manual 097214A Page 15 of 74 5.2 Right Hand Yarding Control With Equal Drum Reverse
WINCH CAPACITIES: MAIN & SLACKPULLER EACH 2550 FT. OF 7/8”ø WIRE ROPE HAULBACK: 4660 FT. OF 7/8”ø WIRE ROPE STRAWLINE: 5440 FT OF 3/8”ø WIRE ROPE
NOTE: The yarding control and three button handle have an inline 2.5A fuse located in the right hand seat pod. Failure of this fuse will make the yarding control inoperable. The fuse should never be replaced with a fuse rated for more than 2.5A, if the fuse blows repeatedly this is an indication of a problem elsewhere in the circuit.
124 Operator's Manual 097214A Page 16 of 74 6 Control Panel Switches
6.1 Mode Selector Rocker switch: • Depress UP to switch to “TRAVEL” mode. • Depress DOWN to switch to “YARD” mode, no pilot pressure to travel pedals. 6.2 Trans Panel Dimmer Rocker switch: • Depress UP for daytime operation. • Depress DOWN to dim the keypad display when operating in low light conditions. This also turn on the gauge backlighting 6.3 Swing Brake Rocker switch: • Depress UP to apply swing brake (brake on). • Depress DOWN to release swing brake (brake off). The swing brake is hydraulically released. The engine must be running to release the swing brake. Always have swing brake switch “on” before starting engine. The swing brake can also be applied momentarily by holding down the left joystick mounted swing brake button. NOTE: The swing brake is not intended to be used during Inhaul. 6.4 Travel Mode Rocker switch: • Depress DOWN to lock in low speed travel. • Depress UP to allow automatic shifting between high and low. Track drive motors have two speeds. Low speed provides high drive torque. High speed provides low drive torque. Lock in low speed when descending grades or loading/unloading machine onto a trailer. To improve control while operating in rough terrain low speed should be engaged. 6.5 House Open / Close Rocker switch: • Depress UP and hold to open house. • Depress DOWN and hold to close house.
124 Operator's Manual 097214A Page 17 of 74 DANGER: Ensure that the engine house area is clear and it is safe to tilt the house, refer to house tilting instructions before operating. 6.6 Buzzer Override Momentary rocker switch: • Depress down to silence warning buzzer. • Buzzer will come on again only if a second warning signal is received. 6.7 Throttle Preset Rocker switch: • Depress UP for high idle • Center for medium idle • Depress DOWN for low idle 6.8 Throttle Mode Rocker switch: • Depress UP for “HAND” mode, throttle is controlled by left hand joystick • Depress DOWN for “PANEL” mode, throttle is controlled by Throttle Preset Switch NOTE: When spooling guylines with the engine at idle, the throttle mode should be set to “PANEL”. 6.9 Engine Diagnostic / Shutdown Override Rocker switch: • Press and hold to activate diagnostic flash codes or override automatic engine shutdown. 6.10 Spare A spare rocker switch opening may be present in instrument panel, depending on original equipment and options. This opening may be hidden by the control panel decal. 6.11 Ignition 3 position key switch: • OFF - Shuts off all electrical power via relay operated battery switch • ON - Switches on electrical power
124 Operator's Manual 097214A Page 18 of 74 • START - Energizes engine starter solenoid (when the pilot control isolator wand (see section8.3) is in the up position), warning light bulb test circuit and warning buzzer. 6.12 Heater - A/C • Turn AC knob to switch the AC System ON or OFF. • Turn the temperature knob to adjust temperature. • Turn fan knob to desired location to control fan speed. 6.13 Wiper Rotary switch: 2 speed • Separate switches control upper & lower wipers 6.14 Diagnostic Plug • A plug is provided for connection of engine diagnostic equipment • It is located at the back of the control panel. 6.15 Circuit Breakers • Circuit breakers provide individual protection to electric circuits. Overloading will cause circuit breaker to trip and the button to pop out. • To reset, push button in. 6.16 Dome Lights • Aircraft style dome light is controlled by a switch incorporated into the light. 6.17 Defroster Fan • Swiveling fan controlled by switch on fan. 6.18 12V Posts • Binding posts for connection of 12V accessories. The converter is mounted inside the control panel and has an internal 15 amp fuse.
124 Operator's Manual 097214A Page 19 of 74 7 Control Panel Indicators
7.1 Clutch Water Temperature Light • Illuminates when water temperature reaches 190°F (88°C), sustained operation above this temperature may result in slip-clutch seal damage. 7.2 Clutch Water Pressure Light • Indicates low water pressure in the slip-clutch (regen) cooling water circuit. At or near idle this light may illuminate, depending on the pressure setting. Check the system in the light fails to go out once throttle is applied. 7.3 Transmission Temperature Light • Indicates that the Allison Electronic Control Module has detected an over- temperature condition in the transmission sump, and transmission function may be affected. Refer to the Allison Operators manual for further information. 7.4 Transmission “Do Not Shift” Light • Indicates a transmission malfunction, the transmission may refuse to shift and the keypad may display a “cat’s eye” symbol instead of the normal number or letter. See the Allison manual for code checking procedure and additional instructions. 7.5 Check Engine Light (Yellow) • Indicates an engine problem that will not cause immediate catastrophic failure, but that must be diagnosed and attended to at the earliest opportunity. 7.6 Stop Engine Light (Red) • Indicates an engine problem that may cause failure. Stop the engine and diagnose immediately. See the Detroit Diesel “Engine Operators Guide” for more detail. 7.7 Low Hydraulic Oil Level Light • Indicates that the oil level in the tank is below the level of the sight glass, top up the tank. Refer to section 15.1 for oil specifications. 7.8 Hydraulic Oil Temperature Light • Indicates that the hydraulic tank temperature is high, continued operation at high temperatures may result in component damage and loss of steering control.
124 Operator's Manual 097214A Page 20 of 74 7.9 Low Fuel Light • Indicates low fuel level in the tank, refuel immediately to prevent fuel pump starvation and loss of prime. 7.10 Air Pressure Gauge • Displays the air pressure in the system reservoir, Do not operate the yarder controls until the gauge shows 120 psi. 7.11 Hourmeter • Displays accumulated machine hours, record and use for maintenance. 7.12 Water Temperature • Engine water temperature reading, DDEC system. 7.13 Engine Oil Pressure • Engine oil pressure reading, DDEC system. 7.14 Voltmeter • Shows charging voltage produced by the alternator, normally 27.5v although a range of 24-30v is acceptable. 7.15 Warning System
SIGNAL LIGHT BUZZER Check Engine YES NO
Stop Engine YES NO
Low Fuel YES NO
Low Clutch YES NO Water Pressure Low Hydraulic YES YES Oil High Clutch Water YES YES Temperature High Hydraulic YES YES Oil Temperature
124 Operator's Manual 097214A Page 21 of 74 8 Additional Cab Controls
8.1 Travel-Left & Right Pedals To maximize undercarriage component life keep the drive sprockets to the rear of the machine. This orientation is assumed for travel direction descriptions. • FORWARD Depress front of both pedals • REVERSE Depress rear for both pedals • STEER LEFT Depress front of right pedal and rear of left pedal to steer left • STEER RIGHT Depress front of left pedal and rear of right pedal to steer right 8.2 Haulback Main and Slackpuller Band Brake Valves These valves are used to supply regulated air pressure to the band brake air pots allowing modulation of the braking torque. NOTE: These brakes are only intended to be used for short-term slipping; they are not designed to be slipped during the entire in/outhaul cycle. The haulback band brake control is located to the left of the travel pedals and the main is located to the right. The slackpuller is located furthest right next to the main band brake. 8.3 Swing Control Machine swing is controlled by side to side motion of the left joystick. The hydraulic circuit utilizes a two stage pressure relief for smooth operation. Note: The 124 has dual powerful swing drives that can stall the engine if too much swing power is demanded while the engine is at low revs, some feathering of the throttle may be required. 8.4 Pilot Control Isolator - Lever On Right Arm Rest The pilot control circuit must be isolated when entering cab to prevent accidental control actuation. An electric switch located in the right pod of the operator’s seat activates a solenoid valve to isolate the pilot control circuit and disable the yarding control handle. Lift the wand to isolate the pilot control circuit and gain access to operator’s seat. Once seated, lower the wand to activate pilot control circuit. 8.5 Horn (Whistle) Button The horn button is located in the left seat control pod, with the guyline controls. There is also a horn button on the left hand joystick trigger, either will sound the horn. Refer to section 16 for inspection and adjustment details.
124 Operator's Manual 097214A Page 22 of 74 8.6 Guyline and Boom Hoist Winch Motor Controls Four dual position toggle switches are located in the left side seat control pod. To use the guyline and boom hoist winch drums the dogs must be released using the toggle valves in the control stand (section 9.3). Operate one drum at a time, checking that line is correctly spooled, correct mis-spooled line immediately. CAUTION: Check that area under boom is clear before lowering; do not allow the boom to free-fall. Check that the boom hoist brake is operating correctly prior to raising or lowering the boom. NOTE: When spooling guylines with the engine at idle, the throttle mode should be set to “PANEL”. 8.7 Strawline Brake Valve The graduated strawline brake valve is located in the left right hand side seat pod. Apply this brake and release the strawline maxi (located in the control stand) then adjust tension as required to hold the strawline tight as it is being pulled out. 8.8 Seat Controls - Air Suspension 1. All adjustment knobs/levers are designated with light gray coloring. 2. Seat height/weight individual adjustment, 3” total movement. Lever is located below seat fore and aft control bar. 3. Fore and aft seat adjustment only. Control handle situated on right hand side front of seat. 4. Fore and aft seat and controls adjustment. Control bar runs across under front of seat. 5. Seat pan angle adjustment from 3 - 11 degrees. Control lever situated at front left center of seat. 6. Seat pan length adjustment between 16.5” and 18.5”. Control lever situated at front right center of seat. 7. Backrest angle adjustment of 80 degrees. Seat back can also be folded forward right onto seat cushion. Control handle situated on left hand side of seat rest. 8. Lumbar support adjustment. Operated by rotating knob on lower left of backrest in either direction. 9. Integrated seat heater. Switch located on upper left edge of back rest. 8.9 Satellite Am/Fm Radio/CD Player • Located below the control panel. • Refer to Instruction Manual for detailed operation.
124 Operator's Manual 097214A Page 23 of 74 9 Control Stand
9.1 Regen Pressure Gauge • Displays the regen or interlock air pressure to the haulback slip clutch (inhaul) or main and slackpuller slip clutches (outhaul). NOTE: The main and slackpuller are biased, one slightly higher pressure than the other, selected via the “grapple/carriage” mode valve under the cab. 9.2 Transmission Selector Keypad • Used to select transmission gear for yarding, and for transmission diagnostics. The display shows the gear selected, and the gear attained. In normal operation, drive will start in 2nd gear Automatic or can be manually shifted from 1 st through 5th using the up/down shift buttons on the left hand joystick. (refer to Figure5.1) 9.3 Toggle Valves • The toggle valves are used for the boom hoist and guyline dogs as well as the strawline clutch and brake and the slackpuller main and haulback maxi brakes. NOTE: Always visually check the guyline and boom hoist winch to confirm that the dogs are properly seated before beginning the yarding operation.
124 Operator's Manual 097214A Page 24 of 74 10 Emergency Escape
The Madill 124 is equipped with an emergency escape option to evacuate the cab in the event of an accident. To ensure the proper operation of this escape, should it be needed, regular inspection and proper maintenance is essential. The latch and knobs should be checked for proper operation regularly and lubricated as required. This escape should be tested/opened monthly to prevent seals from drying out and seizing. WARNING: The Emergency Escape Window MUST NOT be locked while the machine is in operation. 10.1 Emergency Escape Operation The right rear window functions as the emergency escape. Note that there is a stop which prevents this window from accidentally sliding off its hinges under normal operation. The window must be swung out beyond the normal range of motion of the latch to clear the stop before it can be removed (approximately 25°).
124 Operator's Manual 097214A Page 25 of 74
Inside Release: 1. Rotate inside release handle. 2. Swing the window outward. Outside Release: 1. Rotate the outside release handle. 2. Swing the window out clear of the stop. 3. Slide the window toward the back of the machine and off its hinges.
124 Operator's Manual 097214A Page 26 of 74 11 Self-Propelled Travelling
1. Walk around the machine to check for proper track tension. Look for, and remove, obstructions in the tracks and around the crawler. Observe the orientation of the drive sprockets relative to the intended direction. 2. Check that the transmission is in neutral. 3. Check that the swing brake (spring applied) is engaged by means of the swing brake rocker switch in the overhead panel. 4. Set the throttle mode selector to “Panel Mode”. 5. Use the three position throttle preset switch to raise or lower the engine speed. 6. Set the mode selector switch to “Travel” 7. The track motors will automatically switch from “High Speed Travel” to “Low Speed Travel” as the grade increases and more torque is required to keep the machine moving. For safety on grades and low speed inching the track motors can be held in “Low Speed Travel” using the Travel High/Low switch mounted in the control panel.
CAUTION: Ensure that the travel control valves are in the neutral position before leaving the cab; this allows the crawler brakes to automatically engage. If the machine is to be parked switch into “Yarding” mode.
11.1 General Travel Recommendations • Travel with the boom up close to the stops, except in situations such as steep hills or severe cross-road slopes, stability may be improved by traveling in “LOW” with the boom down. • For steep downhill travel, reverse down the hill with the boom lowered and pointing uphill. ( A spotter is recommended for this type of move) • For extended moves, tie the grapple back to the machine rather than have it hanging from the fairleads; especially when traveling in the forward direction downhill. • Start off slowly and work up speed, checking the temperature of the leading track rollers frequently. On long moves stop periodically and spin the crawler to travel in reverse, this will equalize the track roller loading. • For best system performance, the engine speed should be set to max and the steering control should be achieved by adjusting the travel pedals rather than the engine speed. CAUTION: Be alert for overhead hazards such as tree limbs, rock bluffs and, especially power lines.
124 Operator's Manual 097214A Page 27 of 74 12 Transport and Servicing
12.1 Cab and House Tilt The cab tilt switch is located on the house guard wall above the chaincase, immediately behind the haulback slip clutch. The operator’s cab tilt function is activated by a 3-position key switch. The engine house is operated from the operators cab, with a switch located in the control panel. The switches power a hydraulic power-pack run directly off the batteries. The engine does not have to be running to tilt the cab or house. The power pack is mounted in the lower guard frame area on the right (cab) side of the machine. Fluid level should be checked before attempting to lower the cab or house. The reservoir should be full when the cab and house are up. Cab Tilt Before tilting the cab the boom mounted cab guard must either be rotated out of the way or the boom lowered. The cab guard can be rotated by unpinning at the bottom and rotating the guard away front the cab. Secure or remove all loose items in the cab, close the window, shut the engine off and close the door. Remove the hold-down bolts in the riser, at the lower back outside corner and at the upper end of the support post at the inside back corner. Inspect the cab-tilt cylinder and the safety cable under the cab to see that they are in good condition with anchor pins secure, and that they are free to move as the cab comes over. Make sure that the crew is in the clear, and activate the switch to lower the cab. Observe the lowering process carefully from a safe position, to see that the cylinder and safety cable move freely, and to see that there are no obstructions, or pinch-point or falling-object hazards. The cab should be so the weight is carried by the safety cable, not the cylinder. NOTE: If the cylinder bottoms out before the cable is tight, the cable must be replaced with one of the correct length (see the Parts Book). The procedure for raising the cab is essentially the reverse of the lowering procedure, using the opposite position of the activation switch. Make sure that the cab is not tied down or otherwise obstructed, or encumbered with extra weight. Watch (from a safe distance) to see that there are no hoses, wires or cables being pinched as the cab comes up. When the cab is in the upright position, install and tighten the hold-down bolts. WARNING: Do not stand on, under or near the cab or house during the raising and lowering operations. House Tilt The house tilt function operates in a similar manner to the cab tilt, the switch is located inside the cab on the control panel Clear the top deck of loose objects and make sure the handrails are secure. Any other heavy attachments inside or outside the house (engine canopy) should be removed. Raise the house until the cylinders
124 Operator's Manual 097214A Page 28 of 74 are fully extended; lower the house until the guide pins seat in the holes in the guard frame. 12.2 Boom and Gantry Installation and Lift 1. Drive the machine up to the gantry so that the lugs can be lined up. This is best done on level ground, with adequate room for the tracks to drive straight ahead to the gantry. Check the height of the gantry on the trailer, jack it up as necessary. Check the bushings in the gantry lug where it will pin to the yarder. They should be flush with the sides of the lug. Inch the machine forward so the gantry lugs line up with the frame lugs, coat the pins with lubricant and push them into the holes until the retainer bolt holes line up. Install the retainer bolts. CAUTION: Never put hands or fingers into any of the pin holes to check for lug alignment. Sudden movement of the machine or gantry may cause serious, permanently-disabling injury. 2. The cab guard must be positioned either in its working position or released from any boom attachment, so that the guard can pivot to a hanging position while the boom is being raised. 3. Reeve the haulback line through the lifting sheaves as shown in the diagram. The eye in the haulback line is anchored by the bolt between the ears either side of the lifting sheave fixed to the fuel tank. (Note: If the haulback eye has a thimble, the lifting sheaves will likely have to be disassembled to reeve the line because of limited clearance.) 4. Install the jumper hoses supplied with the yarder kit. These are about 22 feet long; 2 medium pressure hydraulic hoses for the boom hoist motor, 1 low pressure hydraulic hose for the hydraulic manifold drain on the gantry, and 1 low pressure air hose for the boom hoist pawl. Connect these to the matching quick disconnects at the rear gantry lugs on the deck. 5. Inspect the reeving and condition of the boom hoist line. The line must be firmly attached at the anchor, and seated properly in the sheaves. Grease the sheaves and other grease points on the boom and gantry as shown in the lubrication instructions. Check the guyline reeving through the fairlead, and make sure that the free ends of the guylines are hooked or tied to the gantry during the raising operation. (Note: During the setup operation, the engine should be run only when necessary, to avoid accidental drive engagement that might create a safety hazard.) 6. Notify the crew, then start the lift by shifting the transmission into 1st gear, releasing the haulback maxi and engaging the haulback pull clutch by pushing the yarding control lever forward 15°. Release the boom hoist pawl (dog), and activate the boom hoist winch switch to pay out the boom hoist line. The gantry legs will spread first, when the stiffleg rollers are against the stops in the rear leg, the whole assembly will lift. Watch the lines and hoses to make sure that no fouling occurs. As the gantry comes up to the yarding position, it may be necessary to hold it against falling into position by controlling the boom hoist line payout. At all positions during the lift, the gantry will be held by either the
124 Operator's Manual 097214A Page 29 of 74 haulback or the boom hoist line, and at some point a crossover will occur, so do not allow excess slack to accumulate in either line. 7. The lower lugs of the rear gantry should self-guide into alignment with the lugs on the deck, but it may be necessary to push the gantry sideways manually to begin the engagement, and to pull the gantry down with the haulback. Do not over-tension the haulback at this point, damage to the gantry or stiffleg may result. Install the pins and retainers. Check that the boom stops have flipped into the yarding position. Remove the jumper hoses and connect all the guyline and boom hoist hoses at the manifold and pawl cylinders. Thread the working lines through the fairleads, then raise the boom. (Make sure that the cab guard is correctly pinned.) NOTE: As the gantry lifts, the boom (where it rests on the supports) will slide toward the yarder by approximately 2 feet. Make provision for this. 12.3 Boom and Gantry Lowering Note: Raise and lower the boom on level ground. The boom is raised and lowered by releasing the boom hoist winch pawl (dog) by means of the toggle valve in the control stand below the left window, and operating the boom hoist control switch (on the left side of the seat) to actuate the directional valve that controls the hydraulic winch motor. Always test the boom hoist brake and counterbalance valve function, immediately after releasing the pawl, by running the boom hoist winch a small amount in or out to see that the boom will hold position when the control switch is released. If the boom does not hold, engage the pawl and correct the problem before proceeding with the raising or lowering operation. Always reset the pawl, and visually inspect it for proper engagement, after operating the boom hoist winch. 1. Determine whether the cab guard has to be rotated out of the way (i.e., if the machine is to be transported in “one piece” with the boom and gantry lowered, the guard must be rotated to allow the cab to tilt). If so, remove the cab guard base pin and pull the guard around as the boom is lowered, rotating the guard until it goes past the boom. This will require external power (loader, truck-mount crane, come-along, etc), and can be done in stages as the boom is lowered. Secure the guard to the boom with a transport chain. 2. Power the guylines in so the free ends can be hooked on the rear gantry leg. 3. If the gantry is to be lowered, check the haulback brake. Prior to lowering the boom and gantry, when pulling the lines in, run the haulback against the brake to warm and clean the brake. This is especially important for gantry-lowering when there is a lot of line on the drum. 4. Disconnect the hydraulic and air connectors for the guyline winches. Install the 22 foot “jumper” hoses for the boom hoist winch motor (2), motor drain (1), and boom hoist pawl (1). 5. Reeve the haulback line through the lifting sheaves as shown in the diagram, with the anchor bolt and spacer through the haulback eye.
124 Operator's Manual 097214A Page 30 of 74 6. Lower the boom, as described above, onto the transport trailer or other support, with the weight taken at the slackpuller fairlead mount . Note: As the gantry is lowered, the boom tip will slide ahead approximately 2 feet, so make provision for this. 7. Tighten the boom hoist line to lift the gantry, and remove the rear gantry leg pins at the fuel tank. 8. Continue to tighten the boom hoist line, to pull the gantry ahead past the balance point, holding back with the haulback brake (release the “maxi” and operate the foot pedal). As the gantry assembly is lowered onto the boom by applying the haulback brake, continue to pick up slack in the boom hoist line. Flip the boom stops up so they allow the gantry to come to rest on the boom at the stubs near the guyline fairlead. 9. When the front gantry leg is resting on the boom, it may be necessary (with the haulback slightly slack) to pull on the stiffleg, or lift the rear leg, to get the rollers moving in the tracks and allow the stiffleg and rear gantry leg to fold down. Use caution when working around the gantry, in case the stiffleg starts to move suddenly, or the guyline fairlead flops over sideways under its own weight. Slack the haulback. If the boom and gantry are to be unpinned, provide blocking under the lower end of the boom, and jacks to take the weight off the pins. Remove the jumper hoses and disconnect the haulback. 10. ALTERNATE LOWERING METHOD USING TRANSMISSION REVERSE: With the transmission in Reverse, pushing the Yarding Control handle forward 15° will cause the haulback line to spool off the drum, but at a rate (at engine idle) which will allow controlled lowering of the gantry against the torque converter. 11. Use caution during the lowering procedure. Keep the engine speed low. Be ready to apply foot brakes and shift the Yarding Control lever to neutral. Ensure that the crew is clear of the moving boom and gantry and away from all pinch points. DO NOT LET THE BOOM OR GANTRY FREE FALL . See also “Boom Hoist Reeving” instructions. WARNING: Do not swing the upper over the side of the crawler with the boom and gantry lowered. Do not travel the machine with the boom and gantry lowered.
124 Operator's Manual 097214A Page 31 of 74 12.4 Haulback Line Reeving For Gantry Raise and Lower
CAUTION: Do not over tighten the haulback. If this occurs when the gantry is in the position shown, permanent damage to the stiff leg can occur. Ensure that the anchor bolt nut is fully threaded on.
124 Operator's Manual 097214A Page 32 of 74 12.5 Boom Hoist Reeving Diagram
NOTE: Refer to the maintenance section for instructions and intervals for inspecting and replacing the boom hoist line.
After installing a new boom hoist line, check the motor and brake function of the boom hoist winch as follows. 1. Raise the boom slightly from the lowered position and check that it can be held with the disk brake and counterbalance valve. 2. Inspect the boom hoist line where it passes over the sheaves, to ensure that the wire rope is seated properly in the sheave grooves while the slack is taken up. Make sure the line is not fouling on other lines or on parts of the structure. 3. Continue the boom raising process checking the brake every two feet, until the boom is 1-2” from contacting the cushion tipped boom stops that hinge off the front gantry. 4. Set the boom hoist topping pawl or dog and visually inspect to make sure that it is seated in the ratchet.
124 Operator's Manual 097214A Page 33 of 74 5. Never allow the crew to work under, or in front of the boom during the raising or lowering operation. Or while the boom hoist dog is released, never leave the machine unattended with the pawl released.
124 Operator's Manual 097214A Page 34 of 74 13 Winch Operation
The yarding operation is controlled by 6 clutches. Each drum shaft has a pulling clutch on one side and a slipping clutch on the opposite side. Having a pulling clutch engaged will pull the line in, having a slipping clutch engaged will always feed out the line. Slipping clutch air pressure should be adjusted to the lowest possible level for maximum line speed. This pressure is normally around 40 PSI - 60 PSI and is controlled by the Yarding Control lever. When pulling in the rigging, the main and slackpuller pulling clutch (P3, P5) and the haulback slipping clutch (S4) are engaged. When pulling the rigging out, the haulback pulling clutch (P1) and the main and slackpuller slipping clutch (S2, S6) are engaged. When the slipping clutch is engaged on a shaft, feeding out line at a slower rate than a shaft that has the pulling clutch engaged, is pulling the line in, tension will build up in the rigging. This tension is controlled by the air pressure in the slipping clutches.
124 Operator's Manual 097214A Page 35 of 74 To obtain the initial tension one of the following methods can be applied: 1. Engage the main and slackpuller band brakes (B8, B9) engage the haulback pulling clutch (P1). Increase the throttle till proper tension is obtained, then engage the main and slackpuller slipping clutch (S2, S6) and disengage the main and slackpuller band brake (B8, B9). You are now in interlock mode pulling out the rigging. This operation is accomplished by pushing the yarder control lever forward while applying throttle. As the lever activates the slip clutches, the brakes are released by easing off the pedals. 2. Engage the haulback band brake (B7) Engage the main and slackpuller pulling clutch (P3, P5) increase the throttle till proper tension is obtained, then engage the haulback slipping clutch (S4) and disengage the haulback band brake (B7). You are now in interlock mode pulling the rigging in. This operation is accomplished by pulling the yarder control lever back from neutral position while applying throttle. As the haulback slip clutch comes on, the brake pedal is released. 3. Engage all your pulling clutches (P1, P3, P5) increase your throttle slowly until required tension is obtained, hold with the brakes (B7, B8, B9), then engage the desired pulling clutch for “inhaul” or “outhaul”. This operation is accomplished by pushing the “All Pull” button on the yarder control lever handle to lift the rigging, then shifting to “outhaul” as shown in step 1, or “inhaul” as shown in step 2.
To open the grapple or pull out slack on a carriage, the slackpuller pulling clutch (P3), the main slipping clutch (S2) and the haulback band brake (B7) must be applied, With drum reverse, the slackpuller pull clutch, reverser clutch and haulback band brake are applied. To close the grapple or pull in slack on a carriage, the main pulling clutch (P5), the slackpuller slipping clutch (S6) and haulback band brake (B7) must be applied. (With drum reverse. the main pull clutch, reverser clutch and haulback band brake are applied.) To open the grapple while the rigging is going out, the main slipping clutch (S2) is momentarily released to tighten the slackpuller line. To close the grapple while the rigging is going out the slackpuller slipping clutch (S6) is momentarily released to tighten the main line. “Opening” and “closing” are controlled by buttons on the yarder control lever handle. The “open” and “close” functions will work in all lever positions but the buttons should be released whenever the lever position is changed, from one mode (inhaul, neutral, outhaul) to another. To open the grapple while the rigging is coming in the main pulling clutch (P5) is momentarily released to tighten the slackpuller line. To close the grapple while the rigging is coming in the slackpuller pulling clutch (P3) is momentarily released to tighten the main line.
124 Operator's Manual 097214A Page 36 of 74 The clutches are activated automatically with the yarding control lever as follows:
Yarding Control Clutch Activation
Engage Haulback Pulling Push Forward 15 DEG Clutch
Engage Haulback Pulling Push Past 15 DEG Clutch, Main and Slackpuller Slipping Clutch
Engage Main and Slackpuller Pull Back 15 DEG Pulling Clutch
Engage Main and Slackpuller Pull Past 15 DEG Pulling Clutch and haulback Slipping Clutch
To lift the grapple straight up from the ground all pulling clutches cab be engaged together with the bottom button of the yarding control handle. The yarding control must be in the neutral or center position. 13.1 Transmission Shifting
The transmission is operated by an electric keypad in the top of the left control panel. This is directly coupled to the transmission electronic control unit (TCM). The shift UP/DOWN buttons are located in the left joystick handle. To operate the winch shift into drive “D”, this will select 2nd gear to start, the TCM will then automatically shift the transmission to the optimal range between 2 nd and 5 th . The operator can override the automatic gear range using the joystick mounted buttons. For example if when pulling in a turn you would like to slow the rigging or expect a high load and the transmission was in 4 th gear, pressing the downshift button would select 3rd gear and set the new automatic range to 2-3. To go back to the full shift range push the upshift button until the select readout is at 5 th .
124 Operator's Manual 097214A Page 37 of 74 First gear should only be selected when required by high loads or the need to keep the line speed low (such as spooling line). First gear can be attained by selecting drive and pressing the downshift button. The shift selector display will show the requested (Select) and attained gear (Monitor), as well as any error codes. Refer to the transmission manual or section 20 for more information. The engine will only start in neutral “N”, which is the normal “power-up” mode of the transmission electronic control unit(ECU). It is recommended that neutral be selected whenever the rigging is stopped. Disengaging the safety lockout switch will put the transmission into neutral, care should be taken to ensure that neutral is not inadvertently selected.
14 Guylines
14.1 Guyline Spooling Before yarding begins, guylines must be anchored and tightened. To pull the guylines out, rotate the guyline drum slightly, using the in/out selector switch, to unseat the drum pawl. Release the pawl using the toggle valve control in the left panel. Flip the toggle in to release the pawl. A counterbalance valve in the hydraulic line prevents the guyline from unspooling and is set to hold up the weight of an extended guyline. To pay out the line, move the selector toggle switch to the “Out” position and control the speed using the throttle. Make sure the line is being pulled up through the fairlead as it unspools. When the guyline is anchored, pull in the slack by moving the selector switch to the “In” position. When the guyline is tight, flip the guyline pawl toggle. With the switch in the “In” position, rev the engine to increase pressure and rotate the drum enough to seat the pawl firmly in the ratchet. Do not begin yarding before checking that all guyline pawls are seated in the ratchets. Control switches are located in the cab on the left side of the seat. NOTE: When spooling guylines with the engine at idle, the throttle mode should be set to “PANEL”. 14.2 Recommended Positioning of Guylines • Guylines shall always be equal to or greater in size and breaking strength than the main or skyline, as per the line specification plate (located on outside of cab riser). • No attachments or auxiliary equipment should be affixed to any guyline or the machine. • Ratchets on guylines must be firmly set, reverse drum to engage pawl before starting to yard in logs.
124 Operator's Manual 097214A Page 38 of 74 • Inspect guylines closely before yarding, damaged lines must be replaced before yarding commences. • Guylines must be made of plow steel or better material • Splicing of guylines is not recommended. • Extensions and connections must be of equal or greater breaking strength than the guyline. • Always rig guylines as shown, keep lines inside the shaded areas. • The load must always be shared equally by two guylines. • Tighten or loosen guylines only with guyline winch motor. Do not tighten lines by walking machine away from stumps. Also do not pull lines off drum by walking the machine, as guyline winch motor damage may result. • Guylines must be positioned at an angle less than 45 degrees below the horizontal. Guyline and gantry loads can be reduced significantly by selecting anchors that result in a shallow (near horizontal) guyline angle. • Guylines may use quick nubbins at the drum end only; the brush end must be poured. • The guyline winch drums must have a minimum of five (5) wraps per drum at all times. • Check local regulations before commencement of yarding.
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124 Operator's Manual 097214- Page 41 of 74
15 Lubrication and Maintenance
In order to properly protect your machine and get the best performance and longest life out of it, schedules of preventive maintenance and lubrication must be adhered to. All maintenance and lubrication schedules are guidelines based upon normal cycles under average working conditions. When unusually severe working conditions or operations are encountered, maintenance and lubrication frequencies must be increased. Operating in extreme temperatures (hot or cold), under constant heavy load, operating intermittently, or operating in very dusty conditions constitute severe conditions and operation. 15.1 Lubrication Keeping your machine properly lubricated is the most effective way to prevent failures and consequent costly repairs. The lubrication chart provides reference to all points requiring lubrication, and to the recommended frequency of lubrication. A. Keep all lubricants and lubricating equipment clean and free of contamination both while in storage and while in use. B. Clean all grease fittings and surfaces before applying a grease gun. Dirt on fittings will be forced through along with the clean grease, and will cause accelerated wear and premature bearing failure. C. Wipe off excess grease and other lubricants. Oily and greasy surfaces collect dirt which may work its way into moving parts and cause wear and failures. D. When greasing fittings under normal working conditions, apply grease until it appears. Under extremely dirty or dusty conditions, apply grease to fittings until old grease has been flushed. Under no circumstances may the recommended lubrication intervals be exceeded. Avoiding service intervals will be constituted as negligence and will void the warranty on the machine.
RECOMMENDED LUBRICANTS LOCATION RECOMMENDED LUBRICANT
WINCH WINCH GEARS WHITMORE'S SURETAC 2000 XD WINCH BEARINGS NLGI EP2 REVERSER GEAR & CLUTCH DRUM BEARING (SLACKPULLER MOBILITH SHC 220 SHAFT) CHAIN CASE 10W MOTOR OIL BOOM & GANTRY FAIRLEAD CASINGS MOBILGREASE XHP 462 MOLY FAIRLEAD SHEAVES & BUSINGS MOBILGREASE XHP 462 MOLY GUYLINE BLOCKS, WINCH DRUM, MOBILGREASE XHP 462 MOLY PAWL & BEARINGS ALL OTHER GREASE POINTS MOBILGREASE XHP 462 MOLY POWER UNIT MOBIL DELVAC 1300 SUPER 15W-40, REFER TO DETROIT ENGINE OIL MANUAL FOR ALTERNATIVES TRANSMISSION OIL REFER TO ALLSON TES 295 OR TES 389 ENGINE COOLANT MOBIL DELVAC EXTENDED LIFE ANTIFREEZE BRAKE & CLUTCH COOLING MOBIL DELVAC EXTENDED LIFE ANTIFREEZE SYSTEM HYDRAULIC OIL MOBIL UNIVIS 46 UNDERCARRIAGE FINAL DRIVES (TRAVEL) MOBILUBE HD PLUS MG 75W SWING DRIVE MOBILUBE HD PLUS MG 75W SLEW RING GEAR WHITMORE'S SURETAC 2000 XD
PNEUMATIC SYSTEM AIR SYSTEM LUBRICATOR PETRO-CANADA; PURITY WO 15, WHITE OIL
124 Operator's Manual 097214- Page 43 of 74
GREASE LUBRICATION
LOCATION HOURS QUANTITY OF LUBRICATION
L.H. HAULBACK SHAFT BRG. HOUSING 40 5 PUMPS WITH GREASE GUN
R.H. HAULBACK SHAFT BRG. HOUSING 40 5 PUMPS WITH GREASE GUN
L.H. MAIN SHAFT BRG. HOUSING 40 5 PUMPS WITH GREASE GUN
R.H. MAIN SHAFT BRG. HOUSING 40 5 PUMPS WITH GREASE GUN
L.H. SLACKPULLER SHAFT BRG. HOUSING 40 5 PUMPS WITH GREASE GUN
R.H. SLACKPULLER SHAFT BRG. HOUSING 40 5 PUMPS WITH GREASE GUN
L.H. POWER INPUT SHAFT BRG. HOUSING 40 5 PUMPS WITH GREASE GUN
R.H. POWER INPUT SHAFT BRG. HOUSING 40 5 PUMPS WITH GREASE GUN
SLEWING RING BEARING 40 SEE SPECIAL INSTRUCTIONS
STRAW DRUM BEARING 500 5 PUMPS WITH GREASE GUN
MAIN 80T GEAR BEARING 40 5 PUMPS WITH GREASE GUN
HAULBACK 80T GEAR BEARING 40 5 PUMPS WITH GREASE GUN 5 PUMPS WITH SYNTHETIC SLACKPULLER 80T GEAR BEARING 40 GREASE GUN MAIN 128T GEAR BEARING 40 5 PUMPS WITH GREASE GUN
HAULBACK 128T GEAR BEARING 40 5 PUMPS WITH GREASE GUN
SLACKPULLER 128T GEAR BEARING 40 5 PUMPS WITH GREASE GUN UNTIL GREASE COMES OUT P.I.P. SHAFT COUPLING 40 OPPOSING LUBE HOLE. (REMOVE PLUG TO CHECK) HAULBACK BAND BRAKE 160 1 or 2 PUMPS AS REQUIRED
MAIN BAND BRAKE 40 1 or 2 PUMPS AS REQUIRED
SLACKPULLER BAND BRAKE 40 1 or 2 PUMPS AS REQUIRED
GUYLINE FLD. SHEAVES, DEFLECTOR SHEAVES 40 2 - 5 PUMPS
BOOM HOIST SHEAVES, PINS 500 2 - 5 PUMPS
124 Operator's Manual 097214- Page 44 of 74
GREASE LUBRICATION cont.
LOCATION HOURS QUANTITY OF LUBRICATION
SLACKPULLER SHEAVE 40 3 – 5 PUMPS
MAIN SHEAVE 40 3 – 5 PUMPS
HAULBACK SHEAVE 40 3 – 5 PUMPS UNTIL GREASE COMES OUT FAIRLEAD SWIVEL BEARINGS 500 UNDER TOP COVER PLATE STRAWLINE SHEAVE, FAIRLEAD BARREL 80 3 – 5 PUMPS AS REQ’D TO MAINTAIN GREASE BOOM PINS, GANTRY PINS 40 FILM BOOM HOIST, GUYLINE WINCH (3 PLACES EACH) 40 3 – 5 PUMPS (1 OR 2 ON DOG)
WATER ROTARY UNIONS 100 SEE SPECIAL INSTRUCTIONS
UPPER L.H. ROLLER (GUYLINE FAIRLEAD) 500 5 PUMPS WITH GREASE GUN
LOWER L.H. ROLLER (GUYLINE FAIRLEAD) 500 5 PUMPS WITH GREASE GUN
UPPER R.H. ROLLER (GUYLINE FAIRLEAD) 500 5 PUMPS WITH GREASE GUN
LOWER R.H. ROLLER (GUYLINE FAIRLEAD) 500 5 PUMPS WITH GREASE GUN 500 GUYLINE FAIRLEAD BUSHINGS 3 – 5 PUMPS MAX GANTRY BRACE ROLLERS 1000 1 – 2 PUMPS
SLEWING RING GEAR 4 OR AS REQUIRED
WINCH GEARS SEE SPECIAL INSTRUCTIONS UNTIL NEW GREASE APPEARS AT HYDRAULIC PUMP DRIVESHAFT (3 PLACES) 40 SEALS ENGINE FAN HUB BEARINGS 1000 1 or 2 PUMPS AS REQUIRED LUBRICATION OF WINCH GEAR TEETH – Button head fittings are provided at the greasing stations to connect the grease gun supplied with the yarder. The grease will drip out of the emitter nozzles onto the tips of the gear teeth and be distributed on the contact surfaces as the teeth mesh. When the grease is well distributed across the surfaces of all the gear teeth, application can be stopped. Check the surfaces of the teeth on all gears at least twice daily on start-up, after the machine has been washed down, or if grease brands are changed to establish a reliable greasing interval. This interval will vary based on machine usage, but should be once a day minimum immediately after start-up. Never let any gear tooth in the winch get to the point where a grease film cannot be detected by a touch on the contact surfaces. NEVER CHECK THE GEAR TEETH WITH THE ENGINE RUNNING.
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15.2 SLEWING RING LUBRICATION
Periodic lubrication is necessary to ensure long life and proper rotation. The slewing ring is equipped with four grease fittings.
Required frequency for lubrication varies with application and amount of usage. Typical recommendations for cranes, excavators and similar intermittently rotating equipment should be lubricated approximately every 40 operating hours. The gear and pinion teeth should be inspected twice daily and lubricated as required.
ALL EQUIPMENT SHOULD BE GREASED AT LEAST TWICE YEARLY REGARDLESS OF AMOUNT OF USAGE.
Some recommended lubricants are shown below:
Race – Lithium grease with EP additives
Gear – Asphalt free gear grease with EP & Moly Additives
It is necessary to distribute the grease around the race by injecting grease through any one fitting as the machine is rotated. Rotate at least two complete revolutions. When complete rotating is impractical, grease may be pumped into each fitting, rotating the device back and forth as far as possible as each fitting is greased.
Under extremely dusty or dirty conditions, sufficient grease should be added to flush out contaminated grease. Under less severe conditions, add grease until it appears at the seal. For general lubrication a lithium base grease with EP additives and rust inhibitors is acceptable. A #2 grade should be used at temperatures above 32 degrees F and #1 at below 32 degrees F. 15.3 WATER ROTARY UNION LUBRICATION
Water rotary unions are normally equipped with lubricated and sealed bearings. These units are equipped with plugs that have been drilled to provide drainage. NO GREASING is required on these units. On some repaired rotary unions where the seal in the bearing has failed and has been removed, a grease nipple will be installed and the following greasing procedure should be followed:
The water rotary unions should be greased with three (3) shots of grease every day per fitting. Have the engine running at sufficient speed to develop a minimum of 10 PSI brake water pressure while the rotary unions are being greased. It is best to grease while the machine is warm. Should you notice an excessive amount of grease being forced out of the union, this is a clear indication that over-greasing is occurring.
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FLUID SCHEDULE FLUID CAPACITY ADD, CHECK, CHANGE
260 IMP. GAL. Check Daily. Avoid running dry as system must be re- FUEL 313 U.S. GAL. primed. 1185 LITRES
SEE MANUFACTURERS Check at refueling. Change as per manufactures ENGINE OIL INSTRUCTIONS-PARTS instructions - see Engine Literature. BOOK Check every two weeks, change annually or as per engine 13 IMP. GAL. manufacturers instructions – see Parts Book (50-50 ENGINE COOLANT 16 U.S. GAL. water/antifreeze mix + DETROIT DIESEL approved 60 LITRES conditioner.) Change as per manufactures instructions - see Transmission Literature. Only use fluids meeting Allison TORQUE 11 IMP. GAL. Transmission specification TES 295 or TES 389 in your CONVERTER & 13.2 U.S. GAL. transmission. For a list of currently approved transmission TRANS OIL 50 LITRES fluids, go to the Allison transmission web site at: www.allisontransmission.com , select SERVICE, Fluids 18 IMP. GAL. Change after 1 month, then every 1000 hours or 6 months. CHAIN CASE OIL 22 U.S. GAL. (10WMotor Oil) – Fill to Sight Glass 82 LITRES
88 IMP. GAL. Change first time after 500 hours, then change every 2000 HYDRAULIC OIL 105 U.S. GAL. hours operation. (AW46 Hyd. Oil with AW additives – See 400 LITRES Lube Chart.)
13 IMP. GAL. CLUTCH COOLING Check level every 2 weeks. Change annually (50/50 16 U.S. GAL. WATER Water-antifreeze mix.) 60 LITRES
3 IMP. OZ. AIRLINE Inside under the stairs. Check daily & add as required. 2.9 U.S. OZ. LUBRICATOR (White Oil 5W.) 85 MILLILITER
1.21 IMP. GAL. SWING DRIVE Check level every 40 hours. Change after 1st month, then 1.45 U.S. GAL. GEARBOX every 1000 hours. (80W-90 Gear Oil) 5.5 LITRES (EACH)
1.87 IMP. GAL. TRACK DRIVE Check level every 40 hours. Change after 1st month, then 2.25 U.S. GAL. GEARBOX every 1000 hours. (80W-90 Gear Oil) 8.5 LITRES
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FILTER SCHEDULE FILTER LOCATION & TYPE CHANGE
As per engine manufacturers. ENGINE OIL Located on side of engine Instructions- see engine literature.
Located on side of engine below ENGINE FUEL air compressor Check intake pipe on clean air side with vacuum gauge (at rated RPM & full In air intake system, dry type air ENGINE AIR load for turbo engines). Change or cleaner element P/N 5813. clean element when gauge reading exceeds 20" H20.
ENGINE- OTHER
On side of engine (“Primary Check pump inlet with vacuum gauge. ENGINE - FUEL WATER Filter”) P/N 7711 (Complete Clean unit & change elements when SEPERATOR Filter) reading is 12" HG. TRANSMISSION/TORQUE Located on bottom of Recommended every 250 hours. See CONVERTER transmission oil pan transmission manufacturers literature.
AIR COMPRESSOR Supplied from engine air system. (ENGINE MOUNTED)
HYDRAULICS - MAIN Suction Line - in-tank strainer – Inspect at hydraulic oil change. PUMP P/N 4237660 Change as required.
HYDRAULICS - PILOT Suction Line-in-tank strainer P/N Inspect at hydraulic oil change. Change PUMP 7332 as required.
HYDRAULICS - PILOT On engine gear case – high Check visual indicator (with oil warm) – PUMP PRESSURE pressure element. P/N 5485 change element every 500 hours. On Hydraulic tank – return line Check visual indicator (with oil warm) – HYDRAULICS - RETURN filter element P/N 6925. (2 Change element every 500 hours. Filters) Inspect daily for operation of drain. Inside Under Stairs, next to AIR LINE Clean element as required with soap & storage tanks water or replace.
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15.4 Fuel Tank Fill the tank daily with diesel fuel. Location of the filler cap is below the rear gantry leg mount. Ensure adequate fuel level is maintained. 15.5 Hydraulic Oil Tank Check this daily for oil level. A sight glass is provided and located on the side of the hydraulic tank. Clean hydraulic oil should be added via the plug on the top of the tank beside the filter cover plate. Never overfill the system. Never run the machine with low oil, this may damage the pumps. 15.6 Engine Crankcase Check the level of the engine oil daily and add the proper oil as necessary (see the manufacturer’s recommendations). Never operate the engine with low oil. Change the oil filter at every oil change. 15.7 Radiator Check the coolant level daily. Be sure to use the appropriate coolant mixture in cold weather. Consult the engine manufacturer’s recommendations. Change the coolant and flush the system as per lubrication & maintenance chart. Keep the radiator and oil cooler fins clean so that the cooling system may operate efficiently. Refer to the engine manufacturer’s manual for specific information on engine coolant and service. 15.8 Batteries Check the water level of both batteries weekly. If it is necessary to fill the battery, use distilled water only. DO NOT USE TAP WATER as it may contain minerals which will contaminate the electrolyte. Batteries are located on the right front corner of the machinery deck, just in front of the hydraulic tank. 15.9 Engine Oil Filter The oil filter is located on the side of the engine to the front of the machine. Service the oil filter as per lubrication and maintenance chart. 15.10 Flywheel Housing The flywheel housing contains a small amount of oil to lubricate the coupling. Service as per lubrication and maintenance chart. 15.11 Primary Fuel Filter/Water Separator Drain water off daily. The filter is remote mounted on the side of the engine. Service as per lubrication and maintenance chart. 15.12 Secondary Fuel Filter The secondary fuel filter is mounted on the side of the engine to the rear of the machine. Service as per lubrication and maintenance chart.
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15.13 Engine Air Cleaner Filter Clean or replace engine air filter element as per lubrication and maintenance chart, or as required by conditions. Remove the filter element and tap against a clean surface to remove dust and particles. DO NOT blow out with compressed air. 15.14 Swing Drive Gearbox Check the level of lubricant in the swing drive gearboxes daily. The level should be checked at the level plug on the top of the gearbox. DO NOT operate the machine with improper lubricant level. Service as per lubrication and maintenance chart.
15.15 Track Drive Gearbox Check the level of the lubricant in both track drive gearboxes daily. The level should be checked at the level plug on the outside cover of the gearbox. Housing should be half filled with lubricant. Track may require rotation to put level plug in correct location as cover rotates with drive sprocket. DO NOT operate the machine with improper lubricant level. Service as per lubrication and maintenance chart.
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15.16 Winch Drive Roller Chain Inspect the drive chain every 2000hrs for wear and elongation, missing broken or cracked rollers, chain misalignment and sprocket tooth wear. If the drive becomes noisy check for missing or broken rollers or chain jumping out of mesh on the sprockets. To check chain adjustment, measure the sag as follows: 1. Push down on top strand to tighten bottom strand. 2. Measure vertical distance between a straight edge placed across the sprockets and the chain rollers at the center. 3. If the sag has become more than 4.5” the chain can be shortened by one pitch.
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15.17 Pressure Settings Hydraulic Pressure Settings
A) Standby Pressure-Pump 500 +/- 10 Psi (All Functions in Neutral) B) Hydraulic Pilot Pressure 450 +/-20 Psi C) Hydraulic Pull Clutches 650 +/-20 Psi D) Pump Pressure Cut-Off Fully tighten threads then back off one (1) turn E) Load Sense Relief Valve 4000 +/- 50 Psi (HIGH), 3000 +/- 50Psi (LOW) F) Converter Non-adjustable, refer to service manual G) Winch Transmission Non-adjustable, refer to service manual H) Clutch Cooling Water 45 Psi MAX I) Carrier Drive(Cross Line Reliefs) 4300 +/- 50 Psi J) Guyline Winches(Valve work port relief) 3000 Psi MAX K) Guyline Counterbalance 2000 Psi L) Guyline Back Pressure 400 Psi M) Swing Pilot 1 Operated Relief 2nd Stage 3400 Psi N) Swing Pilot 1 Operated relief 1st Stage 1500 Psi O) Boom Hoist Counterbalance 2000 Psi
The air system operates within the range of the air compressor governor, 110-130Psi. The regulator used to supply the haulback band brakes is to be set to 105Psi MAX. 15.18 Air Control Panel The main and slackpuller slip clutch air circuit is equipped with a differential pressure control valve WM318A. This valve allows you to change the tension in the two lines when the grapple or carriage is on its way out. To use this tension, have the main slackpuller clutch engaged. Adjust the pressure differential valve untill the pressure on the slackpuller slip clutch is between 3-15 PSI higher than the main slip clutch pressure. This will keep the grapple open when you pull the rigging out. Setting the pressure higher on the main slip clutch would have the opposite effect, and is the method used with a carriage to keep the dropline up on outhaul. A selector valve for “carriage” or “grapple” yarding is provided in the cab riser to change the “bias” without resetting the WM318A valve.
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16 Horn (Whistle)
16.1 Adjustment Instructions
1. Loosen locknuts and setscrews (items 3 & 4) holding the diaphragm retaining ring (item 2). 2. Back off the diaphragm retaining ring, thereby releasing tensions on the diaphragm (item 1). 3. When the diaphragm has a very light amount of tension, test for tone. 4. The proper tone for this whistle is a clear, even tone that is achieved with the least amount of tension. 5. If more tension is necessary, increase by turning the diaphragm retaining ring in about 1/16 turn at a time, testing for proper tone each time the ring is moved. NOTE: Extra tension will shorten the life of the whistle diaphragm. 6. After adjustment lock the diaphragm cap ring with set screws to equalize pressure against the ring, and then tighten the locknuts. CAUTION: The Horn (Whistle) is important for safe operation of the yarder. Follow the trouble shooting and maintenance instructions to ensure optimum performance. Do not operate the machine with a malfunctioning horn.
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16.2 Horn (Whistle) Troubleshooting 1. Horn Stops Blowing - Air not getting to horn / pinched or disconnected airline / plugged inlet. - Wiring open / faulty switch/ circuit breaker tripped / no voltage at valve solenoid. - Solenoid coil defective or voltage not correct. 2. Horn Raspy and Distorted - Cracked diaphragm. - Chips or dirt lodged on diaphragm seat. - Loose cap (adjusting ring). - Water or debris in body. 3. Horn Hisses When Blown - Diaphragm warped and not seating properly. - Excessive pressure. - Diaphragm seat badly scuffed. 4. Change in Character of Sound - Cracked diaphragm. - Worn diaphragm. - Oil or moisture on diaphragm seat. - Solenoid valve failing to open completely. 5. Horn Fails to Shut Off - Solenoid valve plunger stuck. - Valve failing to seat. - Valve iced up. - Short in electrical connection, or faulty switch.
16.3 Horn (Whistle) Maintenance 1. To dismantle, loosen the locknuts (item 3) and machine screws (item 4). Remove the adjusting ring (item 2). 2. Clean thoroughly and inspect the diaphragm (item 1) for unusual wear, cracks or scuff marks. 3. Wipe off and inspect the body (item 5). Remove any particles that are lodged or embedded. This should be done carefully without destroying the inside surface of the body, special on the face where the diaphragm seat. Clean out all oil, moisture and dirt. 4. Replace any damaged or worn parts with factory originals. The diaphragm is made from special mill-ordered material; a substitute material will not provide the same tone or service life. 5. If new parts are installed, clean them first.
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6. Make sure the diaphragm is located properly as the adjusting ring is started on the thread, to avoid damage to the diaphragm. 7. Tension the diaphragm as described in section 16
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17 Machine Rigging
17.1 Grapple Rigging
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17.2 Slackpuller Carriage / Dropline Rigging
17.3 Haulback Drum Rigging Spooling: 1. With the main and slackpuller maxi brakes applied, set engine to idle and engage first gear with transmission controller (mounted in control stand) 2. Move the yarding control a maximum of 15 deg. Forward to engage the haulback pull clutch. 3. Apply the throttle and release the brake to rotate the haulback drum in. Unspooling: 1. With the main and slackpuller maxi brakes applied, set engine to idle and engage reverse with the transmission controller (mounted in control stand)
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2. Move the yarding control a maximum of 15 deg. Forward to engage the haulback pull clutch. 3. Apply the throttle and release the brake to rotate the haulback drum out. NOTE: “IN” and “OUT” speeds are feathered with the service brake foot pedal. NOTE: Return controller and transmission to neutral position, set all spring brakes. 17.4 Main Drum Rigging Spooling: 1. Apply slackpuller and haulback spring brakes. 2. Release mainline spring brake, control drum with mainline service brake. 3. Shift the transmission to first gear 4. Move the rigging control back 15 deg. at idle, to engage the pull clutch. 5. Depress grapple close button to disengage slackpuller drum. Keep the button depressed. 6. Apply throttle and release brake to rotate main drum in. Unspooling: 1. Apply slackpuller and haulback spring brakes. 2. Release mainline spring brakes, control drum with mainline service brake. 3. Shift the transmission to reverse. 4. At idle move the rigging control back 15 degrees 5. Depress grapple close button. Keep it depressed. 6. Apply throttle and release brake to rotate main drum out. 7. NOTE: Return controller and transmission to neutral position, set all spring brakes. 17.5 Slackpuller Drum Rigging Spooling: 1. Apply machine and haulback spring brakes. 2. Release slackpuller spring brake, control drum with slackpuller service brake. 3. Shift the transmission to first gear. 4. Move main control back 15 deg, at idle to engage the pull clutch. 5. Depress grapple open button to disengage mainline drum. Keep the button depressed. 6. Apply throttle and release brake to rotate slackpuller drum in. Unspooling: 1. Apply mainline and haulback spring brakes.
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2. Release slackpuller spring brake, control drum with slackpuller service brake. 3. Shift the transmission to reverse. 4. At idle move the rigging control back 15 degrees 5. Depress grapple open button. Keep it depressed. 6. Apply throttle and release brake to rotate slackpuller drum out. NOTE: Return controller and transmission to neutral position, set all spring brakes.
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18 Trouble Shooting
The electronic control systems will display diagnostic codes for trouble shooting. The procedure is summarized in sections 19 and 20 for the engine and transmission respectively. The engine is programmed to shut down on detection of low oil pressure or coolant level. Some diagnostic codes indicate circuit faults, which can be caused by loose, broken or shorted wires and bent or wet connector pins. Always exercise caution when checking the wiring for faults. If the “STOP ENGINE” or “DO NOT SHIFT” light come on, shut the engine off immediately. NOTE: Due to the location of the coolant level probe in the radiator top tank a low coolant shutdown can occur when operating the machine on any steep angle, unless the radiator is completely filled.
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SYMPTOM POSSIBLE CAUSE ACTION NEEDED LOSS OF POWER (NO LINE ENGINE POWER CHECK ENGINE PERFORMANCE, CHECK FAULT CODES PULL) INADEQUATE FUEL SUPPLY PLUGGED LINE OR FILTER, AIR LEAK TORQUE CONVERTER PRESSURE TO CHECK TRANSMISSION FAULT CODES LOW OR TEMP TOO HIGH MALFUNCIONING RELIEF VALVE ON CHECK FUEL PRESSURE FUEL PUMP CHECK CLUTCH AIR AND OIL PRESSURES CHECK CLUTCHES SLIPPING FOR WATER OR OIL ON CLUTCH PLATES TRANSMISSION CLUTCH PRESSURE REFER TO TRANSMISSION MANUAL FOR PRESSURE TOO LOW CHECK PROCEDURE INTERLOCK CLUTCH APPLIED INTERLOCK CLUTCH AIR PRESSURE TOO HIGH BRAKES ON OR DRAGGING CHECK ACTUATOR VALVES & RELEASE SPRINGS TRANSMISSION NOT IN GEAR CHECK TRANSMISSION CONTROL PANEL NOISY OPERATION LACK OF GEAR LUBRICATION REFER TO LUBRICATION SCHEDULE MACHINE NOT LEVEL, TWIST IN FRAME CHECK GEAR & DRUM ALIGNMENT DAMAGED OR WORN GEAR TEETH INSPECT WINCH GEARS BROKEN CLUTCH OR BRAKE PLATES INSPECT CLUTCHES AND BRAKES BEARING WORN, BROKEN OR LOOSE INSPECT BEARINGS HOUSING CLUTCH OR GEAR RUBBING ON GUARD CHECK THAT GUARDS ARE SECURLEY MOUNTED DRIVE CHAIN TOO SLACK CHECK CHAIN ADJUSTMENT ENGINE OVERHEATING LOW COOLANT OR OIL CHECK ENGINE COOLANT & OIL LEVELS CHECK COOLANT LEVEL, ENSURE ALL VALVES ARE AIR LOCK IN COOLANT SYSTEM OPEN, INCLUDING CAB HEATER FAN BELT SLIPPING CHECK FAN BELT TENSION OBSTRUCTION IN RADIATOR DISCONECT RADIATOR AND TEST FLOW COOLANT LEAK PRESSURE TEST SYSTEM FAULTY THERMOSTAT TEST OPERATION OF THERMOSTAT FAULTY PRESSURE RELIEF VALVE PRESSURE TEST SYSTEM SLIP CLUTCHES OVERHEATING CLUTCH DRAGGING CHECK RETURN SPRINGS LOW COOLANT LEVEL CHECK COOLANT LEVEL, CHECK FOR AIR LOCKS NOTE: CAN ALSO BE CAUSED IF ENGINE SPEED IS TOO LOW, (M IN LOW COOLANT PRESSURE CHECK COOLANT LEVEL, CHECK PUMP DRIVE BELT 1100RPM ) OR IF CLUTCHES ARE FAULTY PUMP INSPECT PUMP FOR DAMAGE/WEAR SLIPPED EXCESSIVLEY OVER CHECK FOR RESTRICTIONS IN SYSTEM, PLUGGED LONG DISTANCE LOW COOLANT FLOW FILTER OR STRAINER TORQUE CONVERTER LOW OIL FLOW CHECK FILTER FOR CONTAMINATES OVERHEATING LOW OIL PRESSURE INTERNALLY REGULATED, REFER TO MANUAL FAULTY CONVERTER SEE TRANSMISSION MANUAL STALLING THE RIGGING AT LOW RPM PROCEDURE RUNNING ENGINE AT HIGH RPM WITH THROTTLE MACHINE BACK NO LOAD IMPROPER SPOOLING EXCESSIVE FLEET ANGLE CHECK MACHINE RIGGING TWIST IN LINE WRONG LAY OF LINE LINE WOUND TOO LOSE ON DRUM ACTUAL LINE DIAMETER(MEASURED) LARGER OR MORE THAN 3% SMALLER CONTACT LINE SUPPLIER THAN PITCH OF DRUM DAMAGED DRUM REMOVE LINE & INSPECT DRUMS LINE RUBBING ON BOOM OR GANTRY CHECK MACHINE RIGGING
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SYMPTOM POSSIBLE CAUSE ACTION NEEDED HYDRAULIC SYSTEM CHANGE TO MANUFACTURERS RECOMMENDED WRONG VISCOSITY OR OIL TYPE FAILURE GRADE
LOW HYDRAULIC OIL CHECK LEVEL TOP UP SYSTEM RUN ALL VALVES, CHECK FLUID LEVEL, CHECK AIR IN SYSTEM PUMP PICKUP MECHANICAL DAMAGE DISMANTLE & REPAIR OR REPLACE INTERNAL OR EXTERNAL LEAKAGE INSPECT MACHINE FOR LEAKS CHANGE FILTER, ISOLATE SOURCE OF CONTAMINATES IN SYSTEM CONTAMINATES CHECK PRESSURES AS PER MANUFACTURERS IMPROPER ADJUSTMENT RECOMMENDATIONS
PLUGGED DIRTY OR LEAKING OIL INSPECT COOLER FOR INTERNAL & EXTERNAL COOLER LEAKS, CHECK OIL FLOW RATE VALVE OR ACTUATOR FAILURE REPAIR OR REPLACE AS REQUIRED NEGLECTING TO FLUSH SYSTEM FLUSH SYSTEM, CLEAN OR REPLACE FILTERS AFTER MAJOUR COMPONENT AS REQUIRED FAILURE LOW SYSTEM PRESSURE CHECK RELIEF VALVE NO SYSTEM PRESSURE CHECK PUMP OPERATION, CHECK FLUID LEVEL CHECK PUMP FOR DAMAGE, CHECK SUCTION EXCESSIVE PUMP NOISE LINE FOR FLOW, CHECK PUMP-MOTOR DRIVE SHAFT SLOW ACCUMULATOR REACTION LOSS OF CHARGE OR OVERCHARGED NO AIR PRESSURE BROKEN COUPLING ON CHECK COMPRESSOR DRIVE COMPRESSOR DRIVE SHAFT
UNLOADER VALVE FAILURE CHECK FOR LEAKS ON UNLOADER VALVE CLEAN & INSPECT STRAINER FOR DIRTY INTAKE STRAINER RESTRICTIONS CHECK AIR GOVERNOR FOR PROPER CUT IN FAULTY AIR GOVERNOR PRESSURE INSPECT FOR CRACKED DIAPHRAGM OR DIRTY FAULTY AIR REGULATOR AND WORN VALVE EXCESSIVE COMPRESSOR RESTRICTION IN CYLINDER HEAD DISSASEMBLE PUMP & INSPECT NOISE OR DISCHARGE LINE
WORN BEARINGS DISSASEMBLE PUMP & INSPECT NO LUBRICATION CHECK COMPRESSOR FLUID LEVELS EXCESSIVE WATER ACCUMULATION CHECK INTAKE STRAINER LEAKS IN AIR SYSTEM MALFUNTIONING CHECK VALVE INSPECT FOR WORN SEAL DISSASEMBLE AND REPLACE SEALS AS LEAKING AIR CYLINDER REQUIRED LEAKING DIRECTION CONTROL DISSASEMBLE AND REPLACE SEALS AS VALVE REQUIRED AIR CONTROLS NOT TEST SOLENOID COIL & SUPPLY VOLTAGE, FAULTY DIRECTION CONTROL FUNCTIONING DISSASEMBLE AND INSPECT VALVE SPOOL & VALVE SEALS ELECTRICAL SYSTEM FAULT REFER TO WIRING DIAGRAMS LOW AIR PRESSURE CHECK AIR SUPPLY SYSTEM
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19 Onboard Diagnostics - DDEC V
Since the DDEC system is electronic, a battery is required to operate the computer. The system operates at 24 volts. However, in the event of a power supply malfunction, the system will continue to operate at reduced voltage. When this occurs the "Check Engine" light will come on.The engine will only operate at reduced rpm until the battery voltage reaches a point where the ECM will no longer function and the engine shuts down. Should the "Check Engine" light come on for any reason, the vehicle can still be operated and you can proceed to your destination. This condition should be reported to a DDEC technician as soon as possible. WARNING: When the "Stop Engine" light comes on, the computer has detected a major malfunction in the engine that requires immediate attention. It is the operator's responsibility to shut down the engine to avoid serious damage. The engine can be configured to give a warning only, to ramp down (reduce power), or to shut down. Ramp down will reduce engine rpm to a predetermined speed, but will not shut down the engine. With the 30 second shutdown option the engine will begin a 30 second, stepped, power-down sequence until it shuts down completely. A "Stop Engine Override" can be supplied in case the vehicle is to oper ate in a critical situation. NOTE: The "Stop Engine Override" and "Diagnostic Request" switch is the same. In this situation the operator may elect to "override" the automatic stop engine sequence by pressing the "Stop Engine Override" switch, located on the instrument panel, until a safe stop can be made. The operator only needs to press the override switch every 15 to 20 seconds to prevent engine shutdown from occurring. The engine should not be restarted after it has been shut down by the engine protection system unless the problem has been located and corrected. The conditions that will cause the "Stop Engine" light (SEL) to come on are: ■ High coolant temperature ■ Loss of coolant ■ High oil temperature ■ Low oil pressure ■ Auxiliary shutdown
It is important to point out that whenever the "Check Engine" light (CEL) or the "Stop Engine" light (SEL) comes on, the DDEC computer will determine where the problem is, and will then store this information in its memory. If the malfunction is intermittent, the "Lights" will come on and go off as the computer senses the changing engine condition.
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A special diagnostic tool (Diagnostic Data Reader or "DDR") is available that can be plugged into the engine computer memory to extract information related to the cause of the problem. Once the malfunction has been cor rected, the DDEC system will return the engine to normal operation. The DDR can distinguish between codes now active and those stored in the ECM memory (inactive). The malfunction code recorded in the computer memory will remain until it is erased by a technician. The malfunction code can also be obtained by the operator. A "Diagnostic Request" switch is provided which, when pressed, will cause the "Check Engine" light (CEL) to flash a code number. It will, for example, flash twice...pause...flash five times...pause. In other words, a code 25. See Figure 15. Code 25 indicates all systems are working satisfactorily. The active codes will be flashed on the "Stop Engine" light (SEL) in the order of most recent to least recent occurrence based on engine hours. If there are no active codes, a code "25" will be lashed. The inactive codes will be flashed on the "Check Engine" light (CEL . If there are no inactive codes, a code "25" will be flashed. Note that only one light will be lashing codes at any time. When code flashing is initiated, the active codes (or code "25") will be flashed on the SEL. Then the active codes (or code "25") will be flashed on the SEL. Then the inactive codes (or code "25") will be flashed on the CEL. When all the inactive codes (or code "25") have been flashed, the process of flashing all the active codes followed by all the inactive codes will repeat until the conditions for code lashing are no longer satisfied. The codes will continue to flash and repeat as long as the diagnostic request switch is held in the "On" position with the ignition on. Other diagnostic codes are listed in Table 2. TO READ CODES : Use the diagnostic data reader or depress and hold the diagnostic request switch with the ignition on, engine at idle or not running. Press and hold the switch. Active codes will be flashed on the "Stop Engine" light (SEL) followed by the inactive codes being flashed on the "Check Engine" light (CEL). The cycle will repeat until the operator releases the diagnostic request switch.
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Table 1: DDEC V System Diagnostic Codes
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20 Transmission Codes
20.1 Checking Fluid Levels To enter the oil level function, the yarder must be parked on a level surface and the transmission shifted to Neutral, apply maxi brakes. Simultaneously press the up and down shift arrows once. (Located on left joystick handle) The fluid level reading may be delayed until the following conditions are met: 1. Engine must be at idle 2. Transmission is in N (Neutral) 3. Output speed must be zero 4. Fluid temperature must be between 140°F (60° C) and 220°F (104°C) 5. Winch must be stationary for two minutes to allow the fluid to settle The shift selector will display the oil level data as follows: • Correct Fluid Level – The fluid is within the correct fluid level zone when OK is shown.
• Low Fluid Level – The display shows the number of quarts the transmission oil is low.
• High Fluid Level – The display shows the number of quarts the transmission oil is overfilled.
Delayed Fluid level Check – If the fluid level check cannot be completed, one of the following oil level display faults will be shown.
To exit the oil level function, press any range button one time.
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20.2 Diagnostic Codes To enter the diagnostic code function, stop the winch and apply maxi brakes, simultaneously press the up and down arrows once. The fluid level will be displayed first, followed by the prognostic and then diagnostic codes. Each code will remain in the display until the mode button is pressed, then the next code will show. Active codes are shown first, newest to oldest, followed by inactive codes still in memory. Up to five codes can be recorded in memory. To exit the diagnostic mode any of the following methods can be used. • Press the up and down buttons simultaneously or press any range button. • Wait approximately 10 minutes, the system will return to normal operating mode • Turn off engine ignition switch.
20.3 Transmission Diagnostic Codes
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21 Lexan & Marguard Windows
21.1 Replacement It is important that damaged Lexan or Marguard windows be replaced with the equivalent product. Substitution with an inferior product may greatly reduce the level of protection to the operator and WCB requirements may not be met. For example, the impact strength of Lexan is 200 times that of glass and 30 times that of acrylic. Protect the operator - do not substitute an inferior product! 21.2 Cleaning Instructions When Lexan sheet is first installed, glazing compound and masking paper adhesive can be easily removed by applying naphtha (VM&P) or kerosene with a soft cloth, followed immediately with a thorough soap and water cleaning. DO NOT USE GASOLINE! Adherence to regular and proper cleaning procedures is recommended to preserve appearance. 21.3 Washing to Minimize Scratching Wash LEXAN XL sheet and LEXAN THERMOCLEAR sheet with a mild soap or deter- gent (e.g. JOY Dishwashing Liquid) and lukewarm water, using a clean sponge or a soft cloth. Rinse well with clean water. Dry thoroughly with a chamois or moist cellulose sponge to prevent water spots. Do not scrub or use brushes on these products; their coating is UV-resistant, not mar-resistant. Fresh paint splashes, grease and smeared glazing compounds can be removed easily before drying by rubbing lightly with a good grade of VM&P naphtha or isopropyl alcohol. Afterward, a warm final wash should be made, using a mild soap or detergent solution and ending with a thorough rinsing with clean water. 21.4 Minimize Hairline Scratches Scratches and minor abrasions can be minimized by using a mild automobile polish. Three such products that tend to polish and fill scratches are Johnson Paste Wax, Novus Plastic Polish No.1 & No.2, Novus Inc. Minneapolis, MN and Micor Glaze plastic polish (M.G.M.10), Mirror Bright Polish Co., Pasadena, CA. It is suggested that a test be made on a sample of LEXAN sheet with the product selected and that the polish manufacturer’s instructions be followed. 21.5 Some Important “Don'ts” • DO NOT use abrasive or highly alkaline cleaners on LEXAN sheet products. • NEVER scrape LEXAN sheet products with squeegees, razor blades or other sharp instruments. • Benzene, gasoline, acetone or carbon tetrachloride should NEVER be used on LEXAN sheet products. • DO NOT clean LEXAN sheet products in hot sun or at elevated temperatures.
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• DO NOT use butyl cellosolve on XL-1 or TC-2.
21.6 Compatible Cleaners for Lexan Sheet Products The following cleaning agents have been found compatible with LEXAN sheet, LEXAN XL sheet and LEXAN THERMOCLEAR sheet. The manufacturer’s recommendations and instructions should be followed. • JOY • Top Job • Freib T.F. • VM&P grade naphtha • Palmolive Liquid • Windex with Ammonia D
21.7 Marguard Sheet Cleaning Instructions Because of this material’s highly mar-and UV resistant coating, avoid the use of abrasive cleaners and/or cleaning implements that may mar or gouge the coating. 21.8 Graffiti Removal for MARGUARD Sheet • Butyl cellosolve works well for removal of paints, marking pen inks, lipstick, etc. • Masking tape, adhesive tape or lint removal tools work well for lifting off old, weathered paints. • To remove labels, stickers, etc., the use of kerosene or VM&P naphtha is generally effective. When the solvent will not penetrate sticker material, apply heat (hair dryer) to soften the adhesive and promote removal. GASOLINE SHOULD NOT BE USED.
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22 Quick Reference Parts List
22.1 Filter Elements: Fuel Filter Primary 7711
Fuel Filter Secondary 8851
Engine Oil Filter PF-2100
Engine Air Filter 9277
Hydraulic Strainer (In Tank) 4317008
Hydraulic Pilot Suction Filter 7332
Hydraulic Pilot Pressure Filter V99052
Hydraulic Return Filter V99053
Allison Transmission Filter Kit V99051
Heater, A/C Air Filter 78R5360
22.2 Engine Belts: Fan Belt V96773
Alternator Belt 7674
Water Pump Belt 7517
22.3 Air System: Valve, Brake Relay 5569
Valve, 4-Way, Solenoid 7344
Valve, Quick Release ½” NPT 7408
Valve, Quick Release 3/8” NPT 810817
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Guyline Pawl Air Cylinder 6352
Air Filter 009132078001
Air Lubricator 075026002001
22.4 Sending Units: Engine Coolant Level Switch 7821
Throttle Pressure Transducer 7630
22.5 Electrical Parts: Button, Yarder Control Handle 5605
22.6 Undercarriage: Track Roller 6299
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