THUNDERBIRD TSY-6355 YARDER OPERATOR`S MANUAL

Transcription

THUNDERBIRD TSY-6355 YARDER OPERATOR’S MANUAL
PDF VERSION
AUGUST 2003
THIS MANUAL CONTAINS MATERIAL THAT WAS SUPPLIED WITH NEW
MACHINES AT THE TIME OF DELIVERY. NO UPDATES ARE PROVIDED
FOR THIS INFORMATION. THIS MANUAL IS TO BE USED ONLY AS A
GUIDE FOR OPERATION AND SERVICE OF THE MACHINE. IT IS NOT A
SUBSTITUTE FOR PROPER TRAINING BY EXPERIENCED OPERATORS. AS
WITH ALL HEAVY EQUIPMENT, SAFE OPERATION REQUIRES CONSTANT
ATTENTION AND COMMON SENSE. ENSURE THAT OPERATION AND
SERVICE OF THIS MACHINE IS IN COMPLIANCE WITH LOCAL
OCCUPATIONAL HEALTH AND SAFETY CODES.
General Warning
CALIFORNIA
Diesel engine exhaust and some of its constituents
are known to the state of California to cause cancer,
birth defects, and other reproductive harm.
GENERAL SAFETY
CONCIDERATIONS
The safety considerations and precautions included in this
manual do not represent an all-inclusive or complete listing,
and knowledge of this manual is not to be taken as a license to
operate this or any other machine. It is the responsibility of
the owner and operator to insure that the operation of this
machine is in accordance with all local, state, and national
safety requirements and regulations, including those specified by the Occupational Safety and Health Act (OSHA) and
local fire, electric, and safety codes.
Instructions for Ordering Parts
To order parts, contact your nearest Ross Corporation Sales, Service, and Parts
Branch:
460 N. Danebo
PO Box 2577
Eugene, OR 97405
(541)689-9400
1-800-777-9555
(541)689-5031
FAX: (541)689-3517
1050 NW Maryland Avenue
PO Box 998
Chehalis, WA 98532
1-800-444-9555
(360)748-8657
FAX: (360)748-7849
When ordering replacement parts, please have the following information at hand:
MACHINE IDENTIFICATION - Know the model number and serial number of the
machine. The serial number can be found on the title page of this manual or on the
metal plate located on the cab.
PART IDENTIFICATION - Know the PART NUMBER, PART NAME, and
QUANTITY of parts that are needed. The part number for each item can be found
on the appropriate parts list.
Maintenance and Operation
PERIODIC SAFETY INSPECTION CHECKLIST
LOG OF REPAIRS AND ADJUSTMENTS
CHAPTER A. INTRODUCTION
INTRODUCTION ....................................................................................................... A
SAFETY CONSIDERATIONS ................................................................................ A-1
SAFETY ................................................................................................................... A-2
NOMENCLATURE.................................................................................................. A-5
SERVICING THE YARDER ................................................................................... A-7
DESCRIPTION ........................................................................................................ A-8
DESIGN SPECIFICATIONS ................................................................................. A-12
POWER TRAIN FORMATION ............................................................................. A-14
ENGINE SPECIFICATIONS ................................................................................. A-15
DIMENSIONS ....................................................................................................... A-17
CHAPTER B. CONTROLS AND INSTRUMENTS
CONTROLS AND INSTRUMENTS ...................................................................... B-1
START-UP CONTROLS.......................................................................................... B-4
WARNING SYSTEM ............................................................................................... B-5
INSTRUMENTS ...................................................................................................... B-7
CIRCUIT BREAKERS ............................................................................................ B-8
CHAPTER C. OPERATING PROCEDURES
PRE-START INSPECTION ..................................................................................... C-1
STARTING THE ENGINE ...................................................................................... C-2
JUMP STARTING ENGINE .................................................................................... C-3
MACHINE WARM-UP ............................................................................................ C-4
SHUTTING DOWN MACHINE ............................................................................. C-5
UNUSUAL OPERATING CONDITIONS .............................................................. C-6
EXTREME COLD ................................................................................................... C-6
EXTREME HEAT .................................................................................................... C-7
HIGH HUMIDITY/SALTWATER ........................................................................... C-9
HIGH ALTITUDES ............................................................................................... C-10
YARDER TRANSPORTING ................................................................................. C-11
TOWER RAISING AND LOWERING ................................................................. C-12
TOPPING LINE REEVING INSTRUCTIONS .................................................... C-14
TOWER PIN LOCATIONS ................................................................................... C-15
SETTING GUYLINES .......................................................................................... C-16
Maintenance and Operation
CHAPTER C. CONTINUED
GUYLINE ARRANGEMENT ............................................................................... C-16
DRUM OPERATION ............................................................................................. C-17
PROCEDURAL AWARENESS ............................................................................. C-20
WORKING WITH HYDRAULICS ....................................................................... C-21
CHAPTER D. MAINTENANCE CHECKS
INTRODUCTION ....................................................................................................... D
DAILY CHECKS...................................................................................................... D-1
WEEKLY CHECKS ................................................................................................. D-5
MONTHLY CHECKS .............................................................................................. D-7
QUARTERLY CHECKS .......................................................................................... D-8
SEMIANNUAL CHECKS ..................................................................................... D-10
ANNUAL CHECKS ............................................................................................... D-11
CHAPTER E. CHARTS
RECOMMENDED LUBRICATION ....................................................................... E-1
LUBRICATION CHART ......................................................................................... E-4
MAINTENANCE CHART ....................................................................................... E-5
FLUID LEVEL CHART........................................................................................... E-6
CHAPTER F. QUICK REFERENCE
CUMMINS NTA855 ENGINE ................................................................................. F-1
CATERPILLAR 3406B ENGINE ............................................................................. F-2
Forward
YARDER PRODUCT SAFETY NOTICE
Compliance of all federal, state and local regulations governing the safe operation and
use of this equipment is the responsibility of the owner and/or operator. Because of
variances of rules and regulations in different areas, this manual will make no reference
to any such rules or regulations.
It is suggested that each owner, and/or operator, check with local authorities of the
area being worked, to guarantee full compliance of current rules and regulations
before beginning operation.
Necessary operation and maintenance manuals are provided with each
THUNDERBIRD Yarder manufactured and sold by Ross Corporation. These manuals
contain all necessary information to provide adequate information and training to those
operating, maintaining or supervising the use of this machinery in a safe and proper
manner.
It is the responsibility of the owner to provide proper training to any persons that
operate, maintain, or supervise THUNDERBIRD equipment.
This equipment is designed and manufactured to operate efficiently under adverse
conditions. Even when operated correctly, under these conditions, parts will wear and
fail. It is very important that an EQUIPMENT INSPECTION PROGRAM be created
in order to keep the machine working properly, reduce repair time, and help prevent
accidents. With an inspection program, properly administered, worn, broken and
loose parts will be discovered before they are the cause of a major problem. It is
suggested that all manuals be fully read and understood before operating any new
Thunderbird equipment. Please contact your Thunderbird manufacturer for assistance
at (541) 689-5031.
Maximum performance level of the Thunderbird can be attained when recommended
operating and maintenance procedures are followed. The Periodic Safety Inspection
Check List should be used. Use of a maintenance log to record all work done on your
machine is advised.
Please provide the machine model and serial number when requesting information on
your machine. This will guarantee receiving correct information. The contents of this
publication is derived from information in effect at time of printing. Ross Corporation
reserves the right to change any part of, or all of, this publication without obligation or
notice.
Periodic Safety Inspection
Visual Inspection *
Overall Cleanliness
Hydraulic System
Hydraulic Tank Fluid Level
Pump Drive Case Fluid Level
Heater and Defroster
Engine Crankcase Fluid Level
Fuel Tank Fluid Level
Radiator Fluid Level
Transmission Fluid Level
Air System
All Control Mechanisms
Instruments and Gauges
Warning Lights
Muffler Exhaust System
Swing Reduction Fluid Level
Traction Drive Case Fluid Level
Air Cleaner Element Signal
Fan Belt Tension
Batteries and Starting System
Gear Bearings
Gears Lubrication
Chain Case Fluid Level
Air Lubricator
Ring Gear Bolt Torque
Track Adjustment
Guards and Catwalks
D
D
W
W
W
W
**
D
W
**
D
D
D
D
D
D
M
W
W
W
M
D
W
W
P
P
P
D - Daily
W - Weekly
M - Monthly
P - Periodic
* Inspect the entire machine for cracks, weld separation, leaks, damage, and evidence of vandalism.
** - See Manufacturers Manual
REPAIR
ADJUST
SATISFACTORY
ITEMS TO BE INSPECTED
INSPECTION
CODE
This Checklist is to be used in conjunction with the information provided in this
manual to properly operate and maintain the yarder.
Repairs and Adjustments Log
ITEM
REQUIRED MAINTENANCE
DATE
Chapter A: Introduction
INTRODUCTION ....................................................................................................... A
SAFETY CONSIDERATIONS ................................................................................ A-1
SAFETY ................................................................................................................... A-2
NOMENCLATURE.................................................................................................. A-5
SERVICING THE YARDER ................................................................................... A-7
DESCRIPTION ........................................................................................................ A-8
DESIGN SPECIFICATIONS ................................................................................. A-12
POWER TRAIN FORMATION ............................................................................. A-14
ENGINE SPECIFICATIONS ................................................................................. A-15
DIMENSIONS ....................................................................................................... A-17
Introduction
RECEIVING THE NEW THUNDERBIRD YARDER
The new THUNDERBIRD Yarder was designed by thoroughly trained professionals,
and manufactured by skilled craftsmen. From start to finish the new yarder was
inspected at numerous points of completion to guarantee that this is the highest quality
yarder available. Upon completion, the new yarder received its final inspection,
consisting of working pressure adjustments, torque adjustments, and a thorough
testing of all functions to factory specifications, to ensure a high quality, fully operable
machine at the time of delivery.
When the new THUNDERBIRD Yarder is delivered, it will be accompanied by a
factory trained serviceman, who will reinspect and give instructions to the purchaser/
operator, and maintenance personnel concerning the operation and maintenance of the
new yarder. All unusual noises, malfunctions, or erratic performance should be noted
in the maintenance log and reported to the owner or factory.
Skilled and unskilled operators and maintenance personnel are advised to study this
manual because of the great many subjects thoroughly covered. After a complete
familiarization of the machine, and this manual, the operator should be ready to use the
new yarder efficiently and safely.
Before initial start-up, reinspect the new yarder using the suggested periodic Yarder
Safety Inspection Checklist.
For information concerning operation and maintenance of the engine, refer to the
Engine Manufacturer’s Manual.
Safety is the responsibility of all personnel assigned to any given project. Safe work
habits must be practiced by all in order to maintain an accident free work site.
All operators and maintenance personnel should read and understand this manual, and
all manufacturers’ publications supplied with this machine.
Since safety measures will differ with each job site, this section will concern only those
more serious conditions and common practices requiring safety precautions. In most
instances, common sense and good judgment, when operating your new Thunderbird
Yarder, will create a safe work site.
A
Safety Considerations
Safety is the responsibility of everyone assigned to any work site. Unsafe acts can
affect many more persons than just the one being unsafe; if noticed that someone is
working in a unsafe manner, take the time to remind him or her of the danger involved.
Jobs or lifes might be saved.
THE SAFETY CONSIDERATIONS AND PRECAUTIONS INCLUDED IN
THIS MANUAL DO NOT REPRESENT AN ALL-INCLUSIVE OR COMPLETE LISTING, AND KNOWLEDGE OF THIS MANUAL IS NOT TO BE
TAKEN AS A LICENSE TO OPERATE THIS OR ANY OTHER MACHINE.
IT IS THE RESPONSIBILITY OF THE OWNER AND OPERATOR TO
INSURE THAT OPERATION OF THIS YARDER IS IN ACCORDANCE
WITH ALL LOCAL, STATE, AND NATIONAL SAFETY REQUIREMENTS
AND REGULATIONS, INCLUDING THOSE SPECIFIED BY THE OCCUPATIONAL SAFETY AND HEALTH ACT (OSHA) AND LOCAL FIRE,
ELECTRIC, AND SAFETY CODES.
SAFETY WARNING LABELS AND DECALS
The Thunderbird 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 OSHA or local regulations.
The terms DANGER, WARNING, CAUTION, and NOTE appear throughout this
manual. These terms denote that special attention to the information following the
term is required.
The term DANGER precedes information about specific immediate hazards which are
HIGHLY LIKELY to result in SEVERE PERSONAL INJURY or DEATH if
disregarded.
The term WARNING precedes information about hazards or unsafe practices which
COULD result in personal injury or death if disregarded.
The term CAUTION precedes information about unsafe conditions or practices that
could result in personal injury or machine damage if disregarded.
The term NOTE precedes information which is critical to the proper operation or
maintenance of the Yarder.
A-1
Safety
Since safety measures will differ with each job site, this section will concern only those
more serious conditions and common practices requiring safety precautions. In most
instances, common sense and good judgment, when operating your new Thunderbird
Yarder ,will create a safe work site.
OPERATOR:
Only trained, qualified personnel should be authorized to operate this machine, and
only when physically and mentally alert. All operators should be aware of hazards of
job site and of safety measures needed to avoid damage to machine or personal injury.
BE SAFE, NOT SORRY:
Never believe the new work day will start just as the preceding day ended. Make it a
daily procedure to check machine and work site for hazardous conditions possibly
created by weather, pressures, vandalism, etc.
BLIND OBSTACLES: When preparing job
site, always allow enough room for free movement of machine on all sides. Remove any
obstacle that could impair the swing or travel of
your Thunderbird Yarder. Be especially cautious
when working around overhead wires. Always
assume any overhead line is LIVE. Know exact
height and reach of your machine. Maintain a
minimum distance of 10 feet from all overhead
lines (Additional distance over 50,000 volts,
check with local and state codes.) In the event
thhe machine should come in contact with a
power line, remember to stay on the machine, in
the seat, and allow no one else on machine. If it
should become necessary to leave the machine,
Jump. Be careful to be completely clear of
machine, even after reaching ground, until the
machine has been safely moved or the power
shut off. When preparing the job site, always be
sure that the Thunderbird Yarder has adequate
room to maneuver and will not have to move or
sit on the edge of unstable ground that could
break away.
A-2
Safety
STEERING:
Use caution in traveling machine. The operator should always know the position of the
yard and travel control.
UNATTENDED MACHINE:
To avoid unwanted operation or movement of machine when unattended, the operator
should always set all brakes, stop engine, lock ignition, remove key, and lock cab door.
MOVING MACHINE:
Never attempt to climb on, or get off a machine while it is in motion.
SERVICE AND ADJUSTMENTS:
A daily SERVICE NEEDED report should be turned into the maintenance personnel
at the end of each work day. Keys to locked ignition and locked cab door should
accompany this report to be sure that only qualified personnel can perform needed
maintenance.
GUARDS:
All guards serve a needed safety function. They must be replaced upon completion of
any maintenance work done on the machine.
BANKS AND SLOPES:
Never leave the machine on or near any bank which may cave, or on the edge of a site
which may give way. Back the machine away from the area when it is to be left idle or
unattended for more than a short period of time. Park on level ground whenever
possible.
BRIDGE CAPACITY:
Check the capacity of any bridge before attempting to cross. Insure the ability of the
bridge to support the weight of the machine.
LUBRICATING:
Always stop the engine of the machine before lubricating or cleaning. The only exception to this rule is when lubricating the drive gears.
A-3
Safety
ENGINE IDLE:
Always maintain sufficient idle speed to charge the battery when idling for extended
periods of time. A voltmeter on the operator’s console module indicates voltage
output. When starting the engine, run at an idle of approximately 1000 RPM for 3 to 5
minutes before engaging any engine functions. When shutting down, run the engine at
half speed or slower with no load for at least 5 minutes before stopping.
NOTE: Cleanliness is the first step toward safe operation of the Thunderbird Yarder.
Tools, grease guns, and the like should be stored in a tool box and NOT in the cab.
The cab must be free of any articles which could create a hazard to the safety of any
workers, or to the safe operation of the machine.
The following sections have all needed information and instructions concerning the
operation and maintenance of the Thunderbird Yarder. All personnel
involved in the operation and maintenance of the yarder should read and thoroughly
understand the information contained in this manual. The terms listed will always have
the same meaning whenever they are used in this manual.
A-4
Nomenclature
TOWER & MAST
SWING FRAME - Entire upper portion of
machine. Includes the cab, drum arrangement,
power unit, hydraulic and fuel tanks.
UNDERCARRIAGE - That portion of the
machine below the carrier frame, including the
track frames, drive motors, etc.
CONTROL CAB - That portion of the machine
where the operator controls the operation of the
machine.
POWER UNIT
DRUMS
CONTROL CAB
SWING FRAME
UNDERCARRIAGE
TOWER & MAST - That portion of the machine above the swing frame, including the
tower, mast assembly, fairlead assemblies and
guyline drum assembly.
POWER UNIT - The power unit is located in
the rear portion of the swing frame,
including the engine, transmission, air compressor, radiator, travel pumps and pump drive.
DRUM ARRANGEMENT - That portion of
the machine located in the middle of the
swing frame, including the Haulback,
Front Main and Rear Main drums, chain case,
drive shaft and brake band installation.
A-5
Nomenclature
HAULBACK FAIRLEAD
REAR MAIN SHEAVE
FRONT MAIN SHEAVE
LIVE TOWER LINE
GUYLINE SHEAVE
ASSEMBLY
TRACK DRIVE - That portion of the undercarriage which provides the travel.
GUYLINE DRUMS - That portion of the
tower that controls the tension of the guylines.
SWING BEARING - Center bearing enables
the swing frame and undercarriage to rotate
independent of one another.
TOPPING WINCH - hydraulicly driven drum
for raising and lowering the tower, with a spring
set air release dogs for positive lock.
TOPPING
WINCH
GUYLINE
DRUMS
TRACK DRIVE
STRAWLINE
FAIRLEAD
FAIRLEAD ASSEMBLIES - That portion of
the tower which enables the operations
cables to change work angles. Each work line
has it’s own fairlead or sheave: haulback, front
main, rear main, strawline and guylines.
SWING BEARING
A-6
Servicing the Yarder
Because of the built-in quality and durability of this yarder, less maintenance and down
time will be recorded than with construction machinery converted for use in this
industry.
To assure the same, dependable operation of the yarder for indefinite periods of time,
FOLLOW THE SCHEDULED MAINTENANCE PROGRAM. Through the
scheduled maintenance program, potential problems can be resolved before they cause
expensive damage or downtime. Servicing procedures, as outlined in this manual, are
to be used by trained serviceman only. STUDY THIS MANUAL. KNOW THE
MAINTENANCE NEEDED FOR CONTINUOUS, TROUBLE FREE
OPERATION. This outline is intended as a guide only, and purchaser/user may or
may not use this outline.
When servicing the machine, be sure to use only genuine Thunderbird factory parts.
Only genuine factory parts have been designed and tested for this yarder to ensure
trouble free operation.
When ordering factory parts, be sure to have serial number, model number, engine
make, and description of any special equipment which was factory installed, to help
identify the correct parts. Serial number and model can be found on a specifications
plate permanently located on the operator’s cab.
REMOVE ALL JEWELRY, CONTAIN
LOOSE CLOTHING, TIE, DANGLING
SHOE/BOOT LACES, ETC., WHEN
SERVICING THE MACHINE.
A-7
Description
This section presents the general arrangement of the TSY6355, with overall dimensions, plus yarder design specifications.
POWER:
The specified engine provides adequate power to drive the power train drum requirements and two hydraulic pumps through a 2 station pump drive transmission for
continuous operation. The pumps, each providing power for the travel functions.
TRACTION HYDRAULIC SYSTEM:
The system made up of one variable diplacement over center piston pump for each
track.
CRAWLER:
The crawler assembly consists of the crawler frames, drive sprockets, idler mechanism,
track rollers and drive units. THUNDERBIRD tracks are cast triple grouser shoes,
bolted to the track chain, and driven by a sprocket which has been bolted to the drive
output flange. Single-flanged, lifetime sealed rollers distribute the machine weight
along the track. The upper carrier slide plate support the weight of the track between
the drive sprocket and idler, and maintain chain alignment.
Each track is driven by one variable Displacement, axial piston motor driving through
a 3-stage planetary reduction. This motor is mounted to the traction drive case and
bolted to the crawler frame. Drive gears are case hardened and splash lubricated.
Multiple disc traction brakes are mounted on each motor drive shaft. Brakes are
spring set, and hydraulically released. Brakes automatically apply when yarder is
stationary.
SWING FRAME:
The power unit, control cab, guarding and drum arrangement are the assembled
carrier frame.
Formed, steel panels, bolted to the upper frame and support posts, shroud the engine,
radiator and hydraulic pumps. Lockable doors provide easy access to the engine
house.
The operator’s cab is shock mounted and lined with 1" thick, closed cell foam latex for
temperature insulation and noise reduction. The front and rear windows are fixed.
The right hand side window slides open to allow adequate ventilation. The hinged
door locks in the open position. All THUNDERBIRD Yarders are equipped with a
heater / AC as standard equipment from our factory to further enhance operator
comfort. A deluxe, specially contoured and cushioned seat, with vertical-horizontal
and weight adjustments is also factory installed and included as standard equipment.
Operator control panels are manufactured as a single unit.
A-8
Description
DRUM ARRANGEMENT:
Fabricated box-type structure, line bored pedestals for accurate gear alignment, with
gears, clutches and water-cooled brakes mounted outboard for ease of maintenance.
TOWER AND MAST
The live tower is a fabricated (hi-tensile) steel A-frame, lattice style structure with a
normal working height of 60’ complete with swivel type fairleads, haulback sheave is
20” dia. main 16” dia., and slackpuller 13” dia. all mounted on tapered roller bearings.
The mast and back support are tube frame structures with a 43’ working height with
three swivel, walkover type guyline fairleads.
The guyline mast is designed so that it is free to swivel about the center of machine
rotation during swing operation.
The mast is supported at the rear by an a-frame backstay which in turn is pinned to the
swing frame.
The backstay is provided with a stiffener between the mast foot and the backstay foot.
This stiffener also acts as a lifting arm during tower and mast erection.
OPTIONAL POWER UNITS:
1)
2)
Cat 3408 (450 HP)
Cummins NTA-855 (430 HP)
DRIVE INPUT HOUSING:
Power is provided from the transmission to the drive input housing. The primary
reduction from the transmission is sprocket and chain drive to the drive shaft. The
primary chain reduction is mounted on the end of the drive shaft.
DRIVE SHAFT:
The drive shaft first provides power through a pinion gear to the drum gears. The
shaft extends on across the drum frame to drive the strawdrum.
STRAW DRUM:
The straw drum is mounted on the end of the drive shaft and is located directly in front
of the power unit on the left side of the machine. It is driven by an air operated plate
clutch keyed to the drive shaft, with the drum mounted on roller bearings for free
wheeling.
The drum is fitted with a large disc brake and is also spring set for parking or emergency use.
The strawdrum is underwound during inhaul.
A-9
Description
MAIN DRUMS
Power is provided to either drum by means of gears (w/clutches) located
outside of main frame.
Dropline functions are powered by means of reversing gears (w/clutches)
located inside of main frame. (Optional)
Pull clutches are hydraulic operated, 26” dia x 7” wide internal expanding BFG located outside of main frame. Machines with S/N S5188 and previous use air-operated, 36” diameter x 5” wide internal expanding shoe style.
Both main drums have a WCB-124 water cooled brake, with a 34” x 5” wide band
brake.
Drums can be either operated indepentently from each other or interlocked
together.
Parts are interchangeable between.
HAULBACK DRUM:
The haulback drum is keyed to the shaft, with the shaft mounted on roller bearings.
The drum is driven by a 26” x 5” hydraulic operated internal expanding BFG clutch,
which is keyed to the shaft.
The shaft has an Eaton 224 water cooled tension brake, keyed to the shaft, located
outboard of the yarder frame on the power unit side.
In addition, the drum is fitted with a two piece, air-operated 5” x 34” diameter band
brake, which is also spring set for parking emergency use.
The haulback drum overwound
GUYLINE DRUM:
The three (3) guyline drums for the TSY6355 are mounted on the tower assembly,
welded to the backstay frame. The guyline drums are bushing mounted on a common
stationary mount. Each drum is driven by a hydraulic drive motor, driving through a
double chain reduction. In addition, each drum has a spring-on, air-off locking dog.
All controls are mounted in the operator’s cab.
A-10
Description
SWING DRIVE
Planetary drive with a radial piston style hydraulic motor and spring-set, hydraulically
released brake, provides swing torque to large diameter slewing ring.
CONTROL CAB
Rear entrance cab, mounted on R.H. side of frame, positioned forward to observe
landing and operation of machine at all times; comes equipped with all yarding controls, as well as wiper, heater, defroster, insulation, tinted windows, escape hatch, wire
screen window guards and tube type front log guard.
A-11
Design Specifications
HAULBACK DRUM
A large fabricated steel drum keyed to shaft, with gear and shaft mounted on bearings
(parts interchangeable with skyline drum). Drive clutch, hydraulic operated, 26”
(66cm) x 7” (17.8cm) internal expanding shoe-type; tension brake, water cooled,
WCB-224; band brake, 34” (86cm) DIA 5” (13cm) wide external contracting.
DRUM SIZE: 28” (71cm) Dia. Barrel
33.25” (84cm) Barrel Length
48” (122cm) Dia. Flange
CAPACITY: 4,600’ (1402m) of 7/8” (22.2mm) dia. cable or 3,000’ (914m) of 1”
(25.4mm) dia. cable.
MAX PULL (Stall): Bare drum = 91,400 lbs. (415.5kn)
Ave. drum = 69,460 lbs. (315.8kn)
Full drum = 56,020 lbs. (254.7kn)
MAX SPEED:
Bare drum = 2,202 FPM (11.2m/s)
Avg. drum = 2,650 FPM (13.5m/s)
Full drum = 3,290 FPM (16.7m/s)
MAIN DRUMS:
Large fabricated steel drums keyed to the shaft and pedestal mounted with bearings.
Main drive clutch, hydraulic operated 26” (66cm) dia. x 7” (17.8cm) wide internal
expanding BFG; tension brake, water-cooled, WCB-124; band brake (each), 34”
(86cm) dia. x 5” (13cm) wide .
DRUM SIZE:
30” (76cm) DIA. Barrel
33.25” (85cm) Barrel Length
41” (104cm) DIA. Flange
CAPACITY: 2,300’ (701m) of 7/8” (2.2cm) dia. cable
MAX PULL MAIN (stall):
Bare drum = 108,200 lbs. (4920kn)
Avg. drum = 94,110 lbs. (428kn)
Full drum = 83,270 lbs. (379kn)
MAX SPEED MAIN:
Bare drum = 1,700 FPM (8.6m/s)
Avg. drum = 1,950 FPM (9.9m/s)
Full drum = 2,200 FPM (11.2m/s)
A-12
Design Specifications
STRAWDRUM:
A large fabricated steel drum mounted on drive shaft on roller bearings, located on the
left side of the machine.
Disk Style Clutch - P.O. 214
Caliper Style Disk Brake
CAPACITY: 4,600 ft. (1402m) of 3/8” (.95cm) dia.
GUYLINE DRUM:
Three (3) hydraulically driven fabricated steel drums, provided with spring set, air
release dogs for positive lock.
CAPACITY (each):
125’ (38m) of 1-1/8” (.34cm) dia. cable.
BARE DRUM PULL: 15,000 lbs. (68.5kn).
A-13
Power Train Formation
TRANSMISSION
ENGINE
THREE GUYLINE DRUMS
CLUTCH
CHAIN DRIVE
HAULBACK
DRUM
STRAWLINE DRUM
WATER
COOLED
BRAKE
REAR MAIN
DRUM
CLUTCH
WATER COOLED BRAKE
FRONT MAIN
(SLACK) DRUM
WATER COOLED BRAKE
CLUTCH
A-14
Engine Specifications
Engine:
Caterpillar 3406B DIT Turbo-Charged
Engine Type:
Diesel - 4 Stroke Cycle
Cylinders:
Six 5.4” Bore x 6.5” Stroke (137mm x 165 mm)
Displacement:
893 Cubic Inches (14.6 Litres)
Manufacturer’s Maximum Rating: 425 HP @ 2000 RPM
Continuous Net Full Load Torque: 592 LB FT (810 NM) @ 1300 RPM
Continuous Net Peak Torque:
598 LB FT (810 NM) @ 1300 RPM
Battery - Size and Rating:
8D - CCA - 24 Volt
Starting System:
24 Volt
Alternator:
24 Volt
Amp Output:
75 Amp
Altitude Derating:
Above 12,000 FT (3,658 M)
A-15
Engine Specifications
Engine:
Cummins NTA-855 Turbo-Charged
Engine Type:
Diesel - 6 Stroke Cycle
Cylinders:
Six 5.5” Bore x 6” Stroke (140mm x 152 mm)
Displacement:
855 Cubic Inches (14.0 Liters)
Manufacturer’s Maximum Rating: 430 HP @ 2100 RPM
Continuous Net Full Load Torque: 592 LB FT (810 NM) @ 1300 RPM
Continuous Net Peak Torque:
598 LB FT (810 NM) @ 1300 RPM
Battery - Size and Rating:
8D - CCA - 24 Volt
Starting System:
24 Volt
Alternator:
24 Volt
Amp Output:
75 Amp
Altitude Derating:
Above 12,000 FT (3,658 M)
A-16
Dimensions
E
G
H
I
F
TSY6355
59’5” (18.11M)
REFERANCE
A
A
45’0” (13.72M)
B
12’1” (3.68M)
C
55-3/4” (1.42M)
D
17’1” (5.21M)
E
19’8-1/2” (6.01M)
F
30” (.76M)
G
12’ (3.66M)
H
84” (2.13M)
I
12’0” (3.66M)
B
C
D
A-17
Chapter B: Controls and Instruments
CONTROLS AND INSTRUMENTS ...................................................................... B-1
START-UP CONTROLS.......................................................................................... B-3
WARNING SYSTEM ............................................................................................... B-5
INSTRUMENTS ...................................................................................................... B-7
CIRCUIT BREAKERS ............................................................................................ B-8
Controls and Instruments
SEE NEXT PAGE
16
17
18
19
20
1
2
3
4
5
6
7
8
21
9
10
11
12
13
14
15
TRANSMISSION SHIFT LEVER SHOWN WILL DIFFER, DEPENDING UPON TRANSMISSION & SERIAL NUMBER
B-1
Controls and Instruments
30
31
32
33
34
35
22
23
24
25
27
26
28
11
29
12
39
38
37
36
TRANSMISSION SHIFT LEVER SHOWN WILL DIFFER, DEPENDING UPON TRANSMISSION & SERIAL NUMBER
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
DESCRIPTION
Warning Light
Travel Hi/Low Control
Wiper Control
Swing Brake On/Off Control
Yard/Travel Control
Main On/Off Control (Rear Main Drum)
Slack On/Off Control (Front Main Drum)
House Lock On/Off Control
Servide Brake On/Off Control
Do Not Shift Indicator
Swing and Throttle Control
Transmission Range Selector Control
Straw DrumClutch control
Strawdrum Brake Air Pressure Guage
Strawdrum Brake Control
Left Travel Brake Control
Haulback Drum Brake Control
Slackpulling Drum Brake Control (Front Main Drum)
Main Drum Brake Control (Rear Main Drum)
Right Travel Brake Control
ITEM
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
DESCRIPTION
Drum Control (All)
Guage, Interlock Air Pressure
Guage, Water Cooled Brake Temprature
Guage, Engine Oil Pressure
Guage, Engine water Temprature
Guage, Transmission Oil Pressure
Guage, Transmission Oil Pressure
Guage, Voltmeter
Guage, System Air Pressure
Maxi Brakes (All Drums)
Guyline Drum Dog Controls
Guyline Drum Motor Controls
Topping Drum Motor Control
Topping Drum Dog Control
Guage, Charge Pressure
Cold Start Control
Guage, Hour Meter
Fuse Panel
Ignition Switch
B-2
Start-up
IGNITION SWITCH:
A key-actuated, three position switch. Position one (1) is the OFF position, the key
can only be withdrawn in this position. Position two (2) is ON, energizing all electrical
circuits. Position three (3) is the START position, which completes the circuit between
the battery and the engine starter motor. Positions one and two are maintained,
position three is only held in place until the engine begins running.
1 OFF
2 ON
! CAUTION
3 START
ALWAYS PLACE IGNITION IN THE
“OFF” POSITION WHEN WORKING ON
MACHINE. ALWAYS REMOVE THE KEY
WHEN MACHINE IS NOT IN USE
ENGINE THROTTLE:
Located at the operator’s left hand, this lever controls engine speed. Lever fully
forward is low idle speed. To accelerate, move lever to rear (towards operator). The
engine will maintain a constant set speed at any position between idle and full.
ENGINE STOP:
Turn keyed ignition switch to the OFF position. In this position, all electric circuits are
de-energized and the engine stops. In addition, the fuel supply solenoid will close,
shutting off the engine fuel supply.
B-3
Start-up
TRACTION DRIVE PEDALS:
Travel and Drum control pedals, located directly in front of the operator’s seat, ensure
positive control and ease of operation. All pedals are linked to their respective functions which, when activated by pedal movement, provide a smooth and positive operation. The traction brakes are the outer most pedals and are hydraulically released
whenever the pedals are moved from the neutral position. To engage the two-speed
travel mode, simply move the switch located on the left-hand control console to the
High or Low position.
PEDAL OPERATION FOR TRAVELING:
COUNTER-ROTATE LEFT- Tip of right pedal down and heel of left pedal down.
COUNTER-ROTATE RIGHT- Tip of left pedal down and heel of right pedal down.
FORWARD TRAVEL- Tip of both pedals down an equal distance.
REVERSE TRAVEL- Heel of both pedals down an equal distance.
ALWAYS TRAVEL WITH TRACTION DRIVE TO REAR.
B-4
Warning System
WARNING LIGHTS AND BUZZER:
A red warning light, located on the Gauge panel, will illuminate and a warning buzzer
will sound whenever certain critical machine functions are not within specified limits.
If these alarms activate, the machine must be moved to a safe location and proper
corrective maintenance performed.
REFERANCE CHART
GUAGE
NORMAL RANGE
ALARM RANGE
205° F and above
Water Brake Temperature
180° F
Engine Water Temperature
180° F
Transmission oil Temperature
230° F
Engine Oil Pressure
30 PSI (Cummins)
40 PSI (Cat)
205° F and above
250° F
4 PSI Tripped
BATTERY VOLTAGE:
A needle gauge located in the control console allows a constant monitoring of battery
voltage. A gauge reading exceeding 30 volts indicates an overcharged condition, most
likely due to a faulty or maladjusted voltage regulator. A gauge reading below 21 volts
indicates an undercharged condition due to a faulty battery or voltage regulator malfunction. Failure to correct either type of condition may result in damage to the electrical system of the loader.
! CAUTION
UNTIL THE CAUSE OF A HIGH OIL
TEMPERATURE PROBLEM HAS BEEN
FOUND AND CORRECTED, DO NOT
CONTINUE TO OPERATE MACHINE.
PERMANENT DAMAGE TO THE ENGINE
COULD RESULT.
B-5
Warning System
ENGINE WATER TEMPERATURE:
A needle gauge located on the control console that gives a constant indication of
engine coolant temperature. An alarm will sound if this temperature exceeds
205° F for Cummins and 215° F for Caterpillar or above. If the alarm is active, shut
down the loader immediately and refer to the troubleshooting section of this publication.
NOTE: A lighter work cycle may be required if the ambient temperature exceeds
115°F.
DO NOT ATTEMPT CONTINUED OPERATION OF THE YARDER WHILE
ALARM REMAINS ACTIVATED.
ENGINE OIL PRESSURE:
Engine lubrication oil pressure is indicated on a needle gauge located on the control
console. The operator should make periodic visual checks of this gauge while the
engine is running. A properly operating engine will have an oil pressure of above 30
PSI when running at full throttle, if less than this value is observed the oil level should
be checked immediately. The oil pressure will show a rise with increased engine RPM
and a decrease as the oil temperature increases. IF PRESSURE DROPS BELOW 10
PSI, SHUT OFF ENGINE IMMEDIATELY.
NOTE: Engine oil pressure may register low when engine is first cold started.
B-6
Instruments
HORN BUTTON:
Depress to sound horn, located on left joystick. A travel alarm automatically sounds
during all steering and tracking operations.
HEATER/ AC UNIT:
The panel is located for the operator’s ease of operation. It contains the necessary
controls for selecting heating within the vehicle.
FAN SWITCH:
A two position turn-type switch located at base of fan.
WINDSHIELD WIPER SWITCH:
A two position switch located on the instrument panel.
HOUR METER:
Accumulates engine operating time up to 9,999 hours. Use to compute log of maintenance checks, fuel consumption and operating costs.
B-7
Circuit Breakers
15
AMP
1
20
AMP
20
AMP
20
AMP
20
AMP
20
AMP
2
4
6
8
10
20
AMP
20
AMP
20
AMP
20
AMP
20
AMP
3
5
7
9
11
ITEM
1
2
3
4
5
6
7
8
9
10
11
DESCRIPTION
12 Volt Supply
VIM
Heater/Wiper
Neutral Start
Guyline and Topping Winch
Whistle
Fuel/Cold Start
Joysticks
Hour Meter and Air Dryer
Two Speed
Fan & Volt Meter
B-8
Chapter C: Operating Procedures
PRE-START INSPECTION ..................................................................................... C-1
STARTING THE ENGINE ...................................................................................... C-2
JUMP STARTING THE ENGINE ........................................................................... C-3
MACHINE WARM-UP ............................................................................................ C-4
SHUTTING DOWN THE MACHINE .................................................................... C-5
UNUSUAL OPERATING CONDITIONS .............................................................. C-6
EXTREME COLD ................................................................................................... C-6
EXTREME HEAT .................................................................................................... C-7
HIGH HUMIDITY OR SALTWATER ..................................................................... C-9
HIGH ALTITUDES ............................................................................................... C-10
YARDER TRANSPORTING ................................................................................. C-11
TOWER RAISING & LOWERING ....................................................................... C-12
TOWER PIN LOCATIONS ................................................................................... C-14
SETTING GUYLINES .......................................................................................... C-15
GUYLINE ARRANGEMENT ............................................................................... C-16
DRUM OPERATIONS ........................................................................................... C-17
PROCEDURAL AWARENESS ............................................................................. C-20
WORKING WITH HYDRAULICS ....................................................................... C-21
Pre-Start Inspection
DAILY PRE-START CHECKLIST IS AS FOLLOWS:
ENGINE OIL LEVEL: Maintain oil level at full mark.
COOLANT: Maintain sufficient coolant level to cover the core inside of the radiator.
LEAKAGE: Always check under, and around, machine for telltale signs of fluid
leakage.
FUEL: Check level and TOP OFF tank, if needed, to assure day long operation. DO
NOT ALLOW FUEL TANK TO RUN DRY.
FUEL SHUT-OFF VALVE: Located on bottom of tank. Assure valve is in the open
position. Do not mistake quick release drain cap for shut-off valve.
LUBRICATION: Lubricate daily all points shown on Lubrication Chart, including all
mounting bushings and pins.
HYDRAULIC SYSTEM: Visually inspect all valves, pumps, motors, connections,
mounting bushings and pins, reservoir sight gauge, and oil temperature gauge.
FUEL FILTERS: Drain accumulated water and sediment from the water trap filters
daily.
GENERAL CONDITION: Perform overall visual check for damage, wear, leakage
and cleanliness. After the daily check is finished, and all systems check satisfactorily,
you may start your engine.
VANDALISM: Look for evidence of vandalism, tampering, unfinished repair work,
or loose tools. Inspect control panels, etc., for obvious disconnects.
AIR OILER: Check air line lubricator oil level.
GEAR TRAIN: Check yarder gear train for adequate lubrication.
AIR TANK: Drain water from wet air tank.
OPERATORS CONTROLS: Place all operator controls in their neutral or off
positions, with all brakes in set position.
BATTERY: Turn battery master switch on.
C-1
Starting the Engine
Note: After completing the daily pre-start checks, the yarder engine may be started
and warmed up as follows:
ENGINE START-UP
A. Place transmission shift selector in neutral.
B. Advance throttle control level slightly above slow idle position. Turn keyed
ignition switch clockwise to start position and hold. Release ignition switch when
engine starts. Should stalling occur, allow engine to stop revolving before attempting
to restart. If engine fails to start within a 30 second period, you must allow starter to
cool at least 2 minutes before trying to start engine again.
! CAUTION
Do not attempt to operate machine until all
pressures and temperatures have reached recommended levels.
C. Immediately after the engine starts, observe the engine oil pressure gauge. If
no oil pressure is indicated within 10-15 seconds, shut the engine down and
inspect the lubrication system levels and connections. (Refer to engine manual
for troubleshooting.)
D. Run the engine at idle speed for approximately five minutes. This will allow air
and oil pressures and engine temperatures to build up to operating levels.
Note: Check the engine and yarder for air or oil leaks; repair any leaks before at
tempting to operate yarder.
C-2
Jump Starting the Engine
! CAUTION
ALWAYS HAVE IGNITION KEY IN OFF
POSITION BEFORE CONNECTING
CABLES.
! CAUTION
ALWAYS HAVE TRANSMISSION IN THE
NEUTRAL POSITION BEFORE
CONNECTING CABLES.
The ground cable must be attached last and removed first to prevent sparks
from occurring near the battery. Sparks could cause battery vapors to explode.
Attach the ground cable from the booster battery to a point away from and below the
battery (use starter ground post of machine to be started).
To prevent possible personal injury, care must be used when removing the cables from
the machine that has been started. Do not allow the cable ends to contact each other
or the machine.
Always connect batteries in parallel: positive to positive, negative to negative. Connect
positive poles first, negative poles second. Disconnect negative poles first, positive
poles second.
1. Attach one cable to ungrounded POSITIVE (+) terminal of battery on machine to
be started. Attach opposite end of cable to POSITIVE (+) terminal of external starting
source.
2. Attach second cable to NEGATIVE (-) terminal of starting source. Attach remaining cable end to the starter post of the machine to be started.
3. Start engine.
4. After engine starts, FIRST remove cable end from starter ground post of machine
just started. NEXT, remove opposite end of cable from negative terminal of starting
source.
5. Remove cable from POSITIVE (+) terminal of battery on machine started. Finally,
remove opposite end of cable from POSITIVE (+) terminal of starting source.
C-3
Machine Warm-up
RECOMMENDED WARM-UP PROCEDURE:
After machine is started, allow adequate time for all oils to warm to operating temperature. Machine warm up is part of daily preventative maintenance. For smooth
response and accurate movement, all oils must flow freely. Warm oils flow freely.
Make it a daily habit to allow engine to idle at about 550 RPM for a period of 3-5
minutes.
C-4
Shutting Down the Machine
RECOMMENDED SHUTDOWN PROCEDURE IS:
A. Remove tension from lines by running butt rigging or carriage out of landing
area.
Note: If using a motorized carriage, it is recommended that the carriage be set on the
ground in the landing area.
B. With no load, allow engine to run at half throttle for 5 minutes to allow engine to
cool before shut down.
C. Apply spring brakes on all drums
D. Place engine ignition switch in OFF position in order to render all controls inoperative. REMOVE THE KEY!
E. Be sure swing brake control is in ON position.
F. To prevent vandalism, close fuel shut off valve at bottom of tank and switch the
battery shut-off.
G. Inspect machine as a part of your scheduled maintenance program, and report, in
writing, all problems found to your maintenance personnel.
H. Latch all windows. Lock cab door, engine house doors, and all access doors.
Special care must be taken to prevent machine damage and component failure when
operating under unusual conditions such as extreme heat/cold/humidity, high altitude,
salt water, or dusty/sandy work sites. By following the recommendations listed for
such conditions, major problems can be avoided.
C-5
Unusual Operating Conditions
EXTREME COLD:
To avoid battery failure, inadequate lubrication, and freeze damage, it is advised that
your machine be winterized before moving to a cold weather situation. Proper winterization is achieved by servicing the cooling system, and by using the correct COLD
WEATHER lubricants (see lube chart).
COOLING SYSTEM:
To avoid freeze damage to cooling system and/or major damage to engine block or
head, system should be completely drained and flushed. Be certain exterior air passages are clear and that cooling fins are free of dirt, grease, etc. Use equal amounts of
antifreeze and water. Check thermostat, radiator hoses, hose clamps and repair or
replace as needed.
FUEL SUPPLY:
To avoid fuel line freeze up caused by condensation in the fuel tank, keep fuel tank as
full as possible.
LUBRICATION:
Change engine oil, and other lubricants not meeting specifications for cold weather
operation, per lubrication chart.
BATTERY:
Battery must be kept fully charged at all times to avoid electrolyte freezing. Be sure
battery is charging when engine is running. When machine is not operating, use an
external charging source to bring battery to full charge. Add water to battery just prior
to starting the engine to allow water to mix with electrolyte while machine is operating. Not allowing water to mix with electrolyte can cause battery freeze up. Removal
of battery, and storage in a heated area if machine is to be idle for a period of time, is
advised.
NOTE: Keep battery post clean and dry. Use soda and water to clean post.
HYDRAULIC OIL:
Perform pre-operation hydraulic oil warm-up before starting any actual cold weather
operation, to avoid hydraulic malfunctions.
C-6
FREEZING:
Upon completion of the work period or whenever the machine is to be left idle for
extended periods, prevent it from being frozen to the ground by parking it on wood,
concrete, asphalt or a mat surface.
EXTREME HEAT:
Extreme heat requires certain precautions to be taken with respect to the cooling
system, the batteries and lubrication. The following procedures are recommended:
1. High temperatures require the use of lubricants which are more viscous and which
resist deterioration at higher operating temperatures. Refer to Chapter E and lubricate
the machine using the lubricants recommended for the expected temperatures. Crankcase oil is particularly important because it helps to dissipate heat. Check the oil level
frequently and add oil as required to maintain proper level. Too little oil will hinder
heat dissipation.
2. To ensure proper coolant circulation, drain and flush the cooling system, clean any
foreign matter from the radiator cooling fins and through-core air passages, replace
defective hoses, tighten hose clamps, tension the water pump drive belt properly,
eliminate any leaks detected, and fill the system with a 50% solution of ethylene
glycol. Engine overheating due to loss of coolant will most often be corrected by
slowly adding coolant, while the engine is running at FAST IDLE. Should this fail to
correct the problem, drain and flush the system and refill with fresh coolant (50%
solution of ethylene glycol) and a corrosion inhibitor.
! CAUTION
ALLOW THE ENGINE TO COOL BEFORE DRAINING AND FLUSHING THE
COOLING SYSTEM.
Water containing more than small concentrations of salt or minerals should not be used
in the cooling system. Salt facilitates corrosion and minerals deposit on the coolant
passage walls. Both processes inhibit proper cooling.
3. Increased evaporation rates will cause the battery electrolyte level to fall even more
rapidly during very hot weather. Check this level frequently and add distilled water as
required to maintain the proper level.
4. Air circulation around the engine and battery must not be restricted. Keep air
intake and exhaust openings clear of leaves, paper or other foreign matter which may
restrict air flow.
5. Keep the engine clean of dirt, grease and other substances which inhibit heat
dissipation.
C-7
6. Operate the engine at full throttle when yarding or tracking the machine.
Run the engine only when engaged in work operations or when moving the machine.
Avoid prolonged periods of running at idle and shut the engine down whenever operations are interrupted.
C-8
High Humidity or Salt Water
In some locations, such as coastal areas, the machine may be exposed to the deteriorating effects of salt, moisture, or both. To protect exposed metallic surfaces, wiring,
paint and other items, keep them dry and well lubricated where salt or high humidity
are encountered. Follow the recommendations below when operating in these conditions:
1. Make frequent inspections for rust and corrosions and remove them as soon as they
are detected. Dry and paint exposed surfaces after rust and corrosion have been
removed.
2. Where paint may not be applied, such as on polished or machined surfaces, coat the
area with grease or lubricant to repel water.
3. Keep bearings and their surrounding surfaces well lubricated to prevent the entry of
water.
4. Drain condensation frequently from air tanks.
5. Check air lubricator for correct operation.
6. Check air dryer system for correct operation.
7. Keep drive gears and pinion mating surfaces well lubricated.
C-9
High Altitudes
Variations in altitude alter the fuel-air mixture burned in the engine and affect the
engine’s performance. At high altitudes, atmospheric pressures are lower and less
oxygen is available for the combustion of fuel. Above 5000', the engine fuel injectors
may have to be changed to ensure proper performance. Consult engine manufacturer
should this problem arise.
Keeping the air cleaner clean and free of obstructions will help alleviate high altitude
problems. At high altitudes, closely monitor the engine and hydraulic oil temperatures
for over heating.
NOTE: On machine equipped with turbocharged engines, engine power will not
decrease at altitude; however, cooling ability does. This can lead to overheating
problems unless the duty cycle is reduced or special cooling packages are added.
C-10
Yarder Transporting
IT IS IMPORTANT TO CHECK ALL STATE AND LOCAL REGULATIONS
REGARDING HEIGHT, WIDTH, AND WEIGHT FOR TRANSPORTING
ANY EQUIPMENT.
! CAUTION
IMPORTANT: Regardless of how the machine
is positioned on the trailer, always be sure to
TIE DOWN attachment SECURELY. This is a
necessary precaution to avoid unnecessary
damage due to vibration, bouncing, etc. while
traveling from one site to another.
C-11
Tower Raising & Lowering
TOWER RAISING PROCEDURE:
1. Flip the diverter valve to the “YARD” position.
2. Reeve the Haulback line as shown in the illustration below. Thread the line from the
Haulback drum to the bottom side of the narrow sheave (1) on the Raising Arm.
3. Then over the top of the narrow sheave (1) to the top of the roller (2) on the main
frame.
4. Thread to the bottom of the wide roller (3) on the Raising Arm.
5. Continue over the top of the wide roller (3) to the Shackle (4) on the bottom of the
Backstay.
4
2
MAIN FRAME
BACKSTAY
1, 3
HAULBACK DRUM
RAISING ARM
6. The Tower must be kept at rest by allowing the Topping line to pay out. Engage the
Haulback clutch, place the Transmission in first gear. Using the Haulback brake pedal
for control, advance the throttle to lift the Raising Arm, Backstay, and Mast only.
Continuue inhauling the Haulback line until the Backstay legs are in position. Insert
and secure the leg pins.
Do not attempt to raise the Tower, Mast and
Backstay at the same time. Control conditions
may become Hazardous. Raise them seperately.
7. Slack and unreeve the Haulback line.
8. Using the illustration on the next page as a guide, reeve the Topping line as described.
9. Engage the Topping drum drive and raise the Tower to the proper working angle.
Engage the Topping drum locking dogs.
C-12
Tower Raising & Lowering
! CAUTION
The proper working angle must be between 15°
and 20° from vertical. Other positions may cause
line scuffing or machine component overlaods.
The line leaves the drum (1) from the top and
runs through the top of the sheave (2) on the
near side of the mast, through the top of the
pendant sheave (3), then under the near mast
sheave (4). It runs back to the middle pendant
sheave (3) then through the lower middle mast
sheave (4). Finally through the far side (3) and
(4) as previously explained. Then through the
end sheave (3) to the anchor on the far side of
the mast near the sheave (2).
TOWER LOWERING PROCEDURE:
The tower may be lowered from any position. However, for transportation, the tower
is normally placed parallel to the tracks and the house lock engaged.
1. Flip the diverter valve to the “YARD” position.
2. Reeve the Haulback line as described in steps one through five of the “Tower
Raising Procedure”. Engage the Haulback clutch, place the transmission in reverse,
and use the Haulback brake pedal for control. Advance the throttle as required to
remove the Haulback line slack.
3. Retract the Topping drum dog and pay out the Topping line until the tower is fully
lowered.
4. Remove the pin from the Backstay feet.
5. Using the Haulback brake pedal for control, inhaul on the Topping drum to tip the
Mast and Backstay. Continue inhauling the Topping line until the Mast and Backstay
are at rest horizontally.
C-13
Topping Line Reeving Instructions
C-14
Tower Pin Locations
TOWER TOPPING ANCHOR PIN
TOWER TOPPING ANCHOR PIN
TOWER STOP PIN
MAST TOPPING ANCHOR PIN
PIVOT PIN
PIVOT PIN
RAISING ARM PIVOT PIN
PIVOT PIN
C-15
Guyline Arrangement
Avoid load bearing guylines being located at an
angle steeper than 45° as possible damage to the
tower abd other components may occur.
ALWAYS MAINTAIN TWO (2) GUYLINES
OPPOSITE FROM PULL DIRECTION.
Setting Yarder Guylines
GUYLINE DRUM OPERATION:
The guyline drums are controlled from the cab.
1. Set guyline dog control valves to “off”
2. Lift toggle levers to pay out guylines
3. Attach guylines to stumps
4. Pick up excess slack in guylines, and set dogs to the “ON” position and assure that
the guyline dogs are fully seated.
5. Put out running lines for whichever system is to be used, leave slack
6. Tighten guylines
Do not overtighten Guylines
C-16
Procedural Awareness
Use extreme caution when using the hand holds and steps while entering the yarder
cab. Always have at least three points of contact (two hands and one foot or one hand
and two feet) solidly in place at all times. Hand holds and steps, made slippery by
water, oil, etc., are especially dangerous and must be used carefully and properly.
All controls on the Thunderbird yarder (with the exception of the tilt cab function)
have been designed to be used by an operator sitting in the seat of the control cab. Do
not attempt to start or operate the yarder from any other position or bypass any of the
interlock systems or controls.
Never allow anyone other than the operator to be in or on the machine while it is in
operation. They are subject to injury by being struck by the load or other moving
objects, by falling, or being thrown from the machine during any machine movement.
Their presence may also distract the operator, or block vision, and thus lead to an
accident or unsafe operation.
UNDER NO CIRCUMSTANCES should
anyone ever ride or be carried on the boom or
any attachment. To do so constitutes an extreme
personnel hazard.
Always have a clear unobstructed view of all parts of the yarder operation before
starting the yarder or moving any load. If visibility is poor, reduce operating speed
accordingly.
Be sure to warn all others in the vicinity of the job site before travelling the yarder. If
the job site is extremely congested, have a coworker precede the machine to warn
others in the area and to signal problems to the operator. Be sure to coordinate hand
signals before you start.
C-20
Working With Hydraulics
With the engine running, pressures as high as 5000 PSI are generated within the
hydraulic system. At these high pressures, even a tiny leak can lead to major problems
in a very short while. It is important to correct problems as soon as possible after they
are discovered, both to prevent hazardous operating conditions and to prevent machine damage.
NEVER check for leaks using your bare hand - hydraulic fluid being ejected under
pressure can cause sever damage to skin tissue. Always use a piece of wood or heavy
cardboard to detect suspected leaks.
All work on the hydraulic system must be performed with the engine off. However,
even with the engine off very high pressures may be trapped in hoses, tubes, and
valves.
Hydraulic fluid can reach extreme temperatures after being worked for a period of
time. Allow sufficient time for the fluid to cool before attempting to service any part of
the hydraulic system.
C-21
Chapter D: Maintenance Checks
INTRODUCTION ....................................................................................................... D
DAILY CHECKS...................................................................................................... D-1
WEEKLY CHECKS ................................................................................................. D-5
MONTHLY CHECKS .............................................................................................. D-7
QUARTERLY CHECKS .......................................................................................... D-8
SEMIANNUAL CHECKS ..................................................................................... D-10
ANNUAL CHECKS ............................................................................................... D-11
Introduction
This section contains safety information, inspection and maintenance checklist for the safe and
reliable operation of the TSY6355 yarder/tower. The conscientious operator will be guided by
the primary rules of safety when operating or servicing the machine and should continuously
update his techniques for efficient performance.
Safety should not be limited to the items listed in this manual, but should include any precaution required by the particular circumstances of the operation and should always include
Local, State, and National safety rules and regulations.
The following is a partial list of common safety practices connected with yarder operations:
1. Watch the load or lines at all times. Stop operation during any distractions.
2. Never leave the operator’s position without securing all drums.
3. Keep all personnel from beneath the load.
4. Never climb on or off the yarder while it is operating.
5. Do not install oversize wire rope.
6. Use properly sized chokers.
7. Inspect all wire rope, carriages, and chokers.
8. Keep all personnel well clear of all lines and attachments during operation or during tower
raising procedure.
! CAUTION
Check vendor materials located in the vendor
section of this manual for additional check lists
and maintenance requirements.
D
Daily Maintenance Checks
LUBRICATION:
Lubricate all points indicated on lubrication chart. (Refer to Chapter E of this section.) Use only those types of lubricants as are specified.
FUEL TANK DRAIN:
Contaminants must be drained from the tank daily. Remove the drain plug, located on
the bottom right hand side of tank. Allow contaminants (moisture and sediment) to
drain from the tank. When fuel appears clear, close the drain. Drain water from the
fuel separator daily.
NOTE: The machine should be level when draining contaminants. Do not mistake
fuel shut off valve for the drain plug. The fuel shut off valve should be closed when
draining contaminants.
FILL NECK
FUEL LEVEL: To avoid contaminants entering fuel tank, always clean around the filler cap
before adding fuel. Tank should be kept as full as
possible with a quality Grade-2 diesel fuel. To
minimize condensation, especially in cold
weather, fill the tank to the bottom of the filler
neck.
DRAIN PLUG
AUXILIARY FUEL FILTER:
Water and sediment can be drained from fuel filters by opening the drain cock at base
of the filter. Allow approximately 1/2 cup of fuel to drain from each filter.
CONTROLS:
Check all controls daily to ensure proper operation. Keep all control components free
of dirt and grease. Malfunctioning controls or instruments should be repaired or
replaced immediately.
! CAUTION
Ensure that all controls are in the NEUTRAL
position before starting the engine.
D-1
ENGINE OIL:
Allow engine oil to drain back to the sump before checking oil level. (About 15
minutes) The dipstick is accessible through rear doors of engine house.
! CAUTION
DO NOT CHECK OIL LEVEL WHILE
ENGINE IS RUNNING!
! CAUTION
DO NOT OPERATE ENGINE IF OIL
LEVEL IS ABOVE FULL MARK OR BELOW THE LOW MARK. DO NOT OVERFILL.
COOLANT LEVEL:
It is recommended that coolant level be checked each morning, before work has
begun. Check coolant level with engine stopped.
! CAUTION
If coolant level requires checking after engine
has run for some time, remember to loosen cap
slowly to relieve pressure. Then removing cap.
PRESSURIZED HOT FLUIDS CAN INFLICT SERIOUS PERSONAL INJURY IF
ALLOWED TO ESCAPE QUICKLY. Maintain coolant level to within 1/2” below fill pipe.
D-2
AIR CLEANER: A clogged air filter restricts
engine power output, and must be checked daily.
A vacuum actuated indicator, mounted on the air
cleaner outlet neck, indicates conditions of
restricted air flow through the air cleaner. If red
signal is in the service level, with engine running
at maximum governed RPM, air filter needs to
be cleaned or replaced. Refer to section IV of
this publication for complete air servicing instructions.
INDICATOR
BREATHER
PUMP DRIVE CASE: Access to pump drive
case, filler/breather and full plug is rear of the
engine house. Oil level, with engine NOT running, should just start coming out the hole when
the full plug is removed. OVER FILLING
COULD CAUSE OVERHEATING OR MALFUNCTIONING! Clean around the filler/
breather before removing it to add oil.
FULL PLUG
DRAIN PLUG
INPUT SHAFT
OUTPUT
COUPLERS
DAILY INSPECTIONS:
1. At the end of the shift, drain the air tanks to remove moisture and accumulated
sediments from the system.
2. Check drum drive gears and drive pinion for proper lubrication.
3. Check for heat and unusual noises that may indicate insufficient lubrication and
bearing damage.
4. Inspect the engine and transmission for signs of oil, fuel, or coolant leakage.
5. Inspect all accessories, such as compressor, pumps, etc., and follow the vendor’s
checklist for each.
D-3
Before loosening any hydraulic component or
connection, make sure there is no residual
pressure in the lines.
HYDRAULIC COMPONENTS:
Clean hydraulic valves, motors, pumps, hoses, tube connections, if needed, and check
for leaks and damage. Check hoses for chaffing or bulges caused by excessive wear.
Keep all fittings and connections tight to eliminate oil leaks. Repair or replace any
damaged components.
NOTE: Make sure O-rings are in place whenever replacing fittings or connections.
Be sure all parts are cleaned before installation. Be sure hoses do not twist when
fittings are being tightened.
HYDRAULIC FLUID LEVEL:
The hydraulic reservoir fluid level indicator tube, decal and filler port are located on
the hydraulic tank. The oil level should be at the high mark of the indicator tube with
all lines full. The reservoir capacity is 85 gallons (321 liters).
FILL NECK
! CAUTION
DO NOT OVERFILL
FILL DECAL
DO NOT OPERATE when the oil level is
below the low mark in the fluid level indicator
tube when all cylinders are fully extended.
VISUAL INSPECTION:
A complete, detailed, visual inspection should be given to the THUNDERBIRD
yarder each day, before the start operations. The discovery of damaged or worn
components, as well as the discovery of potential problems, should be reported to the
proper maintenance personnel immediately. Repair or replace any faulty components
before beginning operation. Always keep the machine clean.
D-4
Weekly Maintenance Checks
Note: Perform the following inspections weekly in addition to the daily inspections.
LUBRICATION:
Using the types of lubricant specified by the manufacturer, lubricate all weekly lubrication points per lubrication chart found in Chapter-E of this manual.
AIR CONDITIONER
COMPRESSOR BELT
ENGINE BELTS: Fan and implement belts are
extremely important parts of your engine and
should be checked at least once a week for
physical condition and proper tensioning. Replace belts which appear cracked and/or frayed.
Belt tension should allow 9/16 to 13/16 deflection, between pulleys.
ENGINE ALTERNATOR BELT
FAN BELT
NOTE: Belts adjusted too tightly will cause
excessive wear to driven bearings. Belts adjusted too loosely will slip.
! CAUTION
HYDRAULIC RESERVOIR: Contaminants
(moisture and sediment) should be drained from
the hydraulic reservoir before the start of each
week’s operations. The Oil Drain plug, at the
base of the tank, is easily accessible.
FILL NECK
FILL DECAL
FILTERS: (Hydraulic Reservoir) After the
initial 60 hours of operation, the suction and
return filter elements must be changed.
! CAUTION
D-5
Weekly Maintenance Checks
BATTERY:
Refer to Chapter-C, UNUSUAL OPERATING CONDITIONS, for proper battery
maintenance instructions. Check the battery electrolyte level and add distilled water as
required to bring level up to that indicated on the top of batteries. (Approximately 1/2"
above top of separators)
VISUAL INSPECTION:
1. Inspect the air system for leaks. This can best be accomplished by building up
full system air pressure, stopping the engine, and operating all controls to full
off and on positions. Check the compressor and air system lubricator and
follow vendor check information.
2. Inspect all lines for wear, abrasions, or fraying. Replace or repair any damaged
cables immediately.
! CAUTION
D-6
Monthly Maintenance Checks
Note: Perform the following inspections monthly in addition to the daily and weekly
inspections.
MONTHLY LUBRICATION:
Refer to Chapter-E of this manual for all of the monthly machine lubrication requirements. Lubricate all monthly lubrication points as indicated on the lube chart with the
type of lubricant specified.
ENGINE OIL CHANGE:
At the end of the work shift, when most of the sediment is still in suspension, remove
drain plug located at base of engine. Clean and replace the plug. When refilling, refer
to engine manufacturer’s manual for the type and weight of oil recommended for
expected ambient temperatures.
! CAUTION
Keep the oil level as close to the full mark as
possible. DO NOT OVERFILL. Never operate
the engine when the oil level is above full mark
or below low mark indicated on dipstick.
RADIATOR:
Clean any foreign matter from radiator cooling fins and through-core cooling passages
by directing compressed air in reverse direction of normal air flow.
VISUAL INSPECTION:
1. Inspect all tower components and fairleads for any visual evidence of unusual
wear or signs of severe stress.
2. Check the drum brakes and clutches for wear. Adjust or replace components
as required.
3. Inspect all machinery guards and ensure that they are secure and have ample
clearance from any moving parts.
! CAUTION
D-7
Quarterly Maintenance Checks
Note: Perform the following inspections in addition to daily, weekly and monthly
inspections.
GENERAL:
Upon completion of quarterly checks, the daily, weekly and monthly checks should be
performed. Refer to Chapter-E of this manual for quarterly lubrication requirements.
Use only those lubricants as are recommended by manufacturer.
TRACK PAD BOLTS:
Check each track pad bolt torque. If any bolt torque is found to be less than correct,
re-torque ALL bolts. See Section-IV of the Maintenance manual for proper torque
settings.
ENGINE OIL FILTERS:
Install clean engine oil filter elements every time oil is changed, or at least every 500
hours. Refer to engine manufacturer’s manual for correct oil changing procedures.
FUEL FILTERS:
Clean spin off element housing before installing new elements.
PUMP DRIVE CASE BREATHER:
Inspect breather element and replace if necessary.
PUMP DRIVE CASE:
After the initial 250 hours of operation and while oil is hot, drain and flush gear case.
Use extreme caution when draining hot gear case oil to avoid personal injury. Check
drained oil for metal particles and contaminants. Clean and reinstall magnetic plug.
NOTE: Over filling will cause pump drive to overheat. Pump drive oil is to be
changed at the time of engine oil replacement or 250 hours.
! CAUTION
D-8
Quarterly Maintenance Checks
BRAKE BAND AND CLUTCH BAND:
Check bands for cleanliness, wear, and glazing. If bands are found to be in need of
repair, address the necessary corrections without delay.
! CAUTION
Dirty, worn, or glazed brake and clutch bands
may lessen or eliminate the standard operation of
the Thunderbird yarder.
TRAVEL BRAKES:
Check the holding power of the travel brake. This is accomplished by disconnecting
the pilot line that applies the brake release function. This can easily be accomplished at
the brake line “quick disconnect” located under the cab. If the travel function over
powers the brake, replacement of the brake is required.
! CAUTION
SWING BRAKE:
The Swing brake is spring applied and hydraulic pressure is required to release or
“hold off” the brake. There should be no yarder swing movement with the Swing
brake control in the “ON” position. Swing brake control is by varying the hydraulic
pressure. There should be no hydraulic leaks from this component.
D-9
Semi-Annual Checks
Note: Perform the following inspections after the first 100 hours and at every 2,500
hours of operation time thereafter. PERFORM ALL PREVIOUS CHECKS IN
ADDITION TO THE FOLLOWING SEMIANNUAL CHECKS.
HYDRAULIC OIL:
Check hydraulic oil for viscosity, water content, and contaminants. Record findings on
your quarterly check list in order to accurately monitor progressive deterioration.
Refer to page E-1 for oil maintenance guidelines.
LUBRICATION:
Perform all lubrication as required per the quarterly check instructions. Use only those
types of lubricants specified by manufacturer.
CRANK CASE BREATHER ASSEMBLY:
Wash assembly in kerosene or clean fuel oil. Replace pad if necessary. Cleaning period
must be adhered to meet your service requirements.
COOLING SYSTEM:
Clean system every 1000 hours or semiannually, whichever comes first. Use of a
radiator cleaning agent is recommended and follow instructions on the container. Flush
with fresh water and refill with a 50% water/50% ethylene glycol solution. Clean
exterior of the radiator, assuring that the fins and through passages are clean.
PUMP DRIVE CASE:
Refer to Quarterly Maintenance Checks for proper maintenance procedures.
HYDRAULIC RELIEFS:
Only a qualified, factory trained, serviceman should be allowed to check relief valve
settings. Improperly adjusted relief valves will affect machine operation.
VISUAL INSPECTION:
1. Check all chain and sprockets for any undue wear, check oil for any metal
flakes or residue.
2. Check hydraulic lines, fittings, and reservoir for leaks, breaks, and deterioration.
Repair or replace as required.
! CAUTION
D-10
Annual Checks
Note: Perform all period checks in addition to the following checks:
TRACK DRIVE PLANETARY CASE:
Remove drain plugs and remove old lubricant. Flush case with kerosene or clean diesel
fuel. Replace drain plugs and remove the oil level plug. Refill with lubricant specified
on fluid level chart in Chapter-E. Tighten the vent plug. Repeat procedure for the
opposite side of the machine.
FILL AND FULL
PLUG
CASE DRAIN PLUG
OTHER PERIODIC INSPECTIONS:
Some of the purchased components not manufactured by Ross Corporation, but used
in the construction of the TSY6355 yarder, will require periodic inspection and maintenance. Vendor data in the vendor section, contains information for these components.
D-11
Chapter E: Charts
LUBRICATION ........................................................................................................ E-1
LUBRICATION CHART ......................................................................................... E-4
MAINTENANCE CHART ....................................................................................... E-7
FLUID LEVEL CHART........................................................................................... E-8
Lubrication
LUBRICATION
One of the primary elements in any preventative maintenance program is adequate
lubrication with the correct lubricant.
This section details recommended lubrication and frequency for normal operating
conditions, location of lube points, and type of lubricant for best protection.
The daily lubrication should be performed prior to start-up or at a shift change when
the yarder is not operating. All other lubrication should be performed at the calendar
or hourly intervals specified.
Make certain that the power unit is shut down
and the operator’s control console is tagged to
prevent inadvertent operation.
RECOMMENDED LUBRICANTS:
Recommended lubricants listed are Texas Refinery Company Products or Mobile.
However, other lubricants of like quality may be substituted if prior approval is received from Ross Corporation’s Engineering Department.
Substituted lubricants must meet the specification requirements for applications.
OPEN GEAR LUBRICATION:
1. During operation, the gear teeth should never show their natural metal color
but should have a lubricant film covering the gear teeth. On new machines it
is necessary to maintain a slightly heavier film on the gear teeth. This run-on period
normally lasts for the first 6 weeks or 250 hours of operation.
2. Whenever gearing is lubricated, the entire surface of the teeth must be covered.
Immediately after gearing is lubricated, gear rotation should be reversed for 23 minutes to spread the lubricant to both sides of the teeth.
3. Best results are achieved when lubricant is applied at the end of the shift. Inspect
all machinery guards to ensure that they are secure and have ample clearance from any
moving parts.
4. Gearing should be inspected at the time of lubrication to check for evidence of
foreign materials or lubricant contamination.
E-1
Lubrication
Note: If a gear lubricant, other than the recommended is substituted, the gears must
be checked frequently for proper lubrication, since dissimilar gear lubricants do not
readily mix and the gears will tend to throw off the substituted lubricant. It
may take several days of continued application before the substituted lubricant will
adhere to the gear teeth.
Since the gear lube must be applied with the
gears slowly turning, care must be taken to
avoid injury. Do no stand on drums or shafts,
even though they many not be turning at that
time. Lubricant should be only applied through
openings provided in the guards for this purpose.
! CAUTION
Various components such as engine, transmission, water pump, and compressor should be
lubricated according to the vendor’s information
located in the vendor section.
The following test should be performed without
cable on the drums.
OPERATING TEST:
The following test should be done after long periods of inactivity and/or after major
maintenance has been performed. This will help ensure that your machine is working
properly before yarding or traveling.
A. Visual inspection per section V-2.
B. Start the engine. Do not increase the RPM’s above idle for at least 2 minutes after
oil the pressure reaches normal operating level.
C. Observe gauges for proper pressure and charging conditions.
E-2
Lubrication
D. Engage drum frictions and operate the drums through all transmission ranges and
at various throttle settings.
E. Set and release brakes on all drums.
F. Listen for any unusual noises in the power unit, drive train, clutches, brakes, etc.
G. Check for hydraulic and air leaks.
H. In the event of any abnormal operation, shut down the engine and perform
corrective maintenance.
E-3
Lubrication Chart
TOWER - YARDER LUBE CHART
LUBRICANT (<32 LUBRICANT
F°)
(>32 F°)
LUBRICANT (<32 LUBRICANT
F°)
(>32 F°)
ITEM DESCRIPTION FITTING(S)
ITEM DESCRIPTION FITTING(S)
FREQUENCY
FREQUENCY
12/04/98 TSY6355 OPER & MAINT
E-4
Maintenance Chart
Number
Component
Fittings
1
PEDESTAL BOLTS
8
2
TRACK PAD BOLTS
3
BULL GEAR / REVERSER /
STRAW DRUM BEARINGS
4
TORQUE DRIVE /
SPROCKET BOLTS
SWING BEARING
BOLTS
5
Frequency
Maintenance Required
1000 HOURS
RE-TORQUE BOLTS
2
500 HOURS
RE-TORQUE BOLTS
5
500 HOURS
CHECK AND SET PRE-LOAD
2
500 HOURS
RE-TORQUE BOLTS
84
1000 HOURS
RE-TORQUE BOLTS
3
3
1
1
1
1
3
3
3
1
1
3
3
1
4
5
1
2
E-5
Fluid Level Chart
FLUID LEVEL CHART
ITEM
FLUID CAPACITIES
FLUID TYPE
ENGINE: CUMMINS NTA-855
OIL AND FILTER
40 QUARTS
(37.8 LITRES)
COOLANT BLOCK
12 QUARTS (11.4 LITRES)
CUMMINS PREMIUM
BLUE CE/SF 15W-40
SEE ENGINE MANUAL
FOR COOLING SPECS
COOLANT RADIATOR
15.8 GAL (61.6 LITRE)
FUEL TANK
370 GAL (1400 LITRE)
ASTM NO. 2D DIESEL
PUMP DRIVE
3.5 QUARTS (3.3 LITRES)
75W-90 SYNTHETIC
TRACK DRIVE GEARBOX
11 QUARTS (10.5
LITRES)
85W-140 GEAR OIL
CARRIER AND TOWER
ALL CARRIER GREASE
POINTS (NOT OPEN
GEARS)
-
ALL TOWER GREASE
POINTS
-
WARM WEATHER EP2
COLD WEATHER
EP0
WARM WEATHER EP2
COLD WEATHER EP2
HYDRAULIC SYSTEM
115 GAL (434.7 LITRES)
WARM WEATHER (AW-46)
HYDRAULIC RESERVOIR
COLD WEATHER (AW-32)
TRANSMISSION
-
CHAIN CASE
2 GAL. (7.56 LITERS)
APPROX.
OPEN GEARS
AS REQUIRED
SEE TRANSMISSION
MANUAL IN VENDOR
SECTION
85W-140 GEAR OIL
TEXAS OIL REFINERY
OPEN GEAR TAKILUBE
TSY-6355 REVISED 12/31/98
OPER./MAINT.
E-6
Fluid Level Chart
FLUID LEVEL CHART
ITEM
FLUID CAPACITIES
FLUID TYPE
ENGINE: CATERPILLAR 3406B
OIL AND FILTER
36 QUARTS
(34.1 LITERS)
COOLANT BLOCK
CATERPILLAR OIL
DEO (CF-4)
SEE ENGINE MANUAL
FOR COOLING SPECS
COOLANT RADIATOR
15.8 GAL (61.6 LITRE)
FUEL TANK
370 GAL (1400 LITRE)
ASTM NO. 2D DIESEL
PUMP DRIVE
3.5 QUARTS (3.3 LITRES)
MOBIL SHC 75W-90
TRACK DRIVE GEARBOX
ISO-VG220-5EP
MOBIL GEAR 630
OR CHEVRON GEAR
COMPOUND 220
CARRIER AND TOWER
ALL CARRIER GREASE
POINTS (NOT OPEN
GEARS)
ALL TOWER GREASE
POINTS
-
-
HYDRAULIC SYSTEM
HYDRAULIC RESERVOIR
TRANSMISSION
-
CHEVRON ULTRA DUTY
GREASE
WARM WEATHER
EP2
COLD WEATHER
EP0
CHEVRON ULTRA DUTY
WARM WEATHER
EP2
COLD WEATHER
EP2
MOBIL HYDRAULIC FLUID
WARM WEATHER DTE 13M
(AW-46)
COLD WEATHER DTE 15M
(AW-32)
SEE TRANSMISSION
MANUAL IN VENDOR
SECTION
CHAIN CASE
2 GAL. (7.56 LITERS)
APPROX.
CHEVRON 85W-140
OPEN GEARS
AS REQUIRED
TEXAS OIL REFINERY
OPEN GEAR TAKILUBE
E-7
Chapter F: Quick References
Cummins NTA-855 Engine ........................................................................................ F-1
Caterpillar 3406B Engine ........................................................................................... F-2
Quick ReferenceCummins NTA855
Most commonly requested replacement parts for Thunderbird TSY6355 Yarder
equipped with Cummins NTA-855 engines. It is recommended that these parts be
kept on hand to expedite routine maintenance.
FILTERS
FUEL FILTER ................................................................................................. P43-0011
WATER FILTER ..............................................................................................P43-0013
FULL FLOW OIL FILTER .............................................................................P43-0016
BY-PASS OIL FILTER ...................................................................................P43-0017
PILOT FILTER ELEMENT ................................................................................. P4391
O-RING FOR PILOT FILTER ........................................................................P34-0219
TRANSMISSION FILTER .................................................................................. T1059
O-RING FOR TRANSMISSION FILTER ......................................................P34-0220
FUEL FILTER .................................................................................................P43-0062
AIR CLEANER ELEMENT ...........................................................................P43-0056
AIR CLEANER SAFETY ELEMENT ...........................................................P43-0057
O-RING FOR AIR CLEANER (UPPER & LOWER) ....................................P25-0087
HYDRAULIC RETURN FILTER ELEMENT .................................................... P2346
HYDRAULIC SUCTION FILTER ELEMENT .............................................P43-0058
ENGINE BELTS
FAN BELT .......................................................................................................P25-0101
ALTERNATOR BELT .....................................................................................P25-0103
AIR CONDITIONER COMPRESSOR BELT ................................................P25-0105
SENDING UNITS
ENGINE / WATER COOLED BRAKE (WCB) WATER TEMPERATURE.. P40-0011
TRANSMISSION OIL TEMPERTURE .........................................................P40-0012
ENGINE OIL PRESSURE ..............................................................................P40-0015
MISCELLANEOUS ELECTRICAL
CIRCUIT BREAKER - 50A ................................................................................ T0516
CIRCUIT BREAKER - 20A ...........................................................................P40-0052
BATTERY ............................................................................................................ T0301
BATTERY DISCONNECT .............................................................................P40-0023
HOUR METER ...............................................................................................P40-0009
VOLTMETER .................................................................................................P40-0038
GUAGES
ENGINE / WATER COOLED BRAKE (WCB) WATER TEMPERATURE..P40-0003
TRANSMISSION OIL TEMPERTURE .........................................................P40-0005
AIR SYSTEM
QUICK RELEASE ............................................................................................... T0176
REGULATOR (main) ........................................................................................... T0177
SAFETY VALVE (air tank) .................................................................................. T0175
CHECK VALVE (air tank) ................................................................................... T1461
UNLOADER VALVE (air tank) ........................................................................... T1533
LUBRICATOR ..................................................................................................... T0625
F-1
Quick Reference Caterpillar 3406B
Most commonly requested replacement parts for Thunderbird TSY6355 Yarder
equipped with Caterpillar 3406B engines. It is recommended that these parts be
kept on hand to expedite routine maintenance.
FILTERS
FUEL FILTER .................................................................................................P43-0439
COOLANT CONDITIONER FILTER ............................................................P43-0440
OIL FILTER ....................................................................................................P43-0441
PILOT FILTER ELEMENT ................................................................................. P4391
O-RING FOR PILOT FILTER ........................................................................P34-0219
TRANSMISSION FILTER .................................................................................. T1059
O-RING FOR TRANSMISSION FILTER ......................................................P34-0220
FUEL FILTER .................................................................................................P43-0062
AIR CLEANER ELEMENT ...........................................................................P43-0056
AIR CLEANER SAFETY ELEMENT ...........................................................P43-0057
O-RING FOR AIR CLEANER (UPPER & LOWER) ....................................P25-0087
HYDRAULIC RETURN FILTER ELEMENT .................................................... P2346
HYDRAULIC SUCTION FILTER ELEMENT .............................................P43-0058
ENGINE BELTS
FAN BELT .......................................................................................................P25-0422
ALTERNATOR BELT .....................................................................................P25-0437
AIR CONDITIONER COMPRESSOR BELT ................................................P25-0438
SENDING UNITS
ENGINE / WATER COOLED BRAKE (WCB) WATER TEMPERATURE.. P40-0011
TRANSMISSION OIL TEMPERATURE ......................................................P40-0012
MISCELLANEOUS ELECTRICAL
CIRCUIT BREAKER - 50A ................................................................................ T0516
BATTERY ............................................................................................................ T0301
BATTERY DISCONNECT .............................................................................P40-0023
HOUR METER ...............................................................................................P40-0009
VOLTMETER .................................................................................................P40-0038
GAUGES
ENGINE / WATER COOLED BRAKE (WCB) WATER TEMPERATURE..P40-0003
TRANSMISSION OIL TEMPERATURE ......................................................P40-0005
AIR SYSTEM
QUICK RELEASE ............................................................................................... T0176
REGULATOR (main) ........................................................................................... T0177
SAFETY VALVE (air tank) .................................................................................. T0175
CHECK VALVE (air tank) ................................................................................... T1461
UNLOADER VALVE (air tank) ........................................................................... T1533
LUBRICATOR ..................................................................................................... T0625
F-2
Section II:
Troubleshooting
A: GENERAL HYDRAULIC INFORMATION
GENERAL INFORMATION & PROCEDURE .......................................... A-1
BASIC TROUBLESHOOTING & NOMENCLATURE ............................. A-2
WARNING LIGHTS AND BUZZERS ....................................................... A-3
B: GENERAL HYDRAULIC PROBLEMS
UNABLE TO SPOOL IN OR OUT ............................................................. B-1
SLOW MOTION IN ONE FUNCTION ...................................................... B-1
LOSS OF MOTION DURING OPERATION ............................................. B-2
OVER HEATING HYDRAULIC OIL ......................................................... B-2
NOISY OPERATION ................................................................................... B-3
STICKING VALVE SPOOL ........................................................................ B-3
LEAKING SEALS ....................................................................................... B-4
FUNCTION REMAINS APPLIED .............................................................. B-4
HYDRAULIC OIL IN PUMP DRIVE CASE ............................................. B-4
PRESSURE SETTING REQUIRES FREQUENT ADJUSTMENT ........... B-5
LEAKS ......................................................................................................... B-5
ALL TRAVEL FUNCTIONS ARE INOPERATIVE ................................... B-6
EXCESSIVE PUMP NOISE ........................................................................ B-6
C: SWING AND GENERAL PROBLEMS
NO SWING AT NORMAL ENGINE SPEED ............................................. C-1
SWING IS SLUGGISH OR ERRATIC........................................................ C-2
SWINGS IN ONE DIRECTION ONLY ...................................................... C-2
SWING MOTOR TEMPRATURE HIGHER THAN NORMAL ................ C-3
HIGH NOISE LEVEL IN SWING PUMP .................................................. C-3
SWINGS IN WRONG DIRECTION ........................................................... C-4
NO POWER TO DRIVE SHAVT ................................................................ C-4
NO POWER TO DRUM GEARS ................................................................ C-5
DRUMS WILL NOT TURN ........................................................................ C-5
DRIVE CLUTCH WILL NOT RELEASE .................................................. C-6
DRIVE CLUTCH WILL NOT ENGAGE ................................................... C-6
BRAKE BAND WILL NOT APPLY OR RELEASE .................................. C-7
WATER BRAKE WILL NOT APPLY OR RELEASE ................................ C-7
LOW AIR PRESSURE................................................................................. C-8
GUYLINE DRUM WILL NOT OPERATE ................................................. C-8
D: ELECTRICAL PROBLEMS
ENGINE WILL NOT CRANK .................................................................... D-1
NO GAUGE READING .............................................................................. D-1
LOW OR DEAD BATTERY ........................................................................ D-2
Section II:
Troubleshooting
E: TRAVEL PROBLEMS
NO TRAVEL ................................................................................................ E-1
TRACK DRIVE SLUGGISH OR ERRATIC............................................... E-2
TRACK DRIVES IN ONE DIRECTION ONLY ........................................ E-2
TRACK DRIVES IN OPPOSITE DIRECTION.......................................... E-3
TRAVEL MOTOR TEMPERATURE HIGHER THAN NORMAL............ E-3
EXCESSIVE NOISE IN TRACTION MOTOR .......................................... E-3
INSUFFICIENT TRACTION MOTOR TORQUE ..................................... E-4
WEAK TRAVEL IN ONE DIRECTION ONLY ......................................... E-4
F: TROUBLESHOOTING WORK RECORDS
TROUBLESHOOTING HISTORY SHEETS .............................................. F-1
WORK SHEET.............................................................................................. F-2
G: SCHEMATICS - HYDRAULIC, ELECTRIC AND AIR
AIR SCHEMATIC ........................................................................................ G-1
HYDRAULIC SCHEMATIC ....................................................................... G-2
ELECTRICAL SCHEMATIC ...................................................................... G-3
NOTE:
SEE SECTION 15 FOR MORE SPECIFIC VENDOR TROUBLE SHOOTING
INFORMATION
A: General Hydraulic
Information
It is the responsibility of the operator to detect any unusual sounds, odors or other
signs of abnormal performance that could indicate trouble ahead.
By detecting any failures in their early stages, unnecessary downtime may be avoided.
It is the responsibility of the operator to use good judgment in detecting potential
failures and repairing them quickly.
Before attempting a repair yourself, assure that you:
•Have the right tools
•Have the right test equipment
• Have correctly diagnosed the cause of the failure
If you decide to attempt a repair yourself, follow a logical TROUBLE SHOOTING
PROCEDURE. Don’t simply replace parts until the trouble is found.
Each trouble shooting procedure consists of a flow chart giving the sequence in which
the trouble shooting tests are performed. Each subsequent test is based on the results
of the preceding test.
General Procedure
1. Know the System. Study this manual and learn what makes the machine work,
how it should behave, sound, and smell.
2. Operate the Machine. Test operate all machine functions. Note all abnormal
sounds, odors, and movements.
3. Inspect the Machine. Look for leaks. Listen for abnormal sounds and locate
them. Detect the origin of unusual odors. Check the condition of the oil and filters.
4. List the Possible Causes. Use good judgment in listing all possible causes of the
failure.
5. Research a Conclusion. Review the list of possible causes and decide which are
the most likely to cause the failure. Consider the most obvious first.
6. Test the Conclusion. Test the conclusions, in order of obviousness, until the
source of the failure is found. The machine can then be repaired at a minimal cost and
downtime.
7. Review Maintenance Procedures. Prevent recurrences of all premature failures
by regularly checking the filters, temperature, adjustments and lubrication. Make daily
inspections.
A-1
General Hydraulic
Information
Base all hydraulic system troubleshooting on a firm foundation of good common sense
and logical procedure. Don’t overlook the obvious; check it first! Never pursue a
course of simply replacing parts until the problem is solved.
Points to remember when troubleshooting hydraulics:
1. Did the problem occur suddenly. or has the condition gradually gotten
worse? A sudden malfunction will generally indicate a break. A gradual worsening
problem indicates a wear condition.
2. Is the engine speed up to specifications? A slow engine will definitely affect
the speed of all operations. Remember: Volume determines speed and vice versa.
Before attempting any hydraulic trouble shooting, become fully acquainted with the
following two basic facts governing any hydraulic system:
1. VOLUME determines the speed of an operation. A hydraulic pump displaces a given amount of oil for every revolution of the pump. This volume is expressed in terms of gallons per minute (gpm). The greater the engine speed, the
greater the pump speed. As a result, the speed of the hydraulic function is directly
related to the speed of the engine. A reduction in the speed of a cylinder or motor is
caused by a smaller quantity of oil being delivered to the components by the pump or
by leakage within actuators.
2. PRESSURE is the amount of force exerted by the hydraulic oil on those
parts of a hydraulic system which are open to the pump. Pressure is automatic and the
result of resistance, in the sense that, when there is no resistance in the system, there is
no pressure. When operating a hydraulic cylinder or motor to accomplish a task, the
amount of resistance required to overcome the task results in pressure being sensed by
the hydraulic pump. This pressure is expressed in terms of pounds per square inch
(psi).
Once a basic understanding of the differences between volume and pressure has been
obtained, accurate troubleshooting of any hydraulic system can be accomplished.
RELIEF VALVES are installed in a hydraulic system to protect system components.
Whenever pressure rises to the relief setting, the effected relief valve opens allowing
excess oil to return to the reservoir through an outlet passage in the valve.
When checking pressure and adjusting relief valves, be sure hydraulic oil is at operating temperature (140°-160° F). Relief pressures will exceed set levels when the
hydraulic system is checked with cold oil.
When adjusting pressures, be sure to use a high quality calibrated hydraulic pressure
gauge.
A-2
General Hydraulic
Information
! CAUTION
NEVER resort to increasing relief valve pressure settings in an attempt to cure the ills of any
hydraulic system. Fully diagnose the problem
and maintain the proper pressure settings of all
relief valves. ALWAYS set hydraulic relief
valves to FACTORY SETTINGS.
! CAUTION
DIRT IS YOUR ENEMY
The majority of hydraulic problems in any hydraulic system can be traced to dirt or
contamination in the system! Do not neglect the hydraulic system. KEEP IT
CLEAN! Change the oil and filters at established intervals.
Whenever ANY PART of the hydraulic system is to be opened, ALWAYS REMEMBER CLEANLINESS! Clean the entire surrounding area before the work is to
performed. NEVER set hydraulic components, seals, rings, etc. in a contaminated
area.
If, in spite of these precautions, improper operation does occur, the cause can be
generally be traced to one of the following causes:
1. Use of the wrong viscosity or type of oil.
2. Insufficient fluid in the system.
3. Presence of air in the system.
4. Internal leakage.
5. Improper adjustments.
The intent of the following hydraulics system troubleshooting guide is to assist in
isolating problems experienced with the machine. Most problems can be solved by
knowing what to look for and where to look. This guide provides a method of identifying and isolating these problems through a logical sequence rather than one of
replacing parts at random. This guide does not provide any repair procedures.
WARNING LIGHTS AND BUZZERS. Occasionally warning lights and buzzers
will give indications of a potential problem. First it will be necessary to assure that it
is not a malfunction of an instrument or a sensor causing the indications.
A-3
B: General Hydraulic Problems
To aid in troubleshooting, refer to the Thunderbird Yarder Pressure Setting Procedure
for test guage information. This procedure assumes gauges are installed. The following was written to aid the troubleshooter in following a logical approach to a system
fault.
UNABLE TO SPOOL IN
OR OUT
CHECK IN SEQUENCE
DIRT IN VALVE
YES
CLEAN AND FLUSH
SCORED SPOOL
YES
REPLACE SPOOL
SCORED VALVE
HOUSING
YES
REPLACE COMPLETE VALVE
SLOW MOTION IN ONE
FUNCTION
CHECK IN SEQUENCE
PORT RELIEF VALVE
LEAKING OR OUT OF
ADJUSTMENT
YES
ADJUST, REPAIR, OR REPLACE
VALVE OPERATING
NO
REPAIR OR REPLACE
INSUFFICIENT
PRESSURE
LOW
SEE SERVICE & ADJUSTMENTS
SECTION FOR PROPER SETTING
AND PROCEDURE
FAULTY COMPONENTS
YES
REPLACE COMPONENTS
B-1
General Hydraulic Problems
LOSS OF MOTION
DURING OPERATION
CHECK IN SEQUENCE
PROPER OPERATION
OF OTHER FUNCTIONS
NO
CHECK PUMP DRIVE OUTPUT
LEAKING FUNCTION
LINE
YES
REPLACE
PILOT LINE
RESTRICTED
YES
CLEAN OR REPLACE
PORT RELIEF STUCK
OPEN
YES
CLEAN OR REPLACE
PROPER PILOT FILTER
OPERATION
NO
CLEAN OR REPLACE
OVER HEATING
HYDRAULIC OIL
CHECK
DIRTY OIL COOLER
YES
CLEAN
COLLAPSED RETURN
LINE
YES
REPLACE
RELIEF PRESSURE
TOO HIGH
YES
ADJUST MAIN RELIEF
ON MAIN VALVE
OPERATING IN
EXCESSIVELY HIGH
AMBIENT TEMPERATURE
YES
CONTACT ROSS CORPORATION
SERVICE DEPARTMENT
OVERLOAD OR
STALLED OPERATION
YES
CHANGE OPERATING
CONDITIONS TO PREVENT
OVERLOAD OR STALL
PLUGGED HYDRAULIC
FILTER(S)
YES
REPLACE ELEMENT(S)
B-2
NOISY OPERATION
CHECK
CHATTERING RELIEF
VALVE
YES
ADJUST OR REPLACE
LOW
HYDRAULIC TANK
LEVEL
YES
ADJUST REGULATOR
IMPROPER PUMP
ADJUSTMENT
YES
AND PROCEDURE
STICKING VALVE
SPOOL
CHECK IN SEQUENCE
SCORED SPOOL OR
BURRS IN VALVE
BORE, PAINT ON
VALVE SPOOL
YES
LAP TO REMOVE BURRS & PAINT
(INSTALL NEW OR REBUILT
VALVE)
DIRT OR FOREIGN
MATTER IN VALVE
BORE
YES
CLEAN VALVE AND SYSTEM
WARPPED VALVE
SPOOL
YES
LAP TO REMOVE BURRS & PAINT
(INSTALL NEW OR REBUILT
VALVE)
EXCESSIVE HIGH OIL
PRESSURE IN VALVE
YES
AND PROCEDURE
B-3
LEAKING SEALS
CHECK IN SEQUENCE
PAINT ON OR UNDER
SEAL
YES
REMOVE AND CLEAN
DIRT UNDER SEAL
YES
REMOVE AND CLEAN
EXCESSIVE BACK
PRESSURE
YES
CHECK FOR RESTRICTION IN
RETURN LINE FILTER
SCORED SPOOL
YES
REPLACE VALVE
CUT OR SCORED SEAL
YES
REPLACE FAULTY PARTS
FUNCTION REMAINS
APPLIED
CHECK
FOREIGN MATERIAL IN
VALVE BODY OR PUMP
DISPLACEMENT
SPOOL
YES
REMOVE,CLEAN OR REPLACE
(REPLACE SYSTEM OIL IF
CONTAMINATED)
HYDRAULIC OIL IN
PUMP DRIVE CASE
CHECK
DAMAGED PUMP
SEAL(S)
YES
CLEAN SURFACE(S) AND
REPLACE SEAL(S)
B-4
PRESSURE SETTING
REQUIRES FREQUENT
ADJUSTMENT
CHECK IN SEQUENCE
FAULTY LINE RELIEF
PROPER ENGINE
PERFORMANCE
YES
CLEAN, REPAIR OR REPLACE
NO
CALL ENGINE MANUFACTURER
DRAIN AND REFILL SYSTEM
WEAR DUE TO DIRT
YES
LOCKNUT AND
ADJUSTING SCREW
LOOSE
YES
TIGHTEN SECURELY
PROPER PILOT
PRESSURE
NO
AND PROCEDURE
MALFUNCTIONING
PUMP
YES
REPAIR OR REPLACE
LEAKS
CHECK IN SEQUENCE
WORN O-RINGS
YES
REPLACE WORN OR DAMAGED
O-RINGS
LEAKING
CONNECTION
YES
CLEAN, TIGHTEN OR REPLACE
YES
INSPECT FOR FREE MOVEMENT
OF COMPONENTS.
PARTS
YES
CHECK SEATS FOR SCRATCHES,
NICKS, OR OTHER MARKS.
PARTS
PARTS STICKING DUE
TO DIRT OR DEPOSITS
DAMAGED VALVE
BODY OR SPOOL
B-5
ALL TRAVEL
FUNCTIONS ARE
INOPERATIVE
CHECK IN SEQUENCE
PROPER PRESSURE
FILTER FUNCTION
NO
REMOVE, CLEAN SURFACE AND
REPLACE FILTER
PROPER CHARGE
PRESSURE
NO
AND PROCEDURE
AIR IN HYDRAULIC
SYSTEM
YES
LOCATE CAUSE OF AIR IN
HYDRAULIC OIL, CORRECT AND
BLEED AIR FROM SYSTEM
PROPER HYDRAULIC
TANK LEVEL
NO
SET REGULATOR TO 15 PSI
YES
REPLACE
FAULTY PUMP DRIVE
INPUT SHAFT OR
DRIVE LINE
EXCESSIVE PUMP
NOISE
CHECK IN SEQUENCE
PROPER OIL LEVEL IN
HYDRAULIC TANK
NO
ADD OIL TO PROPER LEVEL AND
ASSURE THAT IT IS GETTING TO
THE PUMPS
PUMP PULLING AIR
THROUGH SUCTION
SIDE
YES
MALFUNCTIONING
PUMP
YES
REPLACE PUMP
B-6
C: Swing Problems
To aid in troubleshooting, refer to the Thunderbird Yarder Pressure Setting Procedure
for test guage information. This procedure assumes guages are installed. The following was written to aid the troubleshooter in following a logical approch to a system
fault.
CHECK IN SEQUENCE
NO SWING SYSTEM
WITH POWER UNIT
OPERATING AT
NORMAL SPEED
OTHER FUNCTIONS
OPERATING
NO
ASSURE PROPER PUMP OUTPUT
SWING BRAKE VALVE
LEVER IN PROPER
POSITION
NO
PLACE IN PROPER POSITION OR
REPLACE VALVE
NO
FILL TO PROPER LEVEL
IMPROPER
PIPING/HOSING
YES
CORRECT (SEE SCHEMATICS)
BROKEN OR LOOSE
CONNECTIONS
YES
REPAIR OR REPLACE
PORT RELIEF STUCK
OPEN
YES
PLUGGED PILOT
FILTER
YES
DISASSEMBLE, CLEAN CASE
AND REPLACE FILTER ELEMENT
STRIPPED SPLINES ON
SWING MOTOR
YES
REPAIR OR REPLACE COUPLING
OR PUMP AS REQUIRED
PROPER SWING
MOTOR FUNCTION
NO
DISASSEMBLE, CLEAN OR
REPLACE
PROPER SWING PUMP
FUNCTION
NO
DISASSEMBLE, CLEAN OR
REPLACE
PROPER OIL LEVEL IN
HYDRAULIC TANK
C-1
Swing Problems
SWING SYSTEM
SLUGGISH OR
ERRATIC
CHECK IN SEQUENCE
AIR IN HYDRAULIC
SYSTEM
YES
BRAKES FULLY
RELEASED
NO
SET SWING BRAKE LEVER TO
“OFF” OR REPLACE VALVE
SWING MOTOR
CONRTOLLER
PROPERLY ADJUSTED
NO
ADJUST AS REQUIRED
SWINGS IN ONE
DIRECTION ONLY
CHECK IN SEQUENCE
JOYSTICK POPPET
YES
CLEAN AND REPAIR
OR REPLACE
MOTOR DRIVES IN
OPPOSITE DIRECTION
WITH CONTROL LINES
SWITCHED
YES
REPAIR ONE SIDE CONTROL
SIGNAL LINE
PROPER PRESSURE
ON BOTH CONTROL
LINES
NO
REPAIR CONTROL SIGNAL
PROBLEM
YES
REPAIR OR REPLACE RELIEF
VALVE ON NON-DRIVING SIDE
MOTOR DRIVES IN
OPPOSITE DIRECTION
WITH RELIEF VALVES
SWITCHED
C-2
Swing Problems
SWING MOTOR
TEMPRATURE HIGHER
THAN NORMAL
CHECK IN SEQUENCE
OPERATING
TEMPRATURE ABOVE
195° F
SWING PUMP STALLS
INTERMITTENTLY
NO
195° F IS THE MAXIMUM - OIL
COOLER OR LINES MAY NEED
CLEANING
YES
OIL IS BEING HEATED THROUGH
SYSTEM RELIEF VALVES. SHUT
DOWN AND RECTIFY THE CAUSE
OF THE STALL.
HIGH NOISE LEVEL IN
SWING PUMP
CHECK IN SEQUENCE
PROPER OIL LEVEL
NO
FILL TO CORRECT LEVEL
DRIVE COUPLING
PROPERLY INSTALLED
NO
REPAIR OR REPLACE COUPLING
FOAMY OR MILKY
COLORED HYDRAULIC
OIL
YES
BLEED AIR FROM SYSTEM AND
FIND CAUSE OF AIR INDUCTION
C-3
Swing Problems
SWINGS IN WRONG
DIRECTION
CHECK
CONTROL LINES AT
PORTS Y1 & Y2
SWITCHED
YES
SWITCH LINES
SWING MOTOR HOSES
SWITCHED
YES
SWITCH LINES
NO POWER TO DRIVE
SHAFT
CHECK
TRANSMISSION
OUTPUT SHAFT
TURNS
YES
CHECK AND REPLACE BROKEN
DRIVE CHAIN
C-4
General Problems
NO POWER TO DRUM
GEARS
CHECK IN SEQUENCE
DRIVE SHAFT
TURNING
DRIVE GEAR SHAFT
KEY SHEARED OFF
NO
NO
CHECK DRIVE CHAIN
REPAIR AND REPLACE
DRUMS WILL NOT
TURN
CHECK IN SEQUENCE
DRUM CLUTCH
ENGAGING
NO
BRAKE BAND STAYS
APPLIED
YES
ADJUST BRAKE BAND
PEDESTAL BEARINGS
NOT TURNING
YES
REPAIR AND REPLACE
FOREIGN MATERIAL
BETWEEN TEETH
YES
REMOVE MATERIAL AND
INSPECT FOR DAMAGE
ADJUST CLUTCH
C-5
General Problems
DRUM CLUTCH WILL
NOT RELEASE
CHECK IN SEQUENCE
RELAY VALVE
OPERATING
CORRECTLY
NO
CLEAN OR REPLACE
RELAY VALVE
FOREIGN MATERIAL
IN CLUTCH
YES
REMOVE MATERIAL AND
INSPECT FOR DAMAGE
DRUM CLUTCH WILL
NOT ENGAGE
CHECK IN SEQUENCE
DRIVE CLUTCH AIR
CYLINDER OPERATING
CORRECTLY
CHECK AIR PSI AND
MECHANICAL WORKINGS OF DRIVE
CLUTCH
NO
REPAIR OR REPLACE
CLUTCH CYLINDER
NO
SET PSI TO CORRECT SETTING
OR
ADJUST CLUTCH
CONTROL VALVE
OPERATING CORRECTLY
NO
CHECK INTERNAL SPRINGS OR
REPLACE
RELAY VALVE
OPERATING
CORRECTLY
NO
CHECK INTERNAL SPRINGS OR
REPLACE
QUICK RELEASE
OPERATING
CORRECTLY
NO
REPLACE
C-6
General Problems
To aid in troubleshooting, refer to the Thunderbird TSY6355 yarder Pressure Setting
Procedure for test guage information. This procedure assumes gauges are installed.
The following was written to aid the troubleshooter in following a logical approach to
a system fault.
CHECK IN SEQUENCE
BRAKE BAND WILL
NOT APPLY OR
RELEASE
AIR CAN OPERATING
CORRECTLY
NO
CHECK AIR CAN DIAPHRAGM
BRAKE BAND CORRECTLY ADJUSTED
NO
ADJUST
RELAY VALVE OPERATING CORRECTLY
NO
CONTROL VALVE
OPERATING
CORRECTLY
NO
CHECK IN SEQUENCE
REPAIR OR REPLACE
REPAIR OR REPLACE
WATER BRAKES WILL
NOT APPLY OR
RELEASE
NO
SET AIR PSI TO CORRECT
SETTING
AIR BYPASSING
BRAKE PISTON
YES
RESEAL WATER BRAKE
AIR DIAPHRAGM
RUPTURED
YES
REPLACE AND RESEAL BRAKE
BRAKE LINNING
WORN OUT
YES
QUICK RELEASE NOT
OPERATING
YES
REPAIR OR REPLACE
RETURN SPRINGS
BROKEN
YES
REPLACE
AIR PSI CORRECT
REPLACE AND RESEAL BRAKE
C-7
General Problems
LOW AIR PSI
CHECK IN SEQUENCE
YES
CLOSE AND CHARGE
SYSTEM
LEAKING AIR LINES
OR BLOCKAGE IN
SUPPLY HOSE
YES
REPAIR
PSI GOVERNOR
OPERATING
NO
REPAIR OR REPLACE
AIR COMPRESSOR
OPERATING
NO
REPAIR OR REPLACE
IN-LINE CHECK VALVE
OPERATING
NO
REPLACE
FAULTY REGULATOR
OR OILER
YES
REPAIR OR REPLACE
AIR TANK DRAIN OPEN
C-8
General Problems
GUYLINE DRUM WILL
NOT OPERATE
CHECK IN SEQUENCE
DOG CYLINDER
OPERATING
NO
REPAIR OR REPLACE
DRIVE MOTOR
TURNING
YES
BROKEN DRIVE CHAIN
OR STRIPED SPLINES IN DRIVE
SPROCKET
CONTROL VALVE
OPERATING
NO
REPAIR OR REPLACE
BROKEN WIRE TO
CONTROL VALVE
YES
REPAIR OR REPLACE
FRONT MAIN DRUM
WILL NOT OPERATE
CHECK IN SEQUENCE
INTERNAL BEARINGS
BROKEN
YES
REPAIR OR REPLACE
WATER BRAKE
APPLYING
NO
REPAIR OR REPLACE
DRIVE CLUTCH
OPERATING
NO
REPAIR OR REPLACE
MATERIAL IN BULL
GEARS
YES
CLEAN & REPAIR OR REPLACE
C-9
D: Electrical Problems
ENGINE WILL NOT
CRANK
CHECK IN SEQUENCE
BATTERY SHUT-OFF IN
THE CORRECT
POSITION
CABLES CORRODED
OR LOOSE
NO
PUT INTO CORRECT POSITION
YES
BATTERIES IN GOOD
CONDITION
NO
STARTER SOLENOID
OPERATING
NO
IGNITION SWITCH
OPERATING
CORRECTLY
NO
STARTER OPERATING
CORRECTLY
NO
REPLACE
REPLACE
REPAIR OR REPLACE
REPLACE
NO GAUGE READING
CHECK IN SEQUENCE
CIRCUIT BREAKERS
OPERATING
NO
SENDER IN
OPERATING
CONDITION
NO
BROKEN WIRE
GAUGE OPERATING
CORRECTLY
NO
NO
REPLACE
REPLACE
REPLACE
REPLACE
D-1
Electrical Problems
LOW OR DEAD
BATTERY
CHECK IN SEQUENCE
BATTERY SHUT-OFF IN
THE CORRECT
POSITION
CABLES CORRODED
OR LOOSE
BELT ADJUSTED
NO
PUT INTO CORRECT POSITION
YES
NO
VOLTAGE REGULATOR
OPERATING
NO
LOW ELECTROLYTE IN
BATTERY
YES
SHORT IN THE
SYSTEM
DEFECTIVE BATTERY
YES
YES
ADJUST
REPLACE
REPAIR OR REPLACE
REPAIR
REPLACE
D-2
E: Travel Problems
To aid in troubleshooting, refer to the Thunderbird TSY6355 yarder Pressure Setting
Procedure for test guage information. This procedure assumes gauges are installed.
The following was written to aid the troubleshooter in following a logical approach to
a system fault.
NO TRAVEL
CHECK IN SEQUENCE
HYDRAULIC TANK OIL
AT PROPER LEVEL
NO
FILL AS REQUIRED
PROPER PLUMBING
WITH UNDAMAGED
CONNECTORS
NO
REPAIR OR CORRECT PER
HYDRAULIC SCHEMATIC AS
REQUIRED
BRAKES RELEASED
NO
CHECK QUICK RELEASE COUPLING ON BRAKE VALVE BLOCK
UNDER CAB
PROPER CHARGE
PRESSURE WITH
PUMP AT NORMAL
SPEED
NO
AND PROCEDURE
PROPER CHARGE
PUMP SUCTION
NO
CLEAN OR REPLACE PLUGGED
SUCTION FILTER
CHARGE PRESSURE
RELIEF CARTRIDGE
DAMAGED
YES
REPAIR OR REPLACE DAMAGED
COMPONENTS
HOSE TO MANIFOLD
SMASHED
YES
REPLACE
BROKEN MECHANICAL
FINAL DRIVE
COUPLING
YES
REPLACE COUPLING
E-1
Travel Problems
TRACK DRIVE IS
SLUGGISH OR
ERRATIC
CHECK IN SEQUENCE
DIRT UNDER PEDAL(S)
YES
CLEAN PEDAL AREA(S)
BRAKES RELEASED
NO
CHECK QUICK RELEASE
COUPLING ON BRAKE VALVE
BLOCK UNDER CAB
FAULTY RELIEF VALVE
YES
RELIEF VALVE
AIR IN HYDRAULIC
SYSTEM
YES
FAULTY TRAVEL
MOTOR
YES
MOTOR
MANIFOLD
YES
MANIFOLD
TRACK DRIVES IN ONE
DIRECTION ONLY
CHECK IN SEQUENCE
PUMP OPERATES IN
OPPOSITE DIRECTION
WHEN RELIEF VALVES
ARE SWITCHED
YES
REPAIR OR REPLACE FAULTY
RELIEF VALVE
DRIVE RUNS IN BOTH
DIRECTIONS
YES
CHECK FOR MECHANICAL
IMPAIRMENTS OF TRACK
MANIFOLD
YES
MANIFOLD
E-2
Travel Problems
TRACK DRIVES IN
OPPOSITE DIRECTION
CHECK
CORRECT MOTOR
DIRECTION
NO
SWITCH THE HIGH PRESSURE
LINES
PILOT LINES
YES
SWITCH THE LINES
CHECK IN SEQUENCE
OPERATING TEMPERATURE ABOVE
195° F
TRAVEL MOTOR
TEMPERATURE
HIGHER THAN
NORMAL
NO
195° F IS THE MAXIMUM - OIL
COOLER OR LINES MAY NEED
CLEANING
EXCESSIVE NOISE IN
TRAVEL MOTOR
CHECK IN SEQUENCE
DRIVE COUPLING
PROPERLY INSTALLED
AND ALIGNED
NO
REALIGN OR REPLACE AS
REQUIRED
PROPER SUCTION AT
CHARGE PUMP
NO
AND PROCEDURE
AIR IN HYDRAULIC
SYSTEM
YES
E-3
Travel Problems
INSUFFICIENT
TRACTION MOTOR
TORQUE
CHECK IN SEQUENCE
DIRT UNDER PEDAL
USING 0-10,000 PSI
GAUGES, ASSURE
PROPER LOAD SIDE
PRESSURE
PROPER CONTROL
PRESSURE INPUT TO
SPOOL
YES
CLEAN
YES
AND PROCEDURE
NO
AND PROCEDURE
PROPERLY ADJUSTED
TRAVEL PUMPS
NO
MANIFOLD
YES
ADJUST THE SHIFTING SPOOL
CLEAN, & REPAIR OR REPLACE
FINAL DRIVE FILLS
WITH OIL
CHECK IN SEQUENCE
FAULTY TRAVEL
MOTOR SHAFT SEAL
YES
CLEAN AREA & REPLACE SEAL
FAULTY TRAVEL
BRAKE SHAFT SEAL
YES
CLEAN AREA & REPLACE SEAL
CRACKED TRAVEL
MOTOR HOUSING
YES
REPLACE HOUSING
E-4
F: Troubleshooting
Work Records
A complete work record can be of value to the service mechanic when it becomes
necessary to predict future component failures and time estimates for repairs.
The following pages are provided as a convenience. Should additional sheets be
needed, contact Ross Corporation Technical Publications Department.
Throubleshooting History Sheet: Use this sheet when the job is finished. It is the
long term record.
Work Sheet: To aid in diagnosing the problem before beginning the job. Should it be
necessary to call Ross Corporation for assistance, this sheet will provide information
to tell the representative what steps you have taken.
Troubleshooting
History Sheet
DATE
SYSTEM
CAUSE
SOLUTION
F-1
Troubleshooting
History Sheet
DATE
SYSTEM
CAUSE
SOLUTION
F-1
Work Sheet
DATE:
MECHANIC:
PROBLEM
POSSIBLE CAUSE-1
CONCLUSION
POSSIBLE CAUSE-2
CONCLUSION
POSSIBLE CAUSE-3
CONCLUSION
POSSIBLE CAUSE-4
CONCLUSION
NOTES:
F-2
Work Sheet
DATE:
MECHANIC:
PROBLEM
POSSIBLE CAUSE-1
CONCLUSION
POSSIBLE CAUSE-2
CONCLUSION
POSSIBLE CAUSE-3
CONCLUSION
POSSIBLE CAUSE-4
CONCLUSION
NOTES:
F-2
Work Sheet
DATE:
MECHANIC:
PROBLEM
POSSIBLE CAUSE-1
CONCLUSION
POSSIBLE CAUSE-2
CONCLUSION
POSSIBLE CAUSE-3
CONCLUSION
POSSIBLE CAUSE-4
CONCLUSION
NOTES:
F-2
Work Sheet
DATE:
MECHANIC:
PROBLEM
POSSIBLE CAUSE-1
CONCLUSION
POSSIBLE CAUSE-2
CONCLUSION
POSSIBLE CAUSE-3
CONCLUSION
POSSIBLE CAUSE-4
CONCLUSION
NOTES:
F-2
Work Sheet
DATE:
MECHANIC:
PROBLEM
POSSIBLE CAUSE-1
CONCLUSION
POSSIBLE CAUSE-2
CONCLUSION
POSSIBLE CAUSE-3
CONCLUSION
POSSIBLE CAUSE-4
CONCLUSION
NOTES:
F-2
Work Sheet
DATE:
MECHANIC:
PROBLEM
POSSIBLE CAUSE-1
CONCLUSION
POSSIBLE CAUSE-2
CONCLUSION
POSSIBLE CAUSE-3
CONCLUSION
POSSIBLE CAUSE-4
CONCLUSION
NOTES:
F-2
Work Sheet
DATE:
MECHANIC:
PROBLEM
POSSIBLE CAUSE-1
CONCLUSION
POSSIBLE CAUSE-2
CONCLUSION
POSSIBLE CAUSE-3
CONCLUSION
POSSIBLE CAUSE-4
CONCLUSION
NOTES:
F-2
Work Sheet
DATE:
MECHANIC:
PROBLEM
POSSIBLE CAUSE-1
CONCLUSION
POSSIBLE CAUSE-2
CONCLUSION
POSSIBLE CAUSE-3
CONCLUSION
POSSIBLE CAUSE-4
CONCLUSION
NOTES:
F-2
Work Sheet
DATE:
MECHANIC:
PROBLEM
POSSIBLE CAUSE-1
CONCLUSION
POSSIBLE CAUSE-2
CONCLUSION
POSSIBLE CAUSE-3
CONCLUSION
POSSIBLE CAUSE-4
CONCLUSION
NOTES:
F-2
Work Sheet
DATE:
MECHANIC:
PROBLEM
POSSIBLE CAUSE-1
CONCLUSION
POSSIBLE CAUSE-2
CONCLUSION
POSSIBLE CAUSE-3
CONCLUSION
POSSIBLE CAUSE-4
CONCLUSION
NOTES:
F-2
G: Schematics
SCHEMATICS:
AIR SCHEMATIC ........................................................................................ G-1
HYDRAULIC SCHEMATIC ....................................................................... G-2
ELECTRICAL SCHEMATIC ...................................................................... G-3
Section III:
Service & Adjustments
SERIAL NUMBER SPECIFIC PRESSURE SETTING PROCEDURES
HYDRAULIC PRESSURE SETTING PROCEDURE .................... III01-III04
REVISED HYDRAULIC PRESSURE SETTING PROCEDURE .....III01.1-III04.1
AIR PRESSURE SETTING PROCEDURE ............................................. III-05
ADJUSTMENT INFORMATION
DRIVE CLUTCH ADJUSTMENT AND BLEEDING PROCEDURE ... III-06
BRAKE BAND ADJUSTMENT .............................................................. III-09
SWING BEARING ADJUSTMENT ........................................................ III-11
GENERAL HYDRAULIC INFORMATION
AIR CLEANER ......................................................................................... III-13
HYDRAULIC RESERVOIR ..................................................................... III-15
RESERVOIR DRAINING & FLUSHING ................................................ III-15
RESERVOIR INITIAL START UP PROCEDURE ................................. III-15
WELDING INSTRUCTIONS................................................................... III-17
TORQUE WRENCH EXTENSIONS ....................................................... III-18
TORQUE SPECIFICATION (CHART) .................................................... III-19
TRAVEL SYSTEM
TRAVEL PUMP REMOVAL AND INSTALLATION ............................. III-20
TRAVEL PUMP START-UP .................................................................... III-21
UNDERCARRIAGE
TRACK ADJUSTMENT ........................................................................... III-22
TRACK ASSEMBLY INFORMATION .................................................... III-22
TRACK LINK REMOVAL AND INSTALLATION ................................ III-23
LOWER ROLLER ASSEMBLIES ........................................................... III-24
LOWER ROLLER REMOVAL ................................................................ III-25
LOWER ROLLER DISASSEMBLY AND ASSEMBLING .................... III-25
METAL TO METAL SEAL INSTALLATION ......................................... III-25
TRACTION DRIVE DESCRIPTION ....................................................... III-27
TRACTION DRIVE REMOVAL AND INSTALLATION ....................... III-27
TRACTION DRIVE START-UP .............................................................. III-27
TRACTION MOTOR REMOVAL AND INSTALLATION ..................... III-28
TRACTION MOTOR START-UP ............................................................ III-28
TRACTION BRAKE DESCRIPTION ..................................................... III-29
TRACTION BRAKE REMOVAL AND INSTALLATION ...................... III-29
TRACTION DRIVE EXPLODED VIEW ................................................ III-30
OPTIONAL DROP LINE CLUTCH
DROP LINE CLUTCH ADJUSTMENT .................................................. III-31
DROP LINE CLUTCH LINING REPLACEMENT................................. III-31
DIAPHRAM REPLACEMENT ................................................................ III-31
DROP LINE CLUTCH ADJUSTMENT ILLUSTRATION ..................... III-32
TSY6355 04/30/98
MISCELLANEOUS ADJUSTMENTS
DRIVE CHAIN ADJUSTMENT .............................................................. III-33
WATER COOLED BRAKE ADJUSTMENT ........................................... III-34
BULL GEAR BEARING PRELOADS ..................................................... III-35
TSY6355 04/30/98
Introduction
This section will cover Servicing and Adjustment procedures for your TSY6355
yarder. It will provide detailed instructions on performing routine maintenance and
servicing for the yarder. References to part illustrations in the Parts Group will be
made throughout this section.
Hydraulic Pressure Setting Procedure
THUNDERBIRD TSY6355 YARDER, HYDRAULIC PSI SETTING PROCEDURE
(Prior To and Including S/N S5162)
Step 1. Leaks:
Check the machine for leaks or obvious problems that might hinder the hydraulic operation of the machine.
Step 2. Preheat Hydraulic Oil:
A) Bring the hydraulic oil to 120°-130° F before any testing is done. To
preheat the oil, disconnect the travel brake valve “quick disconnect” located
beneath the cab, set the engine at full RPM, hold for 15 seconds the right
forward travel function applied (dead headed).
B) Release the functions.
C) After five seconds of no functions being applied, repeat 2-A and 2-B above
using the left forward travel function.
D) Repeat all the above until the preferred temperature has been reached.
Step 3. Engine: Caterpillar or Cummins 2,100 RPM
A) Place a piece of reflective tape on the vibration dampener of the engine.
(Vibration dampener is located at the front of the engine.) Using an electronic
tachometer, check the engine RPM.
B) If the RPM reading is not up to specifications, set the engine to the proper
RPM. The correct procedure for setting the RPM is found in the engine
owners manual provided with this book.
NOTE: While setting any pressures, always bring the pressure “up” to the proper
PSI, not “down” to the proper PSI.
Step 4. Right Travel Pump Charge PSI:
With the engine at full RPM, place a 1000 PSI gauge on the test port marked
“charge”. This port is located on the right corner of the left engine house door.
Adjust charge PSI by adjusting the relief on the right hand travel pump next to
port “A”.
SETTINGS:
Preferred PSI: 550
Actual PSI________ Changed to________PSI
III-01
THUNDERBIRD TSY6355 YARDER, HYDRAULIC PSI SETTING PROCEDURE
(After S/N S5162 To Date)
Step 1. Leaks:
Check the machine for leaks or obvious problems that might hinder the hydraulic operation of the machine.
Step 2. Preheat Hydraulic Oil:
A) Bring the hydraulic oil to 120°-130° F before any testing is done. To
preheat the oil, disconnect the travel brake valve “quick disconnect” located
beneath the cab, set the engine at full RPM, hold for 15 seconds the right
forward travel function applied (dead headed).
B) Release the functions.
C) After five seconds of no functions being applied, repeat 2-A and 2-B above
using the left forward travel function.
D) Repeat all the above until the preferred temperature has been reached.
Step 3. Engine: Caterpillar or Cummins 2,100 RPM
A) Place a piece of reflective tape on the vibration dampener of the engine.
(Vibration dampener is located at the front of the engine.) Using an electronic
tachometer, check the engine RPM.
B) If the RPM reading is not up to specifications, set the engine to the proper
RPM. The correct procedure for setting the RPM is found in the engine
owners manual provided with this book..
Step 4. Travel Pump Charge PSI:
With the engine at full RPM, place a 1000 PSI gauge on each of the test ports
marked “charge”. These ports are located on the right corner of the right
engine house door. Adjust charge PSI by adjusting the relief marked “Charge”
on the illustration on page III-03, perform this adjustment on both travel
pumps.
SETTINGS:
Preferred PSI: 550
Actual PSI________ Changed to________PSI
REV. DATE 12/96
III-01.1
Step 5. Left Travel Pump Charge PSI:
Repeat the instructions in step 4 while substituting “left hand pump” where
“right hand pump” appears.
SETTINGS:
Preferred PSI: 550
Actual PSI________ Changed to ________PSI
Note: If it is difficult to obtain the proper pilot PSI, check the pilot filter for cleanliness and correct if necessary.
Note: Prior to the setting of any travel reliefs, first disconnect the brake release line
under the cab.
“A” PORT
Step 6. Right Forward Travel PSI:
CHARGE AND PILOT
RELIEF
FORWARD TRAVEL
RELIEF
REVERSE TRAVEL
RELIEF
A) With the engine at full throttle, place a
10,000 PSI gauge on the test port marked
“RHF” located on the right corner of the left
engine house door. Apply and hold the right
travel peddle in the forward position.
B) Adjust the pressure by using the upper relief
located on the left side of the R/H pump.
SETTINGS:
Preferred PSI: 5,800 Actual PSI________ Changed to ________PSI
Step 7. Right Reverse Travel PSI:
A) With the engine at full throttle, place a 10,000 PSI gauge on the test port
marked “RHR” located on the right front corner of the left engine house door.
Apply and hold the right travel peddle in the reverse position.
B) Adjust pressure by using lower relief located on the left side of the R/H
pump.
SETTINGS:
Step 8 & 9. Left Forward and Reverse Travel PSI:
Repeat the instructions in steps 6 and 7 while substituting left hand where right
hand appears.
SETTINGS:
III-02
Step 5. Pressure Cut-off PSI:
marked “RHF” located on the right corner of the right engine house door.
Apply and hold the right travel peddle in the forward position. Adjust pressure
by adjusting the relief marked “Pressure Cut-off” on the right hand pump.
B) Repeat the instructions in step 5A while substituting left pump where right
pump appears, and placing test gauge on the test port marked “LHF”.
SETTINGS:
Note: Prior to the setting of any travel reliefs, first disconnect the brake release line
under the cab.
PRESSURE CUT-OFF
Step 6. Right Forward Travel PSI:
RELIEF
“B” PORT RELIEF
CHARGE RELIEF
“A” PORT RELIEF
A) With the engine at full throttle, place a
10,000 PSI gauge on the test port marked
“RHF” located on the right corner of the right
engine house door. Apply and hold the right
travel peddle in the forward position.
B) Adjust the pressure by using the relief marked
“A” port relief on the illustration, adjust the R/H
pump.
SETTINGS:
Step 7. Right Reverse Travel PSI:
marked “RHR” located on the right front corner of the right engine house
door. Apply and hold the right travel peddle in the reverse position.
B) Adjust pressure by using the relief marked “B” port relief on the illustration,
adjust the R/H pump.
SETTINGS:
Step 8 & 9. Left Forward and Reverse Travel PSI:
Repeat the instructions in steps 6 and 7 while substituting left hand where right hand
appears.
SETTINGS:
REV. DATE 12/96
III-02.1
Step 10. Right Hand Flushing Valve PSI:
A) Adjust the relief located on the R/H flushing valve, two turns from tight.
B) With the engine at full throttle, place a 1,000 PSI gauge on the test port
marked “RHR” located on the right corner of the left engine house door.
Apply and hold the right travel peddle in the forward position. The gauge will
indicate the pressure on the back side of the pressure loop.
C) Adjust the pressure by using the relief located on the R/H flushing valve.
SETTINGS:
Preferred PSI: 410
Step 11. Left Hand Flushing Valve PSI:
A) Adjust the relief located on the L/H flushing valve, two turns from tight.
marked “LHR” located on the right corner of the left engine house door.
Apply and hold the left travel peddle in the forward position. The gauge will
C) Adjust the pressure by using the relief located on the L/H flushing valve.
SETTINGS:
Preferred PSI: 410
Step 12. Guyline and Topping Winch Valve PSI:
A) With the engine at 1/4 throttle, Place a 5,000 PSI gauge on the test port
provided on the guyline valve. Fully apply (dead head) one of the guyline
motors.
B) If the PSI reading is incorrect adjust the relief cartridges located on the
main valve, adjust to the proper pressures.
SETTINGS:
Preferred PSI: 2,550 Actual PSI________ Changed to________PSI
III-03
Step 10. Right Hand Flushing Valve PSI:
A) Adjust the relief located on the R/H flushing valve, two turns from tight.
marked “RHR” located on the right corner of the right engine house door.
Apply and hold the right travel peddle in the forward position. The gauge will
C) Adjust the pressure by using the relief located on the R/H flushing valve.
SETTINGS:
Preferred PSI: 410
Step 11. Left Hand Flushing Valve PSI:
A) Adjust the relief located on the L/H flushing valve, two turns from tight.
marked “LHR” located on the right corner of the right engine house door.
Apply and hold the left travel peddle in the forward position. The gauge will
C) Adjust the pressure by using the relief located on the L/H flushing valve.
SETTINGS:
Preferred PSI: 410
Step 12. Cab Tilt, Swing and Guyline Valve PSI:
A) Prior to testing the swing pressure, apply the swing brake and then apply
the swing function in both directions. If the swing pulls through the swing
brake, the swing brake must be repaired prior to setting the swing pressure.
B) With the engine at 1/4 throttle, Place a 5,000 PSI gauge on the test port
provided on the main valve. Fully apply (dead head) the swing function.
C) If the PSI reading is incorrect adjust the relief cartridge located on the main
valve, adjust to the proper pressures.
SETTINGS:
REV. DATE 12/96
III-03.1
Step 13. Cab Tilt and Swing Valve PSI:
A) Prior to testing the swing pressure, apply the swing brake and then apply
the swing function in both directions. If the swing pulls through the swing
brake, the swing brake must be repaired prior to setting the swing pressure.
B) With the engine at 1/4 throttle, Place a 5,000 PSI gauge on the test port
provided on the main valve. Fully apply (dead head) the swing function.
C) If the PSI reading is incorrect adjust the relief cartridge located on the main
valve, adjust to the proper pressures.
SETTINGS:
Step 14. Swing Motor Deregulation Adjustment:
A) Install a test port and 3,000 PSI gauge into the “G” port located on the
swing motor.
B) Place a 5,000 PSI gauge on the test port provided on the cab tilt & swing
valve. This gauge should have enough hose so that the operator in the cab can
read the gauge.
C) With the engine at full RPM, the operator applies the swing function until
the gauge in the cab reads 1,000 PSI. The operator must maintain 1,000 PSI
throughout this procedure.
D) While the operator is maintaining 1,000 PSI, adjust the set screw located on
the swing motor, until the gauge installed in “G” port just starts to show
movement. Once the “G” port gauge shows pressure, have the operator release
the function. Once the function is completely released, apply the function again
and check the “G” port gauge for accuracy.
Note: When reading the “G” port PSI, the beginning of deregulation is when
the needle just starts to move off of ZERO PSI.
SETTINGS:
III-04
Step 13. Swing Motor Deregulation Adjustment:
A) Install a test port and 3,000 PSI gauge into the “M1” port located on the
swing motor.
B) Place a 5,000 PSI gauge on the test port provided on the main valve. This
gauge should have enough hose so that the operator in the cab can read the
gauge.
C) With the engine at full RPM, the operator applies the swing function until
the gauge in the cab reads 1,000 PSI. The operator must maintain 1,000 PSI
throughout this procedure.
D) While the operator is maintaining 1,000 PSI, adjust the set screw located on
the swing motor, until the gauge installed in “M1” port just starts to show
movement. Once the “M1” port gauge shows pressure, have the operator
release the function. Once the function is completely released, apply the function again and check the “M1” port gauge for accuracy.
Note: When reading the “M1” port PSI, the beginning of deregulation is when
the needle just starts to move off of ZERO PSI.
SETTINGS:
REV. DATE 12/96
III-04.1
Air Pressure Setting Procedure
THUNDERBIRD TSY6355 YARDER AIR PSI SETTING PROCEDURE
Step 1. Leaks:
Check the machine for leaks or obvious problems that might hinder the air
operation of the machine.
Step 2. Building Air Pressure:
Set engine at full RPM until the preferred pressure has been reached.
125 PSI
Step 3. Unloader Valve Pressure:
A) once air pressure has reached the working PSI of 125, adjust the UNLOADER to the recommended PSI.
SETTING FOR LOW END OR LOADING:
Preferred PSI: 125 - 130 Actual PSI________ Changed to ________PSI
SETTING FOR HIGH END OR UNLOADING:
Preferred PSI: 150
Step 4. Air Regulator PSI:
A) Run engine until compressor unloads
B) Adjust pressure by using the set screw and lock nut on the air regulator
assembly.
SETTINGS:
Preferred PSI: 125
REV. DATE 12/96
III-05
Adjustment Information
Drive Clutch Adjustment Procedure For Serial Numbers Prior To S5189 :
Note: See page III-08 for clutch illustration.
This procedure can be performed with the engine off providing the air system is fully
charged. It may become necessary to recharge the air system during this procedure
due to the number of times the clutch is engaged and disengaged.
1. Check the cylinder stroke by applying the clutch and measuring the distance between the base of the yoke (2) and the face of the air cylinder (1).
The stroke should be 3/4 of the overall stroke length of the cylinder. The TSY6355
has an approximate applied stroke length of 3 1/2". If the stroke length is greater or
the clutch is slipping, adjustment may be needed.
Note: The cylinder applied stroke of 3 1/2" is approximate and in some cases may be
less due to the age and use of the clutch.
2. Clutch adjustment:
A) Slack the line tension on the drum and apply the drums maxi brake.
B) De-energize the clutch.
C) Loosen adjusting nuts (3), turn adjusting nut (3A) counterclockwise one
revolution and turn adjusting nut (3B) clockwise until it locks against the
adjusting pin (3C).
D) Energize the clutch and check the cylinder stroke as described in step one.
If the preferred result is not achieved, repeat step two until achieving the
preferred result.
Note: When the clutch stroke has been adjusted, it is also required to adjust the
tension cams and bolt.
3. Tension Cams and Bolt Adjustment:
Note: It is required to adjust the tension cams and bolt if the clutch stroke has been
adjusted. Tension cams are designed to hold the clutch bands in position when
the clutch is de-energized.
A) Energize Clutch
B) Loosen bolts fastening the tension cams to the clutch spider and loosen the
lock nut on the tension bolt.
C) Slip a shim (1/4" wide x 1/16" thick) between the tension cam (4) and the
clutch band (6). Push tension cam (4) against the shim and brake band (6).
Tighten tension cam mounting bolts. Repeat this procedure until all tension
cams have been adjusted.
TSY6355 REVISION DATE 7/2/98
III-06
DANGER
PRIOR TO ANY WORK BEING PERFORMED ON THE DRIVE CLUTCHES, ALL
LINES MUST BE SLACKED TO THE GROUND AND ALL MAXI BRAKES APPLIED.
FAILURE TO FOLLOW THESE INSTRUCTION COULD RESULT IN BODILY HARM.
Drive Clutch Inspection Procedure For Serial Numbers S5189 TO DATE :
Note: Daily inspection of the frame bolts, retract springs and signs of overheating is
recommended. Frequently inspect for lining wear using the method listed below.
A) To check lining wear scribe a line (per dimension “A”) on the brake frame, next to the split
between the frames. (As shown in this illustration.) Apply brake and check lining wear by
looking into opening at the split and compare the
top of the steel shoe, to which the lining is
attached, to the scribed line. If the scribed line is
even with the top of the steel shoe, friction travel
is at its maximum.
B) Dimension “A” is 22/32
REPLACE LINING PRIOR TO THIS CONDITION OCCURRING. CONTINUED USE
COULD RESULT IN A CATASTROPHIC
FAILURE.
III-06
Step Three Continued
SERIAL NO. PRIOR TO S5189
D) Adjust the tension bolt (7) by using the same shim that was used in the
cam adjustment. Place the shim between the adjusting bolt (7) and the clutch
band (6). Turn the tension bolt (7) clockwise until it contacts the shim and
brake band (6). Tighten tension bolt lock nut.
E) After the tensioning cams and bolt have been adjusted, de-energize the
clutch and check the clearance between the clutch band (6) and the drive ring.
Note: Clearance should be no less than .0600", to prevent premature clutch engagement when the clutch is de-energized.
F) If the clearance between the clutch band (6) and drive ring is not enough
and the clutch band (6) has not completely cleared the drive ring. Increase the
shim thickness to 1/8" and repeat step three (3).
III-07
Drive Clutch Bleeding Procedure: SERIAL NO. S5189 TO DATE
! CAUTION
Use a bleeder hose to keep oil off braking
surface and bleed each valve separately
A) Fill reservoir with hydraulic oil, frequently check oil level throughout this process.
B) Hold Clutch in the applied position, open bleeder to vent air. Close bleeder valve
and release from the applied position.. Repeat this every 30 seconds until oil flows
from the bleeder valve.
C) With Bleeder Valve Closed, apply and release clutch, waiting 30 seconds between
each application. Continue this until the clutch shoes make contact with the drum.
D) Do Not Apply clutch, open bleeder valve to vent air from brake, do not close
bleeder valve until flow of oil has stopped completely.
E) Repeat steps “C” & “D” until no air can be detected.
F) Test holding power.
G) After eight (8) hours of working the clutch, open bleeder valves (do not apply
clutch) to release any air that has worked to the top of the system.
NOTE: All other adjustment or rebuild information can be found in the vendor information section of this book.
III-07
1
AIR CYLINDER
4
TENSION
CAMS
2
YOKE
3A
3B
7
TENSION
BOLT
3C
6
CLUTCH
BANDS
3
ADJUSTING NUTS & PIN
5
CLUTCH
SPIDER
SERIAL NO. PRIOR TO S5189
III-08
Brake Band Adjustment Procedure:
Note: See page III-10 for brake band illustration.
This procedure can be performed with the engine off providing the air system is fully
charged. It may become necessary to recharge the air system during this procedure
due to the number of times the brake is engaged and disengaged.
To perform the adjustments in this procedure it will require two (2) qualified people.
Before performing any adjustments to the
band brakes, the drum line must be completely slack with no tension and the drum
line is secured to prevent accidental movement of the drum.
1. All Thunderbird yarders operate with a preferred air can shaft stroke of 1-1/8". The
stroke is measured by releasing the maxi brake and applying the foot treadle. Measure
the center to center distance that the air can shaft clevis pin travels when applying
the foot treadle. If the stroke length is greater than 1-1/8", brake adjustment may be
required.
2. Band Brake Adjustment: With the brake band air can released, loosen adjusting nut
(2A) and turn counterclockwise one revolution. Turn adjusting nut (2B) clockwise
until it locks against the adjusting pin (2C). Apply brake and check air can stroke (see
step one). If the proper stroke is not achieved repeat this procedure until the proper
stroke is achieved.
3. Hold Off Anchor Adjustment: The purpose of the hold off anchor is to prevent the
top radius of the brake band from dragging on the drum brake ring with the brake
released. This is accomplished by presetting the spring tension. It is not necessary to
adjust the hold off anchor after each adjustment to the brake bands, but it is recommended that they should be checked periodically.
Note: Adjustments must be made with the maxi brake applied
Adjusting the hold off anchor is accomplished be loosening and removing lock nut
(3A). Loosen lock nut (3B) until there is no compression tension on the spring (3C).
Turn lock nut (3B) clockwise on the anchor rod (3D) until it is snug against the
compression spring (3C). Turn lock nut (3B) clockwise three (3) revolutions, which
will apply compression to the spring (3C). Install lock nut (3A) and tighten against
lock nut (3B).
III-09
HOLD OFF ANCHOR
3A
3B
3C
3D
BRAKE BAND
2A
2C
2B
ADJUSTMENT LINKAGE
III-10
Swing Bearing
Adjustment
Ring Gear Bolting Sequence
Note: Position inner race hardness gap (marked with stamped “G”) toward side of
machine.
HARDNESS
GAP
FRONT OF MACHINE
The inner race and ring gear assembly is bolted to the carbody with Grade-8 bolts.
The outer race is also bolted to the turntable with Grade-8 bolts.
The following procedure is designed to insure uniform loading of the ring gear and
should be strictly adhered to if premature failure of the swing bearing is to be prevented. A trace of lubricant such as that found on newly purchased bolts should be
applied to the fasteners to prevent galling.
1. Remove bolting cover on the turntable to gain access to the inner race
bolts.
2. Tighten inner race bolts following the bolting sequence in the diagram
III-11
Swing Bearing
Adjustment
above for inner race until all bolts have been pre-tightened to the pre-torque
value specified in the Bolt Torque Specifications later in this section.
3. Continue, in sequence, to tighten inner race bolts until all bolts have been
tightened to the proper torque value as specified in Bolt Torque Specifications
later in this section.
4. Torque outer race bolts following instructions in steps two and three above.
First tighten all bolts, in sequence, to their pre-torque value. Then torque to
their final value per the Bolt Torque Specifications.
5. Recheck all bolts (again in sequence) to be certain parts have not relaxed.
It is important that these bolts be checked and tightened after the first 50 hours
of operation and every 600 hours thereafter. See Torque Wrench Extensions
later in this section.
Axial Play Adjustment
The gear and bearing assembly consists of an inner race and ring gear, an outer race,
bearing balls, ball spacers and a seal ring.
When the machine is in operation, the outer race will rise above the inner race and ring
gear between no load and full load positions. The amount of this rise is the axial play.
This movement is necessary to allow the balls to float and to maintain proper contact
in assuming vertical loads. Determine the amount of axial play by measuring the
difference of distances between the top of the carbody and the bottom of the outer
race; first, with the attachment extended fully out and the grapple slightly above
ground, and second, with the down-pressure fully applied to the attachment. This
measurement should be taken at the counterweight end of the turntable and repeated
at 90° intervals by rotating the upper structure.
The axial play can be measured accurately if the ring gear bolts are properly torqued.
When the clearance reaches the maximum allowable play of 5/64" it does not necessarily mean the bearing needs replacing. It is recommended that as long the clearance is
less than this value and so long as the bearing rotates smoothly without noise or metal
particles in the grease, there is no reason for concern.
INNER
RACE
MEASURE AXIAL
PLAY HERE
OUTER
RACE
If metal particles are found in the grease or if the
swing bearing is noisy (and all other possible
malfunctions have been eliminated), consult the
factory. Any attempt to disassemble the swing
bearing will void the warranty!
CARBODY
III-12
General Information
Air Cleaner Maintenance
1. Release the Filter Seal Gently
The filter fits tightly over the outlet tube, creating the critical seal on the inside diameter of the
filter end cap. The filter should be removed
gently to reduce the amount of dust dislodged.
There will be some initial resistance, similar to
breaking the seal on a jar. Gently move the end
of the filter up and down and side to side or
twist to disengage the seal.
2. Avoid Dislodging Dust from the Filter
Gently pull the filter off the outlet tube and out
of the housing. Avoid knocking the filter against
the housing.
3. Always Clean the Sealing Surface of the
Outlet Tube
Dust on the outer diameter could hinder an
effective seal and cause leakage. Make sure that
all contaminant is removed before the new filter
is installed.
4. Always Clean the Inside of the Outlet
Tube Carefully
Dirt accidently transferred to the inside of the
outlet tube will reach the engine and cause wear.
Be careful not to damage the filter sealing area
on the tube.
III-13
General Information
5. Check Your Old Filter
Your old filter could help you detect foreign
material on the sealing surface that is causing
leakage. A streak of dust on the clean air side of
the filter is the telltale sign. If it exists, be sure
the cause is removed before installing a new
filter.
6. Inspect the New Filter for Damage
Always look for possible shipping or handling
damage . Pay particular attention to the inside
of the open end (sealing area). Check for cuts,
etc. Do not install a damaged filter.
YES
NO
YES
7. Insert the New Filter
The radial seal area is on the inside of the open
end of the filter. This critical sealing area will
stretch slightly, adjust itself and distribute the
sealing pressure evenly on to the outlet tube as
the filter is installed. To complete a tight seal,
apply firm pressure at the outer rim of the filter,
not the flexible center. Due to it’s unique design
cover pressure is not necessary to compress the
filter seal.
8. Check Connections & Ducts for Air Tight
Fit
III-14
General Information
FILL NECK
Hydraulic Reservoir
The Hydraulic reservoir is a fabricated steel
tank. It has two external replaceable
5-micron filter elements. A filler cap / strainer,
and an indicator tube for determining reservoir
level are also located on the tank.
FILL DECAL
Draining and Flushing
If one or more hydraulic pumps have failed and contamination has entered the system,
it is extremely important that the hydraulic tank be drained and flushed when replacing
the pump(s).
The following accessories are required:
• Tank Sprayer
• Cleaning Solvent
• External Filter with 10-micron filtration
• Two 5-micron return filter elements
Initial Start-up Procedure
If any hydraulic filters or pumps have been removed and either repaired or replaced, or
if the hydraulic tank has been drained and flushed, it is extremely important to ensure
that clean hydraulic oil is in all components and that the system is properly bled of air
before starting the engine. Failure to do this will result in damage to the hydraulic
components. Bleed and fill the system by using the following start-up procedure.
! CAUTION
DO NOT START ENGINE until after bleeding
procedure is completed or you will damage the
pumps!
III-15
General Information
1. Assure that the hydraulic reservoir is filled with the proper hydraulic oil.
The tank should be filled to top of indicator or to a point that oil is near the
halfway point of the tube after completing the bleeding procedure. Experience
will help in determining the level required to complete this procedure while
maintaining an adequate supply of oil.
2. Hand fill the cases of any pumps or motors which have been either drained
or replaced. Pressurize the hydraulic tank to 3 PSI. Fill ports for the pumps
and motors are shown below. Each of the fill ports are identified with the
letter “R” or “T”.
“R” PORT
! CAUTION
Failure to ensure that pumps and motors are
filled with hydraulic oil before starting the engine
will result in severe component damage.
“R” PORT
REVISED PUMP
ORIGINAL PUMP
3. With the hydraulic tank pressurized, bleed off air at the following points
shown in the illustration below. Bleed each point until oil is present and then
reseal the connection.
T-PORT
T-PORT
4. Start engine and run at low idle for five minutes. Then pressurize the
hydraulic tank.
III-16
General Information
Welding Instructions
! CAUTION
The following must be observed:
1. All welding must be performed only by qualified and authorized personnel.
Care must be taken to avoid machine damage and personal injury.
2. When doing repair welding, take the necessary precaution of attaching the
ground to the component being welded. This will eliminate the possibility of
arching through a bearing, cylinder, etc. thereby ruining the component.
3. Use caution when welding around fuel tanks, oil reservoir, batteries, tubing
and pressure systems.
4. When welding close to glass, cylinder rods or any polished surface, provide
adequate protection from splatter.
5. NEVER weld when the engine is running. Disconnect the battery cables
before welding.
6. Do not weld on wet surfaces since this will cause hydrogen embrittlement
of the weld.
7. Always have a fire extinguisher on hand in case of fire. Adequate ventilation
and a dry area are absolutely necessary. Protective clothing should be worn by
all persons in the welding area and they should be provided eye protection
The following welding rods are recommended:
•AWS CLASS E7018 Low hydrogen rod for normal repairs on low alloy to
medium carbon steel. These are good for all position welding, good penetration and crack resisting up to 80,000 yield. Also suitable for repair of previous
inter shield welds.
•AWS CLASS E11018G Low hydrogen rod for repair on high strength alloy
steel such as ASTM A514 (T-1), 80,000 to 100,000 yield. All position welding, good penetration and high strength up to 110,000.
NOTE: Low hydrogen rod E7018 must be used within four (4) hours upon removal
from a freshly opened container or from a storage oven. Low hydrogen rod E11018G
must be used within 1/2 hour upon removal from its container or from a storage oven.
.
III-17
General Information
Torque Wrench Extensions
In some applications, a standard torque wrench and socket cannot be fitted to the bolt
to be tightened because of restricted access. In other instances, the torque value
specified cannot be obtained because sufficient force cannot be applied to the standard
length wrench. Both of these problems may be solved by use of appropriate torque
wrench extensions - either commercially made or fabricated by the user. When using
an extension, it must be remembered that the wrench torque (the actual reading or
setting of the wrench) and the wrench force (the force applied to the wrench) must be
adjusted to compensate for the added length and produce the Preferred bolt torque.
Refer to the illustration below when calculating the proper adjusted values for wrench
torque, wrench force and bolt torque.
BOLT TORQUE =
WRENCH TORQUE X (A+B)
A
BOLT TORQUE =
NOTE: DIMENSION “A” IS
MEASURED FROM THE CENTER
OF THE WRENCH HANDLE.
BOLT TORQUE =
BOLT TORQUE X A
(A+B)
WRENCH TORQUE
A
=
WRENCH TORQUE
(A+B)
IV-38
III-18
General Information
Bolt Torque Specification
Most bolts used in Thunderbird equipment are SAE Grade-5. The chart below should
be used to determine the maximum bolt torque. This torque is based on a bolt preload of 75% of material yield strength.
APPLICATION
BOLT SIZE
TORQUE FT/LB
DRY
LUBED
SWING BEARING
DRIVE TO SIDERAIL
SPROCKET TO DRIVE
ROLLER
1-8 UNC
M24
M16
7/8-9 UNC
884
752
232
600
663
564
174
450
The bolts at the left are Grade-8 and
should be torqued to the component
manufacturers specifications. The
pre-torque value is 10-20% of the final
torque.
III-19
Travel System
Travel Pump
The two pumps mounted on the pump drive gear case that supply oil for the travel
circuit are variable displacement axial piston pump used in conjunction with a variable
displacement piston motor in a closed loop circuit.
“R” PORT
INPUT
SHAFT
“R” PORT
H/D CON-
INPUT
REVISED PUMP
MOUNTING
CHARGE PUMP
INLET OR OUTLET
Removal and Installation
1. Label and remove two control pressure lines from the travel pump.
2. Label and disconnect the case drain, suction line, directional pilot lines
from the travel pump.
3. To prevent contamination of the hydraulic system, plug and cover all hose
ends and ports in components
4. Attach a hoist to the pump, remove the two mounting bolts and carefully
remove the pump. Immediately cover the opening to keep dirt out and remove
all traces of old gasket material from the mounting surface of the pump and
pump drive case.
III-20
Travel System
Removal and Installation Continued
5. Prior to installation it is important to hand fill the pump with clean hydraulic
oil using the “R” port. It is located on the top rear portion of the travel pump
and is identified by the letter “R” on the port cover.
6. Reassemble in reverse order. Coat all splines with Never-Seez (or equal)
lubricating compound. Apply a bead of Loctite “gasket eliminator” around the
inside perimeter of the swing pump mounting surface. Coat fasteners with
Loctite Threadlock prior to installation.
! CAUTION
Do not attempt to start the engine without
following initial start- up procedures.
! CAUTION
Before starting the engine, the pump must be
manually filled with oil, as recommended in the
lubrication chart. Add oil through the case drain
port on top of the motor.
Installation and Start-up
The unit is supplied ready for installation, however, WITHOUT being filled with oil.
The internal components are protected by a preservative until oil is added. Before
operating the swing pump, fill through the oil inlet located on the top rear portion of
the swing pump identified by the letter “R” on the port cover. Use only the lubrication
that is called out in the Fluid Level Chart in Chapter-I, Section-E, of this publication..
Do not over fill. Quantity of fluid can also be found in Section-E.
With the pumps and drive case filled to their proper levels, bleed the air from the
pump. Refer to general adjustment section for this procedure. Start the machine and
allow sufficient time for stabilization at moderate pressure and speed prior to running
at full throttle. Refer to the lubrication chart found in Section-E for oil level checks
and replacement time schedules.
III-21
Undercarriage
Track Adjustments
The track is properly adjusted when it has approximately 3/4 (19.1 mm) to 1-1/2 (38.1
mm) sag measured at a point midway between the front idler and the first carrier roller.
3/4“ TO 1-1/2”
Before measuring for track sag, travel the machine forward (with drive cases in the
rear) until the tracks are free of dirt and other foreign material and chain slack is
located at the top.
To tighten the tracks, it is necessary to locate a hydraulic ram (port-a-power)
behind the idler assembly and extend the piston until the proper track tension is
obtained. Once the proper tension is obtained, additional shim stock material must be
placed behind the idler. Adjust each side gradually to prevent binding.
Track Link Assembly
The track link assembly is made up of a series of links to which the track shoes are
attached.
Each link assembly consists of a right hand and a left hand link, one pin, one bushing,
and four cupped washers. A spacer is located behind the cupped washers in the
master link only.
Depending on the number of links, each track assembly contains one or more “master
links” which are identified by a pin with an indentation drilled in both ends.
NOTE: Master link components differ slightly from the rest of the track links. Be
sure to order service parts accordingly.
III-22
Undercarriage
Track Link Removal
Normal Removal Condition:
1. Move the machine or rotate the track until the master pin (identified by a
dimple in the end of the pin) is located atop the idler.
2. Place blocking beneath the unsupported sections of track along the top of
the track frame.
3. Loosen the track.
4. Remove the two track shoes adjacent to and the track shoe with the master
pin.
! CAUTION
To minimize the chance a track pad falling and
causing possible injury, remove the bolts from
one track pad at a time then remove that track
pad before proceeding to the next.
5. Using a track press, remove the master pin.
Track Installation
1. Pull the track end off the ground and block it tight against the idler wheel or
drive sprocket.
2. Pull the top track section until the two separated links are in position to be
reassembled.
3. Insert the spacer and two Belleville washers (with inside diameters touching) into each side of the master link. Push the links together until the bores
line up.
4. Press the master pin into place.
5. Reassemble two track shoes and adjust track tension. When reassembling or
replacing track shoes, the bolts, nuts and washers must be thoroughly cleaned
of all scale and rust.
III-23
Undercarriage
Lower Roller Assemblies
The lower rollers bolted to the bottom of the track frame. Double flange rollers are in
the center with single flange rollers at each end. This combination is designed to carry
the weight of the entire machine. These rollers are oil filled, rotate on bearings and use
metal to metal type seals. See Metal-to-Metal Seal Installation (later in this section).
SHAFT
RETAINER
METAL-TO-METAL SEALS
ROLLER
ASSEMBLY
COLLAR
ROLLER SEAL
SHAFT SEAL
PLUG
Replace the seals if any oil leakage is observed. Replace the bearings if the shaft has
excessive free (vertical or horizontal) movement.
III-24
Undercarriage
Lower Roller Removal
1. Release the tension on the track group.
2. Remove the bolts mounting the rock guards to the side rail. This will afford
access to the lower rollers.
3. Remove the four bolts holding the roller to the bottom of the track frame.
4. Raise the track frame until the roller can be removed.
5. Reassemble in reverse order.
Lower Roller Disassembly - Refer to parts section for replacement part numbers
1. Remove the center plug and drain the oil from the roller.
2. Remove the collar from the end of the shaft. Remove the metal-to-metal
seals from the collar and roller body. Keep them together as a pair.
3. The shaft, with one collar still attached, can now be removed from the
roller. Remove the remaining seals from the collar and roller body. Remove
the O-rings from the shaft.
4. Clean and inspect all parts. After cleaning, wash seal rings with soap and
water to remove any film of solvent or oil.
5. Reverse procedure to reassemble roller - fill with oil to plug hole - install
plug and seal - reinstall in frame.
Metal-to-Metal Seal Installation
Many of the undercarriage components in this section use metal to metal seals. These
are two piece seals with precision ground mating surfaces backed by an O-ring on
each side. Proper installation is critical if the long life that these seals offer is to be
obtained.
Prior to installation, the retaining bores, surrounding areas, and any shafts or pins on
which these seals will be installed must be thoroughly cleaned. If necessary, use a wire
brush and solvent to remove all traces of rust, scale, and oxidation. Inspect the retaining surfaces for nicks and scratches. Smooth them out and wipe the area clean. Be
sure that all surfaces are dry.
The O-rings and the metal face of the seal must be parallel to the surface throughout
the entire circumference of the seal. An installing tool will best accomplish this. If
one is not available, press the O-ring into place with your fingertips.
III-25
Undercarriage
! CAUTION
DO NOT use screwdrivers or other sharp
objects to seat the O-ring and DO NOT oil the
O-ring prior to installation.
After the seals are properly seated, wipe any dust or fingerprints from the metal
surfaces and apply a light film of oil to the metal surfaces only.
Seals are supplied as matched pairs and must be installed as such. Never install a new
seal with a used mating half.
Used seals may be used if the O-rings have not been damaged or distorted, and if the
metal faces are free of nicks and scratches.
If the O-rings are the type with rubber “teeth” around their outer diameter, the two
seals must be installed with the teeth facing each other.
III-26
Undercarriage
Traction Drive
The traction drive unit is a planetary gear drive with an internal plug-in piston style
hydraulic motor, motion control valve and a hydraulically released multiple disk brake.
It is installed as one unit into the side rails of the undercarriage. The gear case and the
hydraulic motor have independent oil reservoirs. Although the motor is integrated,
servicing or replacing the motor can be done without removing of the entire gear
drive. The drives are interchangeable, and can be mounted on either side of the car
body. The gear drive consists of three planetary stages, all torque transmitting
components are made of forged, quenched and tempered high-alloy steel. Two large
taper bearings support the radial loads. The metal face seals protect the unit against
contamination.
1. Remove the covers from the traction motor guards.
2. Remove the traction pressure lines and the case drain and pilot lines from
the motor.
3. Cap all hose ends and inlets on components, so not to contaminate system.
4. Attach a hoist to the drive unit and place blocking inside the guards to
support the motor from underneath.
5. Remove the side rail mounting bolts from the mounting flange of the drive
unit and draw the entire unit away from the mounting surface.
Note: when replacing the entire drive unit, take the sprocket off the old unit
and reinstall it on the new unit. Refer to the torque chart in this section for proper torque.
The internal components are protected by a preservative, until oil is added. Before
operating the drive unit, fill through the oil inlet located on the outside surface of the
gear box. Use only that lubrication that is called out in the Fluid Level Chart in this
publication. (Do not over fill)
With the motor and gear case filled to their proper levels, start the machine and allow
sufficient time for run-in at moderate pressure and speed prior to running at full
throttle. Refer to the lubrication chart found in the Fluid Level Chart in this
publication for oil level checks and replacement time schedules.
III-27
Undercarriage
Traction Motor Removal
Axial piston motors provide traction for the machine by operating the drive unit
through a closed loop system. A motor is mounted to each of the drive units housings
and spline-coupled to the input shaft of the gear box.
the motor.
4. Attach a hoist to the motor or place blocking inside the guards to support
the motor from underneath.
5. Remove the two bolts from the mounting flange of the motor and draw the
motor out of the drive unit housing. Cover the opening to prevent the entry of
dirt and other contamination.
Note: When removing the motor, be careful not to pull the spline adapter out of the drive
unit case.
The motor must be manually filled with oil, as
recommended in the lubrication chart (Section-E
of this manual), before starting the engine. Add
oil through the case drain port on top of the
motor.
The internal components are protected by a preservative, until oil is added. Before
operating the drive motor, fill through the oil inlet located on the upward side of the
motor. Use only that lubrication that is called out in the Fluid Level Chart in this
publication. Do not over fill, quantity of fluid can also be found in section E.
With the motor and gear case filled to their proper levels, start the machine and allow
sufficient time for run-in at moderate pressure and speed prior to running at full
throttle. Refer to the lubrication chart found in this publication, for oil level checks and
replacement time schedules.
III-28
Undercarriage
Travel Brake
The travel brake is spring applied, hydraulically released. This multiple disk brake is a
safety brake, which is normally closed by spring force. The inner disks are splined to
the drive coupler and the outer disks are splined to the drive spindle. When the disks
are compressed by the spring, this gives the required holding torque. When pressurized
oil is supplied to the piston side of the brake, the piston slides against the spring. This
movement compresses the springs and frees the multiple disk stack. The brake is now
released and open.
The minimum brake release pressure must be 260 PSI and the maximum release
pressure should not exceed 725 PSI. Since the brake is for static use only, 350 PSI
must be maintained in the brake release port during the traveling mode of the machine.
This occurs when the travel function is engaged by means of a pilot pressure supplied
as the travel pedals are depressed in either direction.
the motor.
4. Attach a hoist to the motor or place blocking inside the guards to support
the motor from underneath.
5. Remove the two bolts from the mounting flange of the motor and draw the
motor out of the drive unit housing. Cover the opening to prevent the entry of
dirt and other contamination.
Note: When removing the motor, be careful not to pull the spline adapter out of the drive
unit case.
6. Compress the brake assembly and remove the two snap rings that hold the
brake assembly in place.
7. Remove the piston, disks, (inner and outer) and the springs.
Note: Upon overhaul or repair of the brake, replace all disks, springs and seals with a
complete disk and seal kit. See parts group for part numbers.
8. Prior to reassembling the brake, oil the springs, piston seals, backup rings
as well as their contact areas with gear lubrication. Install the backup rings
prior to the piston seals. Arrange the disks alternately, starting and ending with
an outer disk.
9. Reassemble in reverse order. See next page for breakdown
III-29
Optional Drop Line Clutch
Drop Line Clutch Adjustment Procedure:
Note: See the next page for clutch illustration.
Periodic maintenance is required on all units to adjust for lining wear. The capscrews
around the periphery of the unit use spacers to set the gap between the two outer
plates. As the lining wears, the clearance between the lining and the plate increases.
When the total of the two clearances is greater than 1/8”, one of the thin spacers
should be removed from each capscrew. This will reduce the travel required of the
diaphram and progong its life.
Note: The total clearance must not become greater than 1/4” as damage can occur to
the return bolts or to the diaphram.
After the adjustment spacers have been removed, the locknuts on the brackets should
be adjusted to obtain equal clearance between the friction linings and friction surfaces.
Drop Line Clutch Lining Replacement:
The most common repairable problem encountered is lining wear. When the total
clearance gap is greater than 1/8” and there no more adjustment spacers to be removed, the lining should be replaced.
This can be accomplished by replacing the inner-outer torque plate assembly, by
replacing only the torque plate assemblies, or by purchasing linings only and bonding.
If bonding is chosen, the torque plates must be disassembled, including removal of the
diaphram, and the present lining must be removed on a lathe.
To bond new linings, use Ross Corporation Adhesive P74-0201. This is a heat and
pressure curing agent. Apply the adhesive to one side of the lining with a saw tooth
trowel and allow it to cure for 24 hours before bonding.
To bond, apply 100 - 150 PSI clamping pressure over the entire lining area and heat
the lining and torque plate assembly to 400° F for thirty minutes.
Diaphram Replacement:
In most cases, the diaphram should be replaced when the linings are replaced so that
future down time is avoided. Included with a replacement diaphram will be two segments of o-ring material. These seal the diaphram to the torque plate.
Put these o-rings in the grooves of the torque plate and cut them to length to form a
butt joint. Place the diaphram on the torque plate with the black marks on the periphery up and in line with the air hoses. In this position, all the holes in the diaphram
should be aligned with the holes in the torque plate.
III-31
Optional Drop Line Clutch
ADJUSTMENT SPACER
BACKPLATE
PRESSURE PLATE
DIAPHRAM
RELEASE SPRING
HUB
KEYWAY
CENTERING MECHANISM
TORQUE PLATES
FRICTION LINING
CAPSCREWS
CLUTCH ADJUSTMENT REFERENCE ILLUSTRATION
III-32
DRIVE CHAIN ADJUSTMENT:
After prolonged use, the drive chain may need to be adjusted. The chain should move
1/2” up or down at its midpoint. Remove the panel, item-C, from both sides of the
chain drive housing to gain access to the chain.
The following steps should be used for proper chain adjustment:
1. Remove bolts, item-A, from both sides of the sprocket housing.
2. Rotate, item-B from both sides of the sprocket housing counter clockwise until the
proper chain tension is achieved or the bolt holes in item-B line up so that item-A can
be reinstalled. The objective is to obtain as close to the proper setting as possible.
3. Reinstall, item-A on both sides of the sprocket housing and tighten just enough to
hold item-B in place.
4. Check the tension of the drive chain. If the chain moves more than 1/2”, repeat
step one threw three (1-3).
! CAUTION
Do not overtighten the chain
5. Once the proper chain tension is achieved, reinstall items-A. Torque bolts per the
torque chart earlier in this section.
6. Replace the panel, item-C, on both sides of the chain drive housing. Torque bolts
per the torque chart earlier in this section.
“C”
“B”
“A”
III-33
Water Cooled Brake Tensioner Adjustment:
1. Apply approximately 25 PSI (1.7 bar) air pressure to the cylinder (item-1) to engage
the tensioner.
2. Measure the gap between the pressure plate (item-2) and any stop tube (item-3).
3. If the gap is less than 0.015” (0.38mm), the friction discs and/or wear plates are
worn out. The water cooled brake must be disassembled for parts replacement.
3
2
1
GAP
III-34
Bull Gear Bearing Preload Adjustments:
Anyone attempting to perform this procedure sould have a clear understanding
of the following steps prior to starting. Refer to the illustration on the following
page.
1. Pre-Adjustment Inspection:
Using a pry bar placed between the bull gears and the main frame, check the pre-load
side play. If the bull gear can easily be displaced from side to side, continue through
steps (2) two through (8) eight below.
2. Remove the water roto seal and water brake, but not the water brake hub, from the
tensioner end of the drum.
3. Remove the air roto seal from the clutch end of the drum.
4. Bend the lock tabs of item “C” (lockwasher) until iten “B” (locknut) can turn
counter clockwise. Remove item “B” and item “C” from both ends of the drum
assembly.
Note: When applying force to items “E” (clutch spider) and “F” (water brake hub) in
steps (5) five and (6) six, alternate force 180°. Example: apply force above the shaft
and then below the shaft.
5. Use a dead blow hammer to force item “E” to the proper preload of .001” to .002”
tight. This can be achieved by forcing item “E” and then tightening item “D”. This
should be repeated as many times as necessary to achieve the proper preload.
! CAUTION
Overtightening item “D” may result in either
the nut or shaft threads to be stripped.
6. Use a dead blow hammer to force item “F” to the proper preload of .001” to .002”
tight. This can be achieved by forcing item “F” and then tightening item “D”. This
should be repeated as many times as necessary to achieve the proper preload.
! CAUTION
Overtightening item “D” may result in either
the nut or shaft threads to be stripped.
7. Install item “C” then item “B” (tepered side facing inward). Then turn item “B”
clockwise until it is seated against items “C” and “D” and a lock tab slot is lined up
with a lock tab. Bend the lock tab down until it seats in the lock tab slot of item “B”.
8. Repeat steps (1) one and two (2) subsituting “install” where “remove” appears.
TSY6355 04/30/98 III-35
WATER ROTO SEAL
AND TENSIONER END
AIR ROTO SEAL AND
CLUTCH END
F
D
C
E
B
D
C
B
CHECK FOR MOVEMENT AND
PRELOAD HERE
CHECK FOR MOVEMENT AND
PRELOAD HERE
A TYPICAL DRUM SHAFT SECTION ILLUSTRATING
THE BULL GEAR BEARING PRE-LOAD ADJUSTMENT
ITEMS REFERRED TO IN THE INSTRUCTIONS ON THE
PREVIOUS PAGE
TSY6355 04/30/98 III-36

THUNDERBIRD TSY-6355 YARDER OPERATOR`S MANUAL

Transcription

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