THUNDERBIRD TSY-6355 COVER - Logpro · 2016-06-17 · thunderbird tsy-6355 yarder operator’s manual pdf version august 2003 this manual contains material that was supplied with

THUNDERBIRD TSY-6355 YARDER OPERATOR’S MANUAL

PDF VERSIONAUGUST 2003

THIS MANUAL CONTAINS MATERIAL THAT WAS SUPPLIED WITH NEWMACHINES AT THE TIME OF DELIVERY. NO UPDATES ARE PROVIDED

FOR THIS INFORMATION. THIS MANUAL IS TO BE USED ONLY AS AGUIDE FOR OPERATION AND SERVICE OF THE MACHINE. IT IS NOT A

SUBSTITUTE FOR PROPER TRAINING BY EXPERIENCED OPERATORS. ASWITH ALL HEAVY EQUIPMENT, SAFE OPERATION REQUIRES CONSTANT

ATTENTION AND COMMON SENSE. ENSURE THAT OPERATION ANDSERVICE OF THIS MACHINE IS IN COMPLIANCE WITH LOCAL

OCCUPATIONAL HEALTH AND SAFETY CODES.

General Warning

GENERAL SAFETYCONCIDERATIONS

The safety considerations and precautions included in thismanual do not represent an all-inclusive or complete listing,and knowledge of this manual is not to be taken as a license tooperate this or any other machine. It is the responsibility ofthe owner and operator to insure that the operation of thismachine is in accordance with all local, state, and nationalsafety requirements and regulations, including those speci-fied by the Occupational Safety and Health Act (OSHA) andlocal fire, electric, and safety codes.

CALIFORNIADiesel engine exhaust and some of its constituentsare known to the state of California to cause cancer,birth defects, and other reproductive harm.

To order parts, contact your nearest Ross Corporation Sales, Service, and PartsBranch:

460 N. DaneboPO Box 2577Eugene, OR 97405(541)689-94001-800-777-9555(541)689-5031FAX: (541)689-3517

1050 NW Maryland AvenuePO Box 998Chehalis, WA 985321-800-444-9555(360)748-8657FAX: (360)748-7849

When ordering replacement parts, please have the following information at hand:

MACHINE IDENTIFICATION - Know the model number and serial number of themachine. The serial number can be found on the title page of this manual or on themetal plate located on the cab.

PART IDENTIFICATION - Know the PART NUMBER, PART NAME, andQUANTITY of parts that are needed. The part number for each item can be foundon the appropriate parts list.

Instructions for Ordering Parts

ed

MADILL CORP. 680 SENECA ROAD, EUGENE, OR 97402 1-800-777-9555 (541)-689-5031 (541)-689-3517 FAX

PERIODIC SAFETY INSPECTION CHECKLIST

LOG OF REPAIRS AND ADJUSTMENTS

CHAPTER A. INTRODUCTION

INTRODUCTION ....................................................................................................... ASAFETY CONSIDERATIONS ................................................................................ A-1SAFETY ................................................................................................................... A-2NOMENCLATURE.................................................................................................. A-5SERVICING THE YARDER ................................................................................... A-7DESCRIPTION ........................................................................................................ A-8DESIGN SPECIFICATIONS ................................................................................. A-12POWER TRAIN FORMATION ............................................................................. A-14ENGINE SPECIFICATIONS ................................................................................. A-15DIMENSIONS ....................................................................................................... A-17

CHAPTER B. CONTROLS AND INSTRUMENTS

CONTROLS AND INSTRUMENTS ...................................................................... B-1START-UP CONTROLS.......................................................................................... B-4WARNING SYSTEM............................................................................................... B-5INSTRUMENTS ...................................................................................................... B-7CIRCUIT BREAKERS ............................................................................................ B-8

CHAPTER C. OPERATING PROCEDURES

PRE-START INSPECTION ..................................................................................... C-1STARTING THE ENGINE ...................................................................................... C-2JUMP STARTING ENGINE .................................................................................... C-3MACHINE WARM-UP ............................................................................................ C-4SHUTTING DOWN MACHINE ............................................................................. C-5UNUSUAL OPERATING CONDITIONS .............................................................. C-6EXTREME COLD ................................................................................................... C-6EXTREME HEAT .................................................................................................... C-7HIGH HUMIDITY/SALTWATER ........................................................................... C-9HIGH ALTITUDES ............................................................................................... C-10YARDER TRANSPORTING ................................................................................. C-11TOWER RAISING AND LOWERING ................................................................. C-12TOPPING LINE REEVING INSTRUCTIONS .................................................... C-14TOWER PIN LOCATIONS ................................................................................... C-15SETTING GUYLINES .......................................................................................... C-16

Maintenance and Operation

CHAPTER C. CONTINUED

GUYLINE ARRANGEMENT ............................................................................... C-16DRUM OPERATION ............................................................................................. C-17PROCEDURAL AWARENESS ............................................................................. C-20WORKING WITH HYDRAULICS ....................................................................... C-21

CHAPTER D. MAINTENANCE CHECKS

INTRODUCTION ....................................................................................................... DDAILY CHECKS...................................................................................................... D-1WEEKLY CHECKS ................................................................................................. D-5MONTHLY CHECKS .............................................................................................. D-7QUARTERLY CHECKS .......................................................................................... D-8SEMIANNUAL CHECKS ..................................................................................... D-10ANNUAL CHECKS ............................................................................................... D-11

CHAPTER E. CHARTS

RECOMMENDED LUBRICATION ....................................................................... E-1LUBRICATION CHART ......................................................................................... E-4MAINTENANCE CHART ....................................................................................... E-5FLUID LEVEL CHART........................................................................................... E-6

CHAPTER F. QUICK REFERENCE

CUMMINS NTA855 ENGINE ................................................................................. F-1CATERPILLAR 3406B ENGINE ............................................................................. F-2

Maintenance and Operation

YARDER PRODUCT SAFETY NOTICECompliance of all federal, state and local regulations governing the safe operation anduse of this equipment is the responsibility of the owner and/or operator. Because ofvariances of rules and regulations in different areas, this manual will make no referenceto any such rules or regulations.

It is suggested that each owner, and/or operator, check with local authorities of thearea being worked, to guarantee full compliance of current rules and regulationsbefore beginning operation.

Necessary operation and maintenance manuals are provided with eachTHUNDERBIRD Yarder manufactured and sold by Ross Corporation. These manualscontain all necessary information to provide adequate information and training to thoseoperating, maintaining or supervising the use of this machinery in a safe and propermanner.

It is the responsibility of the owner to provide proper training to any persons thatoperate, maintain, or supervise THUNDERBIRD equipment.

This equipment is designed and manufactured to operate efficiently under adverseconditions. Even when operated correctly, under these conditions, parts will wear andfail. It is very important that an EQUIPMENT INSPECTION PROGRAM be createdin order to keep the machine working properly, reduce repair time, and help preventaccidents. With an inspection program, properly administered, worn, broken andloose parts will be discovered before they are the cause of a major problem. It issuggested that all manuals be fully read and understood before operating any newThunderbird equipment. Please contact your Thunderbird manufacturer for assistanceat (541) 689-5031.

Maximum performance level of the Thunderbird can be attained when recommendedoperating and maintenance procedures are followed. The Periodic Safety InspectionCheck List should be used. Use of a maintenance log to record all work done on yourmachine is advised.

Please provide the machine model and serial number when requesting information onyour machine. This will guarantee receiving correct information. The contents of thispublication is derived from information in effect at time of printing. Ross Corporationreserves the right to change any part of, or all of, this publication without obligation ornotice.

Forward

ITEMS TO BE INSPECTED

INSP

ECTI

ON

CO

DE

SATI

SFA

CTO

RY

AD

JUST

RE

PAIR

Visual Inspection * DOverall Cleanliness DHydraulic System WHydraulic Tank Fluid Level WPump Drive Case Fluid Level WHeater and Defroster WEngine Crankcase Fluid Level **Fuel Tank Fluid Level DRadiator Fluid Level WTransmission Fluid Level **Air System DAll Control Mechanisms DInstruments and Gauges DWarning Lights DMuffler Exhaust System DSwing Reduction Fluid Level DTraction Drive Case Fluid Level MAir Cleaner Element Signal WFan Belt Tension WBatteries and Starting System WGear Bearings MGears Lubrication DChain Case Fluid Level WAir Lubricator WRing Gear Bolt Torque PTrack Adjustment PGuards and Catwalks P

This Checklist is to be used in conjunction with the information provided in thismanual to properly operate and maintain the yarder.

Periodic Safety Inspection

D - DailyW - WeeklyM - MonthlyP - Periodic* Inspect the entire machine for cracks, weld separation, leaks, damage, and evidence of vandalism.** - See Manufacturers Manual

Repairs and Adjustments LogITEM REQUIRED MAINTENANCE DATE

Chapter A: IntroductionINTRODUCTION ....................................................................................................... ASAFETY CONSIDERATIONS ................................................................................ A-1SAFETY ................................................................................................................... A-2NOMENCLATURE.................................................................................................. A-5SERVICING THE YARDER ................................................................................... A-7DESCRIPTION ........................................................................................................ A-8DESIGN SPECIFICATIONS ................................................................................. A-12POWER TRAIN FORMATION ............................................................................. A-14ENGINE SPECIFICATIONS ................................................................................. A-15DIMENSIONS ....................................................................................................... A-17

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 wasinspected at numerous points of completion to guarantee that this is the highest qualityyarder available. Upon completion, the new yarder received its final inspection,consisting of working pressure adjustments, torque adjustments, and a thoroughtesting of all functions to factory specifications, to ensure a high quality, fully operablemachine at the time of delivery.

When the new THUNDERBIRD Yarder is delivered, it will be accompanied by afactory trained serviceman, who will reinspect and give instructions to the purchaser/operator, and maintenance personnel concerning the operation and maintenance of thenew yarder. All unusual noises, malfunctions, or erratic performance should be notedin the maintenance log and reported to the owner or factory.

Skilled and unskilled operators and maintenance personnel are advised to study thismanual because of the great many subjects thoroughly covered. After a completefamiliarization of the machine, and this manual, the operator should be ready to use thenew yarder efficiently and safely.

Before initial start-up, reinspect the new yarder using the suggested periodic YarderSafety Inspection Checklist.

For information concerning operation and maintenance of the engine, refer to theEngine Manufacturer’s Manual.

Safety is the responsibility of all personnel assigned to any given project. Safe workhabits 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, andall manufacturers’ publications supplied with this machine.

Since safety measures will differ with each job site, this section will concern only thosemore serious conditions and common practices requiring safety precautions. In mostinstances, common sense and good judgment, when operating your new ThunderbirdYarder, will create a safe work site.

A

Introduction

Safety Considerations

Safety is the responsibility of everyone assigned to any work site. Unsafe acts canaffect many more persons than just the one being unsafe; if noticed that someone isworking 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 INTHIS MANUAL DO NOT REPRESENT AN ALL-INCLUSIVE OR COM-PLETE LISTING, AND KNOWLEDGE OF THIS MANUAL IS NOT TO BETAKEN AS A LICENSE TO OPERATE THIS OR ANY OTHER MACHINE.IT IS THE RESPONSIBILITY OF THE OWNER AND OPERATOR TOINSURE THAT OPERATION OF THIS YARDER IS IN ACCORDANCEWITH ALL LOCAL, STATE, AND NATIONAL SAFETY REQUIREMENTSAND REGULATIONS, INCLUDING THOSE SPECIFIED BY THE OCCUPA-TIONAL 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 warninglabels and decals, to better inform operators of the potential safety hazards. It is veryimportant that these labels be read and understood, and that they are in place andlegible at all times. If you notice that any of these are missing or unreadable due topainting, 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 aviolation of OSHA or local regulations.

The terms DANGER, WARNING, CAUTION, and NOTE appear throughout thismanual. These terms denote that special attention to the information following theterm is required.

The term DANGER precedes information about specific immediate hazards which areHIGHLY LIKELY to result in SEVERE PERSONAL INJURY or DEATH ifdisregarded.

The term WARNING precedes information about hazards or unsafe practices whichCOULD result in personal injury or death if disregarded.

The term CAUTION precedes information about unsafe conditions or practices thatcould result in personal injury or machine damage if disregarded.

The term NOTE precedes information which is critical to the proper operation ormaintenance of the Yarder.

A-1

Safety

A-2

OPERATOR:

Only trained, qualified personnel should be authorized to operate this machine, andonly when physically and mentally alert. All operators should be aware of hazards ofjob 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 adaily procedure to check machine and work site for hazardous conditions possiblycreated by weather, pressures, vandalism, etc.

BLIND OBSTACLES: When preparing jobsite, always allow enough room for free move-ment of machine on all sides. Remove anyobstacle that could impair the swing or travel ofyour Thunderbird Yarder. Be especially cautiouswhen working around overhead wires. Alwaysassume any overhead line is LIVE. Know exactheight and reach of your machine. Maintain aminimum distance of 10 feet from all overheadlines (Additional distance over 50,000 volts,check with local and state codes.) In the eventthhe machine should come in contact with apower line, remember to stay on the machine, inthe seat, and allow no one else on machine. If itshould become necessary to leave the machine,Jump. Be careful to be completely clear ofmachine, even after reaching ground, until themachine has been safely moved or the powershut off. When preparing the job site, always besure that the Thunderbird Yarder has adequateroom to maneuver and will not have to move orsit on the edge of unstable ground that couldbreak away.

Since safety measures will differ with each job site, this section will concern only thosemore serious conditions and common practices requiring safety precautions. In mostinstances, common sense and good judgment, when operating your new ThunderbirdYarder ,will create a safe work site.

Safety

A-3

STEERING:

Use caution in traveling machine. The operator should always know the position of theyard and travel control.

UNATTENDED MACHINE:

To avoid unwanted operation or movement of machine when unattended, the operatorshould 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 personnelat the end of each work day. Keys to locked ignition and locked cab door shouldaccompany this report to be sure that only qualified personnel can perform neededmaintenance.

GUARDS:

All guards serve a needed safety function. They must be replaced upon completion ofany 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 sitewhich may give way. Back the machine away from the area when it is to be left idle orunattended for more than a short period of time. Park on level ground wheneverpossible.

BRIDGE CAPACITY:

Check the capacity of any bridge before attempting to cross. Insure the ability of thebridge to support the weight of the machine.

LUBRICATING:

Always stop the engine of the machine before lubricating or cleaning. The only excep-tion to this rule is when lubricating the drive gears.

Safety

ENGINE IDLE:

Always maintain sufficient idle speed to charge the battery when idling for extendedperiods of time. A voltmeter on the operator’s console module indicates voltageoutput. When starting the engine, run at an idle of approximately 1000 RPM for 3 to 5minutes before engaging any engine functions. When shutting down, run the engine athalf 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 anyworkers, or to the safe operation of the machine.The following sections have all needed information and instructions concerning theoperation and maintenance of the Thunderbird Yarder. All personnelinvolved in the operation and maintenance of the yarder should read and thoroughlyunderstand the information contained in this manual. The terms listed will always havethe same meaning whenever they are used in this manual.

A-4

Nomenclature

A-5

SWING FRAME - Entire upper portion ofmachine. Includes the cab, drum arrangement,power unit, hydraulic and fuel tanks.

UNDERCARRIAGE - That portion of themachine below the carrier frame, including thetrack frames, drive motors, etc.

CONTROL CAB - That portion of the machinewhere the operator controls the operation of themachine.

TOWER & MAST - That portion of the ma-chine above the swing frame, including thetower, mast assembly, fairlead assemblies andguyline drum assembly.

POWER UNIT - The power unit is located inthe rear portion of the swing frame,including the engine, transmission, air compres-sor, radiator, travel pumps and pump drive.

DRUM ARRANGEMENT - That portion ofthe machine located in the middle of theswing frame, including the Haulback,Front Main and Rear Main drums, chain case,drive shaft and brake band installation.

UNDERCARRIAGESWING FRAME

CONTROL CAB

TOWER & MAST

POWER UNIT

DRUMS

Nomenclature

A-6

TRACK DRIVE - That portion of the under-carriage which provides the travel.

GUYLINE DRUMS - That portion of thetower that controls the tension of the guylines.

SWING BEARING - Center bearing enablesthe swing frame and undercarriage to rotateindependent of one another.

TOPPING WINCH - hydraulicly driven drumfor raising and lowering the tower, with a springset air release dogs for positive lock.

FAIRLEAD ASSEMBLIES - That portion ofthe tower which enables the operationscables to change work angles. Each work linehas it’s own fairlead or sheave: haulback, frontmain, rear main, strawline and guylines.

HAULBACK FAIRLEAD

REAR MAIN SHEAVE

FRONT MAIN SHEAVE

SWING BEARINGTRACK DRIVE

GUYLINEDRUMS

STRAWLINEFAIRLEAD

GUYLINE SHEAVEASSEMBLY

LIVE TOWER LINE

TOPPINGWINCH

Servicing the Yarder

Because of the built-in quality and durability of this yarder, less maintenance and downtime will be recorded than with construction machinery converted for use in thisindustry.

To assure the same, dependable operation of the yarder for indefinite periods of time,FOLLOW THE SCHEDULED MAINTENANCE PROGRAM. Through thescheduled maintenance program, potential problems can be resolved before they causeexpensive damage or downtime. Servicing procedures, as outlined in this manual, areto be used by trained serviceman only. STUDY THIS MANUAL. KNOW THEMAINTENANCE NEEDED FOR CONTINUOUS, TROUBLE FREEOPERATION. This outline is intended as a guide only, and purchaser/user may ormay 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 ensuretrouble free operation.

When ordering factory parts, be sure to have serial number, model number, enginemake, and description of any special equipment which was factory installed, to helpidentify the correct parts. Serial number and model can be found on a specificationsplate permanently located on the operator’s cab.

REMOVE ALL JEWELRY, CONTAINLOOSE CLOTHING, TIE, DANGLINGSHOE/BOOT LACES, ETC., WHENSERVICING THE MACHINE.

A-7

This section presents the general arrangement of the TSY6355, with overall dimen-sions, plus yarder design specifications.

POWER:

The specified engine provides adequate power to drive the power train drum require-ments and two hydraulic pumps through a 2 station pump drive transmission forcontinuous 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 eachtrack.

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 driveoutput flange. Single-flanged, lifetime sealed rollers distribute the machine weightalong the track. The upper carrier slide plate support the weight of the track betweenthe drive sprocket and idler, and maintain chain alignment.

Each track is driven by one variable Displacement, axial piston motor driving througha 3-stage planetary reduction. This motor is mounted to the traction drive case andbolted to the crawler frame. Drive gears are case hardened and splash lubricated.Multiple disc traction brakes are mounted on each motor drive shaft. Brakes arespring set, and hydraulically released. Brakes automatically apply when yarder isstationary.

SWING FRAME:

The power unit, control cab, guarding and drum arrangement are the assembledcarrier 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 enginehouse.

The operator’s cab is shock mounted and lined with 1" thick, closed cell foam latex fortemperature insulation and noise reduction. The front and rear windows are fixed.The right hand side window slides open to allow adequate ventilation. The hingeddoor locks in the open position. All THUNDERBIRD Yarders are equipped with aheater / AC as standard equipment from our factory to further enhance operatorcomfort. A deluxe, specially contoured and cushioned seat, with vertical-horizontaland weight adjustments is also factory installed and included as standard equipment.Operator control panels are manufactured as a single unit.

Description

A-8

DescriptionDRUM ARRANGEMENT:

Fabricated box-type structure, line bored pedestals for accurate gear alignment, withgears, 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 anormal working height of 60’ complete with swivel type fairleads, haulback sheave is20” 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 withthree swivel, walkover type guyline fairleads.

The guyline mast is designed so that it is free to swivel about the center of machinerotation during swing operation.

The mast is supported at the rear by an a-frame backstay which in turn is pinned to theswing 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) Cat 3408 (450 HP)2) Cummins NTA-855 (430 HP)

DRIVE INPUT HOUSING:

Power is provided from the transmission to the drive input housing. The primaryreduction from the transmission is sprocket and chain drive to the drive shaft. Theprimary 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. Theshaft 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 frontof the power unit on the left side of the machine. It is driven by an air operated plateclutch keyed to the drive shaft, with the drum mounted on roller bearings for freewheeling.

The drum is fitted with a large disc brake and is also spring set for parking or emer-gency use.

The strawdrum is underwound during inhaul.A-9

DescriptionMAIN DRUMS

Power is provided to either drum by means of gears (w/clutches) locatedoutside 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 lo-cated outside of main frame. Machines with S/N S5188 and previous use air-oper-ated, 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 bandbrake.

Drums can be either operated indepentently from each other or interlockedtogether.

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, locatedoutboard 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 bandbrake, 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 commonstationary mount. Each drum is driven by a hydraulic drive motor, driving through adouble 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, hydraulicallyreleased brake, provides swing torque to large diameter slewing ring.

CONTROL CAB

Rear entrance cab, mounted on R.H. side of frame, positioned forward to observelanding and operation of machine at all times; comes equipped with all yarding con-trols, as well as wiper, heater, defroster, insulation, tinted windows, escape hatch, wirescreen window guards and tube type front log guard.

A-11

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. Barrel33.25” (84cm) Barrel Length48” (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 internalexpanding BFG; tension brake, water-cooled, WCB-124; band brake (each), 34”(86cm) dia. x 5” (13cm) wide .

DRUM SIZE: 30” (76cm) DIA. Barrel33.25” (85cm) Barrel Length41” (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)

Design Specifications

A-12

Design Specifications

STRAWDRUM:

A large fabricated steel drum mounted on drive shaft on roller bearings, located on theleft 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, airrelease 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

HAULBACKDRUM

FRONT MAIN(SLACK) DRUM

TRANSMISSION

ENGINE

THREE GUYLINE DRUMS

STRAWLINE DRUM

A-14

CHAIN DRIVE

REAR MAINDRUM

WATERCOOLEDBRAKE

CLUTCH

CLUTCH

CLUTCHWATER COOLED BRAKE

WATER COOLED BRAKE

Engine Specifications

A-15

Engine:

Engine Type:

Cylinders:

Displacement:

Manufacturer’s Maximum Rating:

Continuous Net Full Load Torque:

Continuous Net Peak Torque:

Battery - Size and Rating:

Starting System:

Alternator:

Amp Output:

Altitude Derating:

Caterpillar 3406B DIT Turbo-Charged

Diesel - 4 Stroke Cycle

Six 5.4” Bore x 6.5” Stroke (137mm x 165 mm)

893 Cubic Inches (14.6 Litres)

425 HP @ 2000 RPM

592 LB FT (810 NM) @ 1300 RPM

598 LB FT (810 NM) @ 1300 RPM

8D - CCA - 24 Volt

24 Volt

24 Volt

75 Amp

Above 12,000 FT (3,658 M)

Engine Specifications

A-16

Engine:

Engine Type:

Cylinders:

Displacement:

Manufacturer’s Maximum Rating:

Continuous Net Full Load Torque:

Continuous Net Peak Torque:

Battery - Size and Rating:

Starting System:

Alternator:

Amp Output:

Altitude Derating:

Cummins NTA-855 Turbo-Charged

Diesel - 6 Stroke Cycle

Six 5.5” Bore x 6” Stroke (140mm x 152 mm)

855 Cubic Inches (14.0 Liters)

430 HP @ 2100 RPM

592 LB FT (810 NM) @ 1300 RPM

598 LB FT (810 NM) @ 1300 RPM

8D - CCA - 24 Volt

24 Volt

24 Volt

75 Amp

Above 12,000 FT (3,658 M)

A-17

Dimensions

TSY6355A 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)

E

FI

H

G

A

59’5” (18.11M)REFERANCE

C

B

D

CONTROLS AND INSTRUMENTS ...................................................................... B-1START-UP CONTROLS.......................................................................................... B-3WARNING SYSTEM............................................................................................... B-5INSTRUMENTS ...................................................................................................... B-7CIRCUIT BREAKERS ............................................................................................ B-8

Chapter B: Controls and Instruments

Controls and Instruments

B-1

1

2

3

4

5

6

7

8

9

16SEE NEXT PAGE

10

11

12

13

14

15

21

17 18 19 20

TRANSMISSION SHIFT LEVER SHOWN WILL DIFFER, DEPENDING UPON TRANSMISSION & SERIAL NUMBER

Controls and Instruments

B-2

11

12

22

23

24

25

2627

2829

30 31 32 33 34 35

ITEM DESCRIPTION

1 Warning Light2 Travel Hi/Low Control3 Wiper Control4 Swing Brake On/Off Control5 Yard/Travel Control6 Main On/Off Control (Rear Main Drum)7 Slack On/Off Control (Front Main Drum)8 House Lock On/Off Control9 Servide Brake On/Off Control10 Do Not Shift Indicator11 Swing and Throttle Control12 Transmission Range Selector Control13 Straw DrumClutch control14 Strawdrum Brake Air Pressure Guage15 Strawdrum Brake Control16 Left Travel Brake Control17 Haulback Drum Brake Control18 Slackpulling Drum Brake Control (Front Main Drum)19 Main Drum Brake Control (Rear Main Drum)20 Right Travel Brake Control

36373839

ITEM DESCRIPTION

21 Drum Control (All)22 Guage, Interlock Air Pressure23 Guage, Water Cooled Brake Temprature24 Guage, Engine Oil Pressure25 Guage, Engine water Temprature26 Guage, Transmission Oil Pressure27 Guage, Transmission Oil Pressure28 Guage, Voltmeter29 Guage, System Air Pressure30 Maxi Brakes (All Drums)31 Guyline Drum Dog Controls32 Guyline Drum Motor Controls33 Topping Drum Motor Control34 Topping Drum Dog Control35 Guage, Charge Pressure36 Cold Start Control37 Guage, Hour Meter38 Fuse Panel39 Ignition Switch

TRANSMISSION SHIFT LEVER SHOWN WILL DIFFER, DEPENDING UPON TRANSMISSION & SERIAL NUMBER

Start-up

B-3

IGNITION SWITCH:

A key-actuated, three position switch. Position one (1) is the OFF position, the keycan only be withdrawn in this position. Position two (2) is ON, energizing all electricalcircuits. Position three (3) is the START position, which completes the circuit betweenthe battery and the engine starter motor. Positions one and two are maintained,position three is only held in place until the engine begins running.

ALWAYS PLACE IGNITION IN THE“OFF” POSITION WHEN WORKING ONMACHINE. ALWAYS REMOVE THE KEYWHEN MACHINE IS NOT IN USE

ENGINE THROTTLE:

Located at the operator’s left hand, this lever controls engine speed. Lever fullyforward is low idle speed. To accelerate, move lever to rear (towards operator). Theengine 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 arede-energized and the engine stops. In addition, the fuel supply solenoid will close,shutting off the engine fuel supply.

1 OFF

3 START

2 ON CAUTION!

Start-upTRACTION DRIVE PEDALS:

Travel and Drum control pedals, located directly in front of the operator’s seat, ensurepositive control and ease of operation. All pedals are linked to their respective func-tions which, when activated by pedal movement, provide a smooth and positive opera-tion. The traction brakes are the outer most pedals and are hydraulically releasedwhenever the pedals are moved from the neutral position. To engage the two-speedtravel mode, simply move the switch located on the left-hand control console to theHigh 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

B-5

WARNING LIGHTS AND BUZZER:

A red warning light, located on the Gauge panel, will illuminate and a warning buzzerwill 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 propercorrective maintenance performed.

REFERANCE CHART

BATTERY VOLTAGE:

A needle gauge located in the control console allows a constant monitoring of batteryvoltage. A gauge reading exceeding 30 volts indicates an overcharged condition, mostlikely due to a faulty or maladjusted voltage regulator. A gauge reading below 21 voltsindicates an undercharged condition due to a faulty battery or voltage regulator mal-function. Failure to correct either type of condition may result in damage to the electri-cal system of the loader.

UNTIL THE CAUSE OF A HIGH OILTEMPERATURE PROBLEM HAS BEENFOUND AND CORRECTED, DO NOTCONTINUE TO OPERATE MACHINE.PERMANENT DAMAGE TO THE ENGINECOULD RESULT.

ALARM RANGEGUAGE NORMAL RANGE

Water Brake Temperature

Engine Water Temperature

Transmission oil Temperature

Engine Oil Pressure

180° F

180° F

230° F

30 PSI (Cummins)40 PSI (Cat)

205° F and above

205° F and above

250° F

4 PSI Tripped

CAUTION!

Warning System

B-6

ENGINE WATER TEMPERATURE:

A needle gauge located on the control console that gives a constant indication ofengine coolant temperature. An alarm will sound if this temperature exceeds205° F for Cummins and 215° F for Caterpillar or above. If the alarm is active, shutdown the loader immediately and refer to the troubleshooting section of this publica-tion.

NOTE: A lighter work cycle may be required if the ambient temperature exceeds115°F.

DO NOT ATTEMPT CONTINUED OPERATION OF THE YARDER WHILEALARM REMAINS ACTIVATED.

ENGINE OIL PRESSURE:

Engine lubrication oil pressure is indicated on a needle gauge located on the controlconsole. The operator should make periodic visual checks of this gauge while theengine is running. A properly operating engine will have an oil pressure of above 30PSI when running at full throttle, if less than this value is observed the oil level shouldbe checked immediately. The oil pressure will show a rise with increased engine RPMand a decrease as the oil temperature increases. IF PRESSURE DROPS BELOW 10PSI, SHUT OFF ENGINE IMMEDIATELY.

NOTE: Engine oil pressure may register low when engine is first cold started.

Instruments

B-7

HORN BUTTON:

Depress to sound horn, located on left joystick. A travel alarm automatically soundsduring all steering and tracking operations.

HEATER/ AC UNIT:

The panel is located for the operator’s ease of operation. It contains the necessarycontrols 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 mainte-nance checks, fuel consumption and operating costs.

Circuit Breakers

B-8

20AMP

20AMP

20AMP

20AMP

20AMP

20AMP

20AMP

20AMP

20AMP

20AMP

15AMP

1

2

3

4

5

6

7

8

9

10

11

ITEM DESCRIPTION

1 12 Volt Supply2 VIM3 Heater/Wiper4 Neutral Start5 Guyline and Topping Winch6 Whistle7 Fuel/Cold Start8 Joysticks9 Hour Meter and Air Dryer

10 Two Speed11 Fan & Volt Meter

Chapter C: Operating ProceduresPRE-START INSPECTION ..................................................................................... C-1STARTING THE ENGINE ...................................................................................... C-2JUMP STARTING THE ENGINE ........................................................................... C-3MACHINE WARM-UP ............................................................................................ C-4SHUTTING DOWN THE MACHINE .................................................................... C-5UNUSUAL OPERATING CONDITIONS .............................................................. C-6EXTREME COLD ................................................................................................... C-6EXTREME HEAT .................................................................................................... C-7HIGH HUMIDITY OR SALTWATER..................................................................... C-9HIGH ALTITUDES ............................................................................................... C-10YARDER TRANSPORTING ................................................................................. C-11TOWER RAISING & LOWERING....................................................................... C-12TOWER PIN LOCATIONS ................................................................................... C-14SETTING GUYLINES .......................................................................................... C-15GUYLINE ARRANGEMENT ............................................................................... C-16DRUM OPERATIONS ........................................................................................... C-17PROCEDURAL AWARENESS ............................................................................. C-20WORKING WITH HYDRAULICS ....................................................................... C-21

Pre-Start InspectionDAILY 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 fluidleakage.

FUEL: Check level and TOP OFF tank, if needed, to assure day long operation. DONOT ALLOW FUEL TANK TO RUN DRY.

FUEL SHUT-OFF VALVE: Located on bottom of tank. Assure valve is in the openposition. Do not mistake quick release drain cap for shut-off valve.

LUBRICATION: Lubricate daily all points shown on Lubrication Chart, including allmounting 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 filtersdaily.

GENERAL CONDITION: Perform overall visual check for damage, wear, leakageand 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 offpositions, with all brakes in set position.

BATTERY: Turn battery master switch on.

C-1

Starting the Engine

C-2

Note: After completing the daily pre-start checks, the yarder engine may be startedand 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 keyedignition switch clockwise to start position and hold. Release ignition switch whenengine starts. Should stalling occur, allow engine to stop revolving before attemptingto restart. If engine fails to start within a 30 second period, you must allow starter tocool at least 2 minutes before trying to start engine again.

Do not attempt to operate machine until allpressures and temperatures have reached recom-mended levels.

C. Immediately after the engine starts, observe the engine oil pressure gauge. Ifno oil pressure is indicated within 10-15 seconds, shut the engine down andinspect the lubrication system levels and connections. (Refer to engine manualfor troubleshooting.)

D. Run the engine at idle speed for approximately five minutes. This will allow airand 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 attempting to operate yarder.

CAUTION!

Jump Starting the Engine

C-3

ALWAYS HAVE IGNITION KEY IN OFFPOSITION BEFORE CONNECTINGCABLES.

ALWAYS HAVE TRANSMISSION IN THENEUTRAL POSITION BEFORECONNECTING CABLES.

The ground cable must be attached last and removed first to prevent sparksfrom 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 thebattery (use starter ground post of machine to be started).

To prevent possible personal injury, care must be used when removing the cables fromthe machine that has been started. Do not allow the cable ends to contact each otheror the machine.

Always connect batteries in parallel: positive to positive, negative to negative. Connectpositive poles first, negative poles second. Disconnect negative poles first, positivepoles second.

1. Attach one cable to ungrounded POSITIVE (+) terminal of battery on machine tobe started. Attach opposite end of cable to POSITIVE (+) terminal of external startingsource.

2. Attach second cable to NEGATIVE (-) terminal of starting source. Attach remain-ing 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 machinejust started. NEXT, remove opposite end of cable from negative terminal of startingsource.

5. Remove cable from POSITIVE (+) terminal of battery on machine started. Finally,remove opposite end of cable from POSITIVE (+) terminal of starting source.

CAUTION!

CAUTION!

Machine Warm-up

C-4

RECOMMENDED WARM-UP PROCEDURE:

After machine is started, allow adequate time for all oils to warm to operating tem-perature. Machine warm up is part of daily preventative maintenance. For smoothresponse 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 3-5minutes.

Shutting Down the Machine

C-5

RECOMMENDED SHUTDOWN PROCEDURE IS:

A. Remove tension from lines by running butt rigging or carriage out of landingarea.

Note: If using a motorized carriage, it is recommended that the carriage be set on theground in the landing area.

B. With no load, allow engine to run at half throttle for 5 minutes to allow engine tocool before shut down.

C. Apply spring brakes on all drums

D. Place engine ignition switch in OFF position in order to render all controls inop-erative. 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 thebattery shut-off.

G. Inspect machine as a part of your scheduled maintenance program, and report, inwriting, 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 whenoperating under unusual conditions such as extreme heat/cold/humidity, high altitude,salt water, or dusty/sandy work sites. By following the recommendations listed forsuch conditions, major problems can be avoided.

Unusual Operating Conditions

C-6

EXTREME COLD:

To avoid battery failure, inadequate lubrication, and freeze damage, it is advised thatyour machine be winterized before moving to a cold weather situation. Proper winter-ization is achieved by servicing the cooling system, and by using the correct COLDWEATHER lubricants (see lube chart).

COOLING SYSTEM:

To avoid freeze damage to cooling system and/or major damage to engine block orhead, system should be completely drained and flushed. Be certain exterior air pas-sages are clear and that cooling fins are free of dirt, grease, etc. Use equal amounts ofantifreeze and water. Check thermostat, radiator hoses, hose clamps and repair orreplace as needed.

FUEL SUPPLY:

To avoid fuel line freeze up caused by condensation in the fuel tank, keep fuel tank asfull as possible.

LUBRICATION:

Change engine oil, and other lubricants not meeting specifications for cold weatheroperation, per lubrication chart.

BATTERY:

Battery must be kept fully charged at all times to avoid electrolyte freezing. Be surebattery is charging when engine is running. When machine is not operating, use anexternal charging source to bring battery to full charge. Add water to battery just priorto starting the engine to allow water to mix with electrolyte while machine is operat-ing. Not allowing water to mix with electrolyte can cause battery freeze up. Removalof battery, and storage in a heated area if machine is to be idle for a period of time, isadvised.

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 weatheroperation, to avoid hydraulic malfunctions.


C-7

FREEZING:

Upon completion of the work period or whenever the machine is to be left idle forextended 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 coolingsystem, the batteries and lubrication. The following procedures are recommended:

1. High temperatures require the use of lubricants which are more viscous and whichresist deterioration at higher operating temperatures. Refer to Chapter E and lubricatethe machine using the lubricants recommended for the expected temperatures. Crank-case oil is particularly important because it helps to dissipate heat. Check the oil levelfrequently and add oil as required to maintain proper level. Too little oil will hinderheat dissipation.

2. To ensure proper coolant circulation, drain and flush the cooling system, clean anyforeign matter from the radiator cooling fins and through-core air passages, replacedefective hoses, tighten hose clamps, tension the water pump drive belt properly,eliminate any leaks detected, and fill the system with a 50% solution of ethyleneglycol. Engine overheating due to loss of coolant will most often be corrected byslowly adding coolant, while the engine is running at FAST IDLE. Should this fail tocorrect the problem, drain and flush the system and refill with fresh coolant (50%solution of ethylene glycol) and a corrosion inhibitor.

ALLOW THE ENGINE TO COOL BE-FORE DRAINING AND FLUSHING THECOOLING SYSTEM.

Water containing more than small concentrations of salt or minerals should not be usedin the cooling system. Salt facilitates corrosion and minerals deposit on the coolantpassage walls. Both processes inhibit proper cooling.

3. Increased evaporation rates will cause the battery electrolyte level to fall even morerapidly during very hot weather. Check this level frequently and add distilled water asrequired to maintain the proper level.

4. Air circulation around the engine and battery must not be restricted. Keep airintake and exhaust openings clear of leaves, paper or other foreign matter which mayrestrict air flow.

5. Keep the engine clean of dirt, grease and other substances which inhibit heatdissipation.

CAUTION!


C-8

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 opera-tions are interrupted.

In some locations, such as coastal areas, the machine may be exposed to the deterio-rating 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 humidityare encountered. Follow the recommendations below when operating in these condi-tions:

1. Make frequent inspections for rust and corrosions and remove them as soon as theyare detected. Dry and paint exposed surfaces after rust and corrosion have beenremoved.

2. Where paint may not be applied, such as on polished or machined surfaces, coat thearea with grease or lubricant to repel water.

3. Keep bearings and their surrounding surfaces well lubricated to prevent the entry ofwater.

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.

High Humidity or Salt Water

C-9

High Altitudes

C-10

Variations in altitude alter the fuel-air mixture burned in the engine and affect theengine’s performance. At high altitudes, atmospheric pressures are lower and lessoxygen is available for the combustion of fuel. Above 5000', the engine fuel injectorsmay have to be changed to ensure proper performance. Consult engine manufacturershould this problem arise.

Keeping the air cleaner clean and free of obstructions will help alleviate high altitudeproblems. At high altitudes, closely monitor the engine and hydraulic oil temperaturesfor over heating.

NOTE: On machine equipped with turbocharged engines, engine power will notdecrease at altitude; however, cooling ability does. This can lead to overheatingproblems unless the duty cycle is reduced or special cooling packages are added.

Yarder Transporting

C-11

IT IS IMPORTANT TO CHECK ALL STATE AND LOCAL REGULATIONSREGARDING HEIGHT, WIDTH, AND WEIGHT FOR TRANSPORTINGANY EQUIPMENT.

IMPORTANT: Regardless of how the machineis positioned on the trailer, always be sure toTIE DOWN attachment SECURELY. This is anecessary precaution to avoid unnecessarydamage due to vibration, bouncing, etc. whiletraveling from one site to another.

CAUTION!

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 theHaulback 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 mainframe.

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 theBackstay.

6. The Tower must be kept at rest by allowing the Topping line to pay out. Engage theHaulback clutch, place the Transmission in first gear. Using the Haulback brake pedalfor 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. Insertand secure the leg pins.

Do not attempt to raise the Tower, Mast andBackstay at the same time. Control conditionsmay 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 de-scribed.

9. Engage the Topping drum drive and raise the Tower to the proper working angle.Engage the Topping drum locking dogs.

C-12

RAISING ARM

BACKSTAYMAIN FRAME HAULBACK DRUM

1, 342

Tower Raising & Lowering

The proper working angle must be between 15°and 20° from vertical. Other positions may causeline scuffing or machine component overlaods.

The line leaves the drum (1) from the top andruns through the top of the sheave (2) on thenear side of the mast, through the top of thependant sheave (3), then under the near mastsheave (4). It runs back to the middle pendantsheave (3) then through the lower middle mastsheave (4). Finally through the far side (3) and(4) as previously explained. Then through theend sheave (3) to the anchor on the far side ofthe mast near the sheave (2).

TOWER LOWERING PROCEDURE:

The tower may be lowered from any position. However, for transportation, the toweris 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 “TowerRaising Procedure”. Engage the Haulback clutch, place the transmission in reverse,and use the Haulback brake pedal for control. Advance the throttle as required toremove the Haulback line slack.

3. Retract the Topping drum dog and pay out the Topping line until the tower is fullylowered.

4. Remove the pin from the Backstay feet.

5. Using the Haulback brake pedal for control, inhaul on the Topping drum to tip theMast and Backstay. Continue inhauling the Topping line until the Mast and Backstayare at rest horizontally.

C-13

CAUTION!

C-14

Topping Line Reeving Instructions

C-15

Tower Pin Locations

PIVOT PIN

RAISING ARM PIVOT PIN

PIVOT PIN

PIVOT PIN

TOWER TOPPING ANCHOR PIN

TOWER TOPPING ANCHOR PIN

TOWER STOP PIN

MAST TOPPING ANCHOR PIN

Guyline Arrangement

Avoid load bearing guylines being located at anangle steeper than 45° as possible damage to thetower abd other components may occur.

ALWAYS MAINTAIN TWO (2) GUYLINESOPPOSITE FROM PULL DIRECTION.

C-16

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 guylines3. Attach guylines to stumps4. Pick up excess slack in guylines, and set dogs to the “ON” position and assure thatthe guyline dogs are fully seated.5. Put out running lines for whichever system is to be used, leave slack6. Tighten guylines

Do not overtighten Guylines

Setting Yarder Guylines

Procedural Awareness

C-20

Use extreme caution when using the hand holds and steps while entering the yardercab. Always have at least three points of contact (two hands and one foot or one handand two feet) solidly in place at all times. Hand holds and steps, made slippery bywater, 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. Donot attempt to start or operate the yarder from any other position or bypass any of theinterlock systems or controls.

Never allow anyone other than the operator to be in or on the machine while it is inoperation. They are subject to injury by being struck by the load or other movingobjects, 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 anaccident or unsafe operation.

UNDER NO CIRCUMSTANCES shouldanyone ever ride or be carried on the boom orany attachment. To do so constitutes an extremepersonnel hazard.

Always have a clear unobstructed view of all parts of the yarder operation beforestarting the yarder or moving any load. If visibility is poor, reduce operating speedaccordingly.

Be sure to warn all others in the vicinity of the job site before travelling the yarder. Ifthe job site is extremely congested, have a coworker precede the machine to warnothers in the area and to signal problems to the operator. Be sure to coordinate handsignals before you start.

Working With Hydraulics

C-21

With the engine running, pressures as high as 5000 PSI are generated within thehydraulic system. At these high pressures, even a tiny leak can lead to major problemsin a very short while. It is important to correct problems as soon as possible after theyare discovered, both to prevent hazardous operating conditions and to prevent ma-chine damage.

NEVER check for leaks using your bare hand - hydraulic fluid being ejected underpressure can cause sever damage to skin tissue. Always use a piece of wood or heavycardboard 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, andvalves.

Hydraulic fluid can reach extreme temperatures after being worked for a period oftime. Allow sufficient time for the fluid to cool before attempting to service any part ofthe hydraulic system.

Chapter D: Maintenance ChecksINTRODUCTION ....................................................................................................... DDAILY CHECKS...................................................................................................... D-1WEEKLY CHECKS ................................................................................................. D-5MONTHLY CHECKS .............................................................................................. D-7QUARTERLY CHECKS .......................................................................................... D-8SEMIANNUAL CHECKS ..................................................................................... D-10ANNUAL CHECKS ............................................................................................... D-11

IntroductionThis section contains safety information, inspection and maintenance checklist for the safe andreliable operation of the TSY6355 yarder/tower. The conscientious operator will be guided bythe primary rules of safety when operating or servicing the machine and should continuouslyupdate his techniques for efficient performance.

Safety should not be limited to the items listed in this manual, but should include any precau-tion required by the particular circumstances of the operation and should always includeLocal, 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.

Check vendor materials located in the vendorsection of this manual for additional check listsand maintenance requirements.

CAUTION!

D

D-1

Daily Maintenance ChecksLUBRICATION:

Lubricate all points indicated on lubrication chart. (Refer to Chapter E of this sec-tion.) 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 onthe bottom right hand side of tank. Allow contaminants (moisture and sediment) todrain from the tank. When fuel appears clear, close the drain. Drain water from thefuel separator daily.

NOTE: The machine should be level when draining contaminants. Do not mistakefuel shut off valve for the drain plug. The fuel shut off valve should be closed whendraining contaminants.

FUEL LEVEL: To avoid contaminants enter-ing fuel tank, always clean around the filler capbefore adding fuel. Tank should be kept as full aspossible with a quality Grade-2 diesel fuel. Tominimize condensation, especially in coldweather, fill the tank to the bottom of the fillerneck.

AUXILIARY FUEL FILTER:

Water and sediment can be drained from fuel filters by opening the drain cock at baseof 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 freeof dirt and grease. Malfunctioning controls or instruments should be repaired orreplaced immediately.

Ensure that all controls are in the NEUTRALposition before starting the engine.

DRAIN PLUG

FILL NECK

CAUTION!

D-2

Daily Maintenance Checks

ENGINE OIL:

Allow engine oil to drain back to the sump before checking oil level. (About 15minutes) The dipstick is accessible through rear doors of engine house.

DO NOT CHECK OIL LEVEL WHILEENGINE IS RUNNING!

DO NOT OPERATE ENGINE IF OILLEVEL IS ABOVE FULL MARK OR BE-LOW THE LOW MARK. DO NOT OVER-FILL.

COOLANT LEVEL:

It is recommended that coolant level be checked each morning, before work hasbegun. Check coolant level with engine stopped.

If coolant level requires checking after enginehas run for some time, remember to loosen capslowly to relieve pressure. Then removing cap.PRESSURIZED HOT FLUIDS CAN IN-FLICT SERIOUS PERSONAL INJURY IFALLOWED TO ESCAPE QUICKLY. Main-tain coolant level to within 1/2” below fill pipe.

CAUTION!

CAUTION!

CAUTION!

D-3

Daily Maintenance ChecksAIR CLEANER: A clogged air filter restrictsengine power output, and must be checked daily.A vacuum actuated indicator, mounted on the aircleaner outlet neck, indicates conditions ofrestricted air flow through the air cleaner. If redsignal is in the service level, with engine runningat maximum governed RPM, air filter needs tobe cleaned or replaced. Refer to section IV ofthis publication for complete air servicing in-structions.

PUMP DRIVE CASE: Access to pump drivecase, filler/breather and full plug is rear of theengine house. Oil level, with engine NOT run-ning, should just start coming out the hole whenthe full plug is removed. OVER FILLINGCOULD CAUSE OVERHEATING OR MAL-FUNCTIONING! Clean around the filler/breather before removing it to add oil.

DAILY INSPECTIONS:

1. At the end of the shift, drain the air tanks to remove moisture and accumulatedsediments 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 andbearing 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’schecklist for each.

INDICATOR

FULL PLUG

BREATHER

DRAIN PLUG

INPUT SHAFT

OUTPUTCOUPLERS

D-4

Daily Maintenance Checks

CAUTION!

Before loosening any hydraulic component orconnection, make sure there is no residualpressure in the lines.

HYDRAULIC COMPONENTS:

Clean hydraulic valves, motors, pumps, hoses, tube connections, if needed, and checkfor 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 anydamaged 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 whenfittings are being tightened.

HYDRAULIC FLUID LEVEL:

The hydraulic reservoir fluid level indicator tube, decal and filler port are located onthe hydraulic tank. The oil level should be at the high mark of the indicator tube withall lines full. The reservoir capacity is 85 gallons (321 liters).

DO NOT OVERFILL

DO NOT OPERATE when the oil level isbelow the low mark in the fluid level indicatortube when all cylinders are fully extended.

VISUAL INSPECTION:

A complete, detailed, visual inspection should be given to the THUNDERBIRDyarder each day, before the start operations. The discovery of damaged or worncomponents, as well as the discovery of potential problems, should be reported to theproper maintenance personnel immediately. Repair or replace any faulty componentsbefore beginning operation. Always keep the machine clean.

FILL DECAL

FILL NECK

D-5

Weekly Maintenance ChecksNote: Perform the following inspections weekly in addition to the daily inspections.

LUBRICATION:

Using the types of lubricant specified by the manufacturer, lubricate all weekly lubrica-tion points per lubrication chart found in Chapter-E of this manual.

ENGINE BELTS: Fan and implement belts areextremely important parts of your engine andshould be checked at least once a week forphysical condition and proper tensioning. Re-place belts which appear cracked and/or frayed.Belt tension should allow 9/16 to 13/16 deflec-tion, between pulleys.

NOTE: Belts adjusted too tightly will causeexcessive wear to driven bearings. Belts ad-justed too loosely will slip.

HYDRAULIC RESERVOIR: Contaminants(moisture and sediment) should be drained fromthe hydraulic reservoir before the start of eachweek’s operations. The Oil Drain plug, at thebase of the tank, is easily accessible.

FILTERS: (Hydraulic Reservoir) After theinitial 60 hours of operation, the suction andreturn filter elements must be changed.


ENGINE ALTERNATOR BELT

AIR CONDITIONERCOMPRESSOR BELT

FAN BELT

CAUTION!

CAUTION!

FILL DECAL

FILL NECK

D-6

Weekly Maintenance Checks

BATTERY:

Refer to Chapter-C, UNUSUAL OPERATING CONDITIONS, for proper batterymaintenance instructions. Check the battery electrolyte level and add distilled water asrequired 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 upfull system air pressure, stopping the engine, and operating all controls to fulloff and on positions. Check the compressor and air system lubricator andfollow vendor check information.

2. Inspect all lines for wear, abrasions, or fraying. Replace or repair any damagedcables immediately.


CAUTION!

D-7

Monthly Maintenance Checks

CAUTION!

Note: Perform the following inspections monthly in addition to the daily and weeklyinspections.

MONTHLY LUBRICATION:

Refer to Chapter-E of this manual for all of the monthly machine lubrication require-ments. Lubricate all monthly lubrication points as indicated on the lube chart with thetype of lubricant specified.

ENGINE OIL CHANGE:

At the end of the work shift, when most of the sediment is still in suspension, removedrain plug located at base of engine. Clean and replace the plug. When refilling, referto engine manufacturer’s manual for the type and weight of oil recommended forexpected ambient temperatures.

Keep the oil level as close to the full mark aspossible. DO NOT OVERFILL. Never operatethe engine when the oil level is above full markor below low mark indicated on dipstick.

RADIATOR:

Clean any foreign matter from radiator cooling fins and through-core cooling passagesby directing compressed air in reverse direction of normal air flow.

VISUAL INSPECTION:

1. Inspect all tower components and fairleads for any visual evidence of unusualwear or signs of severe stress.

2. Check the drum brakes and clutches for wear. Adjust or replace componentsas required.

3. Inspect all machinery guards and ensure that they are secure and have ampleclearance from any moving parts.


CAUTION!

D-8

Quarterly Maintenance ChecksNote: Perform the following inspections in addition to daily, weekly and monthlyinspections.

GENERAL:

Upon completion of quarterly checks, the daily, weekly and monthly checks should beperformed. 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 torquesettings.

ENGINE OIL FILTERS:

Install clean engine oil filter elements every time oil is changed, or at least every 500hours. 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. Checkdrained 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 bechanged at the time of engine oil replacement or 250 hours.


CAUTION!

Quarterly Maintenance Checks

CAUTION!

BRAKE BAND AND CLUTCH BAND:

Check bands for cleanliness, wear, and glazing. If bands are found to be in need ofrepair, address the necessary corrections without delay.

Dirty, worn, or glazed brake and clutch bandsmay lessen or eliminate the standard operation ofthe Thunderbird yarder.

TRAVEL BRAKES:

Check the holding power of the travel brake. This is accomplished by disconnectingthe pilot line that applies the brake release function. This can easily be accomplished atthe brake line “quick disconnect” located under the cab. If the travel function overpowers the brake, replacement of the brake is required.


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 Swingbrake control in the “ON” position. Swing brake control is by varying the hydraulicpressure. There should be no hydraulic leaks from this component.

CAUTION!

D-9

D-10

Semi-Annual ChecksNote: Perform the following inspections after the first 100 hours and at every 2,500hours of operation time thereafter. PERFORM ALL PREVIOUS CHECKS INADDITION TO THE FOLLOWING SEMIANNUAL CHECKS.

HYDRAULIC OIL:

Check hydraulic oil for viscosity, water content, and contaminants. Record findings onyour 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 thosetypes of lubricants specified by manufacturer.

CRANK CASE BREATHER ASSEMBLY:

Wash assembly in kerosene or clean fuel oil. Replace pad if necessary. Cleaning periodmust be adhered to meet your service requirements.

COOLING SYSTEM:

Clean system every 1000 hours or semiannually, whichever comes first. Use of aradiator cleaning agent is recommended and follow instructions on the container. Flushwith fresh water and refill with a 50% water/50% ethylene glycol solution. Cleanexterior 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 valvesettings. Improperly adjusted relief valves will affect machine operation.

VISUAL INSPECTION:

1. Check all chain and sprockets for any undue wear, check oil for any metalflakes or residue.

2. Check hydraulic lines, fittings, and reservoir for leaks, breaks, and deterioration.Repair or replace as required.


CAUTION!

D-11

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 dieselfuel. Replace drain plugs and remove the oil level plug. Refill with lubricant specifiedon fluid level chart in Chapter-E. Tighten the vent plug. Repeat procedure for theopposite side of the machine.

CASE DRAIN PLUG

FILL AND FULLPLUG

OTHER PERIODIC INSPECTIONS:

Some of the purchased components not manufactured by Ross Corporation, but usedin the construction of the TSY6355 yarder, will require periodic inspection and main-tenance. Vendor data in the vendor section, contains information for these compo-nents.

Chapter E: ChartsLUBRICATION ........................................................................................................ E-1LUBRICATION CHART ......................................................................................... E-4MAINTENANCE CHART ....................................................................................... E-7FLUID LEVEL CHART........................................................................................... E-8

LUBRICATION

One of the primary elements in any preventative maintenance program is adequatelubrication with the correct lubricant.

This section details recommended lubrication and frequency for normal operatingconditions, 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 whenthe yarder is not operating. All other lubrication should be performed at the calendaror hourly intervals specified.

Make certain that the power unit is shut downand the operator’s control console is tagged toprevent 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 re-ceived 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 colorbut should have a lubricant film covering the gear teeth. On new machines itis necessary to maintain a slightly heavier film on the gear teeth. This run-on periodnormally 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 2-3 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. Inspectall machinery guards to ensure that they are secure and have ample clearance from anymoving parts.

4. Gearing should be inspected at the time of lubrication to check for evidence offoreign materials or lubricant contamination.

Lubrication

E-1

Note: If a gear lubricant, other than the recommended is substituted, the gears mustbe checked frequently for proper lubrication, since dissimilar gear lubricants do notreadily mix and the gears will tend to throw off the substituted lubricant. Itmay take several days of continued application before the substituted lubricant willadhere to the gear teeth.

Since the gear lube must be applied with thegears slowly turning, care must be taken toavoid injury. Do no stand on drums or shafts,even though they many not be turning at thattime. Lubricant should be only applied throughopenings provided in the guards for this pur-pose.

Various components such as engine, transmis-sion, water pump, and compressor should belubricated according to the vendor’s informationlocated in the vendor section.

The following test should be performed withoutcable on the drums.

OPERATING TEST:

The following test should be done after long periods of inactivity and/or after majormaintenance has been performed. This will help ensure that your machine is workingproperly 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 afteroil the pressure reaches normal operating level.

C. Observe gauges for proper pressure and charging conditions.

Lubrication

CAUTION!

E-2

D. Engage drum frictions and operate the drums through all transmission ranges andat 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 performcorrective maintenance.

Lubrication

E-3

Lubrication Chart

E-412/04/98 TSY6355 OPER & MAINT

��

Maintenance Chart

Number Fittings FrequencyRE-TORQUE BOLTS

Maintenance Required1 PEDESTAL BOLTS

2 TRACK PAD BOLTS RE-TORQUE BOLTS2BULL GEAR / REVERSER /STRAW DRUM BEARINGS

3 CHECK AND SET PRE-LOAD5

1000 HOURS500 HOURS

8

Component

500 HOURS

4 TORQUE DRIVE /SPROCKET BOLTS

2 500 HOURS RE-TORQUE BOLTS

E-5

5 SWING BEARINGBOLTS

84 1000 HOURS RE-TORQUE BOLTS

4 25

1

1

1

1

1

1

1

1

3

3

3

3

3

3

3

TSY-6355 REVISED 12/31/98 OPER./MAINT.

Fluid Level ChartFLUID LEVEL CHART

FLUID TYPE

ENGINE: CUMMINS NTA-855

OIL AND FILTER

COOLANT BLOCK

COOLANT RADIATOR

FUEL TANK

PUMP DRIVE

TRACK DRIVE GEARBOX

CARRIER AND TOWER

ALL CARRIER GREASEPOINTS (NOT OPENGEARS)

ALL TOWER GREASEPOINTS

HYDRAULIC SYSTEM

HYDRAULIC RESERVOIR

T R A N S M I S S I O N

CHAIN CASE

OPEN GEARS

ITEM FLUID CAPACITIES

CUMMINS PREMIUMBLUE CE/SF 15W-40

SEE ENGINE MANUALFOR COOLING SPECS

ASTM NO. 2D DIESEL

75W-90 SYNTHETIC

85W-140 GEAR OIL

WARM WEATHER EP2

COLD WEATHER EP0

WARM WEATHER EP2COLD WEATHER EP2

WARM WEATHER (AW-46)

COLD WEATHER (AW-32)

SEE TRANSMISSIONMANUAL IN VENDORSECTION

85W-140 GEAR OIL

TEXAS OIL REFINERYOPEN GEAR TAKILUBE

40 QUARTS(37.8 LITRES)

12 QUARTS (11.4 LITRES)

15.8 GAL (61.6 LITRE)

370 GAL (1400 LITRE)

3.5 QUARTS (3.3 LITRES)

11 QUARTS (10.5LITRES)

-

-

115 GAL (434.7 LITRES)


-

2 GAL. (7.56 LITERS)APPROX.

AS REQUIRED

E-6

E-7

Fluid Level ChartFLUID LEVEL CHART

FLUID TYPE

ENGINE: CATERPILLAR 3406B

OIL AND FILTER

COOLANT BLOCK

COOLANT RADIATOR

FUEL TANK

PUMP DRIVE

TRACK DRIVE GEARBOX

CARRIER AND TOWER

ALL CARRIER GREASEPOINTS (NOT OPENGEARS)

ALL TOWER GREASEPOINTS

HYDRAULIC SYSTEM

HYDRAULIC RESERVOIR

TRANSMISSION

CHAIN CASE

OPEN GEARS

ITEM FLUID CAPACITIES

CATERPILLAR OILDEO (CF-4)

SEE ENGINE MANUALFOR COOLING SPECS

ASTM NO. 2D DIESEL

MOBIL SHC 75W-90

ISO-VG220-5EPMOBIL GEAR 630OR CHEVRON GEARCOMPOUND 220

CHEVRON ULTRA DUTYGREASEWARM WEATHER EP2COLD WEATHER EP0

CHEVRON ULTRA DUTYWARM WEATHER EP2COLD WEATHER EP2

MOBIL HYDRAULIC FLUIDWARM WEATHER DTE 13M

(AW-46)COLD WEATHER DTE 15M

(AW-32)

SEE TRANSMISSIONMANUAL IN VENDORSECTION

CHEVRON 85W-140

TEXAS OIL REFINERYOPEN GEAR TAKILUBE

36 QUARTS(34.1 LITERS)


15.8 GAL (61.6 LITRE)

370 GAL (1400 LITRE)

3.5 QUARTS (3.3 LITRES)


-

-



-

2 GAL. (7.56 LITERS)APPROX.

AS REQUIRED

Chapter F: Quick ReferencesCummins NTA-855 Engine ........................................................................................ F-1Caterpillar 3406B Engine ........................................................................................... F-2

F-1

Quick ReferenceCummins NTA855Most commonly requested replacement parts for Thunderbird TSY6355 Yarderequipped with Cummins NTA-855 engines. It is recommended that these parts bekept on hand to expedite routine maintenance.FILTERS

FUEL FILTER ................................................................................................. P43-0011WATER FILTER ..............................................................................................P43-0013FULL FLOW OIL FILTER .............................................................................P43-0016BY-PASS OIL FILTER ...................................................................................P43-0017PILOT FILTER ELEMENT ................................................................................. P4391O-RING FOR PILOT FILTER ........................................................................P34-0219TRANSMISSION FILTER ..................................................................................T1059O-RING FOR TRANSMISSION FILTER ......................................................P34-0220FUEL FILTER .................................................................................................P43-0062AIR CLEANER ELEMENT ...........................................................................P43-0056AIR CLEANER SAFETY ELEMENT ...........................................................P43-0057O-RING FOR AIR CLEANER (UPPER & LOWER) ....................................P25-0087HYDRAULIC RETURN FILTER ELEMENT .................................................... P2346HYDRAULIC SUCTION FILTER ELEMENT .............................................P43-0058

ENGINE BELTSFAN BELT .......................................................................................................P25-0101ALTERNATOR BELT .....................................................................................P25-0103AIR CONDITIONER COMPRESSOR BELT ................................................P25-0105

SENDING UNITSENGINE / WATER COOLED BRAKE (WCB) WATER TEMPERATURE..P40-0011TRANSMISSION OIL TEMPERTURE .........................................................P40-0012ENGINE OIL PRESSURE ..............................................................................P40-0015

MISCELLANEOUS ELECTRICALCIRCUIT BREAKER - 50A ................................................................................T0516CIRCUIT BREAKER - 20A ...........................................................................P40-0052CIRCUIT BREAKER - 15A ...........................................................................P40-0053BATTERY ............................................................................................................T0301BATTERY DISCONNECT .............................................................................P40-0023HOUR METER ...............................................................................................P40-0009VOLTMETER .................................................................................................P40-0038

GUAGESENGINE / WATER COOLED BRAKE (WCB) WATER TEMPERATURE..P40-0003TRANSMISSION OIL TEMPERTURE .........................................................P40-0005ENGINE OIL PRESSURE ..............................................................................P40-0001

AIR SYSTEMQUICK RELEASE ...............................................................................................T0176REGULATOR (main) ...........................................................................................T0177SAFETY VALVE (air tank) ..................................................................................T0175CHECK VALVE (air tank) ...................................................................................T1461UNLOADER VALVE (air tank) ...........................................................................T1533LUBRICATOR .....................................................................................................T0625

Quick Reference Caterpillar 3406B

F-2

Most commonly requested replacement parts for Thunderbird TSY6355 Yarderequipped with Caterpillar 3406B engines. It is recommended that these parts bekept on hand to expedite routine maintenance.

FILTERSFUEL FILTER .................................................................................................P43-0439COOLANT CONDITIONER FILTER............................................................P43-0440OIL FILTER ....................................................................................................P43-0441PILOT FILTER ELEMENT ................................................................................. P4391O-RING FOR PILOT FILTER ........................................................................P34-0219TRANSMISSION FILTER ..................................................................................T1059O-RING FOR TRANSMISSION FILTER ......................................................P34-0220FUEL FILTER .................................................................................................P43-0062AIR CLEANER ELEMENT ...........................................................................P43-0056AIR CLEANER SAFETY ELEMENT ...........................................................P43-0057O-RING FOR AIR CLEANER (UPPER & LOWER) ....................................P25-0087HYDRAULIC RETURN FILTER ELEMENT .................................................... P2346HYDRAULIC SUCTION FILTER ELEMENT .............................................P43-0058

ENGINE BELTSFAN BELT .......................................................................................................P25-0422ALTERNATOR BELT .....................................................................................P25-0437AIR CONDITIONER COMPRESSOR BELT ................................................P25-0438

SENDING UNITSENGINE / WATER COOLED BRAKE (WCB) WATER TEMPERATURE..P40-0011TRANSMISSION OIL TEMPERATURE ......................................................P40-0012ENGINE OIL PRESSURE ..............................................................................P40-0015

MISCELLANEOUS ELECTRICALCIRCUIT BREAKER - 50A ................................................................................T0516CIRCUIT BREAKER - 20A ...........................................................................P40-0052CIRCUIT BREAKER - 15A ...........................................................................P40-0053BATTERY ............................................................................................................T0301BATTERY DISCONNECT .............................................................................P40-0023HOUR METER ...............................................................................................P40-0009VOLTMETER .................................................................................................P40-0038

GAUGESENGINE / WATER COOLED BRAKE (WCB) WATER TEMPERATURE..P40-0003TRANSMISSION OIL TEMPERATURE ......................................................P40-0005ENGINE OIL PRESSURE ..............................................................................P40-0001

AIR SYSTEMQUICK RELEASE ...............................................................................................T0176REGULATOR (main) ...........................................................................................T0177SAFETY VALVE (air tank) ..................................................................................T0175CHECK VALVE (air tank) ...................................................................................T1461UNLOADER VALVE (air tank) ...........................................................................T1533LUBRICATOR .....................................................................................................T0625

A: GENERAL HYDRAULIC INFORMATIONGENERAL INFORMATION & PROCEDURE .......................................... A-1BASIC TROUBLESHOOTING & NOMENCLATURE ............................. A-2WARNING LIGHTS AND BUZZERS ....................................................... A-3

B: GENERAL HYDRAULIC PROBLEMSUNABLE TO SPOOL IN OR OUT ............................................................. B-1SLOW MOTION IN ONE FUNCTION ...................................................... B-1LOSS OF MOTION DURING OPERATION ............................................. B-2OVER HEATING HYDRAULIC OIL ......................................................... B-2NOISY OPERATION................................................................................... B-3STICKING VALVE SPOOL ........................................................................ B-3LEAKING SEALS ....................................................................................... B-4FUNCTION REMAINS APPLIED .............................................................. B-4HYDRAULIC OIL IN PUMP DRIVE CASE ............................................. B-4PRESSURE SETTING REQUIRES FREQUENT ADJUSTMENT........... B-5LEAKS ......................................................................................................... B-5ALL TRAVEL FUNCTIONS ARE INOPERATIVE ................................... B-6EXCESSIVE PUMP NOISE ........................................................................ B-6

C: SWING AND GENERAL PROBLEMSNO SWING AT NORMAL ENGINE SPEED ............................................. C-1SWING IS SLUGGISH OR ERRATIC........................................................ C-2SWINGS IN ONE DIRECTION ONLY ...................................................... C-2SWING MOTOR TEMPRATURE HIGHER THAN NORMAL ................ C-3HIGH NOISE LEVEL IN SWING PUMP .................................................. C-3SWINGS IN WRONG DIRECTION ........................................................... C-4NO POWER TO DRIVE SHAVT ................................................................ C-4NO POWER TO DRUM GEARS ................................................................ C-5DRUMS WILL NOT TURN ........................................................................ C-5DRIVE CLUTCH WILL NOT RELEASE .................................................. C-6DRIVE CLUTCH WILL NOT ENGAGE ................................................... C-6BRAKE BAND WILL NOT APPLY OR RELEASE .................................. C-7WATER BRAKE WILL NOT APPLY OR RELEASE ................................ C-7LOW AIR PRESSURE................................................................................. C-8GUYLINE DRUM WILL NOT OPERATE................................................. C-8

D: ELECTRICAL PROBLEMSENGINE WILL NOT CRANK .................................................................... D-1NO GAUGE READING .............................................................................. D-1LOW OR DEAD BATTERY ........................................................................ D-2

Section II:Troubleshooting

Section II:Troubleshooting

E: TRAVEL PROBLEMSNO TRAVEL ................................................................................................ E-1TRACK DRIVE SLUGGISH OR ERRATIC............................................... E-2TRACK DRIVES IN ONE DIRECTION ONLY ........................................ E-2TRACK DRIVES IN OPPOSITE DIRECTION.......................................... E-3TRAVEL MOTOR TEMPERATURE HIGHER THAN NORMAL............ E-3EXCESSIVE NOISE IN TRACTION MOTOR .......................................... E-3INSUFFICIENT TRACTION MOTOR TORQUE ..................................... E-4WEAK TRAVEL IN ONE DIRECTION ONLY ......................................... E-4

F: TROUBLESHOOTING WORK RECORDSTROUBLESHOOTING HISTORY SHEETS .............................................. F-1WORK SHEET.............................................................................................. F-2

G: SCHEMATICS - HYDRAULIC, ELECTRIC AND AIRAIR SCHEMATIC........................................................................................ G-1HYDRAULIC SCHEMATIC ....................................................................... G-2ELECTRICAL SCHEMATIC ...................................................................... G-3

NOTE:SEE SECTION 15 FOR MORE SPECIFIC VENDOR TROUBLE SHOOTINGINFORMATION

A: General HydraulicInformation

A-1

It is the responsibility of the operator to detect any unusual sounds, odors or othersigns 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 potentialfailures 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 SHOOTINGPROCEDURE. Don’t simply replace parts until the trouble is found.

Each trouble shooting procedure consists of a flow chart giving the sequence in whichthe trouble shooting tests are performed. Each subsequent test is based on the resultsof 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 abnormalsounds, odors, and movements.

3. Inspect the Machine. Look for leaks. Listen for abnormal sounds and locatethem. 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 thefailure.

5. Research a Conclusion. Review the list of possible causes and decide which arethe most likely to cause the failure. Consider the most obvious first.

6. Test the Conclusion. Test the conclusions, in order of obviousness, until thesource of the failure is found. The machine can then be repaired at a minimal cost anddowntime.

7. Review Maintenance Procedures. Prevent recurrences of all premature failuresby regularly checking the filters, temperature, adjustments and lubrication. Make dailyinspections.

A-2

General HydraulicInformation

Base all hydraulic system troubleshooting on a firm foundation of good common senseand logical procedure. Don’t overlook the obvious; check it first! Never pursue acourse 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 gottenworse? A sudden malfunction will generally indicate a break. A gradual worseningproblem indicates a wear condition.

2. Is the engine speed up to specifications? A slow engine will definitely affectthe speed of all operations. Remember: Volume determines speed and vice versa.

Before attempting any hydraulic trouble shooting, become fully acquainted with thefollowing two basic facts governing any hydraulic system:

1. VOLUME determines the speed of an operation. A hydraulic pump dis-places a given amount of oil for every revolution of the pump. This volume is ex-pressed in terms of gallons per minute (gpm). The greater the engine speed, thegreater the pump speed. As a result, the speed of the hydraulic function is directlyrelated to the speed of the engine. A reduction in the speed of a cylinder or motor iscaused by a smaller quantity of oil being delivered to the components by the pump orby leakage within actuators.

2. PRESSURE is the amount of force exerted by the hydraulic oil on thoseparts of a hydraulic system which are open to the pump. Pressure is automatic and theresult of resistance, in the sense that, when there is no resistance in the system, there isno pressure. When operating a hydraulic cylinder or motor to accomplish a task, theamount of resistance required to overcome the task results in pressure being sensed bythe 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 beenobtained, 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 allowingexcess 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 operat-ing temperature (140°-160° F). Relief pressures will exceed set levels when thehydraulic system is checked with cold oil.

When adjusting pressures, be sure to use a high quality calibrated hydraulic pressuregauge.

A-3

General HydraulicInformation

CAUTION!

NEVER resort to increasing relief valve pres-sure settings in an attempt to cure the ills of anyhydraulic system. Fully diagnose the problemand maintain the proper pressure settings of allrelief valves. ALWAYS set hydraulic reliefvalves to FACTORY SETTINGS.

DIRT IS YOUR ENEMYThe majority of hydraulic problems in any hydraulic system can be traced to dirt orcontamination in the system! Do not neglect the hydraulic system. KEEP ITCLEAN! Change the oil and filters at established intervals.

Whenever ANY PART of the hydraulic system is to be opened, ALWAYS REMEM-BER CLEANLINESS! Clean the entire surrounding area before the work is toperformed. NEVER set hydraulic components, seals, rings, etc. in a contaminatedarea.

If, in spite of these precautions, improper operation does occur, the cause can begenerally 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 inisolating problems experienced with the machine. Most problems can be solved byknowing what to look for and where to look. This guide provides a method of identi-fying and isolating these problems through a logical sequence rather than one ofreplacing parts at random. This guide does not provide any repair procedures.

WARNING LIGHTS AND BUZZERS. Occasionally warning lights and buzzerswill give indications of a potential problem. First it will be necessary to assure that itis not a malfunction of an instrument or a sensor causing the indications.

CAUTION!

B: General Hydraulic Problems

B-1

To aid in troubleshooting, refer to the Thunderbird Yarder Pressure Setting Procedurefor test guage information. This procedure assumes gauges are installed. The follow-ing was written to aid the troubleshooter in following a logical approach to a systemfault.

PORT RELIEF VALVELEAKING OR OUT OF

ADJUSTMENT ADJUST, REPAIR, OR REPLACEYES

VALVE OPERATING REPAIR OR REPLACENO

CHECK IN SEQUENCE

SLOW MOTION IN ONEFUNCTION

LOWSEE SERVICE & ADJUSTMENTS

SECTION FOR PROPER SETTINGAND PROCEDURE

INSUFFICIENTPRESSURE

FAULTY COMPONENTS REPLACE COMPONENTSYES

YES CLEAN AND FLUSHDIRT IN VALVE

CHECK IN SEQUENCE

UNABLE TO SPOOL INOR OUT

YES REPLACE SPOOL

YES REPLACE COMPLETE VALVESCORED VALVEHOUSING

SCORED SPOOL

B-2

General Hydraulic ProblemsLOSS OF MOTION

DURING OPERATIONCHECK IN SEQUENCE

PROPER OPERATIONOF OTHER FUNCTIONS

CHECK PUMP DRIVE OUTPUTNO

LEAKING FUNCTIONLINE

REPLACEYES

CLEAN OR REPLACEYESPILOT LINERESTRICTED

PORT RELIEF STUCKOPEN

CLEAN OR REPLACEYES

PROPER PILOT FILTEROPERATION

CLEAN OR REPLACENO

CHECK

OVER HEATINGHYDRAULIC OIL

CLEANYESDIRTY OIL COOLER

COLLAPSED RETURNLINE REPLACEYES

RELIEF PRESSURETOO HIGH YES

ADJUST MAIN RELIEFON MAIN VALVE

OPERATING INEXCESSIVELY HIGHAMBIENT TEMPERA-

TURE

YES CONTACT ROSS CORPORATIONSERVICE DEPARTMENT

OVERLOAD ORSTALLED OPERATION YES

CHANGE OPERATINGCONDITIONS TO PREVENT

OVERLOAD OR STALL

REPLACE ELEMENT(S)YESPLUGGED HYDRAULICFILTER(S)

B-3

General Hydraulic Problems

CHECK

NOISY OPERATION

CHATTERING RELIEFVALVE

ADJUST OR REPLACEYES

ADJUST REGULATORYESLOW

HYDRAULIC TANKLEVEL

YESIMPROPER PUMPADJUSTMENT

SEE SERVICE & ADJUSTMENTSSECTION FOR PROPER SETTING

AND PROCEDURE

CHECK IN SEQUENCE

STICKING VALVESPOOL

SCORED SPOOL ORBURRS IN VALVEBORE, PAINT ONVALVE SPOOL

YESLAP TO REMOVE BURRS & PAINT

(INSTALL NEW OR REBUILTVALVE)

YES CLEAN VALVE AND SYSTEMDIRT OR FOREIGNMATTER IN VALVE

BORE

YESWARPPED VALVE

SPOOL

LAP TO REMOVE BURRS & PAINT(INSTALL NEW OR REBUILT

VALVE)

YESEXCESSIVE HIGH OILPRESSURE IN VALVE


AND PROCEDURE

B-4

General Hydraulic ProblemsLEAKING SEALS

CHECK IN SEQUENCE

YESPAINT ON OR UNDER

SEALREMOVE AND CLEAN

YES REPLACE VALVESCORED SPOOL

YESDIRT UNDER SEAL REMOVE AND CLEAN

YESCHECK FOR RESTRICTION IN

RETURN LINE FILTEREXCESSIVE BACK

PRESSURE

YES REPLACE FAULTY PARTSCUT OR SCORED SEAL

HYDRAULIC OIL INPUMP DRIVE CASE

CHECK

YESDAMAGED PUMP

SEAL(S)

CLEAN SURFACE(S) ANDREPLACE SEAL(S)

FUNCTION REMAINSAPPLIED

CHECK

YESREMOVE,CLEAN OR REPLACE

(REPLACE SYSTEM OIL IFCONTAMINATED)

FOREIGN MATERIAL INVALVE BODY OR PUMP

DISPLACEMENTSPOOL

B-5


YESPARTS STICKING DUETO DIRT OR DEPOSITS

INSPECT FOR FREE MOVEMENTOF COMPONENTS.

REPLACE WORN OR DAMAGEDPARTS

YESDAMAGED VALVEBODY OR SPOOL

CHECK SEATS FOR SCRATCHES,NICKS, OR OTHER MARKS.

REPLACE WORN OR DAMAGEDPARTS

YES CLEAN, TIGHTEN OR REPLACELEAKING

CONNECTION

YESWORN O-RINGS REPLACE WORN OR DAMAGEDO-RINGS

CHECK IN SEQUENCE

LEAKS

CHECK IN SEQUENCE

PRESSURE SETTINGREQUIRES FREQUENT

ADJUSTMENT

YES DRAIN AND REFILL SYSTEMWEAR DUE TO DIRT

YES TIGHTEN SECURELYLOCKNUT AND

ADJUSTING SCREWLOOSE

NOPROPER PILOTPRESSURE

YES REPAIR OR REPLACE


AND PROCEDURE

PROPER ENGINEPERFORMANCE

NO CALL ENGINE MANUFACTURER

FAULTY LINE RELIEF YES CLEAN, REPAIR OR REPLACE

MALFUNCTIONINGPUMP

B-6


CHECK IN SEQUENCE

ALL TRAVEL FUNCTIONS ARE

INOPERATIVE

NOPROPER PRESSUREFILTER FUNCTION

REMOVE, CLEAN SURFACE ANDREPLACE FILTER

NOPROPER CHARGEPRESSURE

YES

NO SET REGULATOR TO 15 PSIPROPER HYDRAULICTANK LEVEL

AIR IN HYDRAULICSYSTEM


AND PROCEDURE

YES REPLACEFAULTY PUMP DRIVEINPUT SHAFT OR

DRIVE LINE

LOCATE CAUSE OF AIR INHYDRAULIC OIL, CORRECT AND

BLEED AIR FROM SYSTEM

CHECK IN SEQUENCE

EXCESSIVE PUMPNOISE

NOPROPER OIL LEVEL INHYDRAULIC TANK

ADD OIL TO PROPER LEVEL ANDASSURE THAT IT IS GETTING TO

THE PUMPS

YESPUMP PULLING AIRTHROUGH SUCTION

SIDE

YES REPLACE PUMPMALFUNCTIONING

PUMP



C: Swing Problems

C-1

To aid in troubleshooting, refer to the Thunderbird Yarder Pressure Setting Procedurefor test guage information. This procedure assumes guages are installed. The follow-ing was written to aid the troubleshooter in following a logical approch to a systemfault.

NO SWING SYSTEMWITH POWER UNIT

OPERATING ATNORMAL SPEED

CHECK IN SEQUENCE

OTHER FUNCTIONSOPERATING

NO ASSURE PROPER PUMP OUTPUT

SWING BRAKE VALVELEVER IN PROPER

POSITIONNO

PLACE IN PROPER POSITION ORREPLACE VALVE

PROPER OIL LEVEL INHYDRAULIC TANK NO FILL TO PROPER LEVEL

IMPROPERPIPING/HOSING

YES CORRECT (SEE SCHEMATICS)

BROKEN OR LOOSECONNECTIONS

YES REPAIR OR REPLACE

PORT RELIEF STUCKOPEN

YES CLEAN, REPAIR OR REPLACE

PLUGGED PILOTFILTER

YESDISASSEMBLE, CLEAN CASE

AND REPLACE FILTER ELEMENT

YESREPAIR OR REPLACE COUPLING

OR PUMP AS REQUIREDSTRIPPED SPLINES ON

SWING MOTOR

NOPROPER SWINGMOTOR FUNCTION

NOPROPER SWING PUMPFUNCTION

DISASSEMBLE, CLEAN ORREPLACE

DISASSEMBLE, CLEAN ORREPLACE

Swing Problems

CHECK IN SEQUENCE

SWING SYSTEMSLUGGISH OR

ERRATIC

C-2

YESAIR IN HYDRAULICSYSTEM

BRAKES FULLYRELEASED

SET SWING BRAKE LEVER TO“OFF” OR REPLACE VALVENO

NOSWING MOTORCONRTOLLER

PROPERLY ADJUSTEDADJUST AS REQUIRED

MOTOR DRIVES INOPPOSITE DIRECTIONWITH RELIEF VALVES

SWITCHED

YES REPAIR OR REPLACE RELIEFVALVE ON NON-DRIVING SIDE

PROPER PRESSUREON BOTH CONTROL

LINESNO REPAIR CONTROL SIGNAL

PROBLEM

MOTOR DRIVES INOPPOSITE DIRECTIONWITH CONTROL LINES

SWITCHED

YES REPAIR ONE SIDE CONTROLSIGNAL LINE

CHECK IN SEQUENCE

SWINGS IN ONEDIRECTION ONLY



JOYSTICK POPPET YES CLEAN AND REPAIROR REPLACE

Swing Problems

C-3

CHECK IN SEQUENCE

NO

SWING MOTORTEMPRATURE HIGHER

THAN NORMAL

OPERATINGTEMPRATURE ABOVE

195° F

YESSWING PUMP STALLSINTERMITTENTLY

OIL IS BEING HEATED THROUGHSYSTEM RELIEF VALVES. SHUT

DOWN AND RECTIFY THE CAUSEOF THE STALL.

195° F IS THE MAXIMUM - OILCOOLER OR LINES MAY NEED

CLEANING

CHECK IN SEQUENCE

HIGH NOISE LEVEL INSWING PUMP

PROPER OIL LEVEL

NODRIVE COUPLINGPROPERLY INSTALLED

REPAIR OR REPLACE COUPLING

FOAMY OR MILKYCOLORED HYDRAULIC

OILYES BLEED AIR FROM SYSTEM AND

FIND CAUSE OF AIR INDUCTION

NO FILL TO CORRECT LEVEL

Swing Problems

C-4

CHECK

CONTROL LINES ATPORTS Y1 & Y2

SWITCHED

SWINGS IN WRONGDIRECTION

YES SWITCH LINES

YES SWITCH LINESSWING MOTOR HOSES

SWITCHED

CHECK

TRANSMISSIONOUTPUT SHAFT

TURNS

NO POWER TO DRIVESHAFT

YES CHECK AND REPLACE BROKENDRIVE CHAIN

General Problems

C-5

CHECK IN SEQUENCE

DRIVE SHAFTTURNING NO

NO POWER TO DRUMGEARS

CHECK DRIVE CHAIN

DRIVE GEAR SHAFTKEY SHEARED OFF NO REPAIR AND REPLACE

CHECK IN SEQUENCE

DRUMS WILL NOTTURN

DRUM CLUTCHENGAGING

YES

PEDESTAL BEARINGSNOT TURNING

BRAKE BAND STAYSAPPLIED

ADJUST BRAKE BAND

YES REPAIR AND REPLACE

FOREIGN MATERIALBETWEEN TEETH YES REMOVE MATERIAL AND

INSPECT FOR DAMAGE

NO ADJUST CLUTCH

General Problems

C-6

REMOVE MATERIAL ANDINSPECT FOR DAMAGE

CLEAN OR REPLACERELAY VALVE

CHECK IN SEQUENCE

NO

DRUM CLUTCH WILLNOT RELEASE

RELAY VALVEOPERATINGCORRECTLY

YESFOREIGN MATERIALIN CLUTCH

CHECK IN SEQUENCE

NO

DRUM CLUTCH WILLNOT ENGAGE

DRIVE CLUTCH AIRCYLINDER OPERATING

CORRECTLY

CHECK AIR PSI ANDMECHANICAL WORK-

INGS OF DRIVECLUTCH

NO CHECK INTERNAL SPRINGS ORREPLACE

SET PSI TO CORRECT SETTINGOR

ADJUST CLUTCH

CONTROL VALVEOPERATING COR-

RECTLY

REPAIR OR REPLACECLUTCH CYLINDER

NO

NO CHECK INTERNAL SPRINGS ORREPLACE

RELAY VALVEOPERATING CORRECTLY

NO REPLACEQUICK RELEASE

OPERATING CORRECTLY

General Problems

C-7

To aid in troubleshooting, refer to the Thunderbird TSY6355 yarder Pressure SettingProcedure for test guage information. This procedure assumes gauges are installed.The following was written to aid the troubleshooter in following a logical approach toa system fault.

BRAKE BAND WILLNOT APPLY OR

RELEASECHECK IN SEQUENCE

AIR CAN OPERATINGCORRECTLY CHECK AIR CAN DIAPHRAGMNO

ADJUSTNOBRAKE BAND COR-RECTLY ADJUSTED

NORELAY VALVE OPERAT-

ING CORRECTLYREPAIR OR REPLACE

NOCONTROL VALVE

OPERATING CORRECTLY

REPAIR OR REPLACE

WATER BRAKES WILLNOT APPLY OR

RELEASECHECK IN SEQUENCE

NOAIR PSI CORRECT SET AIR PSI TO CORRECTSETTING

YESAIR BYPASSINGBRAKE PISTON

RESEAL WATER BRAKE

YES REPLACE AND RESEAL BRAKE

YESBRAKE LINNINGWORN OUT

AIR DIAPHRAGMRUPTURED

REPLACE AND RESEAL BRAKE

YESQUICK RELEASE NOTOPERATING

REPAIR OR REPLACE

YESRETURN SPRINGSBROKEN

REPLACE

General Problems

C-8

YES

CHECK IN SEQUENCE

AIR TANK DRAIN OPEN

LOW AIR PSI

CLOSE AND CHARGESYSTEM

LEAKING AIR LINESOR BLOCKAGE IN

SUPPLY HOSE

NOPSI GOVERNOROPERATING

REPAIR OR REPLACE

NOAIR COMPRESSOROPERATING

REPAIR OR REPLACE

IN-LINE CHECK VALVEOPERATING NO REPLACE

YESFAULTY REGULATOR

OR OILERREPAIR OR REPLACE

YES REPAIR

General Problems

C-9

NO

CHECK IN SEQUENCE

DOG CYLINDEROPERATING

GUYLINE DRUM WILLNOT OPERATE

REPAIR OR REPLACE

DRIVE MOTORTURNING

NOCONTROL VALVEOPERATING

REPAIR OR REPLACE

YESBROKEN WIRE TOCONTROL VALVE

REPAIR OR REPLACE

YESBROKEN DRIVE CHAIN

OR STRIPED SPLINES IN DRIVESPROCKET

YES

CHECK IN SEQUENCE

INTERNAL BEARINGSBROKEN

FRONT MAIN DRUMWILL NOT OPERATE

REPAIR OR REPLACE

NOWATER BRAKEAPPLYING

REPAIR OR REPLACE

NODRIVE CLUTCHOPERATING

REPAIR OR REPLACE

YESMATERIAL IN BULLGEARS

CLEAN & REPAIR OR REPLACE

D: Electrical Problems

D-1

NO

CHECK IN SEQUENCE

BATTERY SHUT-OFF INTHE CORRECT

POSITION

ENGINE WILL NOTCRANK

PUT INTO CORRECT POSITION

CABLES CORRODEDOR LOOSE YES CLEAN, REPAIR OR REPLACE

NOBATTERIES IN GOODCONDITION

REPLACE

NOSTARTER SOLENOID

OPERATINGREPLACE

IGNITION SWITCHOPERATINGCORRECTLY

NO REPAIR OR REPLACE

NOSTARTER OPERATINGCORRECTLY

REPLACE

NO

CHECK IN SEQUENCE

CIRCUIT BREAKERSOPERATING

NO GAUGE READING

REPLACE

SENDER INOPERATINGCONDITION

NO REPLACE

NOBROKEN WIRE REPLACE

GAUGE OPERATINGCORRECTLY

NO REPLACE

Electrical Problems

NO

CHECK IN SEQUENCE

BATTERY SHUT-OFF INTHE CORRECT

POSITION

LOW OR DEADBATTERY

PUT INTO CORRECT POSITION

CABLES CORRODEDOR LOOSE YES CLEAN, REPAIR OR REPLACE

NOBELT ADJUSTED ADJUST

NOVOLTAGE REGULATOR

OPERATINGREPLACE

LOW ELECTROLYTE INBATTERY YES REPAIR OR REPLACE

YESSHORT IN THESYSTEM

REPAIR

YESDEFECTIVE BATTERY REPLACE

D-2

E: Travel Problems

E-1

To aid in troubleshooting, refer to the Thunderbird TSY6355 yarder Pressure SettingProcedure for test guage information. This procedure assumes gauges are installed.The following was written to aid the troubleshooter in following a logical approach toa system fault.

CHECK IN SEQUENCE

NO

NO TRAVEL

HYDRAULIC TANK OILAT PROPER LEVEL FILL AS REQUIRED

PROPER PLUMBINGWITH UNDAMAGED

CONNECTORSNO

REPAIR OR CORRECT PERHYDRAULIC SCHEMATIC AS

REQUIRED

NOCHECK QUICK RELEASE COU-

PLING ON BRAKE VALVE BLOCKUNDER CAB

BRAKES RELEASED

PROPER CHARGEPRESSURE WITH

PUMP AT NORMALSPEED

NO

NO CLEAN OR REPLACE PLUGGEDSUCTION FILTER

PROPER CHARGEPUMP SUCTION


AND PROCEDURE

YESCHARGE PRESSURERELIEF CARTRIDGE

DAMAGED

REPAIR OR REPLACE DAMAGEDCOMPONENTS

HOSE TO MANIFOLDSMASHED YES REPLACE

BROKEN MECHANICALFINAL DRIVECOUPLING

YES REPLACE COUPLING

Travel Problems

E-2

CHECK IN SEQUENCE

TRACK DRIVE ISSLUGGISH OR

ERRATIC

YES

NO

CHECK QUICK RELEASECOUPLING ON BRAKE VALVE

BLOCK UNDER CABBRAKES RELEASED

DIRT UNDER PEDAL(S) CLEAN PEDAL AREA(S)

YESAIR IN HYDRAULIC

SYSTEM BLEED AIR FROM SYSTEM

YESCLEAN, REPAIR OR REPLACE

RELIEF VALVEFAULTY RELIEF VALVE

YESFAULTY TRAVEL

MOTORCLEAN, REPAIR OR REPLACE

MOTOR

YESMANIFOLD CLEAN, REPAIR OR REPLACEMANIFOLD

PUMP OPERATES INOPPOSITE DIRECTIONWHEN RELIEF VALVES

ARE SWITCHED

YES REPAIR OR REPLACE FAULTYRELIEF VALVE

CHECK IN SEQUENCE

TRACK DRIVES IN ONEDIRECTION ONLY

YES CHECK FOR MECHANICALIMPAIRMENTS OF TRACK

DRIVE RUNS IN BOTHDIRECTIONS

YESMANIFOLD CLEAN, REPAIR OR REPLACEMANIFOLD

Travel Problems

E-3

CHECK IN SEQUENCE

NO REALIGN OR REPLACE ASREQUIRED

DRIVE COUPLINGPROPERLY INSTALLED

AND ALIGNED

EXCESSIVE NOISE INTRAVEL MOTOR

NOPROPER SUCTION AT

CHARGE PUMP

YESAIR IN HYDRAULICSYSTEM


AND PROCEDURE



CHECK IN SEQUENCE

NO

TRAVEL MOTORTEMPERATUREHIGHER THAN

NORMAL

OPERATING TEM-PERATURE ABOVE

195° F

195° F IS THE MAXIMUM - OILCOOLER OR LINES MAY NEED

CLEANING

NOCORRECT MOTORDIRECTION

SWITCH THE HIGH PRESSURELINES

CHECK

TRACK DRIVES INOPPOSITE DIRECTION

YESPILOT LINES SWITCH THE LINES

Travel Problems

E-4

CHECK IN SEQUENCE

YES CLEAN AREA & REPLACE SEAL

FINAL DRIVE FILLSWITH OIL

FAULTY TRAVELMOTOR SHAFT SEAL

FAULTY TRAVELBRAKE SHAFT SEAL YES CLEAN AREA & REPLACE SEAL

CRACKED TRAVELMOTOR HOUSING YES REPLACE HOUSING

CHECK IN SEQUENCE

INSUFFICIENTTRACTION MOTOR

TORQUE

DIRT UNDER PEDAL YES CLEAN

YESUSING 0-10,000 PSIGAUGES, ASSURE

PROPER LOAD SIDEPRESSURE

NOPROPER CONTROL

PRESSURE INPUT TOSPOOL


AND PROCEDURE


AND PROCEDURE


AND PROCEDURE

NO

PROPERLY ADJUSTEDTRAVEL PUMPS ADJUST THE SHIFTING SPOOL

YESMANIFOLD CLEAN, & REPAIR OR REPLACE

F: TroubleshootingWork Records

A complete work record can be of value to the service mechanic when it becomesnecessary to predict future component failures and time estimates for repairs.

The following pages are provided as a convenience. Should additional sheets beneeded, contact Ross Corporation Technical Publications Department.

Throubleshooting History Sheet: Use this sheet when the job is finished. It is thelong term record.

Work Sheet: To aid in diagnosing the problem before beginning the job. Should it benecessary to call Ross Corporation for assistance, this sheet will provide informationto tell the representative what steps you have taken.

TroubleshootingHistory Sheet

F-1

DATE SYSTEM CAUSE SOLUTION

TroubleshootingHistory Sheet

F-1

DATE SYSTEM CAUSE SOLUTION

Work Sheet

F-2

DATE:

MECHANIC:

PROBLEM

POSSIBLE CAUSE-1 CONCLUSION




NOTES:

Work SheetDATE:

MECHANIC:

PROBLEM





NOTES:

F-2

Work SheetDATE:

MECHANIC:

PROBLEM





NOTES:

F-2

Work SheetDATE:

MECHANIC:

PROBLEM





NOTES:

F-2

Work SheetDATE:

MECHANIC:

PROBLEM





NOTES:

F-2

Work SheetDATE:

MECHANIC:

PROBLEM





NOTES:

F-2

Work SheetDATE:

MECHANIC:

PROBLEM





NOTES:

F-2

Work SheetDATE:

MECHANIC:

PROBLEM





NOTES:

F-2

Work SheetDATE:

MECHANIC:

PROBLEM





NOTES:

F-2

Work SheetDATE:

MECHANIC:

PROBLEM





NOTES:

F-2

G: SchematicsSCHEMATICS:

AIR SCHEMATIC........................................................................................ G-1HYDRAULIC SCHEMATIC ....................................................................... G-2ELECTRICAL SCHEMATIC ...................................................................... G-3

Section III:Service & Adjustments

SERIAL NUMBER SPECIFIC PRESSURE SETTING PROCEDURESHYDRAULIC PRESSURE SETTING PROCEDURE .................... III01-III04REVISED HYDRAULIC PRESSURE SETTING PROCEDURE .....III01.1-III04.1AIR PRESSURE SETTING PROCEDURE ............................................. III-05

ADJUSTMENT INFORMATIONDRIVE CLUTCH ADJUSTMENT AND BLEEDING PROCEDURE ... III-06BRAKE BAND ADJUSTMENT .............................................................. III-09SWING BEARING ADJUSTMENT ........................................................ III-11

GENERAL HYDRAULIC INFORMATIONAIR CLEANER ......................................................................................... III-13HYDRAULIC RESERVOIR ..................................................................... III-15RESERVOIR DRAINING & FLUSHING................................................ III-15RESERVOIR INITIAL START UP PROCEDURE ................................. III-15WELDING INSTRUCTIONS................................................................... III-17TORQUE WRENCH EXTENSIONS ....................................................... III-18TORQUE SPECIFICATION (CHART) .................................................... III-19

TRAVEL SYSTEMTRAVEL PUMP REMOVAL AND INSTALLATION ............................. III-20TRAVEL PUMP START-UP .................................................................... III-21

UNDERCARRIAGETRACK ADJUSTMENT ........................................................................... III-22TRACK ASSEMBLY INFORMATION.................................................... III-22TRACK LINK REMOVAL AND INSTALLATION ................................ III-23LOWER ROLLER ASSEMBLIES ........................................................... III-24LOWER ROLLER REMOVAL ................................................................ III-25LOWER ROLLER DISASSEMBLY AND ASSEMBLING .................... III-25METAL TO METAL SEAL INSTALLATION ......................................... III-25TRACTION DRIVE DESCRIPTION ....................................................... III-27TRACTION DRIVE REMOVAL AND INSTALLATION ....................... III-27TRACTION DRIVE START-UP .............................................................. III-27TRACTION MOTOR REMOVAL AND INSTALLATION..................... III-28TRACTION MOTOR START-UP ............................................................ III-28TRACTION BRAKE DESCRIPTION ..................................................... III-29TRACTION BRAKE REMOVAL AND INSTALLATION...................... III-29TRACTION DRIVE EXPLODED VIEW ................................................ III-30

OPTIONAL DROP LINE CLUTCHDROP LINE CLUTCH ADJUSTMENT .................................................. III-31DROP LINE CLUTCH LINING REPLACEMENT................................. III-31DIAPHRAM REPLACEMENT ................................................................ III-31DROP LINE CLUTCH ADJUSTMENT ILLUSTRATION ..................... III-32

TSY6355 04/30/98

MISCELLANEOUS ADJUSTMENTSDRIVE CHAIN ADJUSTMENT .............................................................. III-33WATER COOLED BRAKE ADJUSTMENT ........................................... III-34BULL GEAR BEARING PRELOADS..................................................... III-35

TSY6355 04/30/98

Introduction

This section will cover Servicing and Adjustment procedures for your TSY6355yarder. It will provide detailed instructions on performing routine maintenance andservicing for the yarder. References to part illustrations in the Parts Group will bemade throughout this section.

Hydraulic Pressure Setting Procedure

III-01

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 hydrau-lic operation of the machine.

Step 2. Preheat Hydraulic Oil:

A) Bring the hydraulic oil to 120°-130° F before any testing is done. Topreheat the oil, disconnect the travel brake valve “quick disconnect” locatedbeneath the cab, set the engine at full RPM, hold for 15 seconds the rightforward travel function applied (dead headed).

B) Release the functions.

C) After five seconds of no functions being applied, repeat 2-A and 2-B aboveusing 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 electronictachometer, check the engine RPM.

B) If the RPM reading is not up to specifications, set the engine to the properRPM. The correct procedure for setting the RPM is found in the engineowners manual provided with this book.

NOTE: While setting any pressures, always bring the pressure “up” to the properPSI, 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 toport “A”.

SETTINGS:Preferred PSI: 550 Actual PSI________ Changed to________PSI


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 hydrau-lic operation of the machine.

Step 2. Preheat Hydraulic Oil:

A) Bring the hydraulic oil to 120°-130° F before any testing is done. Topreheat the oil, disconnect the travel brake valve “quick disconnect” locatedbeneath the cab, set the engine at full RPM, hold for 15 seconds the rightforward travel function applied (dead headed).

B) Release the functions.

C) After five seconds of no functions being applied, repeat 2-A and 2-B aboveusing 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 electronictachometer, check the engine RPM.

B) If the RPM reading is not up to specifications, set the engine to the properRPM. The correct procedure for setting the RPM is found in the engineowners 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 portsmarked “charge”. These ports are located on the right corner of the rightengine house door. Adjust charge PSI by adjusting the relief marked “Charge”on the illustration on page III-03, perform this adjustment on both travelpumps.

SETTINGS:Preferred PSI: 550 Actual PSI________ Changed to________PSI

III-01.1REV. DATE 12/96

III-02


CHARGE AND PILOTRELIEF

FORWARD TRAVELRELIEF

REVERSE TRAVELRELIEF

“A” PORT

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 cleanli-ness and correct if necessary.

Note: Prior to the setting of any travel reliefs, first disconnect the brake release lineunder the cab.

Step 6. Right Forward Travel PSI:

A) With the engine at full throttle, place a10,000 PSI gauge on the test port marked“RHF” located on the right corner of the leftengine house door. Apply and hold the righttravel peddle in the forward position.

B) Adjust the pressure by using the upper relieflocated 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 portmarked “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/Hpump.


Step 8 & 9. Left Forward and Reverse Travel PSI:

Repeat the instructions in steps 6 and 7 while substituting left hand where righthand appears.


(Prior To and Including S/N S5162)

(After S/N S5162 To Date)Step 5. Pressure Cut-off PSI:

A) With the engine at full throttle, place a 10,000 PSI gauge on the test portmarked “RHF” located on the right corner of the right engine house door.Apply and hold the right travel peddle in the forward position. Adjust pressureby adjusting the relief marked “Pressure Cut-off” on the right hand pump.

B) Repeat the instructions in step 5A while substituting left pump where rightpump appears, and placing test gauge on the test port marked “LHF”.


Note: Prior to the setting of any travel reliefs, first disconnect the brake release lineunder the cab.

Step 6. Right Forward Travel PSI:

A) With the engine at full throttle, place a10,000 PSI gauge on the test port marked“RHF” located on the right corner of the rightengine house door. Apply and hold the righttravel peddle in the forward position.

B) Adjust the pressure by using the relief marked“A” port relief on the illustration, adjust the R/Hpump.


Step 7. Right Reverse Travel PSI:A) With the engine at full throttle, place a 10,000 PSI gauge on the test portmarked “RHR” located on the right front corner of the right engine housedoor. 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.


Step 8 & 9. Left Forward and Reverse Travel PSI:Repeat the instructions in steps 6 and 7 while substituting left hand where right handappears.


III-02.1


CHARGE RELIEF

“B” PORT RELIEF

“A” PORT RELIEF

PRESSURE CUT-OFFRELIEF

REV. DATE 12/96


III-03

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 portmarked “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 willindicate 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.


Step 11. Left Hand Flushing Valve PSI:

A) Adjust the relief located on the L/H flushing valve, two turns from tight.

B) With the engine at full throttle, place a 1,000 PSI gauge on the test portmarked “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 willindicate the pressure on the back side of the pressure loop.

C) Adjust the pressure by using the relief located on the L/H flushing valve.


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 portprovided on the guyline valve. Fully apply (dead head) one of the guylinemotors.

B) If the PSI reading is incorrect adjust the relief cartridges located on themain valve, adjust to the proper pressures.

SETTINGS:Preferred PSI: 2,550 Actual PSI________ Changed to________PSI


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 portmarked “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 willindicate 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.


Step 11. Left Hand Flushing Valve PSI:

A) Adjust the relief located on the L/H flushing valve, two turns from tight.

B) With the engine at full throttle, place a 1,000 PSI gauge on the test portmarked “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 willindicate the pressure on the back side of the pressure loop.

C) Adjust the pressure by using the relief located on the L/H flushing valve.


Step 12. Cab Tilt, Swing and Guyline Valve PSI:

A) Prior to testing the swing pressure, apply the swing brake and then applythe swing function in both directions. If the swing pulls through the swingbrake, 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 portprovided 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 mainvalve, adjust to the proper pressures.




(After S/N S5162 To Date)

Step 13. Cab Tilt and Swing Valve PSI:

A) Prior to testing the swing pressure, apply the swing brake and then applythe swing function in both directions. If the swing pulls through the swingbrake, 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 portprovided 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 mainvalve, adjust to the proper pressures.


Step 14. Swing Motor Deregulation Adjustment:

A) Install a test port and 3,000 PSI gauge into the “G” port located on theswing motor.

B) Place a 5,000 PSI gauge on the test port provided on the cab tilt & swingvalve. This gauge should have enough hose so that the operator in the cab canread the gauge.

C) With the engine at full RPM, the operator applies the swing function untilthe gauge in the cab reads 1,000 PSI. The operator must maintain 1,000 PSIthroughout this procedure.

D) While the operator is maintaining 1,000 PSI, adjust the set screw located onthe swing motor, until the gauge installed in “G” port just starts to showmovement. Once the “G” port gauge shows pressure, have the operator releasethe function. Once the function is completely released, apply the function againand check the “G” port gauge for accuracy.

Note: When reading the “G” port PSI, the beginning of deregulation is whenthe needle just starts to move off of ZERO PSI.



III-04


Step 13. Swing Motor Deregulation Adjustment:

A) Install a test port and 3,000 PSI gauge into the “M1” port located on theswing motor.

B) Place a 5,000 PSI gauge on the test port provided on the main valve. Thisgauge should have enough hose so that the operator in the cab can read thegauge.

C) With the engine at full RPM, the operator applies the swing function untilthe gauge in the cab reads 1,000 PSI. The operator must maintain 1,000 PSIthroughout this procedure.

D) While the operator is maintaining 1,000 PSI, adjust the set screw located onthe swing motor, until the gauge installed in “M1” port just starts to showmovement. Once the “M1” port gauge shows pressure, have the operatorrelease the function. Once the function is completely released, apply the func-tion again and check the “M1” port gauge for accuracy.

Note: When reading the “M1” port PSI, the beginning of deregulation is whenthe needle just starts to move off of ZERO PSI.




(After S/N S5162 To Date)

Air Pressure Setting Procedure

III-05

THUNDERBIRD TSY6355 YARDER AIR PSI SETTING PROCEDURE

Step 1. Leaks:

Check the machine for leaks or obvious problems that might hinder the airoperation 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 UN-LOADER 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 Actual PSI________ Changed to ________PSI


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 regulatorassembly.


REV. DATE 12/96

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 fullycharged. It may become necessary to recharge the air system during this proceduredue to the number of times the clutch is engaged and disengaged.

1. Check the cylinder stroke by applying the clutch and measuring the distance be-tween 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 TSY6355has an approximate applied stroke length of 3 1/2". If the stroke length is greater orthe clutch is slipping, adjustment may be needed.

Note: The cylinder applied stroke of 3 1/2" is approximate and in some cases may beless 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 onerevolution and turn adjusting nut (3B) clockwise until it locks against theadjusting 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 thepreferred result.

Note: When the clutch stroke has been adjusted, it is also required to adjust thetension 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 beenadjusted. Tension cams are designed to hold the clutch bands in position whenthe clutch is de-energized.

A) Energize Clutch

B) Loosen bolts fastening the tension cams to the clutch spider and loosen thelock nut on the tension bolt.

C) Slip a shim (1/4" wide x 1/16" thick) between the tension cam (4) and theclutch band (6). Push tension cam (4) against the shim and brake band (6).Tighten tension cam mounting bolts. Repeat this procedure until all tensioncams have been adjusted.

Adjustment Information

III-06TSY6355 REVISION DATE 7/2/98

PRIOR TO ANY WORK BEING PERFORMED ON THE DRIVE CLUTCHES, ALLLINES 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 dimen-sion “A”) on the brake frame, next to the splitbetween the frames. (As shown in this illustra-tion.) Apply brake and check lining wear bylooking into opening at the split and compare thetop of the steel shoe, to which the lining isattached, to the scribed line. If the scribed line iseven with the top of the steel shoe, friction travelis at its maximum.

B) Dimension “A” is 22/32

REPLACE LINING PRIOR TO THIS CONDI-TION OCCURRING. CONTINUED USECOULD RESULT IN A CATASTROPHICFAILURE.


III-06

DANGER

Step Three Continued

D) Adjust the tension bolt (7) by using the same shim that was used in thecam adjustment. Place the shim between the adjusting bolt (7) and the clutchband (6). Turn the tension bolt (7) clockwise until it contacts the shim andbrake band (6). Tighten tension bolt lock nut.

E) After the tensioning cams and bolt have been adjusted, de-energize theclutch 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 engage-ment when the clutch is de-energized.

F) If the clearance between the clutch band (6) and drive ring is not enoughand the clutch band (6) has not completely cleared the drive ring. Increase theshim thickness to 1/8" and repeat step three (3).


III-07

SERIAL NO. PRIOR TO S5189


III-07

Drive Clutch Bleeding Procedure: SERIAL NO. S5189 TO DATE

Use a bleeder hose to keep oil off brakingsurface 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 valveand release from the applied position.. Repeat this every 30 seconds until oil flowsfrom the bleeder valve.C) With Bleeder Valve Closed, apply and release clutch, waiting 30 seconds betweeneach 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 closebleeder 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 applyclutch) 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 infor-mation section of this book.

CAUTION!

ADJUSTING NUTS & PIN

CLUTCHSPIDER

CLUTCHBANDS

3A3B

YOKE2

TENSIONCAMS

4

3

6

5

7TENSION

BOLT

3 C

1AIR CYLINDER


III-08

SERIAL NO. PRIOR TO S5189

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 fullycharged. It may become necessary to recharge the air system during this proceduredue 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 theband brakes, the drum line must be com-pletely slack with no tension and the drumline is secured to prevent accidental move-ment of the drum.

1. All Thunderbird yarders operate with a preferred air can shaft stroke of 1-1/8". Thestroke is measured by releasing the maxi brake and applying the foot treadle. Measurethe center to center distance that the air can shaft clevis pin travels when applyingthe foot treadle. If the stroke length is greater than 1-1/8", brake adjustment may berequired.

2. Band Brake Adjustment: With the brake band air can released, loosen adjusting nut(2A) and turn counterclockwise one revolution. Turn adjusting nut (2B) clockwiseuntil it locks against the adjusting pin (2C). Apply brake and check air can stroke (seestep one). If the proper stroke is not achieved repeat this procedure until the properstroke is achieved.

3. Hold Off Anchor Adjustment: The purpose of the hold off anchor is to prevent thetop radius of the brake band from dragging on the drum brake ring with the brakereleased. This is accomplished by presetting the spring tension. It is not necessary toadjust the hold off anchor after each adjustment to the brake bands, but it is recom-mended 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 thecompression spring (3C). Turn lock nut (3B) clockwise three (3) revolutions, whichwill apply compression to the spring (3C). Install lock nut (3A) and tighten againstlock nut (3B).


III-09

3A

3B

3C

3D

HOLD OFF ANCHOR

BRAKE BAND

ADJUSTMENT LINKAGE

2A2C 2B


III-10

Ring Gear Bolting SequenceNote: Position inner race hardness gap (marked with stamped “G”) toward side ofmachine.

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 andshould be strictly adhered to if premature failure of the swing bearing is to be pre-vented. A trace of lubricant such as that found on newly purchased bolts should beapplied to the fasteners to prevent galling.

1. Remove bolting cover on the turntable to gain access to the inner racebolts.

2. Tighten inner race bolts following the bolting sequence in the diagram

Swing BearingAdjustment

FRONT OF MACHINE

HARDNESSGAP

III-11

Swing BearingAdjustment

above for inner race until all bolts have been pre-tightened to the pre-torquevalue specified in the Bolt Torque Specifications later in this section.

3. Continue, in sequence, to tighten inner race bolts until all bolts have beentightened to the proper torque value as specified in Bolt Torque Specificationslater 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 totheir 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 hoursof operation and every 600 hours thereafter. See Torque Wrench Extensionslater in this section.

Axial Play AdjustmentThe 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 ringgear 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 contactin assuming vertical loads. Determine the amount of axial play by measuring thedifference of distances between the top of the carbody and the bottom of the outerrace; first, with the attachment extended fully out and the grapple slightly aboveground, and second, with the down-pressure fully applied to the attachment. Thismeasurement should be taken at the counterweight end of the turntable and repeatedat 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 necessar-ily mean the bearing needs replacing. It is recommended that as long the clearance isless than this value and so long as the bearing rotates smoothly without noise or metalparticles in the grease, there is no reason for concern.

If metal particles are found in the grease or if theswing bearing is noisy (and all other possiblemalfunctions have been eliminated), consult thefactory. Any attempt to disassemble the swingbearing will void the warranty!

MEASURE AXIALPLAY HERE

INNERRACE

CARBODY

OUTERRACE

III-12

Air Cleaner Maintenance

1. Release the Filter Seal GentlyThe filter fits tightly over the outlet tube, creat-ing the critical seal on the inside diameter of thefilter end cap. The filter should be removedgently to reduce the amount of dust dislodged.There will be some initial resistance, similar tobreaking the seal on a jar. Gently move the endof the filter up and down and side to side ortwist to disengage the seal.

2. Avoid Dislodging Dust from the FilterGently pull the filter off the outlet tube and outof the housing. Avoid knocking the filter againstthe housing.

3. Always Clean the Sealing Surface of theOutlet TubeDust on the outer diameter could hinder aneffective seal and cause leakage. Make sure thatall contaminant is removed before the new filteris installed.

4. Always Clean the Inside of the OutletTube CarefullyDirt accidently transferred to the inside of theoutlet tube will reach the engine and cause wear.Be careful not to damage the filter sealing areaon the tube.

General Information

III-13

5. Check Your Old FilterYour old filter could help you detect foreignmaterial on the sealing surface that is causingleakage. A streak of dust on the clean air side ofthe filter is the telltale sign. If it exists, be surethe cause is removed before installing a newfilter.

6. Inspect the New Filter for DamageAlways look for possible shipping or handlingdamage . Pay particular attention to the insideof the open end (sealing area). Check for cuts,etc. Do not install a damaged filter.

7. Insert the New FilterThe radial seal area is on the inside of the openend of the filter. This critical sealing area willstretch slightly, adjust itself and distribute thesealing pressure evenly on to the outlet tube asthe 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 designcover pressure is not necessary to compress thefilter seal.

8. Check Connections & Ducts for Air TightFit

YES NO YES

General Information

III-14

Hydraulic Reservoir

The Hydraulic reservoir is a fabricated steeltank. It has two external replaceable5-micron filter elements. A filler cap / strainer,and an indicator tube for determining reservoirlevel are also located on the tank.

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 replacingthe 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 ProcedureIf any hydraulic filters or pumps have been removed and either repaired or replaced, orif the hydraulic tank has been drained and flushed, it is extremely important to ensurethat clean hydraulic oil is in all components and that the system is properly bled of airbefore starting the engine. Failure to do this will result in damage to the hydrauliccomponents. Bleed and fill the system by using the following start-up procedure.

DO NOT START ENGINE until after bleedingprocedure is completed or you will damage thepumps!

General Information

CAUTION!

III-15

FILL DECAL

FILL NECK

General Information1. 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 thehalfway point of the tube after completing the bleeding procedure. Experiencewill help in determining the level required to complete this procedure whilemaintaining an adequate supply of oil.

2. Hand fill the cases of any pumps or motors which have been either drainedor replaced. Pressurize the hydraulic tank to 3 PSI. Fill ports for the pumpsand motors are shown below. Each of the fill ports are identified with theletter “R” or “T”.

Failure to ensure that pumps and motors arefilled with hydraulic oil before starting the enginewill result in severe component damage.

3. With the hydraulic tank pressurized, bleed off air at the following pointsshown in the illustration below. Bleed each point until oil is present and thenreseal the connection.

4. Start engine and run at low idle for five minutes. Then pressurize thehydraulic tank.

CAUTION!

“R” PORT

T-PORT

T-PORT

III-16

ORIGINAL PUMP

“R” PORT

REVISED PUMP

Welding Instructions

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 theground to the component being welded. This will eliminate the possibility ofarching through a bearing, cylinder, etc. thereby ruining the component.

3. Use caution when welding around fuel tanks, oil reservoir, batteries, tubingand pressure systems.

4. When welding close to glass, cylinder rods or any polished surface, provideadequate protection from splatter.

5. NEVER weld when the engine is running. Disconnect the battery cablesbefore welding.

6. Do not weld on wet surfaces since this will cause hydrogen embrittlementof the weld.

7. Always have a fire extinguisher on hand in case of fire. Adequate ventilationand a dry area are absolutely necessary. Protective clothing should be worn byall 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 tomedium carbon steel. These are good for all position welding, good penetra-tion and crack resisting up to 80,000 yield. Also suitable for repair of previousinter shield welds.

•AWS CLASS E11018G Low hydrogen rod for repair on high strength alloysteel such as ASTM A514 (T-1), 80,000 to 100,000 yield. All position weld-ing, good penetration and high strength up to 110,000.

NOTE: Low hydrogen rod E7018 must be used within four (4) hours upon removalfrom a freshly opened container or from a storage oven. Low hydrogen rod E11018Gmust be used within 1/2 hour upon removal from its container or from a storage oven.

.

General Information

CAUTION!

III-17

Torque Wrench ExtensionsIn some applications, a standard torque wrench and socket cannot be fitted to the boltto be tightened because of restricted access. In other instances, the torque valuespecified cannot be obtained because sufficient force cannot be applied to the standardlength wrench. Both of these problems may be solved by use of appropriate torquewrench extensions - either commercially made or fabricated by the user. When usingan extension, it must be remembered that the wrench torque (the actual reading orsetting of the wrench) and the wrench force (the force applied to the wrench) must beadjusted to compensate for the added length and produce the Preferred bolt torque.

Refer to the illustration below when calculating the proper adjusted values for wrenchtorque, wrench force and bolt torque.

General Information

WRENCH TORQUEBOLT TORQUE =

A

BOLT TORQUE X ABOLT TORQUE =

(A+B)

WRENCH TORQUE X (A+B)BOLT TORQUE =

A

WRENCH TORQUE=

(A+B)NOTE: DIMENSION “A” ISMEASURED FROM THE CENTEROF THE WRENCH HANDLE.

IV-38

III-18

Bolt Torque SpecificationMost bolts used in Thunderbird equipment are SAE Grade-5. The chart below shouldbe used to determine the maximum bolt torque. This torque is based on a bolt pre-load of 75% of material yield strength.

The bolts at the left are Grade-8 andshould be torqued to the componentmanufacturers specifications. Thepre-torque value is 10-20% of the finaltorque.

APPLICATION

SWING BEARINGDRIVE TO SIDERAIL

SPROCKET TO DRIVEROLLER

BOLT SIZE

1-8 UNCM24M16

7/8-9 UNC

TORQUE FT/LBDRY LUBED

884 663752 564232 174600 450

General Information

III-19

Travel SystemTravel Pump

The two pumps mounted on the pump drive gear case that supply oil for the travelcircuit are variable displacement axial piston pump used in conjunction with a variabledisplacement piston motor in a closed loop circuit.

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 linesfrom the travel pump.

3. To prevent contamination of the hydraulic system, plug and cover all hoseends and ports in components

4. Attach a hoist to the pump, remove the two mounting bolts and carefullyremove the pump. Immediately cover the opening to keep dirt out and removeall traces of old gasket material from the mounting surface of the pump andpump drive case.

III-20

CHARGE PUMP

H/D CON-“R” PORT

INLET OR OUTLET

INPUT

MOUNTINGREVISED PUMP

“R” PORT

INPUTSHAFT

Travel SystemRemoval and Installation Continued

5. Prior to installation it is important to hand fill the pump with clean hydraulicoil using the “R” port. It is located on the top rear portion of the travel pumpand 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 theinside perimeter of the swing pump mounting surface. Coat fasteners withLoctite Threadlock prior to installation.

Do not attempt to start the engine withoutfollowing initial start- up procedures.

Before starting the engine, the pump must bemanually filled with oil, as recommended in thelubrication chart. Add oil through the case drainport 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. Beforeoperating the swing pump, fill through the oil inlet located on the top rear portion ofthe swing pump identified by the letter “R” on the port cover. Use only the lubricationthat 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 thepump. Refer to general adjustment section for this procedure. Start the machine andallow sufficient time for stabilization at moderate pressure and speed prior to runningat full throttle. Refer to the lubrication chart found in Section-E for oil level checksand replacement time schedules.

CAUTION!

III-21

CAUTION!

Undercarriage

3/4“ TO 1-1/2”

Track AdjustmentsThe track is properly adjusted when it has approximately 3/4 (19.1 mm) to 1-1/2 (38.1mm) sag measured at a point midway between the front idler and the first carrier roller.

Before measuring for track sag, travel the machine forward (with drive cases in therear) until the tracks are free of dirt and other foreign material and chain slack islocated 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 isobtained. Once the proper tension is obtained, additional shim stock material must beplaced behind the idler. Adjust each side gradually to prevent binding.

Track Link AssemblyThe track link assembly is made up of a series of links to which the track shoes areattached.

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 themaster link only.

Depending on the number of links, each track assembly contains one or more “masterlinks” 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. Besure to order service parts accordingly.

III-22

Track Link Removal

Normal Removal Condition:

1. Move the machine or rotate the track until the master pin (identified by adimple in the end of the pin) is located atop the idler.

2. Place blocking beneath the unsupported sections of track along the top ofthe track frame.

3. Loosen the track.

4. Remove the two track shoes adjacent to and the track shoe with the masterpin.

To minimize the chance a track pad falling andcausing possible injury, remove the bolts fromone track pad at a time then remove that trackpad 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 ordrive sprocket.

2. Pull the top track section until the two separated links are in position to bereassembled.

3. Insert the spacer and two Belleville washers (with inside diameters touch-ing) into each side of the master link. Push the links together until the boresline up.

4. Press the master pin into place.

5. Reassemble two track shoes and adjust track tension. When reassembling orreplacing track shoes, the bolts, nuts and washers must be thoroughly cleanedof all scale and rust.

Undercarriage

CAUTION!

III-23

UndercarriageLower Roller Assemblies

The lower rollers bolted to the bottom of the track frame. Double flange rollers are inthe center with single flange rollers at each end. This combination is designed to carrythe weight of the entire machine. These rollers are oil filled, rotate on bearings and usemetal to metal type seals. See Metal-to-Metal Seal Installation (later in this section).

Replace the seals if any oil leakage is observed. Replace the bearings if the shaft hasexcessive free (vertical or horizontal) movement.

ROLLERASSEMBLY

ROLLER SEAL

SHAFT SEAL

SHAFT

RETAINER

METAL-TO-METAL SEALS

COLLAR

PLUG

III-24

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 affordaccess 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-metalseals 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 theroller. Remove the remaining seals from the collar and roller body. Removethe O-rings from the shaft.

4. Clean and inspect all parts. After cleaning, wash seal rings with soap andwater to remove any film of solvent or oil.

5. Reverse procedure to reassemble roller - fill with oil to plug hole - installplug and seal - reinstall in frame.

Metal-to-Metal Seal InstallationMany of the undercarriage components in this section use metal to metal seals. Theseare two piece seals with precision ground mating surfaces backed by an O-ring oneach side. Proper installation is critical if the long life that these seals offer is to beobtained.

Prior to installation, the retaining bores, surrounding areas, and any shafts or pins onwhich these seals will be installed must be thoroughly cleaned. If necessary, use a wirebrush and solvent to remove all traces of rust, scale, and oxidation. Inspect the retain-ing surfaces for nicks and scratches. Smooth them out and wipe the area clean. Besure that all surfaces are dry.

The O-rings and the metal face of the seal must be parallel to the surface throughoutthe entire circumference of the seal. An installing tool will best accomplish this. Ifone is not available, press the O-ring into place with your fingertips.

Undercarriage

III-25

Undercarriage

DO NOT use screwdrivers or other sharpobjects to seat the O-ring and DO NOT oil theO-ring prior to installation.

After the seals are properly seated, wipe any dust or fingerprints from the metalsurfaces 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 newseal with a used mating half.

Used seals may be used if the O-rings have not been damaged or distorted, and if themetal faces are free of nicks and scratches.

If the O-rings are the type with rubber “teeth” around their outer diameter, the twoseals must be installed with the teeth facing each other.

CAUTION!

III-26

UndercarriageTraction Drive

The traction drive unit is a planetary gear drive with an internal plug-in piston stylehydraulic 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 thehydraulic motor have independent oil reservoirs. Although the motor is integrated,servicing or replacing the motor can be done without removing of the entire geardrive. The drives are interchangeable, and can be mounted on either side of the carbody. The gear drive consists of three planetary stages, all torque transmittingcomponents are made of forged, quenched and tempered high-alloy steel. Two largetaper bearings support the radial loads. The metal face seals protect the unit againstcontamination.


1. Remove the covers from the traction motor guards.

2. Remove the traction pressure lines and the case drain and pilot lines fromthe 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 tosupport the motor from underneath.

5. Remove the side rail mounting bolts from the mounting flange of the driveunit and draw the entire unit away from the mounting surface.

Note: when replacing the entire drive unit, take the sprocket off the old unitand reinstall it on the new unit. Refer to the torque chart in this section for proper torque.



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. Beforeoperating the drive unit, fill through the oil inlet located on the outside surface of thegear box. Use only that lubrication that is called out in the Fluid Level Chart in thispublication. (Do not over fill)

With the motor and gear case filled to their proper levels, start the machine and allowsufficient time for run-in at moderate pressure and speed prior to running at fullthrottle. Refer to the lubrication chart found in the Fluid Level Chart in thispublication for oil level checks and replacement time schedules.

III-27

UndercarriageTraction Motor Removal

Axial piston motors provide traction for the machine by operating the drive unitthrough a closed loop system. A motor is mounted to each of the drive units housingsand spline-coupled to the input shaft of the gear box.





4. Attach a hoist to the motor or place blocking inside the guards to supportthe motor from underneath.

5. Remove the two bolts from the mounting flange of the motor and draw themotor out of the drive unit housing. Cover the opening to prevent the entry ofdirt and other contamination.

Note: When removing the motor, be careful not to pull the spline adapter out of the driveunit case.


The motor must be manually filled with oil, asrecommended in the lubrication chart (Section-Eof this manual), before starting the engine. Addoil through the case drain port on top of themotor.


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. Beforeoperating the drive motor, fill through the oil inlet located on the upward side of themotor. Use only that lubrication that is called out in the Fluid Level Chart in thispublication. 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 allowsufficient time for run-in at moderate pressure and speed prior to running at fullthrottle. Refer to the lubrication chart found in this publication, for oil level checks andreplacement time schedules.

III-28

Travel Brake

The travel brake is spring applied, hydraulically released. This multiple disk brake is asafety brake, which is normally closed by spring force. The inner disks are splined tothe drive coupler and the outer disks are splined to the drive spindle. When the disksare compressed by the spring, this gives the required holding torque. When pressurizedoil is supplied to the piston side of the brake, the piston slides against the spring. Thismovement compresses the springs and frees the multiple disk stack. The brake is nowreleased and open.The minimum brake release pressure must be 260 PSI and the maximum releasepressure should not exceed 725 PSI. Since the brake is for static use only, 350 PSImust 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 suppliedas the travel pedals are depressed in either direction.





4. Attach a hoist to the motor or place blocking inside the guards to supportthe motor from underneath.

5. Remove the two bolts from the mounting flange of the motor and draw themotor out of the drive unit housing. Cover the opening to prevent the entry ofdirt and other contamination.

Note: When removing the motor, be careful not to pull the spline adapter out of the driveunit case.

6. Compress the brake assembly and remove the two snap rings that hold thebrake 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 acomplete disk and seal kit. See parts group for part numbers.

8. Prior to reassembling the brake, oil the springs, piston seals, backup ringsas well as their contact areas with gear lubrication. Install the backup ringsprior to the piston seals. Arrange the disks alternately, starting and ending withan outer disk.

9. Reassemble in reverse order. See next page for breakdown

Undercarriage

III-29

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 capscrewsaround the periphery of the unit use spacers to set the gap between the two outerplates. 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 spacersshould be removed from each capscrew. This will reduce the travel required of thediaphram and progong its life.

Note: The total clearance must not become greater than 1/4” as damage can occur tothe return bolts or to the diaphram.

After the adjustment spacers have been removed, the locknuts on the brackets shouldbe 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 totalclearance gap is greater than 1/8” and there no more adjustment spacers to be re-moved, the lining should be replaced.

This can be accomplished by replacing the inner-outer torque plate assembly, byreplacing 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 thediaphram, and the present lining must be removed on a lathe.

To bond new linings, use Ross Corporation Adhesive P74-0201. This is a heat andpressure curing agent. Apply the adhesive to one side of the lining with a saw toothtrowel and allow it to cure for 24 hours before bonding.

To bond, apply 100 - 150 PSI clamping pressure over the entire lining area and heatthe 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 thatfuture down time is avoided. Included with a replacement diaphram will be two seg-ments 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 abutt joint. Place the diaphram on the torque plate with the black marks on the periph-ery up and in line with the air hoses. In this position, all the holes in the diaphramshould be aligned with the holes in the torque plate.

III-31

Optional Drop Line Clutch

Optional Drop Line Clutch

III-32

ADJUSTMENT SPACER

BACKPLATE

DIAPHRAM

PRESSURE PLATE

RELEASE SPRING

KEYWAY

HUB

TORQUE PLATES

FRICTION LINING

CENTERING MECHANISM

CAPSCREWS

CLUTCH ADJUSTMENT REFERENCE ILLUSTRATION

Adjustment InformationDRIVE CHAIN ADJUSTMENT:

After prolonged use, the drive chain may need to be adjusted. The chain should move1/2” up or down at its midpoint. Remove the panel, item-C, from both sides of thechain 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 theproper chain tension is achieved or the bolt holes in item-B line up so that item-A canbe 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 tohold item-B in place.

4. Check the tension of the drive chain. If the chain moves more than 1/2”, repeatstep one threw three (1-3).

Do not overtighten the chain

5. Once the proper chain tension is achieved, reinstall items-A. Torque bolts per thetorque chart earlier in this section.

6. Replace the panel, item-C, on both sides of the chain drive housing. Torque boltsper the torque chart earlier in this section.

CAUTION!

III-33

“A”

“B”

“C”

III-34

Adjustment InformationWater Cooled Brake Tensioner Adjustment:

1. Apply approximately 25 PSI (1.7 bar) air pressure to the cylinder (item-1) to engagethe 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 areworn out. The water cooled brake must be disassembled for parts replacement.

GAP

123

Adjustment InformationBull Gear Bearing Preload Adjustments:

Anyone attempting to perform this procedure sould have a clear understandingof the following steps prior to starting. Refer to the illustration on the followingpage.

1. Pre-Adjustment Inspection:Using a pry bar placed between the bull gears and the main frame, check the pre-loadside play. If the bull gear can easily be displaced from side to side, continue throughsteps (2) two through (8) eight below.

2. Remove the water roto seal and water brake, but not the water brake hub, from thetensioner 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 turncounter clockwise. Remove item “B” and item “C” from both ends of the drumassembly.

Note: When applying force to items “E” (clutch spider) and “F” (water brake hub) insteps (5) five and (6) six, alternate force 180°. Example: apply force above the shaftand 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”. Thisshould be repeated as many times as necessary to achieve the proper preload.

Overtightening item “D” may result in eitherthe 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”. Thisshould be repeated as many times as necessary to achieve the proper preload.

Overtightening item “D” may result in eitherthe 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 upwith 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.

CAUTION!

CAUTION!

TSY6355 04/30/98 III-35


E

D

C

B

F

D

C

B

CHECK FOR MOVEMENT ANDPRELOAD HERE

A TYPICAL DRUM SHAFT SECTION ILLUSTRATINGTHE BULL GEAR BEARING PRE-LOAD ADJUSTMENTITEMS REFERRED TO IN THE INSTRUCTIONS ON THE

PREVIOUS PAGE

WATER ROTO SEALAND TENSIONER END

AIR ROTO SEAL ANDCLUTCH END

CHECK FOR MOVEMENT ANDPRELOAD HERE

TSY6355 04/30/98 III-36

Documents

THUNDERBIRD TSY-6355 COVER - Logpro · 2016-06-17 · thunderbird tsy-6355 yarder operator’s manual pdf version august 2003 this manual contains material that was supplied with