80-683 - Allied Systems Company
Contents
1. H D BASE H D PIN K O PIN ENGINE LEFT SIDE AUX H D BASE AUX H D PIN OPTIONAL REMOTE LUBE SYSTEM Figure 5 2a Daily Maintenance and Service Check Points Typical Two Wheel Drive Machine 80 683 Alied COMPANY Lubrication Points DAILY EACH SHIFT Before Engine Startup Check the Following Item No of Fittings Steering Cylinder Pins 4 Boom to Chassis Pins QO Boom to Carriage Pins Hoist Cylinder Pins D 0 N DOO Hinge Bearings 50 HOURS OR WEEKLY amp Tilt Cylinder Pins 4 63 Holddown arm pins 2 82 Kickoff arm pins 2 27 amp Holddown Cylinder Pins 4 amp Kickoff cylinder pins 4 Auxiliary holddown arm pins 2 81 amp 63 Auxiliary holddown cylinder pin 4 87 Swivel Bearing b 1 Front and rear support bearings b 2 3 Driveline converter to transmission a 3 Driveline transmission to front axle a 3 Driveline transmission to front support bearing a b 3 Driveline front support to mid support a b 3 Driveline mid support to rear support a b 3 Driveline rear support to hinge a b 3 Driveline hinge to rear axle a b 3 Fan Drive Bearing Not on all engines 500 HOURS Tailwheel bearing 2 OO Tailpost 1 When operating in water lubricate submerged points more frequently a Use handgun or low pressure adapter lubricate sparingly b Four wheel drive units only Two wheel drive units on2. spread usage of the best possible lubricants for Allied oystems Company products Because many brands of fluid are available it is not prac tical to test each one Selecting the correct fluid should be done with the help of a reputable oil supplier who is responsible for the quality of the fluid Our lubricant rec ommendations are based on commercial products that 80 683 Section 1 0 have given excellent results in a wide range of operating conditions In all cases the lubricant supplier assumes all responsibility for the performance of his product and for product liability Allied Systems Company requires that lubricants meet or exceed the specifications of the oils listed above to avoid component failure and to qualify for warranty consideration Our suggested lubrication and selection and specifi cation list is located in section 10 1 of the service manual If a cross reference to Mobil Oil Corporation specifications is required please consult your local lubri cant dealer When changing fluids use the following guidelines e Add only filtered fluids It is important to service filters and breathers at the proper hourly intervals f adding lubricants other than what is currently in the reservoir a warranty of compatibility should be obtained from the oil supplier When the fluid is changed due to changes in ambient temperatures the system should be com pletely drained and the fluid replaced 17
3. Never rely on the hydraulics to sup port any part of the machine during mainte nance or lubrication If necessary support components with appropriate safety stands NEVER stand under a component that is sup ported only by the hydraulics Make sure itis resting on its mechanical stops or safety stands 4 Four Wheel Drive Install Swivel Locking Pin All four wheel drive units are equipped with swivel locking pins Always install pin when working in the area of the swivel hinge The machine must be ona level surface The swivel locking pin can be installed with the bogie turned right or left NOTE Never operate the unit with the locking pins in the locked position Damage to the machine could re sult 80 683 Locking Pin Storage Hole Swivel Box Chassis Figure 5 1 Typical Swivel Locking Pin Location 5 Stop the Engine Before performing any maintenance or lubrication remove the key from the switch and tag the key swtich with DO NOT START to ensure the engine is not inadvertently started 4 WARNING Before performing any maintenance or lubri cation remove the key from the switch and tag the key switch DO NOT START to ensure that the engine is not inadvertently started 6 Use Safe Ladders Scaffolding It is essential that safe ladders personnel lifts and or scaffolding be used while servicing upper lubrica tion points These areas can be dangerously slippery in wet frosty or oily condition
4. Operator Troubleshooting sm Maintenance Specifications 17 Wheel dag m 17 Tire Inflation Pressure ao an Ced eue te 17 Lubricant Selection and Specifications s 2 80 683 Section 1 0 Maintenance and Lubrication General Machines receiving regular care from its operators and me chanics generally has decreased downtime and greater reliability Information in this section provides guidance to keep the Log Stacker running at top operating efficiency Procedures provided in this section can be performed with a Standard shop tools Safety Precautions The following safety precautions are included for your pro tection Read them carefully prior to performing any main tenance and lubrication procedures 1 Read This Manual Be sure you understand the procedures outlined in this manual prior to performing any machine service or maintenance Pay particular attention to any safety warnings presented Don t hesitate to ask an Allied Systems Company Representitive if there are any questions 2 Perform Maintenance on Level Ground The machine should be on level ground and working or moving equipment whenever possible The park ing brake should be set and the wheels blocked 3 Remove Load The machine should be unloaded with the carriage on the ground WARNING
5. Section 1 0 wagner A Division of Allied Systems Company Maintenance amp Lubrication Logstacker 80 683 4 Allied COMPANY Safety ONS EFFET SENE DU a ee Pre v ntiv Benefits of Preventive Maintenance 4 Establishing a PM PFOOFAM sen 4 Maintenance Record Keeping 4 Shift Maintenance Checklist e rene enne enn annuas 4 Using th CISC t sde dada ee en 4 Scheduled Maintenance Scheduled Maintenance Checklist 5 Using th ses M 5 Scheduled ee eee sn TI TU NN US 5 Daily Maintenance amp Lubrication 6 Pressurized Axle Optional 6 UIT IG ALOR Service Maintenance Check Lists nennen a 13 Before Starting Engine msn be cu names 13
6. Torque to Spec Record engine RPM at idle high free idle and converter stall Empty dust cap bowl on air filter Check transmission oil level at operating temperature Check battery electrolyte level o N 0 m d QO N Visually check for structural damage inspect chassis amp attachments for indication of fatigue or damage 250 HOURS OR MONTHLY Item OK No Add Repair 1 Repeat 50 hour check Take engine oil sample for analysis Change engine oil and all filters Check axle differential and planetary oil level Check all hydraulic pressures and record see hydraulic schematic Check fire suppression system if So equipped 2 3 4 5 Change cooling system filter if so equipped 6 7 8 Check disc brake calipers pads rotors and lines if so equipped 9 Grease all non Lube For Life drivelines 10 Check and adjust the parking brake if required IMPORTANT Consult the engine manufacturers Operation and Maintenance Manual for additional engine related checks and or details 10 80 683 Section 10 Service Maintenance Check Lists 500 HOURS OR QUARTERLY Item OK No Add Repair 1 Repeat 250 hour check Take oil samples of transmission axle and hydraulic systems Drain and refill transmission change filter Service fuel filters per manufacturer s recommendation Service hydraulic filters Qn GI d OO DND Inspect brake systems amp components 1000 HOURS OR SEMI ANNUALLY Item OK No Add Re
7. cs who are knowledgeable of the equipment sys tems and component locations Scheduled maintenance procedures can be found by referring to the appropriate section of the service manual Scheduled Oil Sampling Use scheduled oil sampling SOS to monitor machine condition and maintenance requirements Take oil samples from engine transmission axles and hydraulic system when the oil is hot and well mixed to ensure an accurate analysis Contact an Allied Systems Company Represen tative for complete information and assistance in estab lishing a scheduled oil sampling analysis program for your equipment Allied COMPANY Daily Maintenance amp Lubrication The chart below includes all points referenced in the Daily WARNING Maintenance and Lubrication Check List shown on the The height of the upper lube points and main following page tenance check points make it essential that safe ladders and or scaffolding be used while ser O Circled Numbers Indicate Lubrication Points vicing the machine These areas can be dan gerously slippery under wet frosty icy snowy or oily conditions Boxed Numbers Indicate Maintenance Check Points Pressurized Axle Optional WARNING Note Due to variations in engine types and models the indicated location of engine filters fuel oil cool Some machines have pressurized front axle ant etc are not shown Consult your engine service housings with 3 psi pressure Shut of
8. equired Shift Maintenance Shift maintenance records are the building blocks of a pre ventive maintenance program and are usually completed by the operator It consists of the routine daily and weekly servicing and lubrication of the major systems On a daily basis the operator should identify remedy and or record potential problem areas and recognize any change in the performance of the machine Comments recorded on the shift maintenance report are a valuable tool to the mainte nance department and is important to the overall suc cess of a preventive maintenance program Shift Maintenance Checklist A recommended checklist is provided as an aid in devel oping a practical shift maintenance program A shift main tenance report based on this checklist should be used to report defects found when making maintenance checks at the beginning of each shift Using the Checklist The reference numbers in the left hand column of the check list indicate the physical location of each check point or lubrication point as it appears on the shift maintenance diagram Circled reference numbers on the diagram indi cate lubrication points Boxed numbers indicate mainte nance checkpoints Shift maintenance details are provided in the service main tenance check list These procedures consist of checks easily performed by the operator Scheduled Maintenance Periodic scheduled maintenance should be performed ina well equipped maintenance fac
9. f air sup manual for exact locations ply to the axle then open air drain cock located on axle housing bulkhead before checking axle oil level CES 55 st 6 G2 G3 H D CYL BASE AUX H D CYL BASE Sie ra H D CYL STE san TEE ITEMS LOCATED ON OPPOSITE SIDE OF ENGINE H D ARM PIVOT KICKOFF ARM PIVOT REMOTE LUBE MANIFOLD Figure 5 2b Daily Maintenance and Service Check Points Typical Four Wheel Drive Machine 6 80 683 Section 1 0 o o_e o T ER NH TEE ac eee NM m AN T CARRIAGE NOT SHOWN FOR CLARITY
10. fore each main tenance procedure corresponds with the numbers given in the Daily Maintenance and Service Check Points Fig 5 2 This provides an additional aid in locating each check point Before Starting Engine 5 Engine Oil Level Check the oil level prior to starting the engine Make sure that the area around the dipstick is clean and the machine is sitting on level ground NOTE A 15 minute drain back time is recom mended is the engine has been running The oil level must be maintained between the L low mark and the H high mark but as close to the H mark as possible A CAUTION CAUTION Never operate the engine with the oil level below the L mark or above the H mark Refer to the engine s Operation and Main tenance Manual for detailed engine service in formation Use only approved engine oil See Lubricant Specifications page 5 14 Do not overfill Check engine for leaks Hydraulic Oil Level Always check the hydraulic oil level prior to opera tion The dipstick and fill pipe are located on the RH chassis deck to the right of the operator s cab A CAUTION CAUTION Always open the tank breather pet cock located on the breather pipe before re moving the dipstick filler cap or in tank filter cover plate Failure to vent the tank can result in injury or a substantial oil spill Be sure to close the petcock before operating the ma chine Check the oil level wit
11. h the hoist cylinders retracted down The oil level should be at or near the H high mark on the dipstick Fill with approved hydraulic fluid 80 683 Section 1 0 as required see Lubricant Specifications Do not overfill Engine Coolant Level Daily inspection of the coolant level is recommended Cooling systems using anti aeration baffles restrict visual observation of the true coolant level Although the coolant can be seen the system may not be full To gain a true fill add water slowly up to the bottom of the fill neck and allow a 30 second settling period Remember to compensate for the loss of anti freeze when adding water Never remove the radiator cap if the engine is hot The coolant will be under pressure and could flash to steam with explosive force caus ing severe burns Remove the readiator cap only when the engine is cool NOTE If the engine is hot the coolant level will be higher than when it is cold Inspect the radiator daily for restrictions caused by leaves dust paper or bent fins Inspect the radiator cap hoses and connectors for any signs of leakage or damage Air Cleaner The air cleaner is a cyclonic type dry air filter A ser vice indicator shows the condition of the filter The indicator will show in the green zone when the filter is clean The indicator will show red when the filter is restricted If red appears in the indicator window change the primary element and press the
12. ility by trained mechanics The timely scheduling and completion of these periodic inspections by the maintenance department determine the length of machine downtime Therefore maintenance scheduling relies on a critical balance in the use of labor hours and the availability of equipment 80 683 Scheduled Maintenance Checklist A machine s operating environment affects the maintenance schedule More frequent checks are required for machines operating in severe conditions like heavy dust extreme temperatures or extremely heavy loads These maintenance checklists are designed as a guide until adequate experience is obtained in establishing a schedule to meet your specific needs and operating envi ronment A detailed list of component checks is provided with a suggested schedule basis given in hours of operation or calendar time The engine manufacturer s operation and maintenance manual should be consulted and adhered to for additional engine related checks and or maintenance details Establish a maintenance schedule using these checklists as a guide CAUTION Failure to adhere to adhere to manufacturer s suggested maintenance schedules may result in loss of warranty coverage 80 683 Section 1 0 Using the Checklist Although specific maintenance is identified in these check lists location and procedure references are not provided in the columns Scheduled maintenance is normally performed by trained mechani
13. ly 80 683 O0 Section 1 0 Service Maintenance Check Lists Daily Each Shift Item OK No Add Repair ENGINE Check Oil Level check for leaks HYDRAULIC TANK Check oil level check for leaks RADIATOR Check coolant level check for leaks AIR CLEANER Check indicator clean or change element as req d AIR INTAKE SYSTEM Check for leaks and damage ENGINE BELTS Check for adjustment and wear AIR TANKS Check drain valves for correct operation RADIATOR amp OIL COOLER Are fins clean and unobstructed WHEELS amp TIRES Check condition and pressure HYDRAULIC BRAKE FLUID Check fluid level if so equipped LUBRICATE CHASSIS Refer to lube chart ENGINE Does it sound normal After Starting the Engine Check the Following INSTRUMENTS Check for normal readings 15 Check for normal operation EXHAUST SYSTEM Check for leaks and excessive emissions 19 TRANSMISSION Check oil level check for leaks Note Anything Abnormal Or In Need Of Repair LIGHTS DEFROSTER HORN REVERSE WARNING HORN WINDSHIELD WIPERS HEATER AIR CONDITIONER OPERATOR SUPERVISOR DATE MODEL SERIAL NUMBER HOUR METER 80 683 9 Allied COMPANY Service Maintenance Check Lists 50 HOURS OR WEEKLY Item OK No Add Repair 1 Repeat daily maintenance amp lubrication check list Check for fluid leaks oil fuel and water and correct Check brakes for adjustment and wear Check wheel lug nuts and studs mechanically
14. ny event the intervals and inspection requirements must be planned regular and consistent Specific maintenance should be completed using the fol lowing intervals e 10 hours each shift or daily e 50 hours weekly e 250 hours monthly e 500 hours quarterly e 1000 hours semiannually e 2500 hours annually Each successive schedule e g weekly monthly quarterly etc encompasses the former and is accumulative in na ture For example when performing monthly maintenance take note of the shift maintenance reports and remedy any discrepancy then comply with the shift and weekly maintenance and in addition perform the checks speci fied in the monthly schedule Maintenance Record Keeping Check off each scheduled maintenance form as the in spection and service is performed Quantities of replen 4 ished lubricants and hydraulic pressure readings should be recorded on the schedule form Record all discrepan cies regardless of their status i e whether remedied or pending Operators and mechanics should sign off forms and return them to the maintenance supervisor for approval and retention in an equipment unit file Accurately recorded maintenance forms give maintenance personnel an overall view of how equipment is performing under normal operating conditions Good easy to review records enable maintenance personnel to identify and evaluate problem areas and allow adjustment in the main tenance scheduling as r
15. pair 1 Repeat 500 hour check Clean and flush cooling system 2 3 Check pins and bushings for excess wear 4 Drain flush and refill differentials 5 Drain flush and refill planetaries 2500 HOURS OR ANNUALLY Item No Add Repair 1 Repeat 1000 hour check 2 Check and recharge accumulators record pressure if so equipped 3 Replace hoses as required steam clean engine tighten mounting bolts and turbocharger mounting bolts p Drain hydraulic tank flush tank and refill 9i Change hydraulic oil and filters Normal drain period and filter change intervals are for average environmental and duty cycle conditions Severe or sustained high operating temperatures or very dusty atmospheric conditions will cause accelerated deterioration and contamination Change intervals should be adjusted according to the results of oil sampling analysis Consult your Wagner dealer for assistance in establishing an oil sampling program for your equipment IMPORTANT Consult the engine manufacturers Operation and Maintenance Manual for additional EO Re RE MM related checks and or details 80 683 Allied COMPANY Service Maintenance Check Lists Repairs Problem Parts Mechanic Operator Machine Model Date Shift 12 Supervisor Equipment No Hours Labor Hour Meter 80 683 Maintenance Procedures General Perform the following maintenance procedures at the be ginning of each work shift The number be
16. reset but ton on the indicator Check the safety element and change as required Engine Belts Check the tension of the drive belts by pressing with the thumb halfway between the pulleys The belt should not deflect more than the values shown in the table Fig 5 3 If any belt is loose or worn report to maintenance for corrective action Engine Belt Deflection Inches mm Cummins 3 8 to 5 8 9 5 to 15 9 Caterpillar 1 2 to 3 4 13 to 19 Figure 5 3 Engine Belt Deflection 13 Allied COMPANY Air Tank Valves If Applicable Visually inspect the valves and connections for dam age or leaks There should be signs of water coming from the drain hoses If not report the condition to maintenance 35 50 Wheels and Tires Visually inspect the tires for low air pressure and damage Also check the wheel assemblies for cracks loose or missing lug nuts borken studs etc Hydraulic Brake Fluid Check the fluid level in each of the two brake reserviors Each reservoir must be full Clean the area around the filler cap before removing Fill the reservoirs with transmission fluid Do not use auto motive brake fluid After Starting the Engine 14 Engine After starting check that the engine runs and sounds normal It should come up to operating temperature within a few minutes after starting If you notice un usual noises leaks or excessive smoke shut down the engine and immediately ocntact maintenance Inst
17. rsonnel Engine Engine turns over but fails to star Engine Falls to turn over tank tighten fuel lines and power output is low tank tighten fuel lines replace fuel remove restriction Exhaust smokes badly Engine oil pressure low Check oil level Transmission Converter ____5 ___ Probable Cause Transmission or converter Low oil level Fill to proper level overheats High oil level Restricted airflow for oil cooler Lack of Power Low engine RPM at converter stall Check engine governor High engine RPM at converter stall Check engine governor Failing charge pump Check torque converter Wet Disc Brake System If Applicable Symptom ____ Probable Cause orrective Action Brakes won t release Loss of oil pressure refer to service Troubleshoot as required manual Loss of braking efficiency Air in hydraulic brake system Check the pump Refer to Service Manual Loss of accumulator pressure Troubleshoot as required Low system pressure Wait for system to recharge Also refer to the manufacturer s Operation and Maintenance Manual for additional information 80 683 15 Alied COMPANY Hydraulic System No response to controls Sluggish operation or Allow adequate warm up time response to controls Hydraulic oil cold tank breather leak Hydraulic system Fill tank to proper level overheating over pressure relief or Correct operating procedure or replace excessive system leakage system component
18. ruments Check all the instruments for normal readings imme diately after starting the engine Make sure that tem peratures are within acceptable limits Also check that all controls function properly They should be smooth and responsive Air Intake System Inspect all connections for damage and air leaks Look for damaged fittings and loose connections Do not operate the machine if leaks are present Dirt could enter the engine through the intake and cause se vere damage Exhaust System Check for exhaust leaks Make sure that exhaust gases are not entering the operators cab Mounting brackets must be in place and all connections tight Check for excessive smoke Transmission Oil Level The level should be checked after engine warm up with 180 to 200 showing on the transmission tem perature guage The dipstick and fill tubes are located on the chassis deck directly above the transmis sion Check the level with th engine running at idle at operating temperature and with the transmission in neutral The level should be between the H high and L low marks Fill with approved fluid only See Lubricant Specifications on page 5 14 Do not over fill Inspect for leaks 80 683 Section 1 0 Operator Troubleshooting The following tables list the most common problems that be solved using the corrective actions listed in this table may be encountered by operators If the problem cannot notify maintenance pe
19. s Preventive Maintenance Preventive maintenance is necessary to prevent prema ture equipment failure The preventive maintenance sys tem is based on a series of maintenance checks and ser vicing points To be effective the program demand s strict adherence to a planned schedule Allied COMPANY Benefits of Preventive Maintenance There are several benefits to a good preventive mainte nance program Some benefits include e Promotes Safety equipment operates more efficiently and is more responsive to operator control e Improves Equipment Availability equipment down time is minimized saving money and increasing pro ductivity e Reduces Unexpected Downtime helps avoid oper ating equipment destruction by replacing or rebuilding parts before they fail e Allows Planning of Daily Production by knowing the condition of available equipment e Allows Planning of Maintenance Man Hours by distributing duties and necessary lead time for parts ordering e Provides Complete History of Equipment based on performance frequency and type of repairs and actual labor hours spent on maintenance Establishing a Preventive Maintenance Program The key to an effective preventive maintenance program is diligence in following a maintenance schedule set at regular planned intervals Such intervals should be made compatible with the nature of operation of the equipment and with the capabilities of the maintenance facility In a
20. s Electrical System Engine falls to turn over Other connections loose Tighten connections Voltmeter indicates Alternator drive belt slipping or broken Tighten or replace belt discharge Loose or corroded battery connections Clean tighten terminals Defective alternator or battery Replace battery and or alternator Also refer to the manufacturer s Operation and Maintenance Manual for additional information 16 80 683 Maintenance Specifications Most of the required maintenance specifications such as the hydraulic pressure relief settings can be obtained from the Service Manual and the hydraulic schematic Note Set Hydraulic pressures at 1500 rpm Override should not be over 50 100 psi on control valves Check or set pressures after hydraulic oil is above 100 F with calibrated gauges Wheel Nut Torque Wheel nut torque for specific machines is located in the service manual under Section 3 5 wheels and tires Tire Inflation Pressure Tire inflation pressure for specific machines is located in the service manual under Section 3 5 wheels and tires Lubricant Selection and Specifica tions The efficiency and useful life of mechanical equipment is as dependent on proper lubrication as on proper engi neering design The importance of proper lubrication is increased because of the greater loads and pressures imposed on present day mobile heavy equipment For this reason we are vitally interested in promoting wide
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