OPERATOR S AND PARTS MANUAL. D-4 Series Power Box Rake

Transcription

1 OPERATOR S AND PARTS MANUAL D-4 Series Power Box Rake SERIAL NUMBER: MODEL NUMBER: Manual Number: Release Date: August 2014 Serial Number: & Up Rev I N. Zeeb Rd., Dexter, MI , United States of America Copyright

2 NOTES 2 D-4

3 TABLE OF CONTENTS PREFACE...2 SAFETY STATEMENTS...3 GENERAL SAFETY PRECAUTIONS EQUIPEMENT SAFETY PRECAUTIONS...5 SAFETY DECALS & LABELS INSTALLATION & SET-UP OPERATION MAINTENANCE TROUBLESHOOTING...24 HYDRAULIC SCHEMATIC...25 LABEL ASSEMBLY...26 MAIN FRAME ASSEMBLY...27 ROLLER ASSEMBLY...28 BEARING ASSEMBLY...29 MOTOR ASSEMBLY...30 CASTER ASSEMBLY...31 MOUNTING ASSEMBLY...32 HYDRAULIC ANGLE ASSEMBLY...33 MANUAL ANGLE ASSEMBLY...34 PRODUCT SPECIFICATIONS HYDRAULIC TORQUE BOLT TORQUE...40 WARRANTY...41 D-4 1

4 PREFACE GENERAL INFORMATION This product was carefully designed and manufactured to give you many years of dependable service. Only minor maintenance (such as cleaning and lubricating) is required to keep it in top working condition. Be sure to observe all maintenance procedures and safety precautions in this manual and on any safety decals located on the product and on any equipment on which the attachment is mounted. WARNING! Never let anyone operate this unit without reading the Safety Precautions and Operating Instructions sections of this manual. Always choose hard, level ground to park the vehicle on and set the brake so the unit cannot roll. Unless noted otherwise, right and left sides are determined from the operator s control position when facing the attachment. NOTE: The illustrations and data used in this manual were current (according to the information available to us) at the time of printing, however, we reserve the right to redesign and change the attachment as may be necessary without notification. BEFORE OPERATION The primary responsibility for safety with equipment falls to the operator. Make sure the equipment is operated only by trained individuals that have read and understand this manual. If there is any portion of this manual or function you do not understand, contact your local authorized dealer or manufacturer to obtain further assistance. Keep this manual available for reference. Provide this manual to any new owners and/or operator s SAFETY ALERT SYMBOL SERVICE This is the Safety Alert Symbol used by this industry. This symbol is used to warn of possible injury. Be sure to read all warnings carefully. They are included for your safety and the safety of others working with you. Use only manufacturer replacement parts. Substitute parts may not meet the required standards. Record the model and serial number of your unit on the cover of this manual. The parts department needs this information to insure that you receive the correct parts. SOUND AND VIBRATION Sound pressure levels and vibration data for this attachment are influenced by many different parameters; some items are listed below (not inclusive): prime mover type, age, condition, with or without cab enclosure and configuration operator training, behavior, stress level job site organization, working material condition, environment Based on the uncertainty of the prime mover, operator, and job site, it is impossible to get precise machine and operator sound pressure levels, or vibration levels for this attachment. NOTE: A list of all Paladin Patents can be found at 2 D-4

5 SAFETY STATEMENTS DANGER! WARNING! CAUTION! NOTICE! THIS SIGNAL WORD IS USED WHERE SERIOUS INJURY OR DEATH WILL RESULT IF THE INSTRUCTIONS ARE NOT FOLLOWED PROPERLY. THIS SIGNAL WORD IS USED WHERE SERIOUS INJURY OR DEATH COULD RESULT IF THE INSTRUCTIONS ARE NOT FOLLOWED PROPERLY. THIS SIGNAL WORD IS USED WHERE MINOR INJURY COULD RESULT IF THE INSTRUCTIONS ARE NOT FOLLOWED PROPERLY. NOTICE INDICATES A PROPERTY DAMAGE MESSAGE. THIS SYMBOL BY ITSELF OR USED WITH A WARNING WORD THROUGHOUT THIS MANUAL IS USED TO CALL YOUR ATTENTION TO INSTRUCTIONS INVOLVING YOUR PERSONAL SAFETY OR THE SAFETY OF OTHERS. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN INJURY OR DEATH. GENERAL SAFETY PRECAUTIONS WARNING! WARNING! READ MANUAL PRIOR TO INSTALL Improper installation, operation, or maintenance of this equipment could result in serious injury or death. Operators and maintenance personnel should read this manual as well as all manuals related to this equipment and the prime mover thoroughly before beginning installation, operation, or maintenance. FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL AND THE PRIME MOVERS MANUAL. READ AND UNDERSTAND ALL SAFETY STATEMENTS Read all safety decals and safety statements in all manuals prior to operating or working on this equipment. Know and obey all OSHA regulations, local laws and other professional guidelines for your operation. Know and follow good work practices when assembling, maintaining, repairing, mounting, removing or operating this equipment. KNOW YOUR EQUIPMENT Know your equipment s capabilities, dimensions and operations before operating. Visually inspect your equipment before you start, and never operate equipment that is not in proper working order with all safety devices intact. Check all hardware to assure it is tight. Make certain that all locking pins, latches, and connection devices are properly installed and secured. Remove and replace any damaged, fatigued or excessively worn parts. Make certain all safety decals are in place and are legible. Keep decals clean, and replace them if they become worn and hard to read. WARNING! PROTECT AGAINST FLYING DEBRIS Always wear proper safety glasses, goggles or a face shield when driving pins in or out or when operation causes dust, flying debris, or any other hazardous material. D-4 3

6 GENERAL SAFETY PRECAUTIONS WARNING! WARNING! LOWER OR SUPPORT RAISED EQUIPMENT Do not work under raised booms without supporting them. Do not use support material made of concrete blocks, logs, buckets, barrels or any other material that could suddenly collapse or shift positions. Make sure support material is solid, not decayed, warped, twisted, or tapered. Lower booms to ground level or onto blocks. Lower booms and attachments to the ground before leaving the cab or operator s station. USE CARE WITH HYDRAULIC FLUID PRESSURE Hydraulic fluid under pressure can penetrate the skin and cause serious injury or death. Hydraulic leaks under pressure may not be visible. Before connecting or disconnecting hydraulic hoses, read your prime movers operator s manual for detailed instructions on connecting and disconnecting hydraulic hoses or fittings. Keep unprotected body parts, such as face, eyes, and arms as far away as possible from a suspected leak. Flesh injected with hydraulic fluid may develop gangrene or other permanent disabilities. If injured by injected fluid, see a doctor at once. If your doctor is not familiar with this type of injury, ask him to research immediately to determine proper treatment. Wear safety glasses, protective clothing, and use a sound piece of cardboard or wood when searching for hydraulic leaks. DO NOT USE YOUR HANDS! SEE ILLUSTRATION. WARNING! DO NOT MODIFY MACHINE OR ATTACHMENTS Modifications may weaken the integrity of the attachment and may impair the function, safety, life and performance of the attachment. When making repairs, use only the manufacturer s genuine parts, following authorized instructions. Other parts may be substandard in fit and quality. Never modify any ROPS (Roll Over Protection System) equipment or device. Any modifications must be authorized in writing by the manufacturer. 4 D-4

7 GENERAL SAFETY PRECAUTIONS WARNING! WARNING! SAFELY MAINTAIN AND REPAIR EQUIPMENT Do not wear loose clothing, or any accessories that can catch in moving parts. If you have long hair, cover or secure it so that it does not become entangled in the equipment. Work on a level surface in a well-lit area. Use properly grounded electrical outlets and tools. Use the correct tool for the job at hand. Make sure they are in good condition for the task required. Wear the protective equipment specified by the tool manufacturer. SAFELY OPERATE EQUIPMENT Do not operate equipment until you are completely trained by a qualified operator in how to use the controls, know its capabilities, dimensions, and all safety requirements. See your prime movers manual for these instructions. Keep all step plates, grab bars, pedals, and controls free of dirt, grease, debris, and oil. Never allow anyone to be around the equipment when it is operating. Do not allow riders on the attachment or the prime mover. Do not operate the equipment from anywhere other than the correct operators position. Never leave equipment unattended with the engine running or with this attachment in a raise position. Do not alter or remove any safety feature from the prime mover or this attachment. Know your work site safety rules as well as traffic rules and flow. When in doubt on any safety issue, contact your supervisor or safety coordinator for an explanation. WARNING! WARNING! EQUIPMENT SAFETY PRECAUTIONS EXPOSURE TO RESPIRABLE CRYSTALLINE SILICA DUST ALONG WITH OTHER HAZARDOUS DUSTS MAY CAUSE SERIOUS OR FATAL RESPIRATORY DISEASE. It is recommended to use dust suppression, dust collection and if necessary personal protective equipment during the operation of any attachment that may cause high levels of dust. REMOVE PAINT BEFORE WELDING OR HEATING. Hazardous fumes/dust can be generated when paint is heated by welding, soldering or using a torch. Do all work outside or in a well ventilated area and dispose of paint and solvent properly. Remove paint before welding or heating. When sanding or grinding paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. WARNING! END OF LIFE DISPOSAL. At the completion of the useful life of the unit, drain all fluids and dismantle by separating the different materials (rubber, steel, plastic, etc.). Follow all federal, state and local regulations for recycling and disposal of the fluid and components. D-4 5

8 SAFETY DECALS & LABELS Serial Tag Location Item Qty Part Description Label, Warning, Crush Hazard Label, Warning, Misuse Hazard Label, Warning, High Pressure Fluid Hazard Label, Lift Point, ISO Label, Warning, Crush Hazard Decal, Mandatory Action, Lube, ISO 9. 2 P Decal, Warning, Danger Roller Use part numbers to order replacements for lost or damaged decals. Be sure to read all decals before operating the attachment. They contain information you need to know for both safety and longevity. Placement or replacement of Safety Signs 1. Clean the area of application with nonflammable solvent, and then wash the same area with soap and water. 2. Allow the surface to fully dry. 3. Remove the backing from the safety sign, exposing the adhesive surface. 4. Apply the safety sign to the position shown in the diagram above and smooth out any bubbles. Instructions 1. Keep all safety signs clean and legible. 2. Replace all missing, illegible, or damaged safety signs. 3. Replacement parts, for parts with safety signs attached, must also have safety signs attached. 4. Safety signs are available, free of charge, from your dealer or from SWEEPSTER. 6 D-4

9 SAFETY DECALS & LABELS P D-4 7

10 INSTALLATION & SET-UP SET-UP INSTRUCTIONS The D-4 power rake (Manual or Hydraulic angling) is shipped assembled. The only adjustment is to lower the caster wheels to operating postion. Select a suitable working area. Refer to illustrations, accompanying text, parts lists, and exploded view drawings. For reference, front, back, left and right directions are determined by sitting in the prime movers operator s seat. It is advisable to have a mechanical lifting device to facilitate uncrating. UNPACKING CRATE Be careful of nails in boards when uncrating. 1. Remove top, sides, and ends of crate. 2. Remove rake assembly from crate. 3. Remove loose nails from boards and dispose of crate according to local codes. If you have purchased the rake frame assembly and a mounting system separately, it will be neccessary to clamp the mounting frame to the rake assembly. ANGLING MODEL ASSEMBLY PROCEDURE 1. Install power cord by connecting the red clamp to a positive 12 volt power source and the black clamp to ground. The power cord includes an in-line fuse and spring-loaded battery clamps. The red (positive) cable is fused and should always be connected to the positive side of the battery to ensure proper operation of the electrical circuit. Be careful when routing the cable that sharp edges or moving parts will not damage it. Initial Set-up and Systems Check: 1. Always check with your Loader manual or dealer for counter weight ballast that may be required for machine stability. 2. Air in hydraulic systems can cause erratic operation and allows loads or equipment components to drop unexpectedly. 3. Before operating equipment purge any air in the system by engaging all hydraulic functions. 4. Check that all control lever positions function as instructed in the Operator s Manual. Do not operate until control lever and equipment movements are correct. 8 D-4

11 INSTALLATION & SET-UP 5. Make sure all hydraulic hoses, fittings, and valves are in good condition and not leaking before starting power unit. Check and route hoses carefully to prevent damage. 6. Hoses must not be twisted, bent sharply, kinked, frayed, pinched, or come into contact with any moving parts. 7. Operate moveable components through full operational range to check clearances. Replace damaged hoses immediately. 8. Ensure implement is properly attached, adjusted, and in good condition. Loader coupler lock-pins must be fully extended and properly engaged into attachment retaining slots. 9. If the loader is equipped with ROPS and seat belt/operator restraint, keep ROPS systems in place and keep seat belt/operator restraint securely fastened/engaged. Falling off Loader can result in death from being run over or crushed. D-4 9

12 OPERATION Intended Use: This power rake is designed for removing rock, small debris and for thatching. Use in any other way is considered contrary to the intended use. Compliance with and strict adherence to operation, service and repair conditions as specified by the manufacturer, are also essential elements of the intended use. WARNING! IMPROPER OPERATION CAN CAUSE THE MACHINE TO TIP OR ROLL OVER AND CAUSE INJURY OR DEATH. 1. Keep Loader lift arms and attachment as low as possible. 2. Do not travel or turn with Loader lift arms and attachment raised. 3. Turn on level ground. 4. Go up and down slopes, not across them. 5. Keep the heavy end of the machine uphill. 6. Do not overload the machine. 7. Never use the Loader attachment to carry loads that exceed Loader rated operating capacity or other Loader specifications. Check your Loader manual or with your dealer for Loader rated operating capacity. Exceeding this capacity can cause machine to tip or roll over and cause injury or death. 8. Use of a front safety door, if equiped, on the Loader is recommended for operation of the Power Box Rake. 9. Only engage power when equipment is at ground level. Always disengage power when equipment is raised off the ground. 10. Do not disconnect hydraulic lines until all system pressure is relieved. 11. Hydraulic system leak down, hydraulic system failures, mechanical failures, or movement of control levers can cause equipment to drop or rotate unexpectedly and cause severe injury or death. 12. Never direct discharge toward people, animals, or property. 13. Do not operate equipment while under the influence of alcohol or drugs. 14. Operate only in the daylight or good artificial lighting. 15. Always comply with all state and local lighting and marking requirements. 16. Ensure equipment is properly attached, adjusted, and in good operating condition. Loader coupler lock-pins must be fully extended and properly engaged into attachment retaining slots. 10 D-4

13 OPERATION WARNING! WATCH FOR OPERATING HAZARDS. 1. Look down and to the rear and make sure area is clear before operating in reverse. 2. Watch for hidden hazards on the terrain during operation. 3. Use extreme care when working close to fences, ditches, other obstructions, or on hillsides. 4. Reduce ground speed on slopes and rough terrain. 5. Do not operate on steep slopes. 6. Do not stop, start, or change directions suddenly on slopes. 7. Stop Loader and implement immediately upon striking an obstruction. Dismount Loader using proper procedure. Inspect and repair any damage before resuming operation. D-4 11

14 OPERATION NOTICE! Loaders must be equipped with an auxiliary hydraulic system capable of supplying continuous flow for hydraulic motor operation. This manual contains information for the manual and hydraulic angling models. Refer to the information in this manual for specifications, parts, assemblies, and adjustments. WARNING! Pressurized fluid or air could pierce skin and cause injury or death. Before disconnecting a hydraulic line, turn engine off and operate all controls to relieve pressure. Catch all fluids in a container. ATTACHING POWER RAKE TO LOADER Read the loader Operator s Manual connecting and removing instruction. 1. Cycle attachment drive control to relieve residual pressure at hydraulic couplers. 2. Position attachment on level surface with enough space behind it to accommadate unit. 3. Position hydraulic hoses so they will not be pinched when connecting the power rake. 4. Connect hydraulic hoses to loader auxiliary quick couplers. For optional hydraulic angling models, mount the angle control switch in a convenient, easy-to-reach location. The switch bracket is magnetic and will attach to any flat steel surface. Connect the power cord to the cable coming from the switch. Be careful when routing the cable that sharp edges or moving parts will not damage the cable. The loader coupler handles should be in the unlocked position and the lock pins retracted. Figure 1. Loader Coupler Handles - Unlocked 5. Ensure that connections are secure by pulling on hoses. 6. Move to the loader operator s position and start engine. 7. Lower the loader lift arms to their lowest position and tilt mount plate forward.. 8. Raise lift arms while tilting back mount plate. (figure 2) 9. Roll the loader coupler into the power rake so the coupler handles can be engaged. 12 D-4

15 OPERATION Figure 2. Attaching Power Rake to Loader 10. Turn ignition switch off, set brake, and remove key. 11. Engage lock pin handles to secure attachment to lift plate. NOTICE! To ensure proper connection, verify that bottoms of lock pins are visible under attachment receiver plate. (figure 3) Figure 3. Lock pin connection POWER RAKE FUNCTION The power rake hydraulic motor drives the roller, which digs into the ground, cultivating and pulling up rocks, roots, and debris. The clean soil goes between the roller and barrier, while the rocks, roots, and debris work to the side in a windrow. With the endplates mounted in the working position and the rake straight (endplates parallel with loader tires), material can be moved along, filling in the low spots. Also, rocks, roots, and debris can be collected and moved to another location for hauling away. D-4 13

16 OPERATION Start prime mover engine. Lower power rake slowly to the ground. Engage hydraulic control lever for auxiliary implements. Increase engine rpm to give desired rpm at the roller. Normal operating speed is approximately 270 rpm. If operating in heavy rock, reduce the speed slightly. Move the prime mover forward or backward as desired. For the roller to operate effectively, it must rotate in the opposite direction of the prime mover wheels, see figure 6. Roller rotation direction is controlled by prime mover hydraulic controls. Figure 6. Roller Rotation Ground Speed Ground speed should be between 3 and 5 mph under normal conditions. In heavy rock, reduce the ground speed to 1 to 3 mph. Direction Control Switch (HYDRAULIC ANGLING MODEL ONLY) A three position switch is provided to angle the rake left or right. The switch is equipped with a magnetic mount and may be attached to a convenient steel surface near the operator. The direction valve uses a small amount of hydraulic oil bypassed from the roller drive motor and will only operate with the prime mover auxiliary hydraulic system engaged and with the roller turning clockwise. With the prime mover auxiliary hydraulic system engaged, move the spring loaded switch in one direction and the rake will angle left or right. Return the switch to center position and rake will maintain the angle selected. Pivot rake to place the windrow left or right of the Loader. Hydraulic Drive Motor The hydraulic drive motor runs off the auxiliary circuit of the prime mover. The power rake should be run at 30% power for one hour for proper motor break-in. 14 D-4

17 OPERATION Power Roller Roller should be level with the ground. The power rake should also be level with the ground front to back. To accomplish this, raise or lower casters and/or use the prime mover tilt cylinder. WARNING! DO NOT ADJUST CASTER POSITION WHILE MACHINE IS RUNNING. Make sure machine has been shut down and all moving parts have stopped. To allow the roller to penetrate deeper into the ground, remove the bail pin and raise the casters. Re-pin in new position. To achieve the opposite, lower the casters. During operation, further depth control can be achieved by tilting the rake forward on the casters to raise roller, or by tilting the rake back to raise casters and allow more roller penetration. Be sure to check the air pressure in each tire regularly so that an even, consistent grade will be maintained. The normal gap between the roller and barrier for average conditions is about 1-1/4. This gap can be adjusted either wider or narrower by loosening the 3/8 U-bolts (2) that holds the barrier mount and sliding it up or down. A wider opening will allow more dirt and rock to pass through. For finer raking, reduce the gap. Be careful not to let roller hit barrier. The gap should be the same all the way across. Barrier adjustment is shown in figure 7. MANUAL ANGLE PIN CASTER OPERATING POSITION CASTER STORAGE POSITION CASTER HEIGHT ADJUSTMENT END GATE LOCKING PIN BARRIER ADJUSTMENT Figure 7. Adjustments The roller on the power rake is bi-rotational. You can operate the roller in both directions clockwise and counter-clockwise. The roller operates most efficiently when it rotates in the opposite direction of the prime mover wheels. Operating Depth When power raking, the depth will determine how much dirt is carried ahead of the roller. The ideal depth will vary with conditions and can be anywhere from skimming the surface to about 3 deep. See instructions in Power Roller above to set roller depth. When making the first windrow the level of dirt may be halfway up on the barrier. When moving the windrow two or three times, the level of the dirt may be to the top of the barrier. However, try to prevent material from flowing over the top. D-4 15

18 OPERATION The power rake allows fast raking of large areas of ground by being able to move windrows several times. Of course, the volume or density of the material being raked will dictate how many times a windrow can be moved. Endplates The function of the endplates is to contain the material in front of the roller while the clean material passes between the roller and barrier. With the endplates mounted in the working position and the roller straight (parallel with prime mover), material can be moved along, filling in the low spots.by decreasing the gap between the roller and barrier, more material can be pulled along. Barrier adjustment is shown in figure 7. These plates can be mounted to the front or back of the power rake, depending on the raking direction. When you move the endplates from front to back, you can move the left one to the right side and the right one to the left side. Make sure the disconnected power rake is stored on a hard, level surface. Use the endplates mounted on attachment side of rake to ensure stability. Operator Production Successful operation of the power rake will come with operator experience. The rake s performance also depends on the type and size of the prime mover it s mounted on. An operator that masters the technique of adjusting the angle of attack of the roller against the soil will also find ideal settings under various conditions to give the desired results. NOTICE! Do not drop power rake to the ground with the roller turning. Sudden high speed jolts multiply stress to the drive line and can cause extreme damage. Application Techniques The power rake is capable of many applications. The following are some of the common applications: Pulverizing Topsoil For breaking up compacted soil or conditioning hardened baseball diamonds, the attachment plate is rolled back to take the guide wheels off the ground so only the toothed roller is in contact with the ground. Maintain sufficient RPM to avoid stalling the toothed roller in its progress. The rake can be straight or angled, but the endplates should not be mounted in order to allow material to move out of the way and not slow the process. Debris Removal Once the surface has been loosened, the process of removing debris can begin. The prime mover attachment plate is tilted forward until the guide wheels control the depth of the toothed roller. The roller can be angled at this time for windrowing debris or the roller can be set straight with both endplates installed to collect debris. Prime mover travel speed should be increased for this process. Finish Grading The rake is tilted forward until the teeth of the toothed roller are barely touching the soil. Prime mover speed can be increased for this operation, the idea being to collect material from the high spots and leave it in the 16 D-4

19 OPERATION low areas. Spreading Fill and Topsoil Position rake so it is tilted on casters, since depth of cut is not the objective. Endplates can be installed and the windrow angle set as needed to control the material movement. Changing Grade Grade modification can be accomplished during finish grading by angling the rake to collect and windrow the maximum amount of material toward targeted areas. Thatching Existing Grass Areas The prime mover attachment plate should be tilted forward to support the rake on the front casters and toothed roller raised so teeth are just grazing the surface. Travel speed should be slow and careful. Shutting Down Stop engine. Lower the lift arms and power rake to the ground. Purge any air in the system. Hydraulic system leak down, hydraulic system failures, mechanical failures, or movement of control levers can cause equipment to drop or rotate unexpectedly. Shut off engine, set brake and remove key. Removing Power Rake From Prime Mover Install endplates on attachment side of power rake as shown in figure 7. On a hard level surface, lower attachment to the ground. Shut off engine, set brake and remove key. Move attachment coupler latches to the unlocked position (lock pins must be disengaged). Disconnect hydraulic hoses from quick couplers. Install dust plugs and couple hoses together for storage. Disconnect direction control switch from prime mover power cord and remove switch. Move to the operator s position and start engine. Release brake and roll attachment coupler until it is disengaged from the attachment. The attachment should rest in a stable position for storage. D-4 17

20 OPERATION STORAGE Make sure the disconnected power rake is stored on a hard, level surface. Endplates mounted on attachment side of rake increase stability. WARNING! Block equipment securely for storage. CAUTION! Keep children and bystanders away from storage area. General Storage: Storage: Clean the unit thoroughly, removing all mud, dirt and grease. Inspect for visible signs of wear, breakage or damage. Order any parts required and make the necessary repairs to avoid delays upon removal from storage. Tighten loose nuts, capscrews and hydraulic connections. Coat exposed portions of the cylinder rods with grease. Lubricate grease fittings. Seal hydraulic system from contaminants and secure all hydraulic hoses off the ground to help prevent damage. Store unit in a dry and protected place. Leaving the unit outside will materially shorten its life. Additional Precautions for Long Term Storage: Touch up all unpainted surfaces with paint to avoid rust. Inflate tires to recommended tire pressure. Removal from Storage: Remove cover. Wash unit and replace any damage and/or missing parts. Lubricate grease fittings. Check hydraulic hoses for damage and replace as necessary. 18 D-4

21 OPERATION LIFT POINTS Lifting points are identified by lifting decals where required. Lifting at other points is unsafe and can damage attachment. Do not attach lifting accessories around cylinders or in any way that may damage hoses or hydraulic components. See diagram: Attach lifting accessories to unit at recommended lifting points. Bring lifting accessories together to a central lifting point. Lift gradually, maintaining the equilibrium of the unit. WARNING! TIE DOWN POINTS USE LIFTING ACCESSORIES (CHAINS, SLINGS, ROPES, SHACKLES AND ETC.) THAT ARE CAPABLE OF SUPPORTING THE SIZE AND WEIGHT OF YOUR ATTACHMENT. Secure all lifting accessories in such a way to prevent unintended disengagement. Failure to do so could result in the attachment falling and causing serious personal injury or death. Tie down points are identified by tie down decals where required. Securing to trailer at other points is unsafe and can damage attachment. Do not attach tie down accessories around cylinders or in any way that may damage hoses or hydraulic components. See diagram: Attach tie down accessories to unit as recommened. Check unit stability before transporting. WARNING! VERIFY THAT ALL TIE DOWN ACCESSORIES (CHAINS, SLINGS, ROPES, SHACKLES AND ETC.) ARE CAPABLE OF MAINTAINING ATTACHMENT STABILITY DURING TRANSPORTING and are attached in such a way to prevent unintended disengagement or shifting of the unit. Failure to do so could result in serious personal injury or death. D-4 19

22 MAINTENANCE The information in this section is written for operators who possess basic mechanical skills. Should you need help, your dealer has trained service technicians available. For your protection, read and follow all safety information in this manual. Regular preventive maintenance and immediate repair of broken or worn parts will ensure maximum efficiency and long life. Because of the nature of the jobs the power rake does, site preparation and rock raking, the power rake is constantly vibrating and shaking. Parts may loosen as it is used. One of the most important functions an operator can perform is observing and inspecting the equipment for loose or worn parts to prevent damage or excessive downtime. MAINTENANCE SAFETY 1. Your dealer can supply original equipment hydraulic accessories and repair parts. Substitute parts may not meet original equipment specifications and may be dangerous. 2. Avoid electrical system hazards. Never work on the electrical system unless you are qualified and thoroughly familiar with system details and the special handling requirements. 3. Disconnect battery before working on electrical system. Remove ground cable first. When reconnecting battery, connect ground cable last. 4. Never perform service or maintenance with engine running. 5. Tighten all bolts, nuts, and screws, and check that all cotter pins are installed securely to ensure equipment is in a safe condition before operating. Prodedure Inspect prime movers hydraulic system to be sure hydraulic oil level is adequate Repair hydraulic oil leaks Before each use 40 Hours Lubricate all grease fittings Check tire pressure Inspect and clean safety decals. Replace if damaged. (See safety decal section for location) 20 D-4

23 MAINTENANCE Lubrication Points The following grease fittings should be greased every 40 hours. 1. Roller Bearing (1 fitting) 2. Caster Wheel (2 fittings) 3. Caster Pivot (2 fittings) 4. Pivot Plates (4 fittings) 5. Pivot Bolt (1 fitting) HYDRAULIC MOTOR Removal QUALIFIED TECHNICIAN MAINTENANCE 1. Make sure all pressure is relieved for hydraulic hoses. Remove hydraulic hoses from motor. 2. Remove two bolts holding the motor bucket assembly and slide out of the roller. (See figure 8.) 3. Remove four bolts holding hydraulic motor to motor bucket. Figure 8. Motor Bucket Assembly D-4 21

24 MAINTENANCE BEARINGS Highest quality bearings are used on the power rake. Only triple-seal bearings are used on the roller which operates down in the dirt. Lubrication of the bearings will vary considerably with conditions. As a rule, bearings should be under-lubricated rather than over-lubricated. Over lubrication can cause seals to blow out. NOTICE! Replacement bearings should be only high quality original equipment bearings for longer life. Install new complete bearing housing if needed or just replace the bearing insert. The shafts should be straight, free of burrs, and up to size. If shaft is worn, replace or have the shaft built up to standard prior to completing assembly. Protective Collars The special protective collars protect bearings from vine and wire wrap, and dirt buildup next to the bearing seal. The bearing protector is sandwiched onto the shaft which rotates within a close clearance from the outer race of the bearing. Grease coming from the bearing oozes into the protecting collar, keeping dust and particles from entering the seal area, increasing the bearing life. Right Roller Bearing 1. Remove the hex bolt and bearing cap from outside of bearing. 2. Loosen bolt on the bearing tube that holds cartridge bearing in place. 3. Pry bearing tube apart to free bearing assembly. Have roller blocked up or supported. To replace, reverse the procedure. Be sure all parts and wear surfaces are thoroughly clean and in good condition. ROLLER REPLACEMENT NOTICE! It will be necessary to have a lifting device or additional help while removing and replacing the roller. The roller weighs approximately 80 lbs. 1. Remove two bolts holding the motor bucket assembly and slide the hydraulic motor out of the roller. (See figure 8) 2. Loosen the bolt on the bearing tube of the non-drive end. 3. Slide roller and bearing out of frame. 4. Remove hex bolt, bearing cap, bearing, and protective collar from roller. 5. On roller to be installed, place machine bushing and protective collar against end plate on roller. 6. Place bearing and bearing cap on roller. Clamp in place with hex bolt and lock washer into end of roller shaft. Verify bearing is centrally located in clamp tube. 7. Position roller and bearing into bearing retainer on non-drive end of frame. Tighten bearing cap at this time. 8. Install motor bucket assembly onto frame and into hex drive of roller. Tighten hardware. 9. Check that roller clears the frame on both ends. 10. Run power rake and watch for any interference between roller frame. 22 D-4

25 MAINTENANCE DIRECTIONAL CONTROL VALVE (HYDRAULIC ANGLE MODEL ONLY) A three position switch (normally open) is used to operate the direction control valve. Control power (12 volt) is supplied by the power cord attached to the prime movers electrical system. The switch wires are connected to the direction control valve as shown in figure 9. The direction control valve uses a small amount of hydraulic oil bypassed from the roller drive motor circuit. The prime movers auxiliary hydraulic system must be connected and engaged to provide angle direction adjustment. The roller must be rotating clockwise. PLUG W/ YELLOW WIRE PLUG W/ RED WIRE Figure 9. Direction Control Valve D-4 23

26 TROUBLESHOOTING Problem Possible Cause Possible Solution Roller will not turn Hydraulic valve on Loader not engaged Relief valve setting on Loader not properly adjusted Worn, damaged, insufficient or inadequate pump Insufficient oil in system Hose ends not completely engaged Air in hydraulic lines Obstruction in hydraulic lines Obstruction between roller and barrier See Loader Operator s Manual for auxiliary hydraulic operation procedure Have Loader dealer set relief valve at correct pressure Repair or replace hydraulic pump Service the Loader hydraulic reservoir Check hose coupling and engage properly Cycle Loader auxiliary system several times to remove air from lines Replace obstructed or damaged line Reverse roller to clear obstruction Oil leaks Worn or damaged seal Replace leaking seal Angle cylinder will not extend or retract Angle cylinder will not hold position Loose or damaged hoses Loose or damaged connections Electrical failure Replace damaged hoses and secure loose hoses Replace damaged hose connections and tighten loose fittings See Loader Operator s Manual Hydraulic system not activated Engage roller drive motor before attempting to move angle cylinder Check valve in manifold malfunctioning Solenoid cartridge not returning to closed position Repair or replace check valve Repair or replace solenoid cartridge 24 D-4

27 HYDRAULIC SCHEMATIC FROM LOADER D-4 25

28 LABEL ASSEMBLY Item Part Qty Description Screw, HFH, CL10.9, M6-1 x Manual Holder Label, Warning, Crush Hazard Label, Warning, Misuse Hazard Label, Warning, High Pressure Fluid Hazard Label, Lift Point, ISO Label, Warning, Crush Hazard Decal, Mandatory Action, Lube, ISO 9. P Decal, Warning, Danger Roller 10. P Label, Logo, Harley, White, 2 x 8 26 D-4

29 MAIN FRAME ASSEMBLY Item Part Qty Description Clip, Hairpin, 14Ga x 1 3/ Screw, HHC, Gr8, 5/16-18 x Washer, Lock, Split, Medium, 5/ Screw, HHC, Gr8, 5/16-18 x 1 1/ Screw, HHC, Gr8, 3/8-16 x 1 3/ Nut, Hex, Lock,Gr8, 3/ Pin, Hitch, 5/8 x Weld, Main Frame, 4Ft Barrier, 4Ft Plate, Barrier Retainer Weld, Barrier Weld, Bent Gate, Left Weld, Bent Gate, Right Weld, Idle End Leg Cap Rod, Gate Pin 16. M Pivot Bushing 17. P /8 X 3 X 4 1/4 U-Bolt 18. P Nut,Nylock, 3/ P Washer, Heavy, 3/8 20. RHW Cover, Plate 21. RHW set Hose Cradle 22. RHW Nut, Rivit,.313, Grip D-4 27

30 ROLLER ASSEMBLY Item Part Qty Description Screw,HHC, Gr8,3/8-24 x Washer, Lock, Split, Medium, 3/ Weld, Roller Rod, Bearing, Collar Rod, Bearing, Cap Assembly Bearing, 1-1/4 28 D-4

31 BEARING ASSEMBLY APPLY LOCKTITE ECCENTRIC LOCK TO THIS SIDE 3 ALIGN FEEDER GROOVE TO GROOVE IN HOUSING IPTCI BEARING INSERT NOTE: LOCKING COLLAR SUPPLIED WITH BEARING IS NOT USED Item Part Qty Description Screw, Set, Gr2, 1/4-28 X 1/4, Cup Fitting, Zerk, 1/4-28, Self-Tap 3. P Bearing, Insert, 1.25 x 2.44 x P Tube, 1 1/8 D-4 29

32 MOTOR ASSEMBLY Item Part Qty Description Fitting, 6MF-10MB Motor, 9.9 C.I., 1.25 TPR, Magneto Mount Washer, Flat, Gr8, 1/ Screw, HHC, Gr8, 3/8-16 x 1 1/ Bolt, Carriage, Gr5, 1/2-13 x 1 1/ Washer, Flat, Cl8.8, M Nut, Hex, Lock, St, Gr8, 3/ Nut, Hex, Lock, 1/ Hub Hex, 2 1/2 x 1 1/4, Tapered Bore Weld, Motor Bucket 30 D-4

33 CASTER ASSEMBLY A Item Part Qty Description NOTE: 1. APPLY (NGLI #2 GREASE) WHERE A IS NOTED Pin, Lock, 3/8, Square Bail Fitting, Zerk, 1/4-28, Self Tap Ring, Snap Washer, Flat, CL8.8, M Nut, Hex, Lock, Gr8, 3/ Pin, Clevis, 5/8 x Screw, HHC, Gr8, 3/8-16 x 5 1/ Washer, Flat, 12ga x 2 x Cap, Tube, 1 1/ Bearing, Flange, 1 1/2 x 1 3/ Weld, Caster Fork Weld, Caster Arm Pin, Caster Tube, Wheel Bolt Sleeve 15. P Wheel & Tire 16. RHW Rue Ring, Cotter,.75 D-4 31

34 MOUNTING ASSEMBLY Item Part Qty Description Fitting, Zerk, 1/4-28, Self Tapping Fitting, Zerk, 90º, 1/4-28, Self Tapping * 1 Weld, Mounting (Contact Harley for correct mounting) 4. LAF Fitting, 6MF-12MB 5. M Bolt, Pivot 6. P Nut, Top Lock, 3/ P Quick Disconnect, 8FF, Female, 12FB 8. P Quick Disconnect, 8FF, Male, 12FB 9. RHW Nut, Rivet, 5/16-18, Grip 32 D-4

35 HYDRAULIC ANGLE ASSEMBLY Item Part Qty Description Fitting, 6MB-6MF Fitting, 4MB-6MF Cylinder, 1.5 x.75 x 8, 3.5K Manifold Assembly Hose,.25 x 12, 6FF-6FF, 3K Hose,.38 x 40, 6FF-6FF90, 3K Hose,.38 x 50, 6FF-6FF90, 3K Pin, Cotter, Gr2, 5/32 x 1 1/ Pin, Clevis, 3/4 x 3 1/ Wire Harness, with Box Wire Harness, 108 inches, for Solenoid Wire Harness, Power Lead 13. LAF Fitting, 6MF-12MB 14. P Pin, Clevis, 3/4 x P Washer, Lock, 5/ RHW Screw, HHC, Gr5, 5/16-18 x 1 D-4 33

36 MANUAL ANGLE ASSEMBLY 2 1 Item Part Qty Description Hose,.38 x 80, 6FF-6FF90, 3K Pin, Quick Release, Shoulder, T-Handle 34 D-4

37 NOTES D-4 35

38 PRODUCT SPECIFICATIONS Specifications and Model Views Overall 0º B Raking 0º D Overall Height with Caster Up K Overall Height A J Center of Gravity - Vertical G Raking 20º H Center of Gravity Horizontal Overall Length 0º 20.0 Overall 20º E F Overall 20º 36 D-4

39 Specifications and Model Views PRODUCT SPECIFICATIONS 227 Series 22748M 22748H Overall Height Overall 0º Overall 0º Raking 0º Overall 20º Overall 20º Raking 20º Center of Gravity - Horizontal Center of Gravity - Vertical Overall Height with Caster Up 20.9 inches 55.4 inches 49.1 inches 48 inches 54.1 inches 54.5 inches 45.2 inches 17.2 inches 6.5 inches 42.1 inches Weight (pounds) Flow Range (GPM) 8-15 Hydraulic Motor Displacement (C.I.) 9.9 Maximum Pressure (PSI) 3000 Maximum Articulation 20º Number of Motors 1 D-4 37

40 HYDRAULIC TORQUE SPECIFICATIONS Face Seal: Assembly, Tube to Fitting NOTICE - Face seal fittings have the most reliable sealing method and therefore, should be used whenever possible. Installation 1. Make sure threads and sealing surfaces are free of burrs, nicks, scratches, or foreign materials. 2. Install proper SAE 0-ring to end of fitting if not already installed. Ensure 0-ring is fully seated and retained properly. 3. Lubricate 0-ring with a light coating of clean hydraulic oil. 4. Position tube and nut squarely on face seal of fitting and tighten nut finger tight. 5. Using appropriate torquing device, tighten to given torque rating from the table below. Torque Values SAE Dash Size Tube Side Thread Size In-lbs Ft-lbs -4 9/ ± ± / ± ± / ± ± ± ± / ± ± / ± ± / ± ± ± ± 8 NOTE - ft-lb may be converted to Newton Meters by multiplying by NOTE - in-lbs may be converted to Newton Meters by multiplying by D-4

41 HYDRAULIC TORQUE SPECIFICATIONS Straight Thread O-ring Fitting: Assembly, Fitting to Port NOTICE! Straight thread o-ring fittings are utilized to adapt hydraulic systems to motors, pumps, cylinders, and valves. Installation (Adjustable Fitting) 1. Make sure threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign materials. 2. Install proper SAE o-ring on port end of fitting if not already installed. Ensure o-ring is fully seated and retained properly. 3. Lubricate o-ring with a light coating of clean hydraulic oil. 4. Back off nut as far as possible and push washer up as far as possible. (figure 4 & 5) 5. Screw fitting into port. Hand tighten fitting until backup washer contacts face of port. (figure 6) 6. To position the fitting, unscrew to desired position, but not more than one full turn. 7. Hold fitting in position with wrench. Using appropriate torquing device, tighten nut to given torque rating from table. (figure 7) Fitting Size SAE Port Thread Size In-lbs Ft-lbs -4 7/ ± ± 1-6 9/ ± ± 1-8 3/ ± ± / ± ± / ± ± / ± ± / ± ± / ± ±12 NOTE - ft-lb may be converted to Newton Meters by multiplying by NOTE - in-lbs may be converted to Newton Meters by multiplying by D-4 39

42 NOTE - Nylock nuts are utilized when greater resistance to vibrating loose is required, and greater operating temperatures are not a factor. In addition, like lock nuts, nylock nuts have a safety feature that if the bolt does vibrate loose, the nut will remain on the screw. Install nylock nuts to the standard torque shown above. 40 D-4

43 WARRANTY POLICY Limited Warranty Except for the Excluded Products as described below, all new products are warranted to be free from defects in material and/or workmanship during the Warranty Period, in accordance with and subject to the terms and conditions of this Limited Warranty. 1. Excluded Products. The following products are excluded from this Limited Warranty: (a) Any cable, part that engages with the ground (i.e. sprockets), digging chain, bearing, teeth, tamping and/or demolition head, blade cutting edge, pilot bit, auger teeth and broom brush that either constitutes or is part of a product. (b) Any product, merchandise or component that, in the opinion of Paladin Light Construction 1, has been (i) misused; (ii) modified in any unauthorized manner; (iii) altered; (iv) damaged; (v) involved in an accident; or (vi) repaired using parts not obtained through Paladin Light Construction. 2. Warranty Period. The Limited Warranty is provided only to those defects that occur during the Warranty Period, which is the period that begins on the first to occur of: (i) the date of initial purchase by an end-user, (ii) the date the product is first leased or rented, or (iii) the date that is six (6) months after the date of shipment by Paladin Light Construction as evidenced by the invoiced shipment date (the Commencement Date ) and ends on the date that is twelve (12) months after the Commencement Date. 3. Terms and Conditions of Limited Warranty. The following terms and conditions apply to the Limited Warranty hereby provided: (a) the product. Option to Repair or Replace. Paladin Light Construction shall have the option to repair or replace (b) Timely Repair and Notice. In order to obtain the Limited Warranty, (i) the product must be repaired within thirty (30) days from the date of failure, and (ii) a claim under the warranty must be submitted to Paladin Light Construction in writing within thirty (30) days from the date of repair. (c) Return of Defective Part or Product. If requested by Paladin Light Construction, the alleged defective part or product shall be shipped to Paladin Light Construction at its manufacturing facility or other location specifi ed by Paladin Light Construction, with freight PRE-PAID by the claimant, to allow Paladin Light Construction to inspect the part or product. Claims that fail to comply with any of the above terms and conditions shall be denied. LIMITATIONS AND EXCLUSIONS. THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE AND ANY WARRANTY BASED ON A COURSE OF DEALING OR USAGE OF TRADE. IN NO EVENT SHALL PALADIN LIGHT CONSTRUCTION BE LIABLE FOR CONSEQUENTIAL OR SPECIAL DAMAGES. IN NO EVENT SHALL PALADIN LIGHT CONSTRUCTION BE LIABLE FOR ANY LOSS OR CLAIM IN AN AMOUNT IN EXCESS OF THE PURCHASE PRICE, OR, AT THE OPTION OF PALADIN LIGHT CONSTRUCTION, THE REPAIR OR REPLACEMENT, OF THE PARTICULAR PRODUCT ON WHICH ANY CLAIM OF LOSS OR DAMAGE IS BASED. THIS LIMITATION OF LIABILITY APPLIES IRRESPECTIVE OF WHETHER THE CLAIM IS BASED ON BREACH OF CONTRACT, BREACH OF WARRANTY, NEGLIGENCE OR OTHER CAUSE AND WHETHER THE ALLEGED DEFECT IS DISCOVERABLE OR LATENT. 1 Attachment Technologies Inc., a subsidiary of Paladin Brands Holding, Inc. (PBHI) is referred to herein as Paladin Light Construction. February 10, 2010 D-4 41