Jarraff TRACK All-Terrain Tree Trimmer

Transcription

1 Jarraff TRACK All-Terrain Tree Trimmer SAFETY, OPERATION & MAINTENANCE PROGRAM VERSION 6.2

2 Important Safety Notice Read and understand all procedures and safety instructions before using the Jarraff All-Terrain Tree Trimmer. Observe all safety information on this page and note specific safety requirements as explained by the procedures called out in this manual. Failure to follow these instructions could result in serious personal injury or death. ADVERTENCIA: Favor de leer y comprender todas las instucciones de operación y seguridad antes de usar la máquina. Si Ud. no comprende las instrucciones favor de consultarle a su jefe. READ MANUAL FIRST WEAR HARD HAT WEAR SAFETY GLASSES WEAR SAFETY SHOES WEAR SAFETY GLOVES SEAT BELT EAR PROTECTION Serial Number Location SERIAL # Save this user s guide for future reference. If you have questions on: SAFETY - OPERATIONS - APPLICATIONS

3 B. Engine Choices... 4 C. 80W-90 Gear Lube... 4 D. Mobilux EP 0 Grease Typical Properties... 4 E. Cenex Hydrostatic Fluid 46 MV... 4 F. Electrical System... 5 G. Boom, Saw Head, Winch & Push Blade... 5 H. Operational Capacities... 5 I. Physical Specifications... 5 J. Tracks... 5 Dimensions... 6 Safety Labels... 7 Safe Operating Practices Jarraff Parts, Components & Assemblies... 9 A. Engine Compartment... 9 B. Boom, Saw & Related Components C. Cab, Upright & Cradle D. Undercarriage Engine Service & Inspection: Cummins A. Engine Oil B. Primary Fuel Filter C. Secondary Fuel Filter D. Engine Coolant E. Air Filter F. Hydraulic Fluid G. Electrical System Checks H. Engine & Drive Train Checks I. Fan Belt J. Check Radiator Fins K. Engine Exhaust General Service & Inspection A. Rotation Gearbox Maintenance B. Grease Points All Models C. Saw Blade D. Visual Inspections E. Hydraulic System Checks F. Engine & Drive Train Checks G. Boom Extension Chain Table of Contents 1 General Information Inspection & Service Technical Specifications... 4 A. Undercarriage Track Hubs A. Hydraulic System... 4 B. Undercarriage Final Drives C. Idler Sprockets D. Dual Pump Drive E. Grease Points F. Track Tensioning G. Steel/Rubber Track H. All-Rubber Track Start Up Operation: Boom, Saw & Cab Controls A. Boom B. Cab C. Saw Jarraff Operation A. Release Parking Brake B. Push Blade C. Driving D. Steering E. Braking Field Operation A. Positioning B. Traveling C. Cutting Maintenance Troubleshooting Appendices A. Fiberglass Boom Cleaning B. Boom Assembly Instructions C. Bolt Packages for Boom Installation D. Diagrams & Schematics Warranty MSDS

4 General Information The Jarraff All-Terrain Tree Trimmer is designed to effectively clear and maintain utility right-of-ways. The Jarraff is completely self-contained and does not require out-rigging, allowing the user to cut, trim and maneuver efficiently. The Jarraff s 24-inch carbide tip saw blade operates at 3200 rpm. A non-conductive fiberglass boom extends up to 75 feet and has a 90 + range of motion. A turntable base offers a 360-degree range of motion and a 40-degree lateral tilt. Technical Specifications A. HYDRAULIC SYSTEM Operating Pressure PSI Saw PSI 2850 stalled, 7.5 GPM@2000 Engine RPM (Cummins) Charge 375 PSI B. ENGINE Type- Cummins Diesel, Four-Cylinder, Liquid Cooled, Turbo Power- 130 HP Fuel Capacity- 45 Gallons Efficiency- 2.9 gallons/hour of operation C. 80W-90 GEAR LUBE 80W-90 Gear Lube is a multi-functional product for equipment and automotive applications calling for an 80W-90 viscosity grade lubricant. D. MOBILUX EP 0 GREASE TYPICAL PROPERTIES NLGI Grade...0 Thickener Type...Lithium Color, Visual... Brown Penetration, Worked, 25 C, ASTM D Viscosity of Oil, ASTM D C Timken OK Load, ASTM D 2509, lb Ball Wear, ASTM D 2266, Scar, mm Ball Weld Load, ASTM D 2596, Kg Dropping Point, D 2265, C Rust Protection, ASTM D 6138, Distilled Water E. CENEX HYDROSTATIC FLUID 46 MV ISO Viscosity Grade...46-MV Approximate SAE Grade...(5W-20) Flash Point, C ( F) (445) 100 C, cst SUS (52.1) 40 C, cst SUS (211) Viscosity Index Pour Point, C ( F) (-49) C, cp...11,900 Dielectric Strength, KV...40* * This Dielectric Strength stated is in new sealed drums, totes, and 2 1/2-gallon containers from CHS Lube Manufacturing plants. 4

5 Jarraff Industries recommends the following fluids as suitable hydrostatic fluid substitutes: Mobile DTE 20 Series Texaco Rando HDZ Shell Tellis Please contact Jarraff Industries for question regarding viscosity for your application. F. ELECTRICAL SYSTEM Power Requirements 12V - DC G. BOOM, SAW HEAD, WINCH & PUSH BLADE Boom Construction- High-tensile, non-conductive fiberglass Saw Blade Diameter- 24 inches Saw Blade RPM- 3,200 rpm Push Blade- 8 feet wide, hydraulically powered Winch- 20,000-lb winch; 150 feet of 5/8-inch cable included with chain and hook. H. OPERATIONAL CAPACITIES Maximum Cutting Height- 75 feet Rotation- 360 on turntable Controls- 2 four-way joysticks I. PHYSICAL SPECIFICATIONS Traveling Length- 41 feet 6 inches J. TRACKS Ground Pressure Steel & Rubber Track Undercarriage Steel and rubber track Weight 24,900 lbs. Ground Pressure 3.0 Width 8 feet 4 inches Carrier Length 21 feet Height 11 feet 3 inches 5

6 4. 3. Dimensions 11' 3" Length 40' 5" Length 20' 7" Overall Width 8' 4" 6

7 Safety Labels

8 4. 5. Safe Operating Practices Basic safety rules should be followed by the operator of the Jarraff All-Terrain Tree Trimmer at all times. Careful supervision of the Jarraff is vital for safe operation. Both the operator and ground personnel should make an assessment of the terrain before operation. A visual and physical inspection of steeps, rocks, stumps, swamps, rivers, streams and the general condition of the terrain is essential to ensure safe negotiation in adverse conditions. The safety of personnel, tree trimming production, and the traveling capability of the Jarraff is the sole function of the operator s skill and proficiency. Operating the Jarraff improperly, beyond its stability limits, felling dangerously large tree limbs or improper cutting of tree limbs may cause serious injury to the operator, damage to public or private property, and serous injury to ground personnel also damaging the Jarraff unit itself. Safety is the responsibility of the operator; please follow all of the safety rules outlined in the Jarraff manual. Once the Jarraff All-Terrain Tree Trimmer is in operation, all ground personnel must remain a safe distance away from trimming operations, a minimum of 300 feet. Only one person should be operating the Jarraff at a time and no additional riders should be allowed before, during or after trimming operations. Always wait until the Jarraff is at a complete stop and turned off before exiting the machine. Never jump off a moving Jarraff All-Terrain Tree Trimmer. Not following the outlined safety procedures can result in personal injury or death. OPERATIONAL SAFETY PRECAUTIONS CAUTION! Before operating make sure operator is wearing the proper safety apparel: hard hat, safety glasses, safety shoes, safety gloves, safety vest, ear protection, the seat belt and anything else required by the specifications of the job. CAUTION! NEVER allow ground personnel to stand next to, come into contact with, or mount the Jarraff when the boom is near a power line. In spite of the dielectric characteristics of the non-conducting boom, hydraulic hoses, and insulated chain it is possible for moisture, dirt, debris, vines or etc. To conduct a ground short causing serious personal injury to the operator, ground personnel and others nearby or in contact with the Jarraff. CAUTION! The operator should always be aware of the over hang of the boom at the front of the Jarraff when the boom is in the cradle in the retracted and carry position. CAUTION! When moving in tight quarters, position ground personnel in a sight line with the operator to guide them in avoiding hazards or collisions. CAUTION! Check the height and width clearance of bridges, and also the load limits before traveling with the Jarraff. CAUTION! Watch for proper clearance when traveling. Be aware of overhead or side obstructions to avoid running into them. CAUTION! NEVER operate the Jarraff near a dangerous bank that could possibly cave in. CAUTION! NEVER swing the boom over ground personnel. CAUTION! NEVER get off the Jarraff while it is in motion. 8

9 CAUTION! NEVER allow riders on the Jarraff. CAUTION! NEVER operate with cab door open on the Jarraff. HYDRAULIC DEVICES Escaping fluids under pressure can penetrate the skin and cause serious personal injury. Observe the following precautions to avoid hydraulic hazards: 1. Tighten all connections before applying pressure. Relieve pressure when connecting or disconnecting hoses when servicing the unit. 2. Check for leaks with a piece of cardboard. Do not use hands! 3. Do not exceed working pressure of hydraulic hoses. 4. Visually inspect hoses regularly and replace if damaged. Jarraff Parts, Components & Assemblies The Jarraff All-Terrain Tree Trimmer can roughly be divided into four main sections: A. The Engine Compartment B. Boom, Saw & Related Components C. Cab, Upright and Cradle, D. Undercarriage, Drive line and Tires. Familiarize yourself with the four major areas of the Jarraff and all their associated components before service, inspection or operation. A. ENGINE COMPARTMENT 1. Return Filter Assembly The return filter assembly is a single in-tank filter with magnets. It is located in the top of the oil tank. 2. Engine Enclosure The engine enclosure is located at the front section of the machine. 3. Transport Boom Rest The transport boom rest provides a saddle that supports the boom during machine transport. This boom rest is either fastened to the top of the engine cover or built up from the machine base to reduce damage to the boom during transport. 4. Fuel Tank & Fuel Lines Holds 45 gallons of diesel fuel. 5. Fire Extinguisher 6. Battery Box

10 B. BOOM, SAW & RELATED COMPONENTS 1. Hydraulic Poppet Hose Attachment The hydraulic hoses supplying the saw motor are attached to bulkhead fittings passing through a common bracket that is bolted to the inside top of the inner boom. 2. The Limb Guard Assembly The limb guard is a steel assembly consisting of the limb guard mounted at the top of the outer boom and a bottom steel band that is bolted through ears on both steel bands that clamps the assembly to the boom. 3. Saw Adapter Assembly The saw is a fabricated steel assembly that fits into the forward end of the inner boom. It is fastened with steel bolts that pass through the fiberglass tube and into the steel saw head. 4. Saw Guard Assembly The saw guard is a fabricated steel assembly that mounts to the saw guard base and hydraulic saw motor. 5. Saw Arbor Assembly The saw arbor assembly consists of an aluminum housing, saw arbor shaft, retaining nut, lock set, draw bolt, saw arbor washer bearings and arbor nut Outer Boom The outer boom assembly consists of a heavily reinforced fiberglass tube clamped to the cradle by boom bands and mounting bolts. A chain idler sprocket is mounted to the bottom inside of the boom. 7. Outer Boom Bearing The outer boom bearing is a plastic bearing. It is retained in the end of the outer boom using bolts that pass through the boom into the bearing. This outer bearing has a keyway on top of the inner circumference to prevent rotation of the inner boom. 10

11 8. Inner Boom The inner boom is a fiberglass tube with a fiberglass key fastened the full length of the boom by means of steel bolts. 9. Inner Boom Bearing The inner boom bearing is a plastic bearing that is fastened to the rear outer side of the inner boom also using steel bolts that pass through the glass tube and into the plastic bearing. The inner boom bearing internal cut-away must be oriented with chain puller clamp thru angle. 10. Extension/Retraction Chain The extension/retraction chain is attached to the inner boom with a steel chain puller clamp (see Appendix B, Section G, Page 55). C. CAB, UPRIGHT & CRADLE 1. Base Plate A 1" steel plate fastened to the base unit and bolted to the swing gear bearing. 2. Rotation Gear Bearing The rotation gear bearing is bolted to the top of the base plate; the outer race has gear teeth machined across the face of the outer circumference. The inner race is bolted through the turntable. 3. Turntable The turntable is the 1" steel plate that the entire upper structure is mounted upon Rotation Gearbox A hydraulic motor driven reduction gear case is mounted rigidly on top of the turntable with a pinion gear extending down through the turntable, engaging the fixed teeth of the gear face of the rotation gear Upright The upright is the welded steel structure positioned vertically upward at the rear of the unit. This upright assembly is attached to the turntable. The upward and rear upright arm supports the cradle. The cab is mounted on the right side. 6. Cradle or Boom Cradle The boom cradle is the welded steel structure to which the fiberglass boom is fastened. The rear of the cradle is hinged to the uppermost point of the upright arm. The rod end of the lift cylinder attaches to the bottom side of the cradle pan. 7. Instrument Panel The instrument panel consists of a digital engine monitor, ignition switch, power point, hydraulic temperature gauge, throttle and rocker switches for the parking brake, motor shift, wiper, saw, fan, and beacon light. 8. Hose Reel Assemblies The hose reel assemblies are used for moving storage for saw hydraulic hoses. 11

12 9. Throttle Cable The Cummins machine is supplied with an electronic throttle. 10. Operator s Cab The operator s cab houses all necessary controls and is mounted to the side of the upright. 11. Boom Drive Assembly The boom drive motor along with the extension stop valve and retraction stop valve are attached to an iron frame that slides into the rear of the cradle. The movement of the entire boom drive assembly permits tensioning the extension/ retraction chain by means of an adjusting bolt on either side. 12. Parking Brake Spring applied pressure of brake can be activated from the operator s seat. 13. Rotary Manifold The rotary manifold is located in the center of the rotation bearing. The rotary manifold allows 360 rotation by preventing hydraulic lines from twisting as the cab rotates. D. UNDERCARRIAGE 1. Winch Control: All winches use an electrical pendent control attached with a cable that allows the operation of the winch from the operator s seat, or remotely alongside the machine. The weather tight pendent control is permanently attached or plugged into the vehicle. 2. Tracks Components 3. Push Blade Brush removal to make clear path for trimming. 12

13 Engine Service & Inspection: Cummins NOTE: All Inspection and service operations should be performed when the Jarraff is off and the engine cool. A. CHECK ENGINE OIL Check engine oil daily. Fill as needed with 15W-40 diesel oil. To check oil, remove, clean, and replace dipstick. (See Figure 1) Remove dipstick, check oil level. B. CHANGE ENGINE OIL and OIL FILTER NOTE: Change engine oil and Figure 1. Check Engine Oil oil filter after 50 hours of use. Then refer to the maintenance chart on page 37 for recommended oil change intervals To change oil, drain oil from oil reservoir by removing drain plug. (See Figure 2) Drain and dispose of oil properly. Replace drain plug. 2. To change filter, unscrew existing filter by turning counterclockwise. (See Figure 3) Properly discard filter. Replace with new filter and screw into place by turning new filter clockwise until tight. Do not over tighten. Figure 2. Remove Engine Oil Drain Plug Figure 3. Oil Filter NOTE: The oil filter should be changed when you change the oil. NOTE: Refer to the maintenance chart on page 37 for recommended oil and oil filter replacement intervals. 3. Remove oil reservoir cap by turning counterclockwise. (See Figure 4) Add 10 quarts of 15W-40 diesel oil. Replace oil reservoir cap. Repeat check oil procedure after running engine to ensure that the proper amount of oil has been added. 13

14 Figure 4. Fill as Needed Figure 5. Replace Fuel Filter C. PRIMARY FUEL FILTER Reference chart, replace as needed (See Maintenance Chart, page 37) 1. Replace the primary fuel filter at regular machine service intervals, after approximately 250 hours of use. (See Figure 5) Once replaced, prime system with primer pump. (See Figure 5a) D. SECONDARY FUEL FILTER 1. Replace the secondary fuel filter at regular machine service intervals, after approximately 250 hours of use. (See Figure 6) Figure 5a. Primer Pump Figure 6. Replace Secondary Fuel Filter NOTE: Once replaced, prime system with primer pump. E. ENGINE COOLANT 1. Check engine coolant daily. Radiator should be full. (See Figure 7) Overflow tank should be half full. (See Figure 8) NOTE: When adding coolant, use a 50/50 mixture of Ethylene Glycol & distilled water. 14 F. AIR FILTER 1. Check the air filter condition twice daily. Visually inspect the filter condition by monitoring the filter gauge. The filter gauge will indicate 'service' when the air filter needs replacing.

15 Figure 7. Check and Fill Engine Coolant Figure 8. Check Overflow Coolant Level NOTE: Not replacing or cleaning the air filter will result in poor engine performance and possible engine damage. Dusty operating conditions will warrant more frequent filter inspections. (See Figures 9 & 10) Make sure when replacing the air filter and cover they are seated properly, if not engine damage may occur. NOTE: Inspect air filter housing and plumbing daily for any damage and or loose compartments. Failure to perform this check could lead to engine damage. Figure 9. Check Air Filter Figure 10. Check Air Filter Gauge G. HYDRAULIC FLUID 1. Check the levels of the hydraulic fluid and change filter as necessary. H. ELECTRICAL SYSTEM CHECKS The following electrical system checks are recommended: 1. Check the battery for cracks, corrosion, and other visible damage. 2. Check the battery box, cables, and terminal connections for tightness and damage. (See Figures 11 & 12) 15

16 Figure 11. Check Battery Figure 12. Check Second Battery 3. Check the operating instruments and lights for proper operation. Secure mounting and loose electrical connections. 4. Check the operation of all switches, switch hardware, and the electrical connections. I. ENGINE CHECKS The following checks of the engine are recommended: 1. Check the engine and engine components for loose hardware, oil leaks, fuel leaks and or damage. Tighten any loose hardware as required. (See Figures 13 & 14) Figure 13. Check Engine Components Figure 14. Check Engine Components IMPORTANT: Repair oil or fuel leaks immediately. J. FAN BELT Inspect the fan belt for wear and damage. 16

17 K. CHECK RADIATOR FINS Daily inspect the radiator fins for debris and damage (See Figure 15). Clean as needed to prevent engine overheating and possible engine and radiator damage. Use compressed air or pressure washer to clean Engine cooler. NOTE: Use care when pressure washing cooling fans. Fins can bend if pressure is applied at an angle, only spray water straight through cooler. L. ENGINE EXHAUST Figure 15. Inspect Radiator Fins Daily inspect engine exhaust for leaks and damage. (See Figures 16 & 17) Figure 16. Inspect Exhaust for Leaks Figure 17. Inspect for Damages NOTE: Exhaust leaks can cause excessive engine compartment temperatures and could cause a fire in the engine compartment. 17

18 5. 8. General Service & Inspection: NOTE: All Inspection and service operations should be performed when the Jarraff is off and the engine cool. A. ROTATION GEARBOX MAINTENANCE The gearbox of the Jarraff All-Terrain Tree Trimmer requires regular inspection and service to ensure optimum performance, 1. Visually inspect the gearbox and mounting hardware daily for cracks and signs of wear. (See Figure 1) WARNING: If rotation gearbox shows signs of wear or visual cracks in the mounting base, cease operation of the unit immediately. Figure 1. Inspect Gearbox 2. Check rotation gearbox mounting bolts for tightness daily. Mounting bolts should be torqued to 260-ft lbs. Tighten bolts, if needed, using a torque wrench. (See Figure 2) Figure 2. Torque Bolts Figure 3. Add Grease to the Grease Zerk 3. Grease rotation gearbox grease fitting one pump weekly. (See Figure 3) NOTE: Over greasing will cause gearbox to leak from top cover. 4. Units should be greased with MOBILUX EP 0 Grease or its equivalent. 18

19 Figure 4. Grease Rotation Bearing Zerk on Upright 5. Grease rotation bearing zerk on upright daily. (See Figure 4) 6. Adjust rotation gearbox backlash. NOTE: Rotation Gearboxto-ring backlash should be inspected daily. Adjust backlash as needed. Gearbox should have zero-degree backlash between shaft and ring gear teeth. a. Place machine on level area and set parking brake. b. Raise boom out of boom rest, but do not rotate. c. Slightly loosen the six gearbox mount bolts. (See Figures 5 & 6) Bottom of the Six Gearbox Mounting Bolts Figure 5. Loosen Six Gearbox Mounting Bolts Figure 6. Loosen Six Gearbox Mounting Bolts d. Use spanner wrench tool from Jarraff to rotate the eccentric ring on the gearbox. (See Figure 7) Rotate the eccentric ring counterclockwise with spanner wrench or hammer & punch while rotating the gearbox stub shaft back and forth. (See Figure 8) Contact Jarraff for spanner wrench specifications. Figure 7. Spanner Wrench Tool Figure 8. Rotate Eccentric Ring Counter-clockwise 19

20 e. Gearbox should have zero-degree backlash between shaft and ring gear teeth. f. Torque six gearbox mount bolts to 260-ft lbs. (See Figure 9) NOTE: All Jarraff Tree Trimmers manufactured after August 21, 2009 and with a serial number ending with 708 will have the six bolt rotation gearbox. This unit is factory filled with MOBILUX EP 0 grease. B. GREASE POINTS ALL MODELS 1. Grease the boom lift cylinder in the following three locations daily: a. Two zerks at the bottom of the lift cylinder (See Figure 10) b. One zerk at the top of the cylinder (See Figure 11) 2. Grease the three tilt cylinder zerks daily. a. One at the bottom of the tilt cylinder (See Figure 12) b. Two at the top of the tilt cylinder (See Figure 13) 3. The rotation group and rotary manifold have four areas that need to be greased daily: a. One grease zerk located on top of the rotation bearing (See Figure 14) b. The middle grease zerk (See Figure 15) Figure 9. Torque Gearbox Mounting Bolts c. Two zerks located between the upright brackets. (See Figure 16) 4. Grease the two cradle pin zerks, one on each side of the machine, daily. (See Figure 17) 20

21 Figure 13. Figure 11. Figure 10. Figure 16. Figure 14. Figure 17. Figure 12. Figure

22 C. SAW BLADE 1. GREASE THE SAW ARBOR AFTER EVERY 4 HOURS OF OPERATION TO ENSURE OPTIMUM PERFORMANCE AND PREVENT PREMATURE WEAR. The saw arbor grease zerk is located at the front of the saw head. (See Figure 18) 2. Check the saw blade and carbide tips for wear or damage. Keep the saw blade sharp and replace damaged or broken carbide tips. D. VISUAL INSPECTIONS Figure 18. Grease Saw Arbor 1. Visually inspect the hinges, cylinder pins, hoses, fittings and adapters. Making sure to check for leaks, wear or damage. 2. Check for wet spots on or around the machine daily, as these may indicate leaks or fluid loss. 3. Check the boom for evidence of telescopic motor fluid leakage and visible damage. NOTE: Depending on operating conditions, the boom will need periodic cleaning with warm water and mild soap. Do not pressure wash the boom. Reference boom cleaning instructions in Appendix A pages 44 and Check all moving parts and remove debris, sticks, oil, rags, mud, ice, etc. from machine that may hinder operation. 5. Visually check mountings, structures, cylinders, electrical circuits, hydraulic circuits or mounting hardware for loose or damaged parts. Tighten or replace any loose or damaged parts. WARNING! Failure to perform a daily inspection can result in machine damage and severe personal injury or death. E. HYDRAULIC SYSTEM CHECKS Check the following hydraulic system components regularly for visible damage, leakage and security. Tighten hydraulic lines, fittings and connections and attach hardware as required. 1. Hydraulic oil reservoir, hoses and fittings. NOTE: Hydraulic reservoir level should be half way up in the top sight glass. (See Figure 19) 22 Use only Cenex Hydrostatic 46 MV fluid or equivalent. Do not use universal hydraulic fluid or pump damage may result. Contact Jarraff Industries for further fluid specifications. Figure 19.

23 2. Hydraulic cylinders, pumps, hoses and fittings. 3. Directional valves, valve linkages hoses and fittings. 4. Hydraulic winch. 5. Hose reel hoses, and fittings. 6. Sprockets and coupling lines. 7. Replace the in-tank hydraulic filter, first you will need to remove the cover and then remove the 4 bolts in order to replace the hydraulic filter. (See Figure 20) Figure 20. CAUTION! Tank may be under pressure, remove cover bolts slowly. F. ENGINE CHECKS The following checks of the engine and drive train are recommended: Fill Point for Hydraulic Fluid 1. Check the fuel tank, fuel lines and fittings to make sure there are no fuel leaks. 2. Check the exhaust system for damage, leakage or loose mountings. G. BOOM EXTENSION CHAIN Check boom extension chain regularly for proper tightness. (See Figure 21) 1. Remove extension chain assembly cover. 2. Extend boom to maximum length 3. Extended boom should measure 31 feet from the saw blade to the front side of the boom bearing. (See Figure 22) NOTE: For extension retraction chain adjustment see Appendix B, section M. Figure Feet Figure 22. NOTE: INNER BOOM LENGTH SHOULD BE CHECKED DAILY. IF A RED PAINTED BAND IS VISIBLE ON THE INNER BOOM THE MACHINE SHOULD BE SHUT DOWN IMMEDIATELY AND BOOM CHAIN STOPS SHOULD BE INSPECTED AND REPAIRED AS NEEDED. FAILURE TO REPAIR THIS ISSUE COULD LEAD TO A BROKEN CHAIN AND POSSIBLE DAMAGE TO INNER BOOM. 23

24 5. 9. Inspection and Service A. UNDERCARRIAGE TRACK HUBS Inspect oil levels in undercarriage track hubs daily fill as needed. Visually inspect level on models with clear hub. On all models with protective covers, remove center plug; if lube flows freely, oil level is fine. IMPORTANT: Insufficient oil levels can result in bearing failure. 1. To fill the oil hubs, remove the cap and add the appropriate amount of 80W-90 gear lube. (See Figure 1) Figure 1. Remove Cap & Add Lube Oil B. UNDERCARRIAGE FINAL DRIVES Check fuel levels in the final drives of the undercarriage once per week. (See Figure 2) 1. To fill, place one fill plug at center or in the 12 o clock position, this should position the other plug at the 3 o clock or 9 o clock position. 2. Remove both lubricant reservoir caps. 3. Pour the 80W-90 lubricant into the final drive lubricant reservoir position at the 12 o clock position, until the lubricant begins to flow from the other plug. 4. Replace the reservoir caps. Figure 2. Position Final Drive To Fill With Lubricant 24

25 C. IDLER SPROCKETS Inspect the oil level in the idler sprockets daily, fill as needed. Visually inspect level on models with clear hub. On models with protective covers, remove center plug; if lube flows freely, oil level is fine. IMPORTANT: Insufficient oil levels can result in bearing failure. 1. To fill the oil idler sprocket, remove the cap and add the appropriate amount of 80W-90 gear lube. (See Figure 3) D. DUAL PUMP DRIVE Check the dual pump drive lubricant level daily; fill as needed with 80W-90 gear lube. (See Figure 4) Figure 3. Figure 4. Fill Dual Pump Drive Lubricant As Needed 25

26 E. GREASE POINTS 1. Grease the track push blade on the track Jarraff in the following four locations daily: a. Left side arm zerk, (See Figure 5) b. Right side arm zerk. (See Figure 6) c. Bottom cylinder zerk (See Figure 7) d. Top cylinder zerk (See Figure 8) Figure 5. Figure 6. Figure 7. Figure 8. F. TRACK TENSIONING Daily Check Check the track tension daily. There should be approximately 1 to 3 inches of separation between the wheel and the grouser bar. If separation is less than 1-inch, the track should be tensioned. (See Figure 9) Add Track Tension Before adding tension, be sure the hex head grease fitting on the track tension cylinder is tight and torqued to 37 ± 7 ft. lbs. Then to increase track tension, pump grease through the hex head grease fitting on the track tension cylinder until proper tension is restored. (See Figure 10) 26

27 1 to 3 inches Figure 9. Figure 10. Track Installation/Removal To release track tension, loosen hex head grease fitting very slowly on cylinder until grease starts coming out between the cylinder and the grease fitting. Be sure to tighten the hex head grease fitting on cylinder and torque to 37 ± 7 ft. lbs. Add proper track tension as described above and check for leaks. Figure 11. Grease Zerk Bank Steel/Rubber Model Figure 12. Grease Zerk Bank Steel/Rubber Model G. STEEL/RUBBER TRACK Grease each zerk on the steel/rubber track zerk bank once per day. This grease bank lubricates all walking beam, and front axle shafts. (See Figures 11 & 12) H. ALL-RUBBER TRACK Grease each zerk on the all rubber track zerk bank once per day. This will grease the plate pivot, side plate, and center tension pivot. (See Figure 13) Figure 13. Grease Zerk Bank All Rubber Model 27

28 The all rubber track Jarraff inspection and service includes these additional areas: 1. Grease the walking beam pivot once a day in four places. (See Figure 14) 2. Check the front idler sprocket once a week in two places. (See Figure 15) 3. Grease the bogie wheel hubs once a month in 16 places. (See Figure 16) 4. Check the bogie wheel lug nuts once a week in 16 places. (See Figure 17) 5. Check the final drive oil level once a week in two places. (See Figure 18) Figure 18. Final Drive Figure 17. Bogie Wheel Lug Nuts Figure 15. Front Idler Sprocket Figure 16. Bogie Wheel Hubs Start Up Figure 14. Walking Beam Pivot 1. CONTROLS Check all function controls are free and returning before starting the Jarraff. (See Figure 1) 2. ENGAGE BRAKE Engage the parking brake by pushing down the toggle switch located on the control panel (See Figure 2) NOTE: If the Jarraff is equipped with climate control, make sure the heat selector is in the off position before starting. 28 Figure 1. Check Controls Figure 2. Engage Parking Brake

29 3. START CUMMINS ENGINE To start the Cummins engine, turn ignition key clockwise until the Cummins engine monitor display turns on. Depending upon the ambient and engine temperatures, a Wait to start engine message may display on screen. Once the message clears and the system status information appears on the screen, start engine by turning the ignition key clockwise. Hold ignition in place until engine starts, then release. (See Figure 3) 4. CHECK CHARGE PRESSURE Check the charge pressure gauge located on the right gauge panel. The Jarraff charge standard operating pressure should be at 375 PSI. (See Figure 4) Figure 3. Start Engine - Cummins Figure 4. Check Charge Pressure NOTE: Gauge will only show noted pressure when parking brake is released. 5. CHECK SYSTEM PRESSURE Check the systems pressure gauge located on the right gauge panel. Maximum Jarraff operating pressure is 2000 PSI. (See Figure 5) 6. CHECK HYDRAULIC SAW PRESSURE Check the saw blade hydraulic pressure gauge located on the right gauge panel. Gauge pressure reading will vary depending on the blade load and oil temperature. Typical Pressure (No Load PSI) Maximum Pressure (Blade Stall-2850 PSI). (See Figure 6) NOTE: Always remember to reduce the idle before shutting the Jarraff All-Terrain Tree Trimmer down. Figure 5. Check System Hydraulic Pressure Figure 6. Check Hydraulic Saw Pressure 29

30 Operation: Boom, Saw and Cab Controls Before operating make sure the Jarraff idle is up to 2000 RPM for Cummins machine. To increase the throttle, turn the throttle knob counterclockwise. (See Figures 1 & 1A) Figure 1. Cummins Throttle Figure 1A. Turn Throttle To Idle A. BOOM 1. Raise To raise the boom, engage the right hand joystick back. (See Figure 2) 2. Lower To lower the boom, engage the right hand joystick forward. 3. Extend To extend the boom, engage the left hand joystick forward. (See Figure 3) 4. Retract To retract the boom, engage the left hand joystick back. NOTE: Smooth and slow extension and retraction of the boom is key to the prevention of premature wear of the boom components. 30 Figure 2. Engage Right Hand Joystick To Raise & Lower Boom Figure 3. Engage Left Hand Joystick To Extend & Retract Boom

31 B. CAB The Jarraff cab and upright are capable of tilting laterally 40 degrees to the right and to the left. The turntable base can rotate 360 degrees to the right or to the left. 1. Tilt Left To tilt left, engage the right hand joystick to the left. (See Figure 4 & Illustration B.) 2. Tilt Right To tilt right, engage the joystick to the right. (See Figure 4 & Illustration B.) 3. Rotate Clockwise To rotate the turntable base clockwise, engage the left hand joystick to the right. (See Figure 5 & Illustration C.) 4. Rotate Counterclockwise To rotate the turntable base counterclockwise engage the left hand joystick to the left. (See Figure 5 & Illustration C.) IMPORTANT: Always reverse a full 360-degree turn. To rotate the turn table base during operation engage the left hand joystick. 40 Figure 4. Tilt Cab With Right Hand Joystick 40 Illustration B. 360 Figure 5. Rotate Turntable With Left Hand Joystick Illustration C. 31

32 C. SAW 1. Activate To activate the saw blade, engage the saw blade toggle switch. To engage the toggle switch, release the toggle switch lock by pushing it forward. Then depress the toggle switch to activate the saw blade. Adjust Jarraff idle to 2000 RPM on the Cummins machine, before activating saw blade. (See Figure 6) NOTE: Operating the engine faster than 2000 RPM (Cummins), with the saw blade engaged, may cause damage to the saw blade! Figure 6. Engage Toggle Switch To Activate Saw Blade 32

33 33

34 Jarraff Operation IMPORTANT: To prevent potential injury, only operate the Jarraff All-Terrain Tree Trimmer with the seat belt fastened and the operator cab door closed. A. RELEASE PARKING BRAKE Release the parking brake by pushing the parking brake toggle back. (See Figure 1) B. PUSH BLADE To raise and lower the track Jarraff push blade, engage the push buttons on the right joystick. (See Figures 2 & 3) Figure 1. Release Parking Brake Figure 2. Raise Push Blade Figure 3. Lower Push Blade 1. Raise Push Blade To raise the push blade, press the right button on the joystick. 2. Lower Push Blade To lower the push blade, press the left button on the joystick. IMPORTANT: Raise the push blade before driving the Jarraff. C. DRIVING To drive the tracked Jarraff engage the rocker foot pedals. 1. Drive Forward To travel forward, depress the top of both the right and the left rocker foot pedals. (See Figure 4) Drive in Reverse To travel in reverse, depress the bottom of both the right and the left rocker foot pedals. (See Figure 5) NOTE: Travel speed is increased or decreased dependent upon the usage of the rocker foot pedals.

35 LEFT RIGHT Figure 4. LEFT RIGHT Figure 5. LEFT RIGHT Figure 6. LEFT RIGHT D. STEERING Figure Steer Right To steer the Jarraff to the right, release the right rocker foot pedal and depress the top of the left rocker foot pedal. (See Figure 6) 2. Steer Left To steer the Jarraff to the left, release the left rocker foot pedal and depress the top of the right rocker foot pedal. (See Figure 7) NOTE: To ensure smooth turning, do not completely release the rocker foot pedal. Maintaining a level of engagement on the released rocker foot pedal will help the Jarraff turn gradually rather than abruptly if the pedal is completely released. 35

36 E. BRAKING The Jarraff is equipped with a hydrostatic transmission. To stop the Jarraff, slowly release the rocker foot pedals. After stopping the Jarraff it is advised to engage the parking brake, and lower the push blade. NOTE: Brake system operation should be checked daily. To check operation, slowly drive machine in reverse and apply brakes while in motion. Machine should immediately stop. If machine fails to stop contact Jarraff Industries for further inspection procedures Field Operation The stability of the Jarraff is inherently excellent because the boom is relatively light and the carrier vehicle is heavy enough and wide enough to negotiate most difficult terrains. The track unit undercarriages have limitations, capabilities, grade abilities, stabilities, and ground pressure. A. POSITIONING Positioning the Jarraff while cutting is very important. With the trees on the left side of the Jarraff, uncut limbs do not hinder the operator s vision, and the saw motor does not get caught in the tree or cut tree limbs. IMPORTANT: Operating the Jarraff beyond a 25 slope is not recommended. It is important to stay out of the red zone on the inclinometer, while operating the Jarraff on a slope or hill side. B. TRAVELING When the ground conditions are good and the terrain relatively smooth, it is not necessary to cradle the boom while moving the Jarraff. The boom may be retracted and lowered to a position not interfering with advancing to the next set. This allows for almost continuous cutting. However, if ground conditions are poor and terrain is rough, the boom may be cradled in a matter of seconds. After the boom is cradled a slight down pressure will ensure that the boom will not bounce up and down while in the cradle position. C. CUTTING 1. Cutting Quadrants When cutting, the saw blade may be operated from all quadrants of the Jarraff. Optimum cutting speed is obtained when cutting over the left corner of the Jarraff. Which corresponds to the operator s left hand side Cutting Sequence Maximum production is attained when the operator is free to use all of these cutting strokes. A typical cutting sequence is as follows: the boom is raised and extended to cut the nearest low limb. This gives the operator a point of reference for the rest of the limbs to be reached. With the next cut, an up and out stroke cuts the next limb. Repeat the procedure until all the limbs within reach are cut. The Jarraff is then advanced to the next set of cuts.

37 Maintenance Schedule Maintenance Schedule - Jarraff LGP Key: C = Check, R = Replace, S = Service, I = Inspect, T = Test, 2X = 2 Times PROCEDURE DAILY 50 HRS 100 HRS 125 HRS 250 HRS 375 HRS Engine Oil* C R R R R R Engine Oil Filter* R R R R R 500 HRS Air Filter C Replace when Indicated by Filter Restriction Gauge Primary & Secondary Fuel Filters R R R R R Fuel System Drain Fuel-Water Separator I S ANNUALLY Hydraulic Oil C R In-Tank and Suction Hydraulic Filters R R R R R Pilot Filter Hydraulic System Hydraulic Oil Cooler I I Coolant C T T T T T Cooling Fan Cooling Fins, Brush Clean Engine Belts Rotation Gear Box, Bolts & Motor Electrical System Hydraulic Gauges Saw Head Grease Saw Head (Saw Arbor Zerk) Every 4 hours of Operation I I, S I I I C I (2X) Every 4 HRS Saw Blade I Replace or Repair when 10% of Teeth are Missing Saw Guard I Replace as Needed Boom I Clean as Needed w/mild Detergent (DO NOT PRESSURE WASH) Grease S See Appendix Exhaust System I Battery I See Maintenance Section Super Structure Backup Camera, Clean Lense Drivetrain I C, S I Parking Brake Test T Test Parking Brake Daily Winch Lube Spindle Lube I R Pump Drive Lube I R R Final Drive Lube I R R Boom Chain Tension I * See manufacturer's maintenance manual for variances in service intervals R R 37

38 Troubleshooting PROBLEM: CAUSE: SOLUTION: 1. Engine will not turn over. a) Battery b) Starter c) Key switch d) Fuse or breaker e) Wiring f) Oil cooler fan connected to switch wire a) Check connections charge or replace b) Repair or replace c) Replace d) Replace or reset e) Repair f) Connect to temp switch & relay 2. Engine will not start. a) Fuel b) Hole in fuel line c) Fuel line pinched d) Shut down solenoid e) Oil pressure switch f) Oil temp switch g) Key switch bad h) Water in fan belt switch i) Are there fault codes a) change fuel filters, check fuel pumps b) Replace c) Replace d) Replace e) Replace f) Replace g) Replace h) Replace i) Look at tables on pgs to diagnose problems 3. Engine over heats. a) Air flow restricted b) Fan belt broke or slipping c) Low oil level a) Clean engine & cooling fins b) Replace belt c) Add oil 4. Brake will not hold. a) Switch b) Brake out of adjustment a) Replace b) Adjust, replace pads 5. Hose reel will not reel in. a) Hose reel spring b) Hose reel swivel a) Replace b) Replace 6. Saw runs slow. a) Pump b) Saw poppet c) Saw motor d) Saw motor key a) Set to 2850 PSI, 7.5 GPM, Repair or replace b) Replace c) Repair or replace d) Replace Inner boom drifts back into outer boom a) Deceleration valve b) Boom motor counter balance valve c) Idler sprocket d) Weak drive motor a) Spool sticky, repair or replace b) Clean or replace c) Replace or check chain tension d) Replace

39 PROBLEM: CAUSE: SOLUTION: 8. Boom drifts down. a) Cylinder seal kit b) Counter balance valves a) Rebuild cylinder b) Clean replace 9. Oil cooler fan will not run. a) Fan motor b) Temp sender c) Fan relay d) Wiring e) Battery a) Replace b) Replace c) Replace d) Repair e) Charge 10. Hydraulic oil leak at saw motor. a) Shaft seal b) Hose, fitting or adapter a) Replace b) Replace or tighten 39

40 A. POWERVIEW ERROR MESSAGES PV101 Error Messages Software Versions 2.3 and Section 78 40

41 2 of 4 41

42 42

43 4 of 4 43

44 Appendix - Fiberglass Boom Cleaning 5.3. A. Fiberglass Boom Cleaning and Waxing Procedure -Position the vehicle unit on solid ground adjacent to a water supply -Remove boom inspection plates and covers. Elevate booms slightly for drainage. -Wash booms using lint-free cloth, a garden hose and 40 PSI maximum water pressure. No pressure washers or steam cleaners should ever be used on the fiberglass booms. -For stubborn contamination, products designed for fiberglass products should be used. American Polywater, Rexco, Hastings Fiberglass, Donar Chemicals and Kearney all offer such products. -Raise booms to full height possible and leave upright for 1-2 hours to allow excess moisture to drain from booms and for air to circulate through booms. Allow longer time if possible. Isopropyl alcohol may be poured into the boom to clean and flash moisture remaining. The alcohol is mild enough not to damage the fiberglass boom or any components inside. -Lower boom and wipe/dry booms external and using inspection holes, internal surfaces and components (hoses, leveling rods, air lines, etc) to speed the drying process. -Garage vehicle overnight with the booms raised as high as the garage roof allows. -Leave boom inspection covers and cap open or removed to allow air circulation. -Ensure garage is heated overnight. A fan may also be used to direct hot air up and through the boom structure. -The following morning carry out a visual check of inspection for signs of water/moisture inside the booms. Clean any visible dirt from hose etc, Inside booms. -Once the fiberglass boom is clean, it should be coated with a product designed to protect its surface. The aforementioned companies also offer good wax products designed for use on fiberglass to protect the boom s glossy surface and maintain a barrier against dirt, grease, creosote, etc. Some manufacturers may not recommend waxing, particularly telescoping booms. -After the booms have been cleaned, dried and waxed a dielectric test should be performed in accordance with ANSI A92.2 Section 5.4.3, to assure dielectric integrity. If the booms fail, allow more drying time and test again. -When the booms pass, replace all inspection covers and guards. 44

45 - If during the inspection or cleaning process you discover chips, chaffs or abrasions that may allow moisture to find its way into the fiberglass of the boom, the surface should be recoated or sealed in accordance with the manufacturers recommendations. - This is not intended to replace individual manufacturers recommendations. This is only to be used as a guide. 45

46 5. B. Appendix - Boom Assembly Instructions A. INNER BOOM RAIL INSTALLATION NOTE: Steel bolts with self-locking nuts are used for the inner boom rail. (See Appendix C, Figure 1) Steel bolts still conform and meet same dielectric standards. NOTE: Steel rail bolts should be torqued to 60-ft lbs. 1. With the boom bolt wrench ( ), or suitable substitute, secure rail nuts and align with bolt hole. (See Figure 1) B. INSTALL INNER BOOM BEARING & INNER BOOM PULLER ASSEMBLY 1. Slide inner boom bearing into position, abutting the end of the boom rail. (See Figure 2) Place the thinnest part of the bearing on the top. (See Figure 2A) Figure 1. Insert Bolt and Tighten Figure 2. Position Inner Boom Bearing Figure 2A. Position Inner Boom Bearing 2. Position and align boom bearing. (See Figure 3) 46 Figure 3. Position Boom Bearing

47 NOTE: Clamp inner boom bearing in place while drilling. (See Figure 4) 3. Next, drill holes through inner boom bearing with ⁷ ₁₆-inch bit at the 8:00, 11:00, 2:00 and 5:00 positions. (See Figure 4 & Illustration 1) 4. Ream out holes with ½-inch reaming bit, remove inner boom bearing to smooth off the hole edges. (See Figure 5) 5. Slide inner boom bearing back into place and screw in a coarse thread ½- x 1½-inch bolt and a ½-inch SAE flat washer from the inside of the boom out. (See Appendix C, Figure 3) Tighten until secure. (See Figure 6) 11:00 2:00 8:00 5:00 Figure 4. Drill Holes Through Inner Boom Bearing Illustration 1. Hole Location Figure 5. Ream Holes Figure 6. Attach Bolts 47

48 6. Slide inner boom puller assembly in place until it abuts the inner boom bearing. (See Figure 7) Tap inner boom puller assembly into place. (See Figure 8) Figure 7. Install Inner Boom Puller Assembly Figure 8. Tap Inner Boom Puller Assembly into Place IMPORTANT: Make sure inner boom puller assembly is parallel to the inner boom rail. (See Figure 9) 7. Secure inner boom puller assembly with clamp bolt. (See Appendix C, Figure 2) (See Figure 10) 8. Drill holes through boom with ½-inch bit at the 12:00, 3:00, 5:00 and 8:00 positions. Inner boom puller will have pre-drilled holes in those locations. (See Figure 11) Figure 9. Inner Boom Puller Assembly is Parallel to Inner Boom Rail Figure 10. Tighten Clamp Bolt Figure 11. Drill Holes for Inner Boom Puller Assembly 48

49 9. Secure inner boom puller assembly with ½- x 1½-inch bolts, washers, nuts. (See Appendix C, Figure 2) Torque to 60-ft lbs. (See Figures 12 & 13) Figure 12. Attach Bolts Figure 13. Tighten and Torque Bolts 10. Tighten clamp bolt. (See Figure 14) Figure 14. Tighten Clamp Bolt 49

50 11. Attach chain swivel attachment to inner boom puller. (See Figure 15) (See Appendix C, Figures 10 & 11) 12. Align poppet hose attachment on inner boom and mark drill hole locations. (See Figure 16) 13. Using a ¼-inch bit, drill holes for poppet hose attachment. (See Figure 17) Figure 15. Attach Chain Swivel Attachment to Inner Boom Puller Figure 16. Align Poppet Hose Attachment and Mark Holes Figure 17. Drill Holes 50

51 C. INSTALL SAW GUARD ADAPTER 1. Before installing the saw guard adapter, slide outer boom bearing onto inner boom. (See Figure 18) 2. Slide saw guard adapter in place until it is flush with boom. (See Figure 19) Figure 18. Slide on Outer Boom Bearing Figure 19. Slide on Saw Guard Adapter 3. Position saw guard adapter. (See Figure 20) 4. Clamp saw guard adapter in place, drill holes through saw guard adapter and inner boom with ½-inch bit at the 8:00, 10:00, 2:00 and 4:00 positions. The saw guard adapter will have pre-drilled holes in those locations. (See Figure 21) Figure 20. Position Saw Guard Adapter Figure 21. Clamp Saw Guard Adapter and Drill Holes 5. Ream out holes with ½-inch reaming bit. (See Figure 22) 6. Remove saw guard adapter. (See Figure 23) 51

52 Figure 22. Ream Holes Figure 23. Remove Saw Guard Adapter 7. Install inner boom support collar. (See Figure 24) Slide saw guard adapter and align holes. (See Figure 25) Figure 24. Install Inner Boom Support Collar 8. Secure in place with ½- x 1¾-inch bolts, ½-inch washer and Nylock locking nut. (See Appendix C, Figure 4) 9. Tighten in a 8:00-4:00; 2:00-10:00 progression. (See Figure 26) 10. Torque bolts to 60-ft lbs. (See Figure 27) Figure 25. Slide on Saw Guard Adapter and Align Holes 52 Figure 26. Attach and Tighten Bolts Figure 27. Torque Bolts

53 D. INSTALL INNER BOOM HYDRAULIC HOSES AND POPPET ASSEMBLY 1. Feed hoses with poppet valve assembly through inner boom. (See Figure 28) IMPORTANT: Use only non-conductive hydraulic hoses. E. INSTALL SAW HEAD ASSEMBLY Figure 28. Feed Hoses Through Inner Boom 1. Connect hydraulic hoses to saw head hydraulic fittings and tighten securely. (See Figure 29) Figure 29. Connect Hydraulic Hoses to Saw Head Hydraulic Fittings Figure 30. Return Hose ¾-inch Dia. Pressure Hose ½-inch Dia. IMPORTANT: Make sure to connect the Return hose to the Return fitting and Pressure hose to the Pressure fitting. The return hose is ¾-inch diameter and the pressure hose is ½-inch diameter. (See Figure 30) 2. Orient the saw head. 3. Connect the saw head to the saw guard assembly. (See Figure 31) Figure 31. Connect Saw Head to Saw Guard Assembly 53

54 4. Secure with ½- x 1½-inch bolts and ½-inch Nylock locking nuts. (See Appendix C, Figure 5) 5. Torque bolts to 60-ft lbs. 6. Install saw motor cover. (See Figure 32) Secure with ⁵ ₁₆- x 1-inch bolts and ⁵ ₁₆-inch Nylock locking nuts. (See Appendix C, Figure 6) Figure 32. Install Saw Motor Cover F. OUTER BOOM IDLER SPROCKET PREPARATION 1. Measure and mark bolt hole locations for the idler sprocket on the outer boom using an L square. The first bolt hole should be 6½ inches from the edge of the boom. The second bolt hole should be 8½ inches from the edge of the boom. (See Figure 33) IMPORTANT: The idler sprocket bolt holes need to be in line with the boom itself, from end to end. Misaligned bolt holes will impair the proper function of the boom and could result in boom failure. (See Illustration, Figure 33A) Proper Alignment of Bolt Holes Misaligned Bolt Holes Figure 33. Measure and Mark Bolt Holes for Idler Sprocket Figure 33A. Bolt Holes In line with Boom 2. Using a ½-inch drill bit, drill holes for the idler sprocket, then ream holes with a ½-inch reaming bit. (See Figures 34 & 35) 3. Rotate outer boom, if necessary, so that idler sprocket bolt holes are at the bottom of the outer boom. (See Figure 36) 4. Loosely secure poppet attachment with ¼- x 1¹ ₄-inch bolts, flatwasher and Nylock locking nuts. (See Figure 37) (See Appendix C, Figure 7) 54

55 Figure 34. Drill Holes for Idler Sprocket Figure 35. Ream out Holes Idler Sprocket Bolt Holes Drilled on Top of Boom Rotate Outer Boom 180 so Bolt Holes are on Bottom of Boom Figure 36. Rotate Outer Boom 180 Figure 37. Loosely Attach Poppet Assembly G. INSTALL EXTENSION/RETRACTION CHAIN - OUTER BOOM 1. Using a rodder, throwing weight or similar tool, thread the length of the outer boom with a pulling device (rope, rod, etc) in order to pull the extension/retraction chain into place. 2. Once threaded, attached the extension/retraction chain to the pulling device. (See Figure 38) NOTE: Use high quality #50 chain, approximately 70 feet long, or use the existing chain. Figure 38. Attach Chain and Thread Through Boom 55

56 3. Pull extension/retraction chain into the outer boom, making sure to pull enough chain to accommodate installation of the idler sprocket, approximately 3 to 4 feet. (See Figure 39) H. IDLER SPROCKET PREPARATION 1. Install idler ½-inch by 2¾-inch sprocket bolts and ½-inch SAE washers (See Appendix C, Figure 8) into pre-drilled holes in idler sprocket shaft. (See Figure 40) 2. Thread extension/retraction chain through idler sprocket assembly as shown. (See Figures 41 & 42) Figure 39. Pull Enough Chain to Install Idler Sprocket Figure 40. Install Bolts in Idler Sprocket Figure 41. Thread Chain Through Idler Sprocket IMPORTANT: Make sure chain is straight without twists or bends. IMPORTANT: It is critical to properly install the extension/retraction chain through idler sprocket. Improper installation of extension/retraction chain could result in catastrophic boom failure. 3. Using a forklift or comparable piece of equipment carefully position the inner boom for installation into the outer boom. Figure 42. ChainThreaded Through Idler Sprocket 56

57 4. Attach the end of the extension/retraction chain, threaded through the idler sprocket, to chain swivel attachment on the inner boom pulling assembly using master chain link. (See Figure 43) IMPORTANT: Make sure chain is straight without twists or bends. (See Figure 44) IMPORTANT: It is critical to properly install the extension/retraction chain through idler sprocket. Improper installation of extension/retraction chain could result in catastrophic boom failure. Figure 43. Attach Chain Swivel Attachment Figure 44. Make Sure Chain is Straight without Twists or Bends 5. Slowly feed inner boom into outer boom while simultaneously guiding the extension/retraction chain and sprocket assembly into place. (See Figure 45) 6. Rotate inner boom slightly if necessary to properly orientate to allow for final idler sprocket assembly installation. (See Figure 46) Rotate Inner Boom to allow for Idler Sprocket Installation Figure 45. Slowly Feed Inner Boom into Outer Boom Figure 46. Rotate Inner Boom 57

58 7. Align idler sprocket assembly bolts (½- x 2¾-inch) with bolt holes and secure with ½-inch SAE washer ½-inch Nylock nuts on the outside of the boom. (See Appendix C, Figure 8) (See Figure 47) 8. Once the idler sprocket is installed, complete the inner boom installation. Rotate inner boom back to 12:00 position. (See Figure 48) Figure 47. Attach Bolts on Idler Sprocket Assembly Figure 48. Complete Inner Boom Assembly 9. Install a temporary holding screw through the outer boom and into the outer boom bearing to ensure secure transport of the boom assembly to the Jarraff. (See Figure 49) Figure 49. Install a Temporary Holding Screw 58

59 I. ATTACH BOOM TO UPRIGHT 1. Make sure Jarraff is on flat, level ground and that the upright is level to allow for proper boom installation. (See Figure 50) 2. Attach boom to boom cradle utilizing the boom bands. (See Figure 51) Figure 50. Make Sure Jarraff Upright is Level Figure 51. Attach Boom to Boom Cradle 3. Tighten bands per instructions on next page. 4. Attach hydraulic hoses to hydraulic poppet assembly. (See Figure 52) Figure 52. Attach Hydraulic Hoses to Hydraulic Poppet Assembly 59

60 J. BOOM BAND TORQUE SPECIFICATION AND PROCEDURE 1. Set the park brake, fully retract the boom, place the boom in the boom rest, and shut the engine off. 2. Starting at the outer end of the boom (the saw end), loosen all four bolts on the outer band and re-torque the bolts following the procedure below. 3. Initially torque each bolt to 20 ft-lbs in the order shown. (See Illustration 2) 4. Repeat step 3 but torque the bolts to (40 ft-lbs for 5 8" or 35 ft-lbs for 1 2"), in the same order, multiple times until all bolts are within specification. 5. Repeat Steps 1-4 for each of the boom bands. NOTE: When performing this or any other repair to a Jarraff All-Terrain Tree Trimmer, take all safety precautions including, but not limited to the following: wearing of eye and hearing protection. If you have any questions please, contact the Jarraff Service Department at Illustration 1. Boom Band and Bolt Placement Overview Illustration 2. Torque Bolt Procedure 60

61 K. SECURE OUTER BOOM 1. Once the boom is oriented and attached to the cradle. The outer boom can be secured to the outer boom bearing. 2. Remove the temporary holding screw from the outer boom and outer boom bearing. (See Figure 53) 3. Check level of saw head assembly. Make sure saw head assembly is perpendicular to the ground, on a flat, level surface. Adjust if necessary before securing the outer boom bearing. (See Figure 54) Figure 53. Remove Temporary Holding Screw Figure 54. Check Level of Saw Head Assembly 4. Drill holes through outer boom and into the outer boom bearing with ½-inch bit at the 8:00, 10:00, 2:00 and 4:00 positions 2 inches from the outer edge of the boom. (See Figures 55 & 56) 10:00 2:00 8:00 4:00 Figure 55. Drill Holes Figure inches from Outer Edge 5. After drilling each hole, screw in a coarse thread ½- x 1½-inch bolt and a ½-inch SAE flat washer. (See Appendix C, Figure 9) Tighten until secure. (See Figures 57 & 58) 61

62 Figure 57. Drill Holes Through Outer Boom IMPORTANT: Make sure to drill holes no deeper than approximately 1¾ inches to avoid drilling into the inner boom. L. SET EXTENSION AND RETRACTION STOPS 1. Remove the protective metal mailbox enclosure surrounding the chain extension/retraction assembly. (See Figure 59) 2. Remove the top plate over the extension/retraction assembly by loosening and removing the bolts attaching the plate, total of four. (See Figure 60) 3. With the boom installed and retracted, and the extension/retraction chain in place, install the retraction stop as shown. Figure 58. Screw in a Coarse Thread Bolt and Flatwasher Figure 59. Remove "Mailbox" Enclosure (See Figure 61) (See Appendix C, Figure 12) With the boom retracted there should be approximately 3" between Saw Adapter and Outer Boom Bearing. 62 Figure 60. Remove Safety Cover Figure 61. Install Retraction Stop

63 4. Slowly extend the inner boom until it reaches 31 feet, measured from the outer boom bearing to the beginning of the saw head adapter. (See Figure 62) 31 Feet Figure 62. Extend Inner Boom NOTE: INNER BOOM LENGTH SHOULD BE CHECKED DAILY. IF A RED PAINTED BAND IS VISIBLE ON THE INNER BOOM THE MACHINE SHOULD BE SHUT DOWN IMMEDIATELY AND BOOM CHAIN STOPS SHOULD BE INSPECTED AND REPAIRED AS NEEDED. FAILURE TO REPAIR THIS ISSUE COULD LEAD TO A BROKEN CHAIN AND POSSIBLE DAMAGE TO INNER BOOM. 5. With the boom extended, install the extension stop as shown. (See Figure 63) (See Appendix C, Figure 13) Replace safety cover. (See Figure 60) Figure 63. Install Extension Stop 63

64 M. Extension Retraction Chain Adjustment 1. Extend the inner boom. Chain tension should be such that the chain stays engaged with the drive sprocket teeth. Spring compression should measure approximately 3.5 inches between the jam nut and the spring stop. (See Figure 64). Figure 64. Spring Compression Figure 65. Increase or Decrease Chain Tension 2. To increase chain tension, first, loosen jam nuts on both boom motor mount adjustment rods. Then evenly rotate clockwise each adjuster nut until proper tension is achieved. Finally, retighten the jam nut against the adjuster nut. (See Figure 65) 3. To reduce chain tension, first, loosen jam nuts on both boom motor mount adjustment rods. Then evenly rotate counter-clockwise each adjuster nut until chain has loosened to desired tension. Tighten the jam nut against the adjuster nut after proper tension is achieved. (See Figure 65) 64

65 65

66 5. C. Appendix - Bolt Packages and Parts for Boom Installation The following Bolt Packages are used in the Boom Installation process. NOTE: In 2012 Bolts were changed to Steel Bolts for the Rail Package. (See Figure 1) Top Bolt Figure 1. Rail Package Figure 2. Inner Boom Puller Assembly Figure 3. Inner Boom Bearing Figure 4. Adapter Ring to Boom 66

67 Figure 5. Saw Motor Cover to Saw Guard Figure 6. Saw Motor Cover Figure 7. Poppet Attachment Figure 8. Idler Sprocket Assembly Figure 9. Outer Boom Bearing Figure 10. Chain Swivel Attachment Parts 67

68 Figure 11. Chain Swivel Attachment Parts Assembled Figure 12. Retraction Stop Figure 13. Extension Stop 68