Caterpillar Forest 2124 Loader OPERATOR’S MANUAL

Download

Page 1

OPERATOR’S MANUAL

Knuckleboom Loader

2124

Part No. 30012174

March 2012

Rev. C

Page 2

Page 3

To The Operator

i

Page 4

iI

To The Operator

Page 5

To The Operator

INTRODUCTION

THIS MACHINE MAY NOT BE USED UNLESS OPERATOR FIRST READS AND UNDERSTANDS THIS MANUAL, AND HAS THE NECESSARY TRAINING AND AUTHORIZATION TO OPERATE AND PROPERLY MAINTAIN THIS MACHINE.

REMEMBER THAT THE OPERATOR IS THE KEY TO SAFETY. GOOD SAFETY PRACTICES PROTECT THE OPERATOR AND THE PEOPLE AROUND THE OPERATOR. MAKE THIS MANUAL A WORKING PART OF THE SAFETY PROGRAM.

iII

2124 Loader

The intended use of this loader is for picking up trees or parts of trees from the ground, or from a vehicle and piling or stacking them on to a vehicle or to the ground. The loader is normally mounted to a truck body or trailer (per the manufacturer’s precautions and recommendations). The loader should conduct the movement of the trees or parts of trees with the truck or trailer securely parked on at / level terrain with the A Frame stabilizers deployed as the upper structure is normally capable of 360 degree swing.

The loader can move trees or parts of trees that are within the object handling capacity of the loader. Ensure the loader is congured to meet local regulations and use approved attachment handling devices.

To safely operate this machine, follow the instructions in this operator’s manual. Directions in this manual are referenced from the operator’s seat facing forward (see diagram below).

FORWARD

LEFT RIGHT

BACK

Please help improve this manual. If you nd any mistakes, or if you know of a way to improve procedures, please let us know. Mail your suggestions or comments to the attention of Technical Publications, Caterpillar Forest Products, Inc., 3249 South County Road 45, PO Box 568, Owatonna, MN 55060-0568.

This operator’s manual includes information available and current at the time of approval for printing. Caterpillar Forest Products, Inc., reserves the right to improve its product without giving prior notice or incurring obligation.

This operator’s manual should be regarded as part of the machine. Suppliers of both new and second hand machines are advised to retain documentay evidence that this manual was provided with the machine.

Page 6

iV

To The Operator

SAFETY SYMBOLS

SAFETY ALERT SYMBOL

The Safety Alert Symbol means

ATTENTION!

BE ALERT! YOUR SAFETY IS INVOLVED!

This safety symbol is used to convey important safety messages. To avoid personal injury and/or property damage, when this symbol is seen, follow the corresponding safety message.

Understand signal words: DANGER, WARNING, and

CAUTION are used with the SAFETY ALERT SYMBOL.

DANGER IDENTIFIES A HAZARD OR UNSAFE PRACTICE THAT WILL RESULT IN SEVERE PERSON AL INJURY OR DEATH.

WARNING identies a hazard or unsafe practice that could result in severe personal injury or death.

CAUTION identies a hazard or unsafe practice that could result in personal injury or property damage.

NOTICE identies important installation, operation, or maintenance information.

Page 7

CONTENTS

v

To The Operator

PRODUCT PROTECTION PLAN .............................................i

Loader ................................................................................i

Attachment ......................................................................... ii

00 TO THE OPERATOR ...........................................................iii

Safety Symbols .................................................................iv

01  GENERAL SAFETY ........................................................11

Safety Alert Symbol .....................................................1-1

Safety Mounting Message .........................................1-1

Operator Preparation ..................................................1-1

Avoid Contact With Stabilizers .................................1-1

Battery Safety .................................................................1-2

Electric Lines ...................................................................1-3

Electric Storm .................................................................1-3

Falling or Swinging Logs ............................................1-4

First Aid Kit ......................................................................1-4

Fire Prevention & Explosion Prevention ...............1-5

Battery & Battery Cables .............................................1-6

Wiring ...........................................................................1-7

Lines, Tubes & Hoses ....................................................1-7

Ether ...........................................................................1-8

Fire Extinguisher ...........................................................1-8

Fluids Under Pressure..................................................1-9

Hand Holds and Steps .................................................1-9

Hand Signals ................................................................ 1-10

Hoses and Fittings ..................................................... 1-10

No Riders on Machine .............................................. 1-11

Operator Safety .......................................................... 1-11

Practice Safe Maintenance .....................................1-12

Pressure Settings .......................................................1-12

Protective Clothing ...................................................1-12

Protective Devices / Equipment ........................... 1-13

Radiator Cap ................................................................ 1-13

Refueling ....................................................................... 1-13

Seat Belt ........................................................................1-14

Unauthorized Welding ............................................. 1-14

Unstable Platform ...................................................... 1-14

02  SAFETY DECALS ...........................................................21

2124 Loader ....................................................................2-1

Do Not Operate Machine ...........................................2-2

Electrocution ..................................................................2-2

Seat Belt ...........................................................................2-2

Transit Lock .....................................................................2-2

Additional Messages ...................................................2-3

Altering A-Frame ...........................................................2-3

Avoid Contact with Stabilizers .................................2-3

Daily Inspection ............................................................2-3

Excessive Pressure ........................................................2-3

Falling or Swining Logs ...............................................2-4

Fluids Under pressure .................................................2-4

Improper Positioning of Loader ..............................2-4

unstable Platform .........................................................2-4

03  COMPONENT TERMINOLOGY .................................31

04  CONTROLS AND INSTRUMENTS ............................41

2124 Operator’s Station ..............................................4-1

Left Joystick ....................................................................4-2

Right Joystick .................................................................4-2

Stabilizer Controls ........................................................4-3

Swing Pedal ....................................................................4-4

Hydraulic Reservoir Sight Gauge ............................4-4

Seat Belt (optional) .......................................................4-4

Transit Lock .....................................................................4-4

Lights (optional) ............................................................4-5

Stop Switch (optional) ................................................4-5

05  PRESTART INSPECTION ............................................51

Pre-Start Checks on the Ground .............................5-1

Pre-Start Checks on the Platform ............................5-2

Fire Prevention ...............................................................5-3

06  OPERATION.....................................................................61

General Guidelines .......................................................6-1

Electrocution Danger ..................................................6-2

Overhead Load Danger ..............................................6-3

Getting on Machine .....................................................6-3

Machine Start Up ..........................................................6-4

Engaging Power Take O (PTO) ...............................6-4

Adjusting Operator’s Seat ..........................................6-5

Seat Belt ...........................................................................6-5

Unlocking Transit Lock ................................................6-6

Warm Up Period ............................................................6-6

Feathering the Controls .............................................6-7

Using the Stabilizers ...............................................6-8–9

Landing Layout ........................................................... 6-10

Picking up Logs .......................................................... 6-10

Grapple Control .......................................................... 6-11

Stopping the Machine ............................................. 6-11

Getting o Machine .................................................. 6-12

Page 8

vI

To The Operator

07  BREAKIN PERIOD ........................................................71

After First 10 Hours ......................................................7-1

After First 100 Hours ....................................................7-2

08  TRANSPORTING ............................................................81

09  LUBRICANTS ...................................................................91

Hydraulic Oil ...................................................................9-1

Grease ...........................................................................9-1

Grease for Swing Drive Bearing

and Swing Drive Motor ............................................9-2

Lubricant for Pinion and

Swing Gear Teeth .......................................................9-2

Cylinder Rod Corrosion Preventive ........................9-2

Storing Lubricants ........................................................9-3

10  MAINTENANCE SAFETY .......................................... 101

Before Maintenance............................................. 10-1–3

Practice Safe Maintenance ................................. 10-1

Hydraulic Safety ..................................................... 10-2

Protective Clothing ............................................... 10-2

Servicing Controls Valves, Cylinders,

Pumps and Motors .............................................10-3

Unauthorized Welding ........................................ 10-3

During Maintenance ............................................ 10-4–5

Diesel Exhaust ........................................................10-4

Fluids Under Pressure .......................................... 10-4

Fuels and Lubricants ............................................10-5

Pinch Points ............................................................. 10-5

After Maintenance ..................................................... 10-6

Disposing of Waste ............................................... 10-6

11  SCHEDULED/PERIODIC MAINTENANCE ............

SERVICES 111

Lubrication and Maintenance Intervals ............... 11-1

Lubrication Notice ....................................................... 11-1

Position Machine for Maintenance ........................ 11-1

As Required .................................................................... 11-2

Daily or Every Ten Hours ............................................ 11-3

Weekly or Every 50 Hours ......................................... 11-4

Monthly or Every 250 Hours ..................................... 11-5

Every Three Months .....................................................11-6

Every Six Months .......................................................... 11-7

Maintenance Details ............................................11-8–24

As Required .................................................................... 11-2

Check Electrical System ............................................. 11-8

Drain and Replace Hydraulic Oil ............................. 11-8

Inspect Safety Decals .................................................. 11-8

Inspect Ladder Structure and Fasteners .............. 11-9

Daily or Every Ten Hours ............................................ 11-3

Perform Daily Visual Inspection ............................11-10

Lube Adaptor Knuckle ..............................................11-10

Lube Main Boom Pivot Pin ......................................11-11

Lube Main Boom Cylinder Base Ends .................11-11

Lube Main Boom Cylinder Rod Ends ...................11-11

Lube Main / Stick Pivot Pin .....................................11-11

Lube Stick Boom Cylinder Base End ....................11-12

Lube Stick Boom Cylinder Rod End .....................11-12

Lube Swing Bearing ..................................................11-12

Lube Pinion Gear ........................................................11-12

Check Hydraulic Oil Level ........................................11-13

Filling Hydraulic Oil Reservoir ................................11-13

Inspect Electrical Components .............................11-14

Inspect Seat Fasteners ..............................................11-14

Weekly or Every 50 Hours ......................................... 11-4

Perform Weekly Inspection ....................................11-15

Inspect Loader Mounting Bolts.............................11-16

Check Boom and Cylinder

Attaching Pins ...........................................................11-16

Check Stabilizer Attaching Pins ............................11-16

Check Hydraulic Oil Res Hdwe ..............................11-16

Check Hydraulic Connections ...............................11-17

Check Hydraulic Oil Reservoir

for Contaminants .....................................................11-17

Inspect Joystick Boots ..............................................11-17

Lubricate Stabilizer Cylinder Rod Ends...............11-18

Lubricate Stabilizer Cylinder Base Ends .............11-18

Monthly or Every 250 Hours ..................................... 11-5

Perform Seat Maintenance ..................................... 11-19

Check Swing Drive Fasteners .................................11-19

Every Three Months or 600 Hours .......................... 11-6

Replace Hydraulic Ret Line Filters ........................ 11-20

Replace Case Drain Filter .........................................11-20

Ck Outer Swg Brng Fastener Torque ...................11-21

Ck Inner Swg Brng Fastener Torque ....................11-21

Lubricate Joystick .......................................................11-21

Every Six Months or 1200 Hours ............................. 11-7

Change Hydraulic Reservoir Oil ............................11-22

Filling Hydraulic Reservoir ......................................11-22

Check / Clean Collector Ring..................................11-23

12  STORAGE ...................................................................... 121

Preparing Machine for Storage ............................. 12-1

Taking Machine Out of Storage ............................ 12-2

13  TROUBLESHOOTING ................................................ 131

2124 Hydraulic System ............................................ 13-1

Cleanliness of Hydraulic Components ............... 13-2

14  SPECIFICATIONS ........................................................141

15  SERIAL NUMBERS ......................................................151

16  MATERIAL SAFETY DATA SHEETS .......................161

Page 9

Safety Section

WARNING

Do not operate this machine without reading and understanding the opera-

tor’s manual.

SAFETY ALERT SYMBOL

Read all safety messages.

To avoid personal injury and/or property damage, follow safety messages.

SAFETY MOUNTING MESSAGE

Read all safety messages.

To avoid personal injury and/or property damage, do not use controls or joysticks as hand holds or footholds when mounting or dismounting loader. When PTO is engaged and/or throttle set, controls are active.

11

OPERATOR PREPARATION

Operator must be fully trained, qualied, and authorized to operate this machine. Before operating this machine, operator must know the location and purpose of

• controls

• indicator lights

• instruments

• safety and instruction decals

(See Safety Decals Section)

AVOID CONTACT WITH STABILIZERS

Coming into contact with

stabilizers can cause serious personal injury or death.

Clear all personnel from work area before raising or lowering stabilizers.

Position the machine on rm, level ground, Avoid slopes and unstable soil conditions that could cause stabilizers to loose their eectiveness. Clear away snow, ice and/or debris form beneath wheels and stabilizer pads.

Page 10

12

WARNING

Safety Section

BATTERY SAFETY

Batteries produce explosive

gases that can cause severe personal injury or death.

Battery acid is poisonous and can cause severe burns. If acid is taken internally, call a physician immediately. If acid contacts skin or clothing, ush with water immediately. Keep batteries away from children.

Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Keep sparks, ames, and cigarettes away from batteries. Ventilate properly when charging or using batteries in enclosed space. Always shield eyes with goggles and wear a face shield when working near batteries. Do not lean over batteries during this operation. Always connect positive (+) to positive (+) and negative (-) to negative (-). For further instructions, see Jump Starting Battery in Section 6, Operation. If battery acid contacts eyes, ush them with water for 15 minutes and seek immediate medical attention.

Never charge a battery or jump start engine if battery is frozen. Warm battery to 60°F (16°C) or it may explode. Be sure vent caps are tight. When jump starting from another machine, be sure machines do not touch. This machine has a 12-volt starting system. Use equal voltage for jump starting.

Page 11

13

DANG ER

WARNING

Safety Section

ELECTRIC LINES

SERIOUS INJURY OR DEATH WILL RESULT FROM CONTACT WITH ELECTRIC LINES.

Never move any part of machine or load closer than 10 feet plus twice the line insulator length to electric lines. A line insulator is what connects an electric line to an electric pole.

For example, if a line insulator is 6 inches long, operator must stay at least 10 feet plus twice the line insulator length (2x6 =12 inches or 1 foot) from electric line, which means machine must stay at least 11 feet from the electric line.

If machine touches an electric line, stay inside the cab. Carefully move machine or load away from electric line, without pulling the line down.

DO NOT allow anyone else to touch machine while it is touching an electric line. If machine cannot be moved away from the electric line without pulling line down, have someone contact the utility company to disconnect power from line. If this is not possible, or if machine begins to burn, jump away from machine to the ground with both feet together, in one smooth jump. Do not run or walk away from machine. Jump with feet together (“bunny hop”) away from machine. DO NOT touch machine and ground at the same time or else electricity in the line will go through your body. Get away from machine after jumping.

Notify the utility company immediately. DO NOT let anyone near the machine while it is touching an electric line.

ELECTRICAL STORM

Electrical storms (lightning)

can cause severe personal injury or death.

When lightning is striking in the vicinity of the machine, the operator should NEVER attempt the following procedures:

Mount the machine

Dismount the machine

If you are in the operator’s station during an electrical storm, stay in the operator’s station. If you are on the ground during an electrical storm, stay away from the vicinity of the machine.

Page 12

14

CAUTION

WARNING

Safety Section

FALLING OR SWINGING LOGS

Falling or swinging logs, booms, or attachments can cause severe personal injury or death.

Never operate the boom, attachment or load over or near personnel.

FIRST AID KIT

injury and/or machine damage.

Much of the material found in forestry operations is highly ammable, including limbs, bark, leaves, saw dust, small wood chips and pine needles. When the forestry debris is soaked in fuel or lubricants, the risk of re is greatly increased. Doing a daily inspection before every shift, or more often based on the work activity and build-up of debris, is the best way to prevent a machine re. Frequent inspections and thorough machine cleaning are critical when engaged in forestry operations, and even minor leaks or electrical malfunctions should be repaired as soon as possible.

Keep machine clean. Highly ammable debris such as leaves, twigs, saw dust, small wood chips and pine needles can collect on and in equipment used in forestry operations. If allowed to accumulate, the debris can rapidly become the fuel component of a machine re. Clean all accumulations of forest debris in the engine compartment or around other hot areas and hot parts on the machine at the completion of each work shift or more frequent when working in conditions where large amounts of forest debris are present.

Fires can cause personal

Repair all hydraulic and fuel leaks immediately. Do not operate machine with hydraulic or fuel leaks.

Fire prevention beats re ghting. Remove debris from all compartments after every 8 hours of operation, or more often, if warranted by working conditions.

Install a rst-aid kit in the cab.

Properly maintain rst-aid kit and re extinguisher. Follow instructions provided with them.

Page 13

15

Safety Section

FIRE PREVENTION AND EXPLOSION PRE VENTION

GENERAL

All fuels, most lubricants, and some coolant mixtures are ammable.

To minimize the risk of re or explosion, Caterpillar recommends the following actions.

Always perform a Walk-Around Inspection, which may help you identify a re hazard. Do not operate a machine when a re hazard exists. Contact your Caterpillar dealer for service.

Understand the use of the primary exit and alternative exit on the machine. Refer to Operation and Maintenance Manual, “Alternative Exit”.

Do not operate a machine with a uid leak. Repair leaks and clean up uids before resuming machine operation. Fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a re. A re may cause personal injury or death.

Remove ammable material such as leaves, twigs, papers, trash, etc. These items may accumulate in the engine compartment or around other hot areas and hot parts on the machine.

of each work shift or more frequently when working in conditions where large amounts of forest debris are present.

Keep the access doors to major machine compartments closed and access doors in working condition in order to permit the use of re suppression equipment, in case a re should occur.

Clean all accumulations of ammable materials such as fuel, oil and debris from the machine.

Do not operate the machine near any ame.

Keep shields in place. Exhaust shields (if equipped) protect hot exhaust components from oil spray or fuel spray in case of a break in a line, in a hose, or in a seal. Exhaust shields must be installed correctly.

Do not weld or ame cut on tanks or lines that contain ammable uids or ammable material. Empty and purge the lines and tanks. Then clean the lines and tanks with a nonammable solvent prior to welding or ame cutting. Ensure that the components are properly grounded in order to avoid unwanted arcs.

Dust that is generated from repairing nonmetallic hoods or fenders may be ammable and/or explosive. Repair such components in a well ventilated area away from open ames or sparks. Use suitable Personal Protection Equipment (PPE).

Inspect all lines and hoses for wear or deterioration. Replace damaged lines and hoses. The lines and the hoses should have adequate support and secure clamps. Tighten all connections to the recommended torque. Damage to the protective cover or insulation may provide fuel for res.

Much of the material found in forestry operations is highly ammable, including limbs, bark, leaves, saw dust, small wood chips and pine needles. When the forestry debris is soaked with fuel or lubricants, the risk of re is greatly increased. Doing a daily inspection before every shift, or more often based on the work activity and build-up of debris, is the best way to prevent a machine re. Frequent inspections and thorough machine cleaning are critical when engaged in forestry operations, and even minor leaks or electrical malfunctions should be repaired as soon as possible.

Highly ammable debris such as leaves, twigs, saw dust, small wood chips and pine needles can collect on and in equipment used in forestry operations. If allowed to accumulate, the debris can rapidly become the fuel component of a machine re. Clean all accumulations of forest debris in the engine compartment or around other hot areas and hot parts on the machine at the completion

Page 14

16

Safety Section

Store fuels and lubricants in properly marked containers away from unauthorized personnel. Store oily rags and ammable materials in protective containers. Do not smoke in areas that are used for storing ammable materials.

Use caution when you are fueling a machine. Do not smoke while you are fueling a machine. Do not fuel a machine near open ames or sparks. Always stop the engine before fueling. Fill the fuel tank outdoors. Properly clean areas of spillage.

Follow practices for safe fueling that are described in the “Operation” section of the Operation and Maintenance Manual section and follow local regulations. Never store ammable uids in the operator compartment of the machine.

BATTERY AND BATTERY CABLES

Caterpillar recommends the following in order to minimize the risk of re or an explosion related to the battery.

Do not operate a machine if battery cables or related parts show signs of wear or damage. Contact your Caterpillar dealer for service.

Follow safe procedures for engine starting with jump start cables. Improper jumper cable connections can cause an explosion that may result in injury. Refer to Operation and Maintenance Manual, “Engine Starting with Jump Start Cables” for specic instructions.

Do not charge a frozen battery. This may cause an explosion.

Gases from a battery can explode. Keep any open ames or sparks away from the top of a battery. Do not smoke in battery charging areas.

Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter or a hydrometer.

Daily inspect battery cables that are in visible areas. Identify cables, clips, straps, and other restraints for damage. Replace these items if necessary. Look for signs of the following, which can occur over time due to use and environmental factors:

• Fraying

• Abrasion

• Cracking

• Discoloration

• Cuts on the insulation of the cable

• Fouling

• Corroded terminals, damaged terminals, and loose terminals

Page 15

17

Safety Section

Replace damaged battery cable(s) and replace any related parts. Eliminate any fouling, which may have caused insulation failure or related component damage or wear. Ensure that all components are reinstalled correctly.

An exposed wire on the battery cable may cause a short to ground if the exposed area comes into contact with a grounded surface. A battery cable short produces heat from the battery current, which may be a re hazard.

An exposed wire on the ground cable between the battery and the disconnect switch may cause the disconnect switch to be bypassed if the exposed area comes into contact with a grounded surface. This may result in an unsafe condition for servicing the machine. Repair components or replace components before servicing the machine.

Fire on a machine can result in personal injury or death. Exposed battery cables that come into contact with a grounded connection can result in res. Replace cables and related parts that show signs of wear or damage. Contact your Caterpillar dealer.

LINES, TUBES AND HOSES

Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged. Use the appropriate backup wrenches in order to tighten all connections to the recommended torque.

Check lines, tubes and hoses carefully. Wear Personal Protection Equipment (PPE) in order to check for leaks. Always use a board or cardboard when you check for a leak. Leaking uid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If uid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

WIRING

Check electrical wires daily. If any of the following conditions exist, replace parts before you operate the machine.

• Fraying

• Signs of abrasion or wear

• Cracking

• Discoloration

• Cuts on insulation

• Other damage

Make sure that all clamps, guards, clips, and straps are reinstalled correctly. This will help to prevent vibration, rubbing against other parts, and excessive heat during machine operation.

Attaching electrical wiring to hoses and tubes that contain ammable uids or combustible uids should be avoided.

Consult your Caterpillar dealer for repair or for replacement parts.

Replace the aected parts if any of the following conditions are present:

• End ttings are damaged or leaking.

• Outer coverings are chafed or cut.

• Wires are exposed.

• Outer coverings are swelling or ballooning.

• Flexible parts of the hoses are kinked.

• Outer covers have exposed embedded armoring.

• End ttings are displaced.

Make sure that all clamps, guards, and heat shields are installed correctly. During machine operation, this will help to prevent vibration, rubbing against other parts, excessive heat, and failure of lines, tubes and hoses.

Do not operate a machine when a re hazard exists. Repair any lines that are corroded, loose or damaged. Leaks may provide fuel for res. Consult your Caterpillar dealer for repair or for replacement parts. Use genuine Caterpillar parts or the equivalent, for capabilities of both the pressure limit and temperature limit.

Keep wiring and electrical connections free of debris.

Page 16

18

Safety Section

ETHER

Ether (if equipped) is commonly used in cold weather applications. Ether is ammable and poisonous.

Follow the correct cold engine starting procedures. Refer to the section in the Operation and Maintenance Manual with the label “Engine Starting”.

Do not spray ether into an engine if the machine is equipped with a thermal starting aid for cold weather starting.

Use ether in well ventilated areas. Do not smoke while you are replacing an ether cylinder or while you are using an ether spray.

Do not store ether cylinders in living areas or in the operator compartment of a machine. Do not store ether cylinders in direct sunlight or in temperatures above 49° C (120.2° F). Keep ether cylinders away from open ames or sparks.

Dispose of used ether cylinders properly. Do not puncture an ether cylinder. Keep ether cylinders away from unauthorized personnel.

FIRE EXTINGUISHER

As an additional safety measure, keep a re extinguisher on the machine.

Be familiar with the operation of the re extinguisher. Inspect the re extinguisher and service the re extinguisher regularly. Follow the recommendations on the instruction plate.

Consider installation of an aftermarket Fire Suppression System, if the application and working conditions warrant the installation.

Page 17

19

WARNING

Safety Section

FLUIDS UNDER PRESSURE

Fluids escaping under pressure can penetrate skin and cause severe personal injury or death. Wear eye and personal protection equipment (PPE)!

Always use a board or cardboard when checking oil hoses, lines, and ttings for leaks, cracks, or defects. Be sure all clamps are in their proper position and torqued as required and specied. Be sure hoses are not twisted or touching parts.

DO NOT use hands to search for leaks. Escaping uids can penetrate skin and enter the bloodstream. Before disconnecting lines, relieve all pressure.

DO NOT apply pressure to a damaged line, hose, or tting.

If ANY uid is injected into the skin, seek medical attention immediately. A serious infection or reaction can result without proper medical treatment.

HAND HOLDS AND STEPS

Slips and falls can cause severe personal injury or death.

Use provided hand holds and steps while maintaining at least 3 points of support (1 foot and 2 hands or 2 feet and 1 hand) when getting on and o machine. Face machine when getting on and o of it.

Never use controls as hand holds. Never use steering wheel as a hand hold. Moving the steering wheel from its center position will COMPLETELY turn machine right or left.

DO NOT mount machine if hand rails or steps are broken or missing. Get them repaired rst.

DO NOT jump on or o machine unless it has touched a live electrical wire and it must be exited.

Ensure rm foot position when getting on and o machine. Be careful of slippery conditions on platform, steps, and hand holds when getting on and o machine.

Remove oil, grease, mud, ice, etc. before mounting or dismounting machine.

To prevent slips and falls, replace skid-resistant material if it is worn, damaged or missing.

Page 18

110

WARNING

Safety Section

HAND SIGNALS

Accidents can cause severe personal injury or death.

Know and use the hand signals required for particular jobs.

Know who has the responsibility for signaling.

HOSES AND FITTINGS

Mismatched brands or types of hoses and ttings can blow apart and cause severe personal injury or death.

DO NOT interchange brands or types of hoses and ttings.

DO NOT install a tting from one manufacturer on a hose from a dierent manufacturer.

DO NOT install crimp ttings on hoses meant for reusable ttings.

Wear eye and personal protection equipment (PPE)!

Always use a board or cardboard when checking oil hoses, lines, and ttings periodically for leaks, cracks or defects. Be sure all clamps are in their proper position and torqued as required and specied. Be sure hoses are not twisted or touching parts.

Page 19

111

WARNING

Safety Section

NO RIDERS ON MACHINE

Machine riders can fall from machine or be injured by movement of machinery, causing severe personal injury or death.

Do not allow riders on any machine that is operating or moving.

OPERATOR SAFETY

Flying debris, tree limbs, and/or other material can cause severe personal injury or death.

When operating machine:

1. Cab door must stay closed.

2. Window material and/or cab guarding MUST be in

place.

3. All cab openings (front, side, and rear) MUST be

covered with window material (no glass) and/or protective screen.

4. Window guarding MUST be locked

in place.

Page 20

112

WARNING

Safety Section

PRACTICE SAFE MAINTENANCE

Understand service procedures before performing maintenance. When performing maintenance, keep area around machine clean and dry.

DO NOT service machine while it is moving. Keep away from power-driven parts. Lower attachment to the ground. Disengage power. Shut engine down. Move controls in all directions to relieve hydraulic pressure. Remove key from ignition. Allow machine to cool down.

Support all raised equipment.

Keep all machine parts in good condition, and be sure parts are properly installed. Repair damage immediately. Repair all hydraulic and fuel leaks immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

Disconnect battery ground cable (-) before adjusting the electrical system.

PRESSURE SETTINGS

Excessive hydraulic pressure can cause component or structural failure, which may result in severe personal injury or death.

Wear eye and personal protection equipment (PPE)!

DO NOT exceed factory-adjusted pressure settings.

PROTECTIVE CLOTHING

Wear OSHA or local governing body-approved protective clothing when working on or near this machine, such as

• ear protection • hard hat

• gloves • orange vest

• goggles • steel-toed shoes

Wear snug, protective clothing that is belted where required.

Remove jewelry before working on or near this machine.

Page 21

113

CAUTION

WARNING

Safety Section

PROTECTIVE DEVICES/EQUIPMENT

Misuse, interference and ignorance of protective equipment or devices can cause severe personal injury or death.

Alarms, re prevention equipment, ROPS/FOPS/OPS, and other safety equipment is installed on machine for your protection.

Never ignore, disconnect, disable or modify protection equipment in any manner.

RADIATOR CAP

tem can cause scalding burns.

Wear eye and personal protection equipment (PPE)!

Do not remove radiator cap unless engine is cool. Allow system to cool. Remove cap slowly to relieve pressure before removing completely.

REFUELING

cause severe personal injury or death.

Handle fuel with care. It is highly ammable.

Pressurized cooling sys-

Fires and explosions can

DO NOT refuel machine while smoking or when near open ame or sparks.

Always stop engine before refueling. Fill fuel tank outdoors. Prevent res by keeping machine clean of trash, grease, and debris. Always clean up spilled fuel.

Page 22

114

WARNING

NOTICE

G.020.05

WARNING

Safety Section

SEAT BELT OPTIONAL

A roll over or sudden stop

can cause severe personal injury or death.

To reduce risk of personal injury resulting from a roll over or sudden stop, always wear a seat belt fastened snugly when operating this machine.

This machine can change directions rapidly. It can start and stop quickly. See Operation Section in this manual for instructions on properly using the seat belt.

UNAUTHORIZED WELDING

Unauthorized welding can cause structural failure and/or severe personal injury or death.

DO NOT weld on any structural member. Any unauthorized welding or repair will void the warranty.

Once authorized, be sure to turn battery disconnect master switch OFF and place welding ground (stinger) as close to weld site as possible. Do not allow weld current to pass through bearings or pivot points.

Unauthorized welding can

cause damage to the electrical system.

UNSTABLE PLATFORM

Unstable platform can cause severe personal injury or death.

Lower all stabilizers before operating machine.

Page 23

21

Safety Decals

The following safety decals are located in position on the machine as continual reminders of HAZARDS. Serious injury or property damages can occur if safety instructions are not followed.

Keep all safety decals clean and readable. Use a soft cloth, water, and soap to clean decals if they are too dirty to read. DO NOT clean safety decals with solvent. Solvent can damage them.

Replace safety decals immediately if they are damaged, missing, or hard to read. Contact an authorized dealer for replacement safety decals. Authorized dealers will provide free replacement safety decals if given a valid serial number for this machine.

When replacing a part containing a safety decal, apply a new safety decal to the replace-

ment part. Before putting a new decal on the machine or part, be sure the surface where the decal will be mounted is clean and dry.

2124 LOADER

Page 24

22

WARNING

Safety Decals

Do Not Operate Machine

This warning is located on the surface of the seat riser.

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance manuals. Failure to follow the instructions or head the warnings could result in injury or death. Contact your authorized dealer fro replacement manuals. Proper care is your responsibility.

Seat Belt (optional)

This warning is located on the surface of the boom (visible from the operator’s seat).

A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn. Failure to wear a seal belt during machine operation may result in serious injury or death.

Electrocution

This warning is located on the surface of the boom (visible from the operator’s seat).

Electrocution Hazard! Keep the machine and attachments a safe distance from electrical power. Stay clear 3 m (10ft) plus twice the line insulator length. Read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions and warnings will cause serious injury or death.

Transit Lock

This warning is located on the operator platform next to the Transit Lock.

Engage Transit Lock before transporting loader. Failure to engage transit lock can cause severe personal injury or death.

Page 25

23

WARNING

Safety Decals

Additional Safety Messages: Altering A-Frame

DO NOT ALTER AFRAME STRUCTURE. DO NOT WELD OR MACHINE AFRAME STRUCTURE. IF A FRAME IS DAMAGED, CONTACT AN AUTHORIZED DEALER.

Structural damage, an overturn, modication, alteration, or improper repair can impair this structure’s protection capability thereby voiding this certication. Do not weld on or drill holes in the structure. This will void the certication. Consult an authorized dealer to determine this structure’s limitations without voiding its certication.

Daily Inspection

PERFORM A DAILY INSPECTION OF THE FOLLOWING COMPONENTS: STRUCTURES, BOOMS, CYLINDERS, TURNTABLE, SWING BEARING, LOAD BEARING ITEMS & ALL MOUNTINGS.

Failure to perform a daily inspection of the loader could result in severe personal injury or machine damage.

Excessive Pressure

DO NOT EXCEED FACTORY–ADJUSTED RELIEF PRESSURE SETTINGS.

Avoid Contact with Stabilizers

CLEAR ALL PERSONNEL FROM WORK AREA BEFORE LOWERING STABILIZERS.

Contact with stabilizers could result in severe personal injury or property damage.

Excessive hydraulic pressure can cause component or structural failure causing severe personal injury or death.

Page 26

24

WARNING

Safety Decals

Falling or Swinging Logs

NEVER OPERATE THE BOOM OR LOAD OVER OR NEAR PERSONNEL.

Do not operate the boom or load over or near personnel. Falling or swinging logs can cause severe personal injury or death.

Fluid Under Pressure

REFER TO OPERATOR’S MANUAL FOR MAINTENANCE INSTRUCTIONS.

Improper Positioning of Loader

DO NOT TRANSPORT LOADER WITHOUT PLACING ALL COMPONENTS IN TRANSPORT POSITION AND ENGAGING TRANSIT/SWING LOCK.

DImproper positioning of loader can cause severe personal injury or death.

Unstable Platform

LOWER ALL STABILIZERS BEFORE OPERATING.

Unstable platform can cause severe personal injury or machine damage.

Fluid escaping under pressure can penetrate skin and cause severe personal injury or death.

Page 27

2124 LOADER

31

Component Terminology

1. Stabilizer Leg

2. Swing Bearing

3. Swing Drive

4. Grapple

5. Main Boom Cylinder

6. Main Boom

7. Stick Boom Cylinder

8. Stick Boom

9. Main Boom Pivot Pin

10. Stick Boom Pivot Pin

11. Grapple Pivot Pin

12. Adapter Knuckle

13. Turntable Assembly

Page 28

32

Component Terminology

Page 29

41

Controls & Instruments

2124 OPERATOR’S STATION

1. Operator’s Seat

2. Swing Pedal

3. Left Joystick: Controls grapple open close and main boom

4. Right Joystick: controls grapple rotate, stick boom and telescopic boom (optional)

5. Left Stabilizer Control Switch

6. Right Stabilizer Control Switch

7. Light Switch (optional)

8. Stop Switch (optional)

Page 30

42

DOWN

CCW

S T

I C K

B O O M

GRAPPLE ROTATE

OPEN

B O O

GRAPPLE

DOWN

Controls & Instruments

LEFT JOYSTICK CONTROL

USING THE MAIN BOOM

Push left joystick back to raise boom.

Push left joystick forward to lower main boom.

OPENING AND CLOSING GRAPPLE

Push left joystick to the left to open grapple.

Push left joystick to the right to close grapple.

RIGHT JOYSTICK CONTROL

USING THE STICK BOOM

Push right joystick back to raise stick boom.

Push right joystick forward to lower stick boom.

ROTATING GRAPPLE

Pull right joystick to the right to rotate grapple clockwise.

Pull right joystick to the left to rotate grapple counterclockwise.

Page 31

RIGHT JOYSTICK CONTROL CONT.

CCW

I C K

B O O M

GRAPPLE ROTATE

TELE EXTEND/RETRACT

RETRACT

EXTEND

USING THE TELESCOPING BOOM OPTIONAL

Pull right joystick to the right with switch depressed to extend telescoping boom.

Pull right joystick to the left with switch depressed to retract telescoping boom.

STABLIZER CONTROLS

MOVING STABILIZERS

43

Controls & Instruments

Unstable platform can cause platform to tip or operator to fall, resulting in severe personal injury or death.

Lower both stabilizers before operating.

Coming into contact with stabilizers can cause serious personal injury or death. Clear all personnel from work area before lowering stabilizers.

Push right stabilizer control switch (A) down to lower stabilizer.

Pull right stabilizer control switch (A) up to raise stabilizer.

Push left stabilizer control switch (B) down to lower stabilizer.

Pull left stabilizer control switch (B) up to raise stabilizer.

Page 32

44

Controls & Instruments

HYDRAULIC RESERVOIR SIGHT GAUGE

The hydraulic reservoir sight gauge (C) is located on the hydraulic oil tank.

SEAT BELT OPTIONAL

A roll over or sudden stop can cause severe personal injury or death.

To reduce risk of personal injury resulting from a roll over or sudden stop, always wear a seat belt fastened snugly when operating this machine.

This machine can change directions rapidly. It can start and stop quickly. See Operation Section in this manual for instructions on properly using the seat belt.

SWING PEDAL

Use the swing pedal to control the upper frame swing as follows:

Press LEFT side of pedal (A) to swing upper frame to

the left.

Press RIGHT side of pedal (B) to swing upper frame to the right.

Page 33

45

Controls & Instruments

TRANSIT LOCK

The transit lock (D) must be removed to operate loader, and must be in place during transport.

Before removing transit lock and operating loader, check around truck and loading area for personnel and obstructions. Remove any personnel from immediate work area.

LIGHTS OPTIONAL

Toggle light switch (A) to turn lights on and o.

STOP SWITCH OPTIONAL

To stop engine, pull toggle stop switch (B) toward operator.

This stop switch can be used to stop truck engine when needed.

restarted from operator’ s station. Be sure that loader is positioned to allow the operator to safely dismount loader using the ladder before shutting engine down.

Truck engine can not be

Page 34

46

Controls & Instruments

Page 35

51

Pre Start Inspection

This machine may not be used until operators have read, studied, and understand this

manual, and have learned how to properly operate this machine. Operating this machine without reading, studying, and understanding this manual could result in severe personal injury or death.

Failure to perform a daily inspection of the machine could result in machine

damage and severe personal injury.

Inspector’s Initials

Machine Serial NumberDate of Inspection

PRESTART CHECKS: ON THE GROUND

Check for protective clothing (wear it) and safety equipment (know where it is).

Check entire machine by performing a thorough walk-around inspection.

Check for loose or missing parts. Tighten loose parts; replace missing parts.

Check for leaks in hydraulic hoses and /or lines (replace defective hoses and/or lines).

Check hydraulic hoses and lines for wear and/or damage. Replace any defective hoses and/or lines.

Check that machine has been properly lubricated as described in Scheduled and Periodic Maintenance Services section.

Check shields and guards. They must be in place and undamaged. Replace damaged shields and guards.

Check that safety decals are on machine and that they are readable.

Check that shut-o valves are open (if equipped).

Check for dirt and grime on all hydraulic components. Remove dirt and grime to help prevent overheating.

Check for ice, snow, oil, mud, and grease on ladders and walkways. Clear away ice, snow, oil, mud, and grease to prevent slips and falls.

Check for any loose or worn skid-resistant mats. Replace if loose or worn.

Check hydraulic oil reservoir level. Add hydraulic oil to reservoir if necessary.

Check for combustible or ammable materials. Remove them from machine, if found.

Check mounting hardware. Tighten, if necessary.

Check that machine will not be near electrical wires. See Operation section, for more details.

Check swing bearing for loose or missing fasteners. Tighten loose fasteners. Replace missing fasteners.

Check boom for damage, cracks, debris, mounting pin retention, and other problems. Immediately report any structural problems (cracks) to an authorized dealer for diagnosis and repair or replacement.

Check that truck/trailer is on rm, level ground, and that parking brake is set.

Check electrical system for worn or frayed wires and/or loose connections.

Pages in this section may be copied. Check o each inspection item before operating machine. File the copy as a record of inspection as required by OSHA or local governing body.

Page 36

52

Pre Start Inspection

PRESTART CHECKS: ON THE PLATFORM

HAND HOLDS AND STEPS

Slips and falls can cause severe personal injury or death.

Never use controls as hand holds. Never use steering wheel as a hand hold. Moving the steering wheel from its center position will COMPLETELY turn machine right or left.

DO NOT mount machine if hand rails or steps are broken or missing. Get them repaired rst.

DO NOT jump on or o machine unless it has touched a live electrical wire and it must be exited.

Ensure rm foot position when getting on and o machine. Be careful of slippery conditions on platform, steps, and hand holds when getting on and o machine.

Remove oil, grease, mud, ice, etc. before mounting or dismounting machine.

To prevent slips and falls, replace skid-resistant material if it is worn, damaged or missing.

Inspector’s Initials

Check hydraulic hoses in platform/boom end area for leaks, abrasions, excessive wear, or other damage. Replace defective hoses and/or lines.

Check safety decals. They must be present and readable.

Check control levers for free movement.

Check booms for damage, cracks, debris, mounting pin retention, and other problems. Immediately report any structural problems (cracks) to an authorized dealer for diagnosis and repair or replacement.

Check fuel tank (ll tank and end of shift to reduce water condensation).

Machine Serial NumberDate of Inspection

Check that seat belt (if equipped) works properly. Replace worn or damaged seat belt .

Pages in this section may be copied. Check o each inspection item before operating machine. File the copy as a record of inspection as required by OSHA or local governing body.

Page 37

53

Pre Start Inspection

FIRE PREVENTION

Fires can cause personal

injury or machine damage.

Keep machine clean. Remove debris, especially from heat sources. Fire prevention beats re ghting. Hourly or daily inspections can reduce the possibility of re.

.Forest debris can collect

on the machine and cause a re. When forest debris mixes with ammable uids in a hot, conned space, the risk of a re starting greatly increases. KEEP THE MACHINE CLEAN.

Check machine daily for re hazards. Remove debris from areas of the machine that create heat and that are potential re start points. Depending on machine model, check for ammable debris in the following locations:

• Engine block • Turbocharger • Electrical connections

• Exhaust manifold • Battery • Control valves

Fire needs fuel. Remove combustible material (fuel for re) from heat sources. Keep the machine clean. Remove the following materials, and other combustible materials from areas of the machine that create heat:

• Pine needles • Twigs • Debris

• Shop rags • Oil spills • Coolant mixture

• Leaves • Sticks • Sawdust

• Grease • Bark • Diesel fuel

Keep the machine clean. Risk of re increases if combustible materials and amma-

ble materials build up on machine. This machine is not designed to house or store combustible materials.

Much of the material found in forestry operations is highly ammable, including limbs, bark, leaves, saw dust, small wood chips and pine needles. When the forestry debris is soaked with fuel or lubricants, the risk of re is greatly increased. Doing a daily inspection before every shift, or more often based on the work activity and build-up of debris, is the best way to prevent a machine re. Frequent inspections and thorough machine cleaning are critical when engaged in forestry operations, and even minor leaks or electrical malfunctions should be repaired as soon as possible. Regularly remove ammable materials (such as diesel fuel, engine oil, hydraulic oil, and grease) from all areas of the machine. Clean up after working. Keep the fuel and hydraulic systems in good repair.

Check hydraulic hoses, fuel lines, and ttings for leaks. Tighten loose ttings. If hoses or lines are bent, kinked, or show signs of wear, install new parts. Check electrical connections to be sure they are clean and secure.

Frayed or worn insulation on battery cables or other wires may lead to electrical res. Check cables and wires and replace if insulation is frayed, worn, or damaged.

At the end of each shift ALWAYS stay with the machine for 30 minutes after shutting down

the engine to ensure there is no forest debris/trash re start up. Keep a re extinguisher ready during this 30 minute cool down period.

Page 38

54

Pre Start Inspection

Page 39

Operation

GENERAL GUIDELINES

Only a trained, qualied, and authorized operator shall be allowed to operate this machine. Only use this machine after carefully reading this manual and learning how to safely operate and maintain this machine. Unsafe operation can cause severe personal injury or death.

OPERATOR PREPARATION

Operator must be fully trained, qualied, and authorized to operate this machine.

Before running this machine, operator must know the location and purpose of

• controls

• indicator lights

• instruments

• local operating safety rules and procedures

• safety and instruction decals (see Safety Decals section)

61

Operators must be at least 18 years old to operate this machine (Code of Federal Regulations: Labor).

Never operate this machine while under the inuence of drugs or alcohol. Use of prescription or over-the-counter drugs or medications requires advice from a medical practitioner on whether or not machine can be safely operated.

Operators may not run this machine if subject to dizziness, seizures, or motion disturbance.

Do not operate this machine unless it is properly mounted to a truck or trailer for stability.

Never operate this machine with stabilizers in raised position.

No riders are allowed on this machine. Machine riders can fall from machine or be injured by movement of machinery, causing severe personal injury or death. Do not allow riders on a machine that is operating or moving.

Follow all safety operating instructions and practices. (See General Safety section.)

Keep machine away from power lines.

If this manual is lost, contact an authorized dealer for a new manual. Keep manual in the manual storage pouch in the cab.

Report any noticeable machine problems to people who can repair the problems before machine is used.

Be sure cab windows are clean before operating machine. Cab windows must be clear of ice and frost. Replace windows that are cracked, yellow, and/or hazy.

Do not operate delimber within 300 feet (91 meters) of personnel or property.

REMEMBER, OPERATORS ARE KEY TO THE SAFE OPERATION OF THIS MACHINE.

Page 40

62

Operation

ELECTROCUTION DANGER

CONTACTING ELECTRIC LINES WITH BOOM, LINE, OR LOAD WILL CAUSE SEVERE INJURY OR DEATH. WATCH FOR OVER HEAD POWER LINES. TREAT ANY LINE AS LIVE AND DANGEROUS. IF AT ALL POSSIBLE, HAVE THE POWER LINE DISCONNECTED BEFORE STARTING WORK.

Never move any part of the machine or load closer to electric lines than 10 feet plus twice the line insulator length. A line insulator is what connects an electric line to an electric pole.

For example, if a line insulator is 6 inches long, stay at least 10 feet plus twice the line insulator length (2 x 6 = 12 inches or 1 foot) from the electric line, which means stay at least 11 feet from this electric line.

If the machine touches an electric line, stay in the machine. Carefully move machine or load away from the electric line, without pulling the line down.

DO NOT let anyone else touch the machine while it is touching the electric line. If machine cannot be moved away from the electric line without pulling the line down, have someone contact the utility company to disconnect power from the line. If this is not possible, or if the machine begins to burn, jump away from the machine to the ground with both feet together, in one smooth jump. DO NOT touch the machine and the ground at the same time or else the electricity in the line will go through your body. Get away from the machine by jumping with both feet together.

Notify the utility company immediately. DO NOT let anyone near the machine while it is touching the electric line.

Page 41

OVERHEAD LOADS

booms can cause severe injury or death.

The loader operator is responsible for ensuring that booms or loads are never suspended over or near personnel.

• Always know where other people are working at

the job site in relation to the loader.

• Maintain good communication with everyone on

the job.

• Stop operations if someone on the ground ap-

proaches the machine.

63

Operation

Falling or swinging logs or

GETTING ON MACHINE

HAND HOLDS AND STEPS

severe personal injury or death.

Never use controls as hand holds. Never use steering wheel as a hand hold. Moving the steering wheel from its center position will COMPLETELY turn machine right or left.

DO NOT mount machine if hand rails or steps are broken or missing. Get them repaired rst.

DO NOT jump on or o machine unless it has touched a live electrical wire and it must be exited.

Ensure rm foot position when getting on and o machine. Be careful of slippery conditions on platform, steps, and hand holds when getting on and o machine.

Slips and falls can cause

Remove oil, grease, mud, ice, etc. before mounting or dismounting machine.

To prevent slips and falls, replace skid-resistant material if it is worn, damaged or missing.

Page 42

64

Operation

MACHINE START UP

1. Postion truck on rm, level ground.

2. Perform a pre-start inspection (refer to

Section 5, Pre-Start Inspection).

3. Before start up, walk completely around machine

and make sure no obstacles or personnel are in the area.

4. Maintain adequate distance between machine

and other equipment and personnel.

5. Mount loader (refer to Getting on Machine in this

section).

6. Lower stabilizers (refer to Lowering Stabilizers in

this section).

7. Remove transit lock (refer to Unlocking Transit

Lock in this section).

ENGAGING POWER TAKE OFF PTO

1. Park truck in safe location.

2. Check around truck and loading area for person-

nel and obstructions.

3. Set parking brake.

4. Be sure truck transmission is in neutral position.

5. Perform pre-start inspection (see Section 5, Pre-

Start Inspection).

6. Engage power take o (PTO) to activate the pump.

7. Increase engine speed to achive recommended

pump speed of 1750 rpm. Engine speed depends on pump drive ratio.

tioned so that all functions can be cycled through their full range without obstructions when starting operations.

maximum recommended PTO speed of 1750 rpm.

Machine should be posi-

Do not exceed

Page 43

ADJUSTING OPERATOR’S SEAT

WARNING

Adjust operator’s seat using the following guidelines:

SEAT FRONT AND REAR POSITION

Side lever (A) left or right.

While seated, slide seat to desired position.

Release lever.

65

Operation

ARMREST

To adjust armrest position, turn knob (B) clockwise or counterclockwise until armrest is in desired position. Push down on arm rest to lower while operating loader.

SEAT BACK

When transporting loader, fold seat back down. Do this by pulling up on lever (C) and pushing down on back (toward seat).

To raise seat back, pull up on lever (C) adjusting seat to desired position. Release lever to lock into desired position.

SEAT BELT OPTIONAL

A rollover or sudden stop can cause severe personal injury or death.

Always wear your seat belt, fastened snugly, when operating machine to reduce the risk of personal injury resulting from a rollover or sudden stop.

Page 44

66

Operation

UNLOCKING TRANSIT LOCK

Transit lock (A) must be removed to operate loader. To remove, pull up rmly on transit lock. Store lock in space left of operator’s seat (B).

Check around truck and loading area for personnel and obstructions. Any person in the immediate area (300 feet), must be aware that work will begin soon.

WARM UP PERIOD

1. Be sure area is clear of personnel.

2. Engage PTO.

3. Run transport engine at idle speed for 5 minutes.

It is important to allow the hydraulic system to reach operating temperature before beginning operation. Cold and thick oil cannot ow fast enough to the pump to meet output demand. Cavitation and extreme damage may be caused by operating the machine when the hydraulic oil is too cold to ow easily.

4. Warm up the hydraulic system by

• engaging and disengaging controls to help speed warm up of hydraulic components, and;

• cycling all controls to allow warm oil to circulate through all cylinders and lines.

Page 45

FEATHERING THE CONTROLS

67

Operation

Rough operation can be dangerous, hard on the machine, and hard on the operator.

DO NOT jerk control levers to full speed, or from one direction to another.

Feather controls this way:

1. Move joystick control gently from neutral to start motion.

2. After a slow, smooth start, move joystick control to desired speed position.

3. Just before stopping movement, move joystick control gently back to neutral.

This method of carefully manipulating the controls is called feathering. Work can done more eciently by feathering controls than by jerking controls.

There is a rhythm to operating this machine. Feathering the controls will help the operator nd and take advantage of this rhythm.

Page 46

68

Operation

USING STABILIZERS

cause severe personal injury or machine damage. Lower both stabilizers before operating machine.

stabilizers can cause serious personal injury or death. Clear all personnel from work area before lowering stabilizers.

It is the responsibility of the operator to make sure all

personnel are clear of the stabilizers (A) before lowering them. When setting the stabilizers, make sure they are sitting on rm, solid ground.

DO NOT set stabilizers on rocks, stumps, curbs, edge of paving, etc. or on soft or unstable ground.

1. Position loader on rm, level ground.

Unstable platform can

Coming into contact with

STABILIZER CONTROL SWITCHES

Left Stabilizer (B) Forward Position (away from seat):

Lower stabilizer

Rear Position (toward seat):

Raise stabilizer

Right Stabilizer (C) Forward Position (away from seat):

Lower stabilizer

Rear Position (toward seat):

Raise stabilizer

2. Double check to ensure no persons are close to truck and/or loader.

3. Clear ice and snow from the area where the stabilizer pads will be lowered. Do not operate or position loader on slippery surfaces.

4. Lower stabilizer legs until partial load has been removed from truck or trailer tires to achieve stable operating position. The truck or trailer tires should not be o the ground.

5. Follow these stabilizer operating guidelines:

• Never allow another person to be on the

loader or in and around the truck when lowering or raising stabilizers.

• Lift boom from transport position and make

a test lift to check ground conditions under stabilizers.

• Never operate machine with stabilizers in

raised position.

• Use extra precautions at maximum reach until

additional weight of payload adds to loader’s stability.

Page 47

69

Operation

RETRACTING STABILIZERS IN THE EVENT OF LOSS OF ELECTRICAL POWER

Coming into contact with stabilizers can cause serious personal injury or death. Keep all personnel clear of stabilizers.

1. Equipment needed: 5/32 steel rod and rope or

strap.

2. Verify pump is running and truck engine is at idle

speed.

3. Engage transit/swing lock.

4. Fully depress and hold swing pedal with rope or

strap.

5. Depress override switch on stabilizer valve (A), us-

ing 5/32 steel rod.

6. Stabilizer valve will shift, allowing cylinder retrac-

tion.

Page 48

610

Operation

LANDING LAYOUT

• The loader operator is in one of the best positions

on the work site to notice a problem and warn others. The loader operator is responsible for the safety of people on the ground.

• All landings (decks) should provide an area clear

of suspended loads for landing personnel (deck hands) to work. Remember, logs can roll or be thrown a considerable distance.

• If clearance of suspended loads cannot be pro-

vided, STOP loading operations and lower grapple while deck hands are working on the landing.

• All obstructing trees should be removed to ensure

clearance for loading.

• Never locate landing near overhead electrical

lines. See Electrocution Dangers in this section for instructions.

PICKING UP LOGS

• Never pinch a log. Always make sure the grapple

wraps around the log.

• Never swing load or grapple over truck cab.

• Make sure other personnel are away from truck

and loader when operating loader.

• Take care when rotating logs to make sure they

clear the loader and other obstructions.

Page 49

GRAPPLE CONTROL

Study and learn the grapple control functions (see Section 3, Controls and Instruments). Improper rotation of grapple or accidental opening of grapple will cause loss of control of the load.

• Do not change function arrangement.

• Use proper grapple to match application.

• For log handling always use a log bypass, or com-

bination bypass/pulp grapple.

• For short wood handling, use a log bypass, combi-

nation bypass or butt-style pulpwood grapple.

• Never swing and load a single log or branch by

pinching the sides of the log or stem with the grapple jaw tips. Always clamp the log or branch within the grapple jaws.

611

Operation

STOPPING THE MACHINE

1. Bring loader to a complete stop.

2. Lower attachment to truck bed with the main and

stick booms extended. The grapple should be open with the jaw tips on the truck bed.

3. Engage transit/swing lock pin.

4. Slow engine to LOW IDLE. Run engine at low idle

for at least 2 minutes to cool engine.

5. Turn key switch to OFF to stop the engine.

6. Remove key from ignition switch.

Page 50

612

Operation

GETTING OFF MACHINE

HAND HOLDS AND STEPS

Slips and falls can cause severe personal injury or death.

Never use controls as hand holds. Never use steering wheel as a hand hold. Moving the steering wheel from its center position will COMPLETELY turn machine right or left.

DO NOT mount machine if hand rails or steps are broken or missing. Get them repaired rst.

DO NOT jump on or o machine unless it has touched a live electrical wire and it must be exited.

Ensure rm foot position when getting on and o machine. Be careful of slippery conditions on platform, steps, and hand holds when getting on and o machine.

Remove oil, grease, mud, ice, etc. before mounting or dismounting machine.

To prevent slips and falls, replace skid-resistant material if it is worn, damaged or missing.

Page 51

71

Break In Period

2124 LOADER

3 4

AFTER FIRST 10 HOURS OF OPERATION

KEY COMPONENT SERVICE SPECIFICATION

1. Hydraulic Reservoir* Check uid level - 42 gallons (159 L) Full mark. Use Premium A.S. Hydraulic Fluid

2. Loader* Visually check for any loose hardware or uid leaks.

3. Outer Swing Bearing Check tightness; torque if necessary 360 ft-lbs (490 N•m) Fasteners

4. Inner Swing Bearing Check tightness; torque if necessary 730 ft-lbs (993 N•m) Fasteners

* - Not shown

The above uid capacity is approximate value. Be sure to check level after lling. DO NOT OVERFILL.

ner capscrews on the swing bearing can cause the upper and lower frame to separate, causing severe injury or death. Read and follow all torque instructions in this manual.

Loose outer bolts or in-

Page 52

72

Break In Period

AFTER FIRST 100 HOURS OF OPERATION

KEY COMPONENT SERVICE SPECIFICATION 

1. Hydraulic Return Replace Use genuine parts Line Filters

2. Swing Drive Fasteners Check tightness; torque if necessary 160 ft-lbs (218 N•m)

3. Swivel Fasteners Check tightness; torque if necessary 76-84 ft-lbs (103-114 N•m)

* - Not shown

Loose outer bolts or inner capscrews on the swing bearing can cause the upper and lower frame to separate, causing severe injury or death. Read and follow all torque instructions in this manual.

DURING THE FIRST 100 HOURS OF OPERATION

1. Check all accessible hardware for tightness.

2. Check hydraulic uid regularly.

TO TIGHTEN A LOOSE BOLT OR CAPSCREW, DO THE FOLLOWING:

1. Torque the bolt or capscrew to recommended ft-lbs. Recheck every 10 hours.

2. Check the two adjacent bolts (on either side of loose bolt) for proper torque and recheck every 10 hours.

3. If any of these bolts or capscrews do not take the torque, or come loose again, they must be replaced, in-

cluding adjacent bolts/capscrews. Replace with factory-approved parts.

Page 53

81

Transporting

The safety of the operator and those in the immediate work area depend on the operator using care and good judgement in operating this equipment. Know the positions and functions of all controls, and make sure all personnel are clear of the work area before attempting to operate this machine. See Operation section for more information.

Failure to engage Transit Lock can cause personal injury or property damage.

Engage Transit Lock before transporting loader.

Improper positioning of loader during transport or movement could cause personal

injury or property damage.

BEFORE transporting this equipment, perform the following:

• Mount loader as if for operation (see Operation section).

• Swing upper frame clear of obstacles until it centers with grapple carrier.

• Lower booms until they rest in cradles. Lower grapple until it rests in grapple carrier.

• Engage turntable Transit Lock.

• Raise stabilizers.

• Recline seat.

• Dismount (see Operation section).

• Disengage PTO to shut down hydraulic pump.

• Secure grapple to grapple carrier with chain.

• Secure any attachment(s) with chain.

• Observe all highway height and weight limitations (13.5 ft. [4.15 m] maximum load height).

• Do not ride on loader while moving truck or transporting loader.

Page 54

82

Transporting

Page 55

Fuels & Lubricants

HYDRAULIC OIL

Hydraulic systems have been lled from the factory with Premium All-Season Hydraulic Oil 46.

Use the following hydraulic oils in your machine.

AMBIENT TEMP AMBIENT TEMP AMBIENT TEMP 25°F TO 80°F 10°F TO 95°F 0°F TO 105°F 32°C TO 27°C 23°C TO 35°C 18°C TO 41°C

Premium All-Season Premium All-Season Premium All-Season Hydraulic Oil 32 Hydraulic Oil 46 Hydraulic Oil 68

The hydraulic reservoir capacity is approximately 42 gallons (159 L).

Check with an authorized dealer for hydraulic uid recommendations and compatibilities.

91

BE SURE hydraulic uid selection is compatible with the hydraulic system.

BE SURE hydraulic uid selection assistance is from a reputable supplier.

BE SURE hydraulic specications meet or exceed the Premium All Season Hydraulic Oil specications. See a Prentice machine dealer.

BE SURE to use a mineral-base hydraulic oil.

GREASE

Most lubricated ttings require Premium Moly-Lith EP #2 Grease. However, there are special requirements for the swing bearing and swing drive motor (see Grease for Swing Bearing and Swing Drive Motor in this section).

Page 56

92

Fuels & Lubricants

GREASE FOR SWING DRIVE BEARING AND SWING DRIVE MOTOR

Follow these specications when selecting a grease for the swing bearing and swing drive motor.

AMBIENT TEMPERATURE RECOMMENDED LUBRICANT

Above 32°F (0°C) Premium Moly-Lith EP #2 Grease

Below 32°F (0°C) EP1 Grease

LUBRICANT FOR PINION AND SWING GEAR TEETH

When lubricating the pinion gear and swing gear teeth, use moly-lith open gear lubricant.

When the gear path becomes contaminated, clean with solvent to remove contamination. Relubricate gear with moly-lith open gear lubricant, available from an authorized dealer.

CYLINDER ROD CORROSION PREVENTIVE

If machine will be stored for an extended period, or stored in a corrosive environment (such as salt air or industrial pollution), apply Chrome Kote Corrosion Preventive on all portions exposed to air. See Storage section for more information.

Page 57

93

Fuels & Lubricants

STORING LUBRICANTS

Store lubricants in a clean area that will keep them protected from water, dirt, or other contamination.

Always use clean containers when handling lubricants.

Storing lubricant drums or other containers outdoors is poor practice. To minimize the harmful eect of unavoidable outdoor storage, a few simple precautions and procedures can be very helpful.

1. Generally, lubricants in containers smaller than drums (55-, 30-, and 16-gallon oil drums, and 400- and 120-pound grease drums) should never be stored outdoors. When drums must be stored outdoors, a temporary shelter or lean-to, or a waterproof tarp will protect them from rain or snow.

2. Drums should be placed on their sides with the bungs approximately horizontal. In this position, bungs are below the level of the contents so that breathing of water or moisture is greatly reduced and water cannot collect inside chine (ridge of drum). For maximum protection, drums should be stood on end with bung end down on a welldrained and contained surface. Where all of these approaches are not practical, drum covers may be used. Drum covers are available in metal and plastic.

3. When drums must be stored outdoors with bung end up, they should be blocked up with bungs parallel to the block to keep water away from the bung openings.

4. Drums that have a bung on the side should be stored either on end or on their side with the bung down. Regardless of their position, drums should always be placed on blocks or racks several inches o the ground to avoid moisture damage.

DISPOSE OF USED FLUIDS PROPERLY.

If machine will be stored for an extended period, or stored in a corrosive environment

(such as salt air or industrial pollution), using a sponge, apply Chrome Kote Corrosion Preventive to portions exposed to air. See storage section for more information.

Page 58

94

Fuels & Lubricants

Page 59

BEFORE MAINTENANCE

Maintaining this machine improperly could result in severe personal injury or

death. Read this manual before doing maintenance. Follow all safety instructions.

1. Read all safety and maintenance instructions in this operator’s manual.

2. Position machine on rm, level ground.

3. Lower attachment to the ground.

4. Shut engine down.

5. Move controls in all directions to relieve hydraulic pressure.

6. Remove key from ignition.

101

Maintenance Safety

PRACTICE SAFE MAINTENANCE

Read service and maintenance manuals and understand service procedures before performing service/ maintenance.

Understand service procedures before performing maintenance. When performing maintenance, keep area around machine clean and dry.

DO NO service machine while it is moving. Keep away from power-driven parts. Lower attachment to the ground. Disengage power. Shut engine down. Move controls in all directions to relieve hydraulic pressure. Remove key from ignition. Allow machine to cool down.

Support all raised equipment.

Disconnect battery ground cable (-) before adjusting the electrical system.

Lower stabilizers to the ground. Do not support machine weight on stabilizers.

Page 60

102

Maintenance Safety

HYDRAULIC SAFETY

Fluids escaping under pressure can penetrate skin and cause severe personal injury or death. Wear eye and personal protection equipment (PPE).

If ANY uid is injected into the skin, seek medical attention immediately. A serious infection or reaction can result without proper medical treatment.

Before working on the hydraulic system,

1. Lower boom and grapple to the ground.

2. Raise stabilizers so loader rests on carrier tires.

Then lower stabilizers to they touch the ground without raising the loader.

3. Shut engine down.

4. Move joysticks in all directions to relieve hydraulic

pressure on boom.

5. Disengage pilot controls by moving pilot shut o

lever UP.

6. Remove key from ignition switch.

7. Purge air from hydraulic reservoir by depressing

relief valve button.

Hot hydraulic oil can cause severe burns. DO NOT work on hydraulic system if oil temperature exceeds 120°F (49°C).

Wear eye and personal protection equipment (PPE)!

PROTECTIVE CLOTHING

Wear OHSA-approved protective clothing when working on or near this machine, such as

• ear protection • gloves

• goggles • hard hat

• orange vest • steel-toed boots

Wear snug, protective clothing that is belted where required.

Remove jewelry before working on or near this machine.

Page 61

103

Maintenance Safety

SERVICING CONTROL VALVES, CYLINDERS, PUMPS, AND MOTORS

Increasing relief valve settings could cause machine or component failure resulting in severe personal injury or death. Do not change pressure settings. Do not switch lines from one valve to another.

Wear eye and personal protection equipment (PPE)!

Special tools and training are required to service control valves, cylinders, pumps, and motors. If these parts need service, see an authorized dealer.

UNAUTHORIZED WELDING

Unauthorized welding can cause structural failure and/or severe personal injury or death.

DO NOT weld on any structural member. Any unauthorized welding or repair will void the warranty.

Once authorized, be sure to turn battery disconnect master switch OFF.

Unauthorized welding can

cause damage to the electrical system

Page 62

104

Maintenance Safety

DURING MAINTENANCE

DIESEL EXHAUST

Diesel exhaust fumes contain elements that are hazardous to health. Always run engine in a well ventilated area. If in an enclosed area, vent exhaust outside.

FLUIDS UNDER PRESSURE

Fluids escaping under pressure can penetrate skin and cause severe personal injury or death.

Wear eye and personal protection equipment (PPE)!

Always use a board or cardboard when checking oil hoses, lines, and ttings periodically for leaks, cracks, or defects. Be sure all clamps are in their proper position and torqued as required and specied. Be sure hoses are not twisted or touching parts.

DO NOT use hands to search for leaks. Escaping uids can penetrate skin and enter the bloodstream. Before disconnecting lines, relieve all pressure.

DO NOT apply pressure to a damaged line, hose, or tting.

If any uid is injected into the skin, seek medical attention immediately. A serious infection or reaction can result without proper medical treatment.

Page 63

105

Maintenance Safety

FUELS AND LUBRICANTS

Fires and explosions can cause severe personal injury or death.

• Handle fuels and lubricants carefully.

• DO NOT smoke when fueling or working with or

around fuel.

• Clean up, and properly dispose of all spilled lubri-

cants, grease and solvents.

• Use proper tools and procedures for making

repairs.

• Wear approved eye and personal protection

equipment (PPE).

PINCH POINTS

Placing hands or any portion of the body where the machine moves can cause severe personal injury or death. Never place hands or any portion of the body where injury could occur if machine moves. Never check pin hole alignments with ngers.

Page 64

106

Maintenance Safety

AFTER MAINTENANCE

DISPOSING OF WASTE

Follow local, state, federal, and international regulations when disposing of waste. Waste may include, but is not limited to oil, fuel, coolant, brake uid, lters, and batteries.

Use leakproof containers when draining uids. Do not use food or beverage containers. Do not pour waste on the ground, down a drain, or into any water source.

Clean up all spilled fuel, oil, grease, etc. and dispose of per local, state, federal, or international regulations.

STORING FLAMMABLE MATERIALS

• Do not smoke where ammable materials are

stored.

• Store fuels and lubricants in properly marked

containers.

• Store oily rags and other ammable materials in

protective containers.

Page 65

Scheduled & Periodic Maintenance

LUBRICATION AND MAINTENANCE INTERVALS

Maintenance requirements for lubrication, adjustments and checks are shown on the maintenance charts in this section.

Intervals of maintenance are based on normal operating conditions. If operating under more demanding conditions, observe a shorter time interval between maintenance.

Demanding conditions include but are not limited to:

• Frequent handling of near maximum capacity loads

• High duty cycle operation

• Dry work area with heavy blowing dust

• Extreme cold, -20°F (-6°C) and below

• Extreme heat, 90°F (32°C) and above

111

• Multiple shift operation

LUBRICATION NOTICE

Listed maintenance intervals are for normal use applications. When greasing lubrication ttings, if grease is not forced out the bushing ends with the recommended shots, increase number of shots used until grease is forced out. If grease cannot be forced out, check for blocked grease passageways.

If the lubricating areas are dry at the end of a normal operating day, increase the frequency of lubricating time periods instead of increasing the amount of grease used at one lubrication period.

POSITION MACHINE FOR MAINTENANCE

To avoid serious personal injury or property damage, follow the steps below before performing any maintenance on this machine.

1. Park machine on level ground.

2. Lower boom and grapple to ground.

3. Raise stabilizers so loader rests on carrier tires.

Then lower stabilizers so they touch the ground without raising the loader.

4. Shut truck engine down.

5. Remove key from ignition switch.

6. Move joysticks in all directions to relieve hydraulic

pressure on boom.

Page 66

112

Sheduled & Periodic Maintenance

MAINTENANCE CHART USAGE

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.

AS REQUIRED

KEY COMPONENT SERVICE SPECIFICATION

1. Electrical System* Check Inspect harness and connections

2. Hydraulic Oil* Drain/replace Seasonally AS Hyd. Oil

3. Safety Decals* Clean Replace Use only genuine parts

4. Ladder Check Inspect ladder structure and fasteners Use only genuine parts

* - Not shown

** Do not alter A-Frame

MATERIAL USED

structure. Do not weld or machine A-Frame structure. Immediately report structural problems (cracks and/or bends) to an authorized dealer for diagnosis and repair or replacement.

Page 67

113

Scheduled & Periodic Maintenance

17 16

MAINTENANCE CHART USAGE

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.

DAILY OR EVERY 10 HOURS

KEY COMPONENT SERVICE SPECIFICATION

*DAILY VISUAL INSPECTION** Inspect Inspect loader for damage, see detail

5. Adapter Knuckle Lubricate Lubricate until grease is forced out Prem. Grease

6. Main Boom Pivot Pin Lubricate Lubricate until grease is forced out Prem. Grease

7. Main Boom Cylinder Base End Lubricate Lubricate until grease is forced out Prem. Grease

8. Main Boom Cylinder Rod End Lubricate Lubricate until grease is forced out Prem. Grease

9. Main/Stick Pivot Pin Lubricate Lubricate until grease is forced out Prem. Grease

10. Stick Boom Cylinder Base End Lubricate Lubricate until grease is forced out Prem. Grease

11. Stick Boom Cylinder Rod End Lubricate Lubricate until grease is forced out Prem. Grease

12. Swing Bearing Lubricate Lubricate while rotating 2 complete Prem. Grease revolutions

13. Pinion Gear Lubricate Lubricate gear with open gear lube Open gear lube

14. Hydraulic Oil Reservoir* Check level Add hydraulic oil if necessary Hyd. Oil

15. Electrical Components* Inspect Check for fraying, loose connections See details in section

16. Seat Fasteners Check/replace Tighten. Replace if missing. Wrench

17. Seat belt (optional) Inspect Replace if damaged Use genuine parts

* - Not shown

Lubricate with Premium

Moly-Lith EP #2 Grease.

** Do not alter A-Frame structure. Do not weld or machine A-Frame structure. Immediately report structural problems (cracks and/or bends) to an authorized dealer for diagnosis and repair or replacement.

MATERIAL USED

Page 68

114

Sheduled & Periodic Maintenance

MAINTENANCE CHART USAGE

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.

WEEKLY OR EVERY 50 HOURS

KEY COMPONENT SERVICE SPECIFICATION

*. WEEKLY INSPECTION Inspect Check for damage, see detail

18. Loader Mounting Bolts Inspect Check for stability of loader position

19. Boom / Cylinder Pin Retainers Check Snap rings in place. Replace if missing. Use genuine parts

20. Stabilizer Cylinder Pins Check Snap rings in place. Replace if missing. Use genuine parts

21. Oil Reservoir Hardware* Check Tighten Wrench

22. Hydraulic connections* Inspect Tighten Wrench

23. Hydraulic Oil Reservoir* Check oil If contaminated, replace Prem AS Hyd Oil

24. Joystick boots Inspect

25. Stabillizer Cylinder Rod End Lubricate Lubricate until grease is forced out Prem. Grease

26. Stabilizer Cylinder Base End Lubricate Lubricate until grease is forced out Prem. Grease

* - Not shown

Check for cracks and damage. Replace if damaged.

** Do not alter A-Frame

MATERIAL USED

Use genuine parts

structure. Do not weld or machine A-Frame structure. Immediately report structural problems (cracks and/or bends) to an authorized dealer for diagnosis and repair or replacement.

Page 69

115

Scheduled & Periodic Maintenance

MAINTENANCE CHART USAGE

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.

MONTHLY OR EVERY 250 HOURS

KEY COMPONENT SERVICE SPECIFICATION

27. Seat Inspect/Lube Lubricate seat position adjustment Silicone spray

28. Swing Drive Fasteners Check Tighten to 160 ft-lbs (218 N•m) Torque wrench

MATERIAL USED

Page 70

116

Sheduled & Periodic Maintenance

29 30

MAINTENANCE CHART USAGE

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.

EVERY THREE MONTHS OR 600 HOURS

KEY COMPONENT SERVICE SPECIFICATION

29. Hydraulic Oil Return Line Filter Install new* Replacement lter Use genuine parts

30. Return/Case Drain Filter Install new* New lter Use genuine parts

31. Outer Swing Bearing Fasteners Check Tighten to 360 ft-lbs (490 N•m) Torque wrench

32. Inner Swing Bearing Fasteners Check Tighten to 730 ft-lbs (993 N•m) Torque wrench

33. Joystick Lubricate Grease ttings beneath joystick boot Prem. Grease

* - Change interval can vary depending on operating conditions

MATERIAL USED

Page 71

117

Scheduled & Periodic Maintenance

MAINTENANCE CHART USAGE

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.

EVERY SIX MONTHS OR 1200 HOURS

KEY COMPONENT SERVICE SPECIFICATION

34. Hydraulic Oil* Drain/replace See details in section Premium AS Oil

35. Collector Ring Check/clean Spray contacts, check brushes and wire Contact cleaner connections

MATERIAL USED

* - Not shown

Page 72

118

Sheduled & Periodic Maintenance

AS REQUIRED

1. CHECK ELECTRICAL SYSTEM

Check all electrical wires daily. Wiring must be kept in good condition. All electrical wires must be properly routed and securely attached. Repair any wires that are loose or frayed before starting the engine. Clean and tighten all electrical connections.

Arcing or sparking could cause a re. Securing connections and maintaining recommended wiring will help to prevent arcing or sparking.

If electrical problems occur, check wire harness and connectors.

2. DRAIN AND REPLACE HYDRAULIC OIL

Hydraulic oil must be changed based on the ambient (outside) air temperature. Certain grades of hydraulic oil work best in certain temperature ranges.

Follow Caterpillar Forest Product’s hydraulic oil specications. If oil is not changed seasonally, as required, the hydraulic system can be damaged.

Refer to Lubricants section for hydraulic oil recommendations.

Hydraulic oil capacity is 42 gallons (160 L)

DO NOT mismatch brands or

weights of hydraulic oil.

3. INSPECT SAFETY DECALS

Inspect safety decals and replace as needed when damaged or unreadable.

Decals will not adhere to

dirty or wet surfaces. Thoroughly clean and dry any area where a decal or slip resistant mat is to be placed.

Page 73

119

Scheduled & Periodic Maintenance

4. INSPECT LADDER STRUCTURE AND FASTENERS

Check that the upper ladder mounting fasteners (A) are torqued at 266-294 ft-lbs (361-399 N•m) torque. Check that the lower ladder mounting fasteners (B) are torqued at 76-84 ft-lbs (103-114 N•m) torque.

If damaged or missing, replace with new.

Caterpillar Forest Products engineering does not approve installation of a 90 degree ladder on the service side of the loader. Do not congure machine with two 90 degree ladders.

Page 74

1110

Sheduled & Periodic Maintenance

DAILY OR EVERY 10 HOURS

PERFORM A DAILY VISUAL INSPECTION

Failure to perform a daily inspection of machine can result in machine damage and severe personal injury or death.

In addition to the required daily inspection outlined in Pre-Start Inspection section perform a daily inspection of the following components:

• Structures • Swing bearing

• Booms • Load-bearing items

• Cylinders • All mountings

• Turntable

Unauthorized welding can cause structural failure and/or severe personal injury or death.

DO NOT weld on any structural member. Any unauthorized welding or repair will void the warranty.

Once authorized, be sure to turn battery disconnect master switch OFF.

5. LUBRICATE ADAPTER KNUCKLE

Lubricate adapter knuckle (A) with Premium Moly-Lith EP #2 until grease is forced out.

Page 75

1111

Scheduled & Periodic Maintenance

6. LUBRICATE MAIN BOOM PIVOT PIN

Lubricate main boom pivot pin (A) with Premium Moly-Lith EP #2 until grease is forced out.

7. LUBRICATE MAIN BOOM CYLINDER

BASE ENDS

Lubricate main boom cylinder base ends (B) with Premium Moly-Lith EP #2 until grease is forced out.

8. LUBRICATE MAIN BOOM CYLINDER

ROD ENDS

Lubricate main boom cylinder rod ends (C) with Premium Moly-Lith EP #2 until grease is forced out.

9. LUBRICATE MAIN/STICK PIVOT PIN

Lubricate main/stick pivot pin (D) with Premium MolyLith EP #2 until grease is forced out.

Page 76

1112

Sheduled & Periodic Maintenance

10. LUBRICATE STICK BOOM CYLINDER

BASE END

Lubricate stick boom cylinder base end (A) with Premium Moly-Lith EP #2 until grease is forced out.

11. LUBRICATE STICK BOOM CYLINDER ROD END

Lubricate stick boom cylinder rod end (B) with Premium Moly-Lith EP #2 until grease is forced out.

12. LUBRICATE SWING BEARING

The swing bearing grease tting (C) is located left of the operator’s seat, near the transit lock.

Lubricate swing bearing with Premium Moly-Lith EP #2 while rotating loader 2 complete revoluti

ns.

Rotate turntable slowly. Boom can strike people or property, which can cause personal injury or property damage. Be sure loader is clear of obstructions, remove personnel, and make sure those not performing maintenance are clear of the machine.

13. LUBRICATE PINION GEAR

Coat pinion gear teeth (D) with Heavy Duty Open Gear Lube to prevent bare metal contact.

Page 77

1113

Scheduled & Periodic Maintenance

14. CHECK HYDRAULIC OIL RESERVOIR LEVEL

1. Position loader properly for an accurate reading.

Booms should be in transport position and stabilizers should be raised.

2. Move joysticks in all directions to relieve hydraulic

pressure.

3. Visually check the oil level by observing the sight

gauge (A) on the hydraulic reservoir while oil is warm. Sight gauge is located on hydraulic tank.

4. Add clean, ltered oil, if necessary (see instruc-

tions below).

FILLING HYDRAULIC RESERVOIR

1. Clean area around ller cap (B).

2. Remove ller cap.

3. Insert clean hose into oil supply container with

nozzle end in hydraulic oil reservoir.

4. Fill reservoir until oil reaches the top of the

hydraulic reservoir sight gauge (C). Hydraulic oil capacity is 42 gallons (159 L).

Page 78

1114

Sheduled & Periodic Maintenance

15. INSPECT ELECTRICAL COMPONENTS

Loose, frayed, or worn

electrical components may result in electrical shock or re, causing severe personal injury or death.

Arcing or sparking could cause a re. Securing connections and maintaining recommended wiring will help to prevent arcing or sparking.

16. INSPECT SEAT FASTENERS

Loose, broken or dam-

aged fasteners can cause seat to be unstable, causing severe personal injury or death.

Check all seat fasteners daily. If loose, tighten. If broken, damaged or missing, replace with new fasteners.

Damaged, loose or missing fasteners could cause seat to be unstable.

17. INSPECT SEAT BELT OPTIONAL

Replace seat belt if any sign of wear is visible. Failure to replace worn seat belt as needed can result in serious personal injury or death.

Check seat belt (A) for any sign of wear or fraying. If any sign of wear is visible, replace seat belt.

Page 79

WEEKLY OR EVERY 50 HOURS

PERFORM A WEEKLY INSPECTION USING THE FOL LOWING GUIDELINES

1. Clean the structure thoroughly. Remove all dirt, mud, grease, oil, debris, and snow.

2. Look for rust lines in the paint, and missing or cracked paint. These are indications of crack sites.

3. Inspect all welds and adjacent areas on booms, cylinders, turntable, swing gear mounting, and grapple for signs of cracks.

4. Inspect the grapple around cylinder and jaw mountings, the jaws, the rotator mounting, and frame.

5. Check all boom cylinders and pin keeper retainers for broken fasteners. If broken or damaged, replace with new fasteners.

1115

Scheduled & Periodic Maintenance

6. Check the mounting to the truck or trailer frame. Ensure that the fasteners are tight and any spacers are in good condition and in their correct locations.

7. Check the sub-frame and stabilizers. Check the areas around the swing bearing mounting, the stabilizer, and their mounting ears, and the stabilizer cylinders and their mounting.

Unauthorized welding can

cause structural failure and/or severe personal injury or death.

DO NOT weld on any structural member. Any unauthorized welding or repair will void the warranty.

Once authorized, be sure to turn battery disconnect master switch OFF.

. Unauthorized welding can

cause damage to the electrical system.

8. Inspect safety decal and replace as needed when damaged or illegible (unreadable).

Page 80

1116

Sheduled & Periodic Maintenance

18. INSPECT LOADER MOUNTING BOLTS

Inspect and tighten loader mounting bolts, ensuring loader position has not moved.

19. CHECK BOOM AND CYLINDER AT

TACHING PINS

Inspect and tighten all boom and cylinder attaching pins and pin retaining hardware.

20. CHECK STABILIZER ATTACHING PINS

Inspect and tighten all stabilizer attaching pins (A). Verify that all snap rings are in place and secure.

21. CHECK HYDRAULIC OIL RESERVOIR

HARDWARE

Inspect and tighten hydraulic oil reservoir hardware. If damaged, replace with new. Torque mounting band clamp fasteners to 17-19 ft-lbs (23 - 26 N•m) torque.

Overtightening of fasteners

can result in damage to reservoir.

Page 81

1117

Scheduled & Periodic Maintenance

22. CHECK HYDRAULIC CONNECTIONS

Inspect and tighten all hydraulic connections.

23. CHECK HYDRAULIC OIL RESERVOIR

FOR CONTAMINANTS

1. Loosen drain plug (A) on bottom of hydraulic reservoir.

2. Using a catch pan to collect hydraulic oil, visually inspect hydraulic oil for contamination.

If contamination such as water is visible, the hy-

draulic oil reservoir must be drained, cleaned, and lters replaced. For procedures on changing the hydraulic oil, see Changing Hydraulic Reservoir Oil in this section.

3. Tighten drain plug.

4. Dispose of used hydraulic oil properly.

24. INSPECT JOYSTICK BOOTS

Inspect joystick boots (B) for cracks, tears, or other damage that may expose the components beneath them. Replace joystick boots if damaged.

Page 82

1118

Sheduled & Periodic Maintenance

WEEKLY OR EVERY 50 HOURS

25. LUBRICATE STABILIZER CYLINDER

ROD ENDS

Lubricate stabilizer cylinder rod ends with Premium Moly-Lith EP #2 until grease is forced out. Grease tting is located inside hole (A).

26. LUBRICATE STABILIZER CYLINDER

BASE ENDS

Lubricate stabilizer cylinder base ends (B) with Premium Moly-Lith EP #2 until grease is forced out.

Page 83

Scheduled & Periodic Maintenance

MONTHLY OR EVERY 250 HOURS

27. PERFORM SEAT MAINTENANCE

1. Inspect all moving and pivoting parts of the seat. If damaged, replace with new.

and track hardware are secure. Verify tracks and seat back lock rmly into place. Seat can become unstable causing serious personal injury or property damage.

2. Lubricate the all of the moving and pivoting parts as needed.

28. CHECK SWING DRIVE FASTENERS

1119

Verify arm pivot screws

Check that the swing drive fasteners (A) are tightened to 160 ft-lbs (218 N•m) torque.

If fasteners are damaged, replace with new using threadlock.

Page 84

1120

Sheduled & Periodic Maintenance

EVERY THREE MONTHS OR 600 HOURS

29. REPLACE HYDRAULIC RETURN LINE FILTERS

1. Lower boom and grapple to ground. Shut engine

down and remove key.

2. Move joysticks in all directions to relieve hydraulic

pressure.

3. Open reservoir ller/breather to release reservoir

pressure.

4. Remove hydraulic oil lters (A).

5. Fill new lters with hydraulic oil.

6. Lubricate gasket with new hydraulic oil.

7. Install new lters.

8. Run at idle speed for 5 minutes. Check for leakage

around lter gaskets.

9. Dispose of used lters properly.

30. REPLACE CASE DRAIN FILTER

1. Lower boom and grapple to ground. Shut engine

down and remove key.

2. Move joysticks in all directions to relieve hydraulic

pressure.

3. Open reservoir ller/breather to release reservoir

pressure.

4. Remove case drain lter (A).

5. Fill new lter with hydraulic oil.

6. Lubricate gasket with new hydraulic oil.

7. Install new lter.

8. Run at idle speed for 5 minutes. Check for leakage

around lter gasket.

9. Dispose of used lter properly.

Page 85

1121

Scheduled & Periodic Maintenance

31. CHECK OUTER SWING BEARING FAS TENER TORQUE

Check that the outer swing bearing fasteners (A) are torqued at 360 ft-lbs (490 N•m) torque.

If fasteners are damaged, replace with new.

If a fastener will not tighten to the specied torque, replace with a new fastener. Also remove and replace the 2 fasteners on either side of the damaged (replaced) fastener.

32. CHECK INNER SWING BEARING FAS TENER TORQUE

Check that all inner swing bearing fasteners (B) are tightened to 730 ft-lbs (993 N•m) torque.

If fasteners are damaged, replace with new.

If a fastener will not tighten to the specied torque, replace with a new fastener. Also, remove and replace the 2 fasteners on either side of the damaged (replaced) fastener.

33. LUBRICATE JOYSTICK

Remove protective boot to gain access to joystick components.

If signs of corrosion, moisture and/or oil leakage are present, contact an authorized dealer.

Lubricate joystick moving parts.

Page 86

1122

Sheduled & Periodic Maintenance

EVERY SIX MONTHS OR 1200 HOURS

34. CHANGE HYDRAULIC RESERVOIR OIL

1. Position the machine on level ground. The boom

should be in transport position and stabilizers should be raised.

2. Shut engine down and remove key.

3. Move joysticks in all directions to relieve hydraulic

pressure.

4. Open reservoir ller/breather to release reservoir

pressure.

5. Gain access to the hydraulic drain plug (A).

6. Clean around drain plug.

7. Remove the drain plug and drain hydraulic oil into

properly-sized catch pan. Dispose of oil properly.

8. Reinstall drain plug.

FILLING HYDRAULIC RESERVOIR

1. Clean area around ller cap (B).

2. Remove ller cap.

3. Insert clean hose into oil supply container with

nozzle end in hydraulic oil reservoir.

4. Fill reservoir until oil reaches the top of hydraulic

reservoir sight gauge (C). Hydraulic oil capacity is 42 gallons (159 L).

Page 87

1123

Scheduled & Periodic Maintenance

35. CHECK/CLEAN COLLECTOR RING

1. Shut engine down and remove key.

2. Remove collector ring cover (A).

3. Spray collector with quality contact cleaner.

4. Check wire conections and brushes. Replace, if

necessary.

5. Replace collector cover.

Page 88

1124

Sheduled & Periodic Maintenance

Page 89

121

Storage

PREPARING MACHINE FOR STORAGE

If possible, store machine under cover and out of weather, in well-ventilated area. Store

attachment on rm, level ground. Block tires to prevent accidental machine movement. See engine operator’s manual for proper engine storage.

. If machine will be stored for an extended period, or stored in a corrosive environment (such as salt air or industrial pollution), using a sponge, apply Chrome Kote Corrosion Preventive to portions exposed to air. Also apply Chrome Kote Corrosion Preventive to radiator, oil cooler ns, and all wiring connections. Reapply Chrome Kote Corrosion Preventive every 3 months while machine remains in storage.

1. Operate machine long enough to warm uids. Check for leaks after machine warms up.

2. Drain hydraulic oil, ush oil reservoir.

3. Change hydraulic lters, rell hydraulic tank.

4. Repair worn or damaged parts. Install new parts, if necessary.

5. Grease machine thoroughly. Lubricate all grease points. Grease threads on bolts used for adjustments.

Coat exposed cylinder rods with Chrome Kote Corrosion Preventive to retard rusting.

6. Restart and operate machine long enough to warm uids. Check for leaks after machine

warms up.

7. Thoroughly wash machine and attachments.

8. Repaint machine where necessary.

9. Store loader in transport position (refer to Transporting Section in this manual).

10. Wipe up lube spills.

11. Dispose of rags and trash. Dispose of used uids properly.

12. Block tires to prevent accidental truck movement.

13. Seal openings with moisture-resistant tape to prevent animals and insects from building nests inside ma-

chine.

14. See engine operator’s manual for proper engine storage.

15. See truck operator’s manual for proper truck storage.

Page 90

122

Storage

TAKING THE MACHINE OUT OF STORAGE

1. Clean machine and attachments thoroughly.

2. Remove sealing tape from engine openings.

3. Check all oil levels. If low, check for leaks; add oil as required.

4. See engine operator’s manual for information on restoring engine to service.

5. See truck operator’s manual for information on restoring truck to service.

9. Cycle all hydraulic functions several times.

10. Check condition of all hoses and connections.

11. Review this operator’s manual.

Chrome Kote Corrosion Preventive is compatible with hydraulic oil and seal materials. It does not have to be removed when taking machine out of storage. When using a dierent brand of corrosion preventive, be sure to check manufacturer’s recommendations on whether it should be removed prior to operation.

Page 91

131

Troubleshooting

HYDRAULIC SYSTEM

PROBLEM POSSIBLE CAUSE SOLUTION

Hydraulic system does not work. Low hydraulic oil level. Add hydraulic uid.

PTO not engaged. Engage PTO.

Plugged suction line. See an authorized dealer.

Defective pump drive. See an authorized dealer.

Hydraulic system is noisy, vibrating. Air in system. Check uid level and see an authorized dealer if problem persists.

Cylinder “settle.” Leaking piston seals. See an authorized dealer.

Controls slow and/or lack power. Lack of hydraulic oil. Check/add hydraulic oil (see Lubricants section for recommended hydraulic oils).

Aeration in suction lines. Tighten hose ttings.

Improper adjustment of relief valves. See an authorized dealer.

Cylinder functions poorly and/or lacks Cold oil. Warm up system. power. Engine at idle speed. I

Wrong hydraulic oil. Replace hydraulic oil (see Lubricants section for recommended hydraulic oils).

Damage to cylinder seals. Replace seals.

Aeration in cylinders. Bleed air from line.

Malfunctioning control valve. Repair or replace control valve.

Swing is slow or impossible to move. Transit lock engaged. Remove transit lock pin.

Obstruction under swing pedal. Remove obstruction.

Control valve problem. Repair or replace control valve.

Swing motor problem. Repair or replace swing motor.

Damage to swing gears. Repair or replace swing gear.

Damage to swing bearing. Repair or replace swing bearing.

Hydraulic uid is foaming. Suction line air leak. Repair or replace suction line.

Low hydraulic oil leak. Add hydraulic oil.

Water in hydraulic uid. Replace hydraulic uid and lters.

Hydraulic uid temperature is too high. Wrong viscosity oil. Replace hydraulic oil.

Engine speed too high. See an authorized dealer.

Worn pump. See an authorized dealer.

Defective relief valve. See an authorized dealer.

Internal cylinder leakage or control valve. See an authorized dealer.

Control valve reliefs. See an authorized dealer.

Loader is being operated over approved relief Install new lters/see dealer. pressure settings.

Plugged lters. Install new lters/see dealer.

ncrease engine speed ot recomended speed.

Page 92

132

Troubleshooting

CLEANLINESS OF HYDRAULIC COMPONENTS

Cleanliness in hydraulics is essential. Be sure to keep contaminants out of the machine’s hydraulic system. Maintain the loader properly to reduce the risk of contaminating hydraulic components.

Clearances in hydraulic components can be very small. Many hydraulic systems have clearances of less than 25 microns, or .001 inch. Abrasive particles can enter the space between moving parts and honed surfaces to wider clearances. Increased clearance decreases the eciency of pumps, motors, and cylinders. This damage wastes horsepower and generates potentially damaging system heat.

The following gure lists the sizes of dierent common particles in inches and microns to show how even very small particles can contaminate hydraulic components.

NOTE: Contaminant particle size is measured in microns. One micron equals one millionth of a meter, or .000039 inch.

INCHES MICRONS

130

.005

.004

.003

.002

.001

120

110

100

Table salt

200 Mesh screen Human hair

Pollen

Fog

Visibility limit

White blood cells

Talcum

Bacteria

Red blood cells

Page 93

2124 DIMENSIONS

PRENTICE 2124 SELF-LOADER TRUCK MOUNT

99”

20”

16”

24” 39”

74”

111”

122”

20”

118”

162” Road

Restriction

Center of Gravity

81” A-Frame Height

Truck Frame

40” Truck Height

Ground

Allow 6” to 12”

Between Cab

and Loader if

BC Mounted

26”

A-Frame

Width

Before mounting any loader: consult the truck body manufacturer for installation precautions and recommendations. Failure to follow manufacturers recommendations could result in damage to the truck.

Minimum Carrier is a single axle truck with frame section modules of 18 cu. in. and GVW rating of 27,000 lbs. Recommended Carrier is a live tandem truck with frame section modules of 18 cu. in. and GVW rating of 32,000 lbs.

PRENTICE 2124 SELF-LOADER TRAILER MOUNT

20”

102”

Center of Gravity

Trailer Frame

64”

A-Frame

Height

56” Trailer Height

Ground

26”

A-Frame

Width

141

Specications

Page 94

142

2124 LIFT CAPACITY

NOTES:

Capacities shown in “Black” are 100% of main cylinder hydraulic capability; capacities shown in “Red” are 87% of hydraulic capacity. Notice that some of the lifts in “Red” are higher than main only, since the stick has mechanical advantage and the limiting lift is the main relief.

Lift Capacity Chart PRENTICE 2124 • Boom Type: Knuckleboom • Boom length: 22’ (6.7m)

9.1m (30’/)

7.6m (25’/)

6.1m (20’/)

4.6m (15’/)

3m (10’/)

1.5m (5’/)

0 0.0

Lift Capacity Chart PRENTICE 2124 • Boom Type: Knuckleboom • Boom length: 25’ (7.62m)

lbs.

3974

4898

kg.

1802

2222

lbs.

5528

6842

7626

9325

8900

9058

8608

6544

6172

kg.

2507

3103

3459

4230

4037

4109

3904

2968

2800

lbs.

4613

5302

5198

5358

6030

5755

6363

6056

5974

5664

4087

3838

kg.

2092

2405

2358

2430

2735

2610

2886

2747

2710

2569

1854

1741

lbs.

3324

4070

4545

4591

4538

3582

4349

3369

kg.

1508

1846

2062

2082

2058

1625

1972

1528

2962

2500

2298

2314

2242

2327

3329

lbs.

12762

14727

5077

5835

6522

7496

kg.

5789

6680

2303

2647

2958

3400

lbs.

7960

8074

9332

8864

8191

7736

kg.

3611

3662

4233

4021

3715

3509

lbs.

3975

4569

3915

4500

4099

4645

4802

5169

6059

5764

6243

5915

5390

5077

kg.

1803

2072

1776

2041

1859

2107

2178

2345

2748

2614

2831

2683

2445

2303

lbs.

3259

3745

3663

4211

4169

4352

4706

4456

4460

4207

3216

3001

kg.

1478

1699

1661

1910

1891

1974

2134

2021

2068

1908

1459

1361

1995

1693

1634

1769

1693

1642

2592

1.5m (5’/) 4.6m (15’/) Full Reach3m (10’/) 6.1m (20’/)

9.1m (30’/)

7.6m (25’/)

6.1m (20’/)

4.6m (15’/)

3m (10’/)

1.5m (5’/)

0 0.0

Specications

Page 95

2124 SPECIFICATIONS

HYDRAULIC SYSTEM

Type Split ow tandem circuit hydraulic system. System pressure 3200 psi. (2,249,822.7 kg) Operation Fully independent simultaneous operation of main boom and swing. Flow diverted to operate stabilizers. Control Valves Stack sections with mechanical joysticks. Valves contain port reliefs and anti-cavitation valves for loader protection and cont rol. Port relief

settings are 2,671,664.4 kg (3800 psi.) Cylinders 114.3 cm (4.5”) Main and stick double acting with solid rods. Diagnostic Nipples Located at control valves. Oil Filter Two return spin on lters, 2 nominal/10 absolute micron lter. Twenty ve micron case drain lter. Oil Reservoir 159 liters (Forty two [42] gallon) capacity. Filtered breather, sight gauge. Cylindrical design, aluminum fabrication. Pump Mounting Direct mounted PTO driven, bi-rotational, delivering 151liters (40 GPM). (Optional Chassis mount conguration.) Loader Pump Tandem gear type (21 + 19) operating at 1650 rpm (max) through PTO. Pump rated for 2,460,743.5 kg (3500 psi.) Swivel Steel barrel with Durabar core. Five passages for pressure, return and stabilizers. Eight ring electric collector standard for optional light

packages. Hoses & Hydraulic Tubes 2,812,278.3 kg (4000 psi) rated hose with wear resistant coating. Steel ORS tubing. Fittings ORS ttings.

KNUCKLE BOOM

Boom Length 6.7 m (22’) horizontal reach. 10.3 m (34’) working height to boom tip. (Optional Tele-Boom): 10.3 m (25’) horizont

al reach. 11. 2 m (37’)

working height to boom tip. Boom Structure Boom is high tensile steel fabrication. Main boom equivalent to 25.4 cm (10”) x 15.2 cm (6”) Spar tube. Stick boom equivalent t o

20.3 cm (8”) x 15.2 cm (6”) spar tube.

Construction Welded high tensile steel “Knuckle type” boom with heat treated high alloy steel pins and aluminum-bronze pivot bushings; self- aligning

bushings at both ends of main and stick boom cylinders. Boom & cylinder pin bushings are greased through pins. Castings at bas e end,

stick end and midpoint of mainboom assembly

STABILIZERS

Type Telescopic A-frame stabilizers with individual platform control s for uneven terrain. Structural Stabilizer legs are 17.8 cm (7”) x 17.8 cm (7”) high tensile steel tubing. Stab Pads Stabilizer pads measure 25.4 cm (10”) x 38.1 cm (15”). Clearances Ground clearance for stabilizers in retracted position is 50.8 cm (20”). Below grade reach in extended position is 40.6 cm (16” ). Stowed Stabilizers stowed position 251.4 cm (99”) wide. Width at grade level 284.4 cm (112”) on 101.6 cm (40”) truck. Width fully ext ended

284.4 cm (122”).

STRUCTURAL

Pedestal “A-Frame” pedestal design is formed high strength steel plate. Swing System Continuous rotation; ring and pinion gear set driven by an axial piston hydraulic motor through a planetary gearbox. Slewing ri ng is

65.1 cm (25.65”) diameter. Swing torque 71,014.91 kg (14,545 ft.lbs.). Travel Swing system is secured by house lock during transit. Travel Height 33.5 cm (13’ 2”) maximum stowed height above ground 101.6 cm (40”) truck frame height Weight 2,585.4 kg (5,700 lbs) for the 6.7 m (22’) xed boom model and 2744.23 kg (6,050 lbs) for the 7.62 m (25’) tele boom model. Mounting “A-frame” mounting base is 90.8 cm (35 3/4”) wide x 66 cm (26” ) long for mounting on standard truck chassis.

CYLINDERS

Main Boom (1) 11.4 cm (4.5”) Bore x 6.3 cm (2 1/2”) Rod Stick Boom (1) 11.4 cm (4.5”) Bore x 6.3 cm (2 1/2”) Rod Stabilizers (2) 7.6 cm (3”) Bore x 5 cm (2”) Rod

OPERATION OF LOADER

Operator’s Platform Platform right side mounted with fold over seat. Access to platform by single ladder. Seat Fold down seat with armrests Controls Two mechanical joysticks and proportional teleboom controls. Swing pedal with mechanical linkage. Individual controls for activ ation

of stabilizer. WEIGHT 5700 lbs. with 22’ boom Add 250 lbs for 25’ teleboom option

CAPACITY (Note: SAE Standard 87% Ratings) Radius Elevation Lift Capacity

Radius

1.5 m (5’) 3 m (10’)

4.5 m (15’) 6 m (20’)

6.7 m (22’)

1.5 m (5’)

Lift Capacit

p y

2,290.6 kg 3,865.9 kg 2,525.1 kg 1,481.4 kg

945.2 kg

Note: Deduct grapple weight for payload

(5,050 lbs.) (8,523 lbs.)

( 5,567 lbs.)

(3,266 lbs.) (2,084 lbs.)

143

Specications

Page 96

144

Specications

HYDRAULIC CONNECTION TORQUE SPECIFICATIONS

SAE 37° FLARE CONNECTION

HOW CONNECTION WORKS: HOW TO TIGHTEN CONNECTION:

This connection seals on two mating 37° seats. Use a torque wrench to rotate and tighten nut. Turn nut to value shown in table below.

TORQUE

DASH SIZE THREAD SIZE INCHLBS NEWTONMETERS

-3 3/8 - 24 8-9 11-12

-4 7/16 - 20 11-12 15-16

-5 1/2 - 20 14-16 19-21

-6 9/16 - 18 18-20 25-27

-8 3/4 - 16 36-39 49-53

-10 7/8 - 14 57-63 77-84

-12 1 1/16 - 12 79-88 108-118

-14 1 3/16 - 12 83-92 113-2124

-16 1 5/16 - 12 108-113 147-153

-20 1 5/8 - 12 127-133 172-180

-24 1 7/8 - 12 158-167 215-225

-32 2 1/2 - 12 245-258 332-350

The above torque values are good for:

• machined adapters and hose ttings

• ared tubed (with sleeve and nut)

• universal radius ared tubes

Page 97

HYDRAULIC CONNECTON TORQUE SPECIFICATION

ORING FACE SEAL CONNECTION

G.158.02

HOW CONNECTION WORKS

This connection seals with an o-ring on the male against a at surface.

HOW TO TIGHTEN CONNECTION

Use a torque wrench to rotate and tighten nut. Turn nut to value shown in table below.

145

Specications

TORQUE

DASH SIZE THREAD SIZE INCHLBS NEWTONMETERS

-4 9/16 - 18 19 26

-6 11/16 - 16 31 42

-8 13/16 - 16 46 62

-10 1-14 71 96

-12 1 3/16 - 12 91 123

-16 1 7/16 - 12 130 176

-20 1 11/16 - 12 171 232

-24 2 -12 210 285

Make sure the o-ring does not fall out of the male end before connection is made. Proper lubrication helps.

Page 98

146

Specications

TORQUE CHART FOR ENGLISH FASTENERS

This torque chart applies to lubricated threads for bolts, capscrews, and studs.

These specications do not apply to self-locking nuts or capscrews. To obtain proper torque, do not use lock washers. Hardened at washers are recommended.

GRADE 8 FASTENERS

COARSE THREAD FINE THREAD

Nominal Size Torque (ft-lbs) Torque (N•m) Nominal Size Torque (ft-lbs) Torque (N•m)

1/4 - 20 8-9 11-12

5/16 - 18 17-19 23-26

3/8 - 16 33-36 45-49

7/16 - 14 52-57 71-77

1/2 - 13 76-84 103-114

9/16 - 12 105-115 142-156

5/8 - 11 162-178 220-241

3/4 - 10 266-294 361-399

7/8 - 9 437-483 593-655

1 - 8 646-714 876-968

1 1/8 - 7 912-1008 1237-1367

1 1/4 - 7 1292-1428 1752-1936

1 1/2 - 6 2242-2478 3040-3360

1 3/4 - 5 3048-3688 4133-5001

2 - 4 1/2 4610-5096 6251-6910

1/4 - 28 9-10 12-14

5/16 - 24 19-21 26-28

3/8 - 24 35-37 46-50

7/16 - 20 53-58 72-79

1/2 - 20 86-94 117-128

9/16 - 18 2124-136 168-184

5/8 - 18 171-189 232-256

3/4 - 16 304-336 412-456

7/8 - 14 475-525 644-712

1 - 12 703-777 953-1054

1 1/8 - 12 979-1081 1328-1466

1 1/4 - 12 1425-1575 1932-2136

1 1/2 - 12 2527-2793 3427-3787

1 3/4 - 12 4004-4424 5429-5999

2-12 6116-6760 8293-9167

Use these torque values unless otherwise specied. Exceptions are noted where applicable. SAE Grade 8 fasteners (A.S.T.M. A354, Grade BD) are made from quenched and tempered medium carbon steel. Grade 8 fasteners have 6 equally spaced radial lines embossed on the head of the fastener (see illustration below).

Page 99

Specications

M4 x .70 Pitch 8.8 3.1 2.2 2.30 1.65

M5 x .80 Pitch 8.8 6.1 5.5 4.58 4.13

M6 x 1.00 Pitch 8.8 10.4 9.5 7.80 7.13

M7 x 1.00 Pitch 8.8 17.0 15.5 12.75 11.63

M8 x 1.25 Pitch 8.8 25.0 23.0 18.75 17.25

M8 x 1.00 Pitch 8.8 27.0 24.5 20.25 18.38

M10 x 1.50 Pitch 8.8 51.0 46.0 38.25 34.50

M10 x 1.00 Pitch 8.8 57.0 52.0 42.75 39.00

M10 x 1.25 Pitch 8.8 54.0 49.0 40.50 36.75

M12 x 1.75 Pitch 8.8 87.0 79.0 65.25 59.25

M12 x 1.25 Pitch 8.8 96.0 87.0 72.00 65.25

M12 x 1.50 Pitch 8.8 92.0 83.0 69.00 62.25

M14 x 2.00 Pitch 8.8 140.0 125.0 105.00 93.75

M14 x 1.50 Pitch 8.8 150.0 135.0 112.50 101.25

M16 x 2.00 Pitch 8.8 215.0 195.0 161.25 146.25

M18 x 2.50 Pitch 8.8 300.0 280.0 225.00 210.00

M20 x 2.50 Pitch 8.8 430.0 390.0 322.50 292.50

M22 x 2.50 Pitch 8.8 580.0 530.0 435.00 397.50

M24 x 3.00 Pitch 8.8 740.0 670.0 555.00 502.50

M6 x 1.00 Pitch 10.9 15.5 14.0 11.63 10.50

M8 x 1.25 Pitch 10.9 37.0 34.0 27.75 25.50

M10 x 1.50 Pitch 10.9 75.0 68.0 56.25 51.00

M12 x 1.75 Pitch 10.9 160.0 117.0 97.50 87.75

M14 x 2.00 Pitch 10.9 205.0 185.0 153.75 138.75

M16 x 2.00 Pitch 10.9 310.0 280.0 232.50 210.00

Size Class Zinc Plated Unplated Zinc Plated Unplated

Newton Meters Foot Pounds

Torque-Chart-2

GRADE 8.8 & 10.9 FASTENERS

TORQUE CHART FOR METRIC FASTENERS

This torque chart applies to lubricated threads for bolts, capscrews, and studs.

These specications do not apply to self-locking nuts or capscrews. To obtain proper torque, do not use lock washers. Hardened at washers are recommended.

147

Page 100

148

SNOITACIFICEPSEUQROTREDNILYC

yrD,swercSpaCdaeHxeHdetalp–cniZ8edarG

eziShsaD euqroT

.sbl.tf m•N

CNU41– 48–67 411–301

CNU31– 511–501 651–241

sdaerhTdetacirbuL,hsiniFliOdna.sohP,stuNkcoLcitsalE8edarG

eziShsaD euqroT

.sbl.tf m•N

FNU41–1 045 237

11/

FNU21– 057 7101

13/

FNU21– 0001 6531

11/

FNU21– 0021 7261

13/

FNU21– 0051 4302

21/

FNU21– 0052 0933

Specications

CYLINDER TORQUE SPECIFICATIONS