Falcon Winch Assist Operator's Manual PDF

FALCON Winch Assist Operator's Manual Revision 1 March 2022 WA000-MANU-A0325-1 Version 1.0 dcforestryequipment.com © 2022 Falcon Forestry Equipment™. All rights reserved. The information, diagrams, images, and specificat...

FALCON Winch Assist Operator's Manual Revision 1 March 2022 WA000-MANU-A0325-1 Version 1.0 dcforestryequipment.com © 2022 Falcon Forestry Equipment™. All rights reserved. The information, diagrams, images, and specifications in this manual are based on the latest product information available at the time of publication. As Falcon Forestry Equipment is continuously improving its products and advancing their design, it reserves the right to modify or change the specification of its products at any time without notice. You may copy parts of this manual for your personal reference, but you may not use its contents for any other purpose without the prior consent of Falcon Forestry Equipment. Falcon Forestry Equipment endeavors to ensure that the contents of this manual, including images, are correct but does not accept any liability for error, omission, or differences with the finished product. Whenever a question arises regarding the product, or this manual, consult your Falcon Forestry Equipment authorized dealer for the latest available information. 2 | Operator's Manual Warranty and service Falcon Forestry Equipment warrants that new equipment sold by them is free from defects in material and workmanship subject to the following provisions. During the first six months from the date of delivery to the special, indirect or consequential damage, are expressly initial user or after 1000 hours of operation of the Winch excluded. Assist (whichever occurs first), a new part or a repaired Falcon Forestry Equipment reserves the right to make part, whichever Falcon Forestry Equipment elects, will be changes in design or to make additions to or provided along with labor for the installation of such parts, improvements in their products without imposing any in place of any parts which are found upon its inspection obligation upon themselves to install them on their to be defective in material or workmanship. Such parts products previously manufactured. and labor will be provided without charge to the user during normal working hours. This warranty does not include any transportation costs and does not apply to normal maintenance service (such as tuning, tightening bolts or nuts, and so on) or to normal replacement of service items (such as hydraulic filters, fittings, and so on). This warranty also does not include damage caused by abuse including collision, overloading, or neglect of maintenance. Replacement parts provided under the terms of this warranty are warranted for the remainder of the warranty period applicable to the product in which they are installed as if such parts were original components of that product. No warranty is made with respect to items made by others when such items are warranted by their respective makers (such as engines, batteries, radios) or when they are supplied by Falcon Forestry Equipment on special order. This warranty is in lieu of any other warranties, express or implied, including any warranty of merchantability or fitness for a particular purpose. Remedies under this warranty are expressly limited to the provision of parts, as specified above. Any claims for loss arising out of failure of the product to operate for any period of time, or any other economic or moral loss, or direct, immediate, Operator's Manual | 3 Foreword Literature information Regular maintenance and care is essential to keep your Winch Assist operating correctly. Falcon This manual shall be stored in the machine's operating Forestry Equipment provides certified product servicing compartment, in the literature holder or storage pocket at by a Falcon Forestry Equipment authorized service the back of the operator's seat. technician. This manual contains safety information, operation Troubleshooting instructions, troubleshooting instructions, transportation information, and maintenance information. The troubleshooting section contains a full list of the common problems that you may encounter with your Some photographs and illustrations in this manual show Winch Assist product, their possible causes, and the componentry that may be different from your machine. corrective actions you may take to resolve them. Illustrations and other graphics are simplified for instructional purposes. Alterations and customizations Safety It is prohibited to remove, alter, or render inoperative any component of the Winch Assist system. Certain elements The safety section includes safety information for of the Winch Assist engine, hydraulics, electrical system, working with the Winch Assist system. Ensure that you and cooling system are designed in strict compliance with read and understand the instructions in this section emissions and safety regulations. before operating or servicing the machine. Additional, unapproved attachments or modifications Operation may exceed the machine's rated capacity, which in turn The setup and operation sections describe the machine may affect the performance and safety characteristics of controls, operator interface, transportation, and the product. Modifications may include any changes to requirements for safe operation of the Winch Assist the brakes, controllers, and protective structure (ROPS) of system. the base machine. Maintenance The maintenance section describes how you shall care for and maintain your Winch Assist to keep it in an optimum working condition. Use the winch hours meter to determine the service intervals. Recommended service intervals should always be performed at the interval that occurs first. Operator's Manual | 4 Contents Safety Troubleshooting General safety information 9 General troubleshooting 84 Exclusion zones 15 Alarms troubleshooting 87 Tethered machine safety information 17 Radio troubleshooting 88 Precautions for inspection and service 20 Video troubleshooting 90 Safety features 21 Safety alarms 27 Appendix A: Winch PLC operational parameters Specifications Dimensions 32 Appendix B: Rope inspection General specifications 33 Appendix C: Chain and rigging inspection Rigging specifications 34 Base machine work modes 36 Appendix D: Steep slope risk assessment Tightening torque specifications 37 Gearbox oil specifications 39 Appendix E: Radio status indicators Introduction Appendix F: Polycarbonate inspection and About your Winch Assist 42 maintenance Using your Winch Assist machine as an excavator 43 Transporting your Winch Assist 44 Setup Winch Assist machine setup 48 Tethered machine setup 52 Advanced setup 54 Operation Operator interface 60 Operator controls 68 Pre-start inspection 70 General operation 71 Advanced operation 74 Maintenance Rope replacement 78 Maintenance schedule 80 Operator's Manual | 5 6 | Operator's Manual  CHAPTER 1 Safety General safety information⯇ Exclusion zones⯇ Tethered machine safety information⯇ Precautions for inspection and service⯇ Safety features⯇ Safety alarms⯇ Operator's Manual | 7 8 | Operator's Manual General safety information Read the safety messages in this manual and follow the instructions carefully. Review them frequently. Safety messages cannot cover every potential cause of Indicates information considered important, NOTICE but not hazard-related (for example, injury or equipment damage, but can highlight common messages relating to property damage). causes of hazards. It is the installer's responsibility to Operate or service only if qualified read and understand all instructions in this manual prior to installing or maintaining the Winch Assist and to seek advice before operating the equipment in a manner other than that described in this manual. Consult your Falcon Forestry Equipment authorized service technician before operating the system or performing maintenance. l Ensure that all operators of this machine understand every safety message. l Know and observe all safety rules that may apply to your work situation and your work site. l Replace the operator’s manual and safety labels immediately if they are missing or damaged. Recognize safety information This is the safety alert symbol. When you see this symbol on your machine or in this manual, become alert to the possibility of Machine operation or servicing must only be performed hazards or personal injury. by trained and experienced personnel who work in This manual uses the following safety symbols to indicate accordance with the operation and servicing manuals. the different levels of precautions that are required when operating machinery. Indicates an imminently hazardous DANGER situation that, if not avoided, will result in death or serious injury. WARNING Indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. Indicates a hazardous situation that, if not CAUTION avoided, could result in minor or moderate injury. Operator's Manual | 9 Inspect the machine before operation or service Wear Personal Protective Equipment (PPE) l Inspect the machine carefully each day by walking l Guard against injury from flying pieces of metal or around it before starting work. debris. Wear a face shield, goggles or safety glasses. l Test all controls and machine functions with the l Wear close fitting clothing and safety equipment machine in an open area before starting to work. appropriate for the job. l Inspect the job site and surroundings before l Prolonged exposure to loud noise can cause operating. impairment or loss of hearing. Wear suitable hearing l Keep all guards and shields in good condition and protection such as earmuffs or earplugs to protect ensure that they are properly installed. against objectionable or uncomfortably loud noises. l Fix damaged parts and replace worn or broken parts l Wear strong gloves when handling wire rope and using proper tools. Pay special attention to rigging, rigging equipment. hydraulic hoses, and electrical wiring. l When using pressurized air for cleaning, wear a safety l Before servicing the machine, ensure that face shield and protective clothing. Use 30 psi n the machine is stable and has been isolated; and, maximum air pressure. n all pressure is released from the hydraulic system (unless specified otherwise). l Attach warning tags to the operator controls while servicing the machine. l Complete a hazard assessment prior to undertaking maintenance and servicing. 10 | Operator's Manual Stay clear of moving parts products or attachments, may affect the system’s function or reliability and create a hazard for the operators or others nearby. l The installer of any modification which may affect the electronic controls of this machine is responsible for ensuring that the modification does not adversely affect the machine or its performance. l Always contact your Falcon Forestry Equipment authorized dealer before making modifications that change the intended use, weight or balance of the machine, or that alter machine controls, performance or reliability. l Dismantling or removal of components or devices of the Winch Assist system and fault-finding tasks should only be undertaken by a trained and approved Entanglement in moving parts can cause serious injury. service provider. l Isolate the machine before examining, adjusting or Prevent fires maintaining any part of it. l Keep guards and shields in place. Replace any guard or shield that has been removed for access as soon as the service or repair is complete. l Tie long hair behind your head. l Do not wear a necktie, scarf, loose clothing, rings, or other jewelery when working near machine tools or moving parts. Avoid unauthorized machine modifications l Clean the machine regularly. Keep trash, pine needles, debris, grease, and oil from accumulating around fuel lines, hydraulic lines, exhaust components, and electrical wiring. Clean up any fuel or oil spills. l Maintain hoses and wiring. Replace hydraulic hoses immediately if they begin to leak, and clean up any oil spills. l Examine electrical wiring and connectors frequently Modifications of the Winch Assist system or its for damage. associated equipment, or the addition of unapproved l Be wary of the fire risk when using cutting tools. Operator's Manual | 11  l Always keep a multipurpose fire extinguisher on or Drive metal pins safely near the machine. l Know how to use the fire extinguisher properly. Make welding repairs safely l Always wear protective goggles or safety glasses and other protective equipment before striking hardened l Avoid welding or high-temperature operations near parts. pressurized fluid lines. Flammable spray may result l Hammering hardened metal parts such as pins may and cause severe burns if pressurized lines fail as a dislodge chips at high velocity. result of heating. Do not let heat go beyond the work l Use a soft hammer or a brass bar between the area to nearby pressurized lines. hammer and object to prevent chipping. l Use a qualified welding technician for structural Use genuine parts repairs. l Make sure there is good ventilation. Worn or damaged parts or equipment should only be l Wear eye protection and protective equipment when replaced with genuine Falcon Forestry Equipment parts or welding. equipment. Refer to the parts manual for part numbers. Disable electrical power before welding. The use of non-genuine parts may create hazardous NOTICE situations. Falcon Forestry Equipment takes no l Separate the harness connectors to the engine and vehicle microprocessors. responsibility for issues relating to the use of non-genuine l Keep the welder ground clamp as close to the welded area as possible to avoid parts or equipment. welding current from traveling through the electrical system. 12 | Operator's Manual Use appropriate lifting equipment Beware of falling logs and overhead hazards l When removing components always use appropriate l Ensure that no person is closer than two tree lengths lifting equipment. to the working ropes while the winch is operating l Ensure a lift plan is in place and a safety assessment unless they are protected by a certified protective has been completed prior to lifting heavy components. structure. l Do not place tools or other items on top of the winch WARNING Lifting strops, slings or chains may move during lifting resulting in unexpected machine while persons are working below it. component movement and crush injuries. l Be aware of the environment that you are working in l Always keep limbs clear of components and identify any branches, logs, rocks, or debris that being lifted. l Never put limbs under a suspended load. are above the working area and are at risk of falling. l When operating near power lines, ensure that you take Be cautious around rope and rigging into account the height added to the boom by the WARNING If a rope is wedged or stuck and requires Winch Assist and avoid setting up the machine in freeing from a high point on the machine, complete a working-at-heights plan and wear areas where the power lines are low. appropriate PPE before carrying out this work. Prepare for emergencies l When changing the rigging, multiple pinch points exist which pose a risk of a crushing injury. l Practice caution in the presence of a twisted chain as it may move unexpectedly. l Wire ropes have sprags that present a cutting or puncturing hazard. Wear strong gloves when handling these. l Rigging components such as sheaves and skiving have sharp edges and pinch points. Wear strong gloves when handling these. Operator's Manual | 13  l Keep a first aid kit and fire extinguisher on or near the injected into the body, it must be surgically removed machine. within a few hours of the injury, or gangrene may l Read the instructions on the label that is attached to result. the fire extinguisher and use it properly. l Ensure that the fire extinguisher is in good working Practice safety at heights condition and read for use. Check and service the fire extinguisher at regular intervals, as recommended by the manufacturer. l Keep emergency phone numbers for doctors, ambulance service, hospitals, and fire department near your telephone. Avoid high pressure liquids l When you get on or off the machine, always face the machine. l Use three points of contact with the steps and handholds—especially in icy or wet conditions. l When working on the machine bonnets or at heights, complete a working-at-height plan and use appropriate PPE. WARNING Fluids such as diesel or hydraulic oil, when under pressure can penetrate the skin or eyes, causing serious injury, blindness, or death. l Always release the pressure in the hydraulic system before disconnecting hydraulic or other hoses. l Wait for 10 minutes after the engine stops before you perform any service or repair on high pressure lines. l Make sure that all connectors are properly connected before pressurizing the system. l Use a piece of cardboard or other test surface when searching for leaks; wear proper protective clothing to protect your hands and body from high pressure fluids and wear a face shield or goggles to protect your eyes. l If an accident occurs, see a doctor who is familiar with these types of injuries immediately. If any fluid is 14 | Operator's Manual Exclusion zones WARNING Numerous serious hazards exist in close proximity to the Winch Assist machine and the tethered machine. Appropriate exclusion zones around the machines and rigging shall be established and policed. SAFETY INSTRUCTIONS ▪A 20 m (66 ft) exclusion zone (A) shall be set up on both sides of the rope, forward of the dog bone sheave. ▫If using a binding or side-washing arrangement, the 20 m (66 ft) exclusion zone shall extend around the boundary of the bight (B) as well. ▪A 6 m (20 ft) exclusion zone (C) shall be set up around the Winch Assist machine. ▪An exclusion zone (D) shall be set up around the tethered machine in accordance with local regulations for the operation taking place. This is typically two tree lengths for felling operations. Note - Operational exclusion zones vary depending on the geography and type of operation and may extend beyond the recommended exclusion zones, use an operational safety analysis to determine zone boundaries. Operator's Manual | 15 16 | Operator's Manual Tethered machine safety information WARNING Serious hazards exist for the tethered machine operator. Before using the Winch Assist system, ensure that the tethered machine complies with Falcon Forestry Equipment's requirements and recommendations. Requirements as logs, root balls, and stumps. l The operator's seat should be fitted with a four-point l The Winch Assist shall only be attached to machines harness. that comply with all regulatory safety standards and l The operator should wear an impact protection requirements governed by local and national harness at all times. authorities. l Wheeled-type tethered machines should be fitted with l The tethered machine shall be suitable for forestry a pivot seat. operations and, in particular, for use with the Falcon l The operator should maintain regular radio Winch Assist forestry system. communication with all nearby machines. l The tethered machine, including its protective l To reduce operator fatigue, the operator should be structure and point of attachment to the Winch Assist, changed over at regular intervals. shall be certified by a Chartered Professional Engineer. l The tethered machine shall be fitted with an Safety inclinometer that is mounted in an appropriate SAFETY INSTRUCTIONS location so that it is clearly visible by the operator at all ▪The tethered machine shall, at all times, be able to times. The inclinometer must be suitable for all support itself on the slope without the assistance of intended angles of operation of the machine. l The maximum operating weight of the machine shall the Winch Assist machine. ▪Operating the tethered machine on steep slopes is not exceed 69 tonnes (76 US tons). l If more than one tethered machine is used with the physically and mentally demanding. Machine same Winch Assist, the tethered machines must be operators shall be fit to perform the task, shall take fitted with a key lock switch instead of a push button regular breaks, and shall stay properly hydrated. ▪The cutover presents multiple hazards including to start the Winch Assist. Furthermore, only one key is uneven ground and debris that may compromise the permitted on the premises, to prevent accidental stability of the machine. Extreme caution shall be simultaneous operation of the Winch Assist by taken when operating in the cutover zone. different tethered machines. ▪Before moving the machine onto the work slope, a Recommendations hazard assessment shall be completed by the crew supervisor, foreman, or other experienced personnel. l The tethered machine should be fitted with a purpose- Refer to Appendix D Steep slope risk assessment for built cab that incorporates ISO-certified specialized more information. protective structures for operator safety (OPS), ▪The tethered machine shall only be operated in rollover protection (ROPS), and falling object accordance with regional best practices and the protection (FOPS). The OPS protective structure machine manufacturer's recommendations for should be rated to withstand the egress of debris such maximum operating slope. Operator's Manual | 17 ▪ The tethered machine shall have a system to ensure Rope or rigging failure the stability of the machine on the slope and shall meet the following requirements: ▫The system employed shall include a secondary stopping device, such as a hydraulic attachment that can be lowered to stabilize the machine. ▫The system employed shall ensure that the machine remains stable in the event of a rope, rigging, or Winch Assist anchoring failure. Working with a wheeled-type tethered machine SAFETY INSTRUCTIONS ▪The tethered machine shall only be used with a Winch Assist that is fitted with a 75:1 ratio gearbox. ▪The tethered machine shall be speed-limited to the In the unlikely event of a rope or rigging failure rated bare-drum line speed of your Winch Assist. l Immediately stop operating the tethered machine. Refer to General specifications for more information. l Ensure that the machine is stable and in a zero-energy ▪Ensure that all personnel and equipment not involved state. Use the machine's lifting arm to stabilize the in the operation are at a safe distance from the work machine, if required. area. l Stay in the cab until the Winch Assist machine, ▪The tethered machine operator shall wear tethered machine, and surrounding area have been appropriate PPE at all times. assessed to be safe and the tethered machine is in a ▪When ascending or descending the slope, the zero-energy state. Refer to Precautions for inspection tethered machine shall not exceed a 30° lead angle. and service for more information. l Before resuming operation an authorized technician Working with an excavator-type tethered machine shall conduct an inspection of the full rope, rigging, SAFETY INSTRUCTIONS and Winch Assist system and repair or replace the ▪Perform a job safety analysis (JSA) to identify and damaged parts. manage the risks involved in working on the winch Radio communication failure system. ▪Ensure that all personnel and equipment not involved In the event of loss of radio communication between the in the operation are at a safe distance from the work two machines, the tethered machine's PLC is area. programmed to ensure that the Winch Assist's drum ▪Wear appropriate PPE. delivers sufficient torque to keep the tethered machine stable on the slope. If the winch is in Tension Setting 1 or 2, it is switched up to Tension Setting 3; if the winch is in Tension Setting 3 or higher, it is maintained at its current Tension Setting until radio communication is restored. 18 | Operator's Manual WARNING When radio communication is lost, the resulting tensioning of the wire rope is abrupt and immediate, which may seriously injure nearby personnel and destabilize the machine. Ensure that you do not lose radio communication at any time while working at a low Tension Setting. Operator's Manual | 19 Precautions for inspection and service l Before you service the machine, ensure that the Winch Assist machine and the tethered machine are in zero energy state as follows: n Ensure that the Winch Assist system is turned off. n Lower the boom and dipper arm. n Use the bail arm to lock the machine's hydraulics (hydraulic lockout). n Release all the potential energy from both machines. n Ensure that both machines are stable and are not supported by the rope or the boom. l Allow enough time for the hydraulic system to cool before commencing an inspection or maintenance. l If undertaking maintenance or servicing other than daily maintenance checks, the Winch Assist machine should be disconnected from the tethered machine. l For any major work, it is recommended that the winch be moved to a workshop where appropriate equipment is available. 20 | Operator's Manual Safety features The Winch Assist is equipped with the following safety features. Hydraulic brake The winch's planetary gearboxes have inbuilt brakes which are spring-applied and hydraulically released. During normal operation, the brake is spring applied when the Winch Assist is not in winch mode, but releases hydraulically when you use manual pay-out or wind-in. When winch mode is selected, the brake remains released at all times other than an emergency situation, where it acts as a fail-safe. WARNING When the brake is applied in an emergency situation, the rope tension may exceed the safe working load of the system. All ground personnel shall be alerted and moved to a safe distance from the Winch Assist system before proceeding. Emergency braking The hydraulic brakes are engaged automatically in an emergency, when continued operation of the Winch Assist may pose a significant risk to equipment or personnel. Emergency braking is engaged in the following sequence: 1. If the tethered machine is fitted with track lockout, the tracks are locked. 2. The Tension Setting ramps up to the maximum permitted rope tension. 3. Four seconds after emergency braking is activated, the Winch Assist's hydraulic brakes are applied. 4. Eight seconds after emergency braking is activated, the engine is shut down if the activation is caused by any of the following critical faults. n Low hydraulic oil level n Low boost pressure n Emergency stop (E-Stop) Emergency stop (E-Stop) Two emergency stop buttons are located on the rear panels of the Winch Assist machine. Push either switch to activate the E-Stop. Turn the switch counterclockwise to reset the E-Stop. Note - The engine is shut down when emergency stop is activated. Operator's Manual | 21 Movement switch The movement switch is an electromechanical interlock that is installed at the rear of the Winch Assist. A lanyard is attached to the actuator of the switch and the other end of the lanyard is tied to an anchor that is pushed into the ground. The switch is activated when the Winch Assist machine moves in the forward direction and the actuator slides out of the actuator head. Insert the actuator back into the actuator head to reset the switch. Fire suppression system (optional feature) Falcon Forestry Equipment can fit the Winch Assist with a fire suppression system that is thermally activated. The system consists of three hermetically sealed fire suppression canisters that are filled with a stable, solid aerosol-forming compound that is not pressurized. This makes the canisters ideally suited to harsh forestry conditions. The canister is activated in the event of a fire or when you remove the R-clip from the actuator. When a canister is activated, the aerosol- forming compound in the canister produces an ultra-fine aerosol extinguishing spray out of the bottom of the canister. The canisters are installed in the pump bay, battery bay, and engine bay. WARNING The fire suppression canisters automatically activate at temperatures above 123 °C (254 °F). Remove the canisters before conducting maintenance that requires welding. 22 | Operator's Manual  WARNING When the fire suppression canisters discharge, the chemical reaction results in high heat in the canisters. Fire suppression canisters should not be handled without the appropriate PPE if they have been activated. NOTICE Weekly visual inspections should be conducted to ensure that the canisters are intact. Reinforced cab (optional feature) The cab is fitted with polycarbonate glass and a metal grille over the front window, which protects the operator from flying debris while maintaining optimum visibility during operation. The structure of the cab is ROPS certified. In an emergency, up to three egress points may be used to exit the machine by breaking the glass at the top (q), side (w), or rear (e) of the cab. Polycarbonate glazing The polycarbonate glazing provides increased resistance to abrasion and wear. It must be regularly inspected and maintained. Refer to Polycarbonate inspection and maintenance for more information. WARNING Ensure that the polycarbonate glazing is in good condition before operation. Damage or deterioration of the polycarbonate glazing reduces the structural integrity of the cab and may cause it to fail on impact. Operator's Manual | 23 Camera monitoring system The Winch Assist is fitted with three cameras. l A camera is installed at the rear of the base machine to ensure safety of personnel while moving the base machine. l Two cameras are positioned over the drum to monitor the state of the winch and the rope using the display mounted in the tethered machine's cab. The cameras are equipped with an infrared light source for use in low light and low visibility conditions. The camera feed is wirelessly transmitted to the display in the tethered machine's cab so that the operator may monitor the drum and wire rope. 24 | Operator's Manual Angle indicators To ensure that the Winch Assist base machine is properly anchored and its bucket correctly dug-in, two visual indicators are provided on the body of the machine as follows: l A two-color boom-dipper angle indicator at the dipper-boom pivot pin. The machine is correctly anchored when you can see the green bar from the operator's seat in the cab. l A boom inclination indicator on the cab window. The machine is correctly anchored when you see the top of the boom above the green level. Both indicators must be positive (green) before operation. Hydraulic travel lockout (optional) The travel lockout valve is fitted in the hydraulic circuit that controls the tethered machine's tracks or wheels. It is activated in any of the following conditions: l The tethered machine's speed exceeds the maximum pay-out speed of the Winch Assist's drum (drum overspeed) while traveling. l Emergency stop activation. l Movement alarm activation. l Low boost pressure alarm activation (along with low winch pressure). l Low hydraulic fluid alarm activation. l Engine stop activation. Operator's Manual | 25 The travel lockout valve inhibits the reverse travel of the tracks or wheels, immediately decreasing the travel speed of the tethered machine until it stops moving. Note - Tethered machine reverse travel is disabled by the travel lockout valve when it is not in winch mode. Note - The travel lockout valve is disengaged from the machine's hydraulic circuit when it is not tethered to the Winch Assist machine and the machine may travel at full speed in the reverse direction. 26 | Operator's Manual Safety alarms See also: Alarms troubleshooting WARNING If any of these alarms are activated during operation, immediately stop operating the tethered machine and follow the safety instructions in this section. WARNING Do not move the tethered machine away from the Winch Assist machine while the brake is engaged as this may overload the Winch Assist machine and rigging, which may damage and destabilize the Winch Assist machine. NOTICE Operating the Winch Assist machine while the alarm is active may result in mechanical damage or machine failure. Alarm Problem System response SAFETY INSTRUCTIONS Cab door open The Winch Assist ▪An on-screen alert is displayed. 1. Put the tethered machine in a machine's door is ▪An audible alarm sounded in the safe state. open. cab. 2. Stop the Winch Assist remotely. 3. Investigate the unauthorized entry into the cab. 4. Resume operation when the cause(s) of the fault have been addressed and the alarm is no longer displayed. Communication The radio ▪A signal failure on-screen alert is 1. Do not operate the on-screen failure communication displayed. controls or change the settings as link between the ▪An audible alarm is sounded in the alarms and operational two machines is cab. information are not transmitted. lost. ▪If the winch is in Tension Setting 1 2. Move the tethered machine back or 2, it is switched up to Tension towards the Winch Assist Setting 3; if the winch is in Tension machine until radio Setting 3 or higher, it is maintained communication is reestablished. at its current Tension Setting until 3. Resume operation when the radio communication is restored. cause(s) of the fault have been addressed and the alarm is no longer displayed. Cable tension The tension on the ▪An on-screen alert is displayed. 1. Reduce the tension on the rope. alarm rope has ▪An audible alarm is sounded in the ▫Select a lower Tension Setting. cab. ▫Disengage the brake to relieve increased above the Winch Assist's the strain on the rope. High Tension 2. Inspect the Winch Assist Alarm setpoint. machine's structure and the tethered machine's attachment points for damage. 3. Resume operation when the cause(s) of the fault have been addressed and the alarm is no longer displayed. Low engine oil The oil pressure in ▪An on-screen alert is displayed. 1. Check if the engine is running. pressure the system is low. ▪An audible alarm is sounded in the 2. Check the engine oil pressure cab. sensor and sensor circuit for ▪Winch mode is deactivated. faults. 3. Resume operation when the cause(s) of the fault have been addressed and the alarm is no longer displayed. High engine The Winch ▪An on-screen alert is displayed. 1. Stabilize the tethered machine coolant Assist's engine is ▪An audible alarm is sounded in the and stop operating it. temperature overheating. cab. 2. Shut down the Winch Assist engine. 3. Follow the troubleshooting instructions to resolve the Operator's Manual | 27 Alarm Problem System response SAFETY INSTRUCTIONS problem. See Troubleshooting for more information. 4. Resume operation when the cause(s) of the fault have been addressed and the alarm is no longer displayed. High hydraulic The hydraulic ▪An on-screen alert is displayed. 1. Decrease the Tension Setting or loop temperature manifold is ▪An audible alarm is sounded in the pay-out speed or both. overheating. cab. 2. Resume operation when the cause(s) of the fault have been addressed and the alarm is no longer displayed. Low hydraulic oil The hydraulic oil ▪An on-screen alert is displayed. 1. Stabilize the tethered machine boost pressure pressure from the ▪An audible alarm is sounded in the and stop operating it. boost circuit is cab. 2. Shut down the Winch Assist low. ▪Winch mode is deactivated. engine. ▪The winch engine is shut down 3. Contact your Falcon when the system's hydraulic Forestry Equipment authorized pressure cannot sustain winch service technician. operation. High hydraulic oil The hydraulic oil ▪An on-screen alert is displayed. 1. Stabilize the tethered machine temperature temperature in the ▪An audible alarm is sounded in the and stop operating it. Winch Assist cab. 2. Shut down the Winch Assist machine is not in ▪The emergency brake is applied. engine. ▪The winch engine is shut down. 3. Follow the troubleshooting the acceptable range. instructions to resolve the problem. See Troubleshooting for more information. 4. If the problem persists, contact your Falcon Forestry Equipment authorized service technician. Low cable alarm There is only 20 m ▪An on-screen alert is displayed. 1. Stop the current operation. (stage 1) of rope on the ▪An audible alarm is sounded in the 2. Move the tethered machine back Winch Assist's cab. towards the Winch Assist drum that is ▪All screen functions are disabled machine until the alarm is available for pay- except for the Tension Setting deactivated. out controls. 3. Resume work only at the current ▪The system will apply the safe distance. emergency brake when the Low cable alarm (stage 2) is activated. Low cable alarm There is no more ▪An on-screen alert is displayed. 1. Stabilize the tethered machine. (stage 2) rope on the Winch ▪An audible alarm is sounded in the 2. Use the manual wind-in function Assist's drum that cab. to slowly wind the rope back onto is available for pay ▪Only the manual wind-in function is the drum while walking the out enabled. All other functions are tethered machine back towards disabled. the Winch Assist machine. ▪The emergency brake is applied. 3. Resume work only at the current safe distance. Remote The emergency ▪An on-screen alert is displayed. 1. Stabilize the tethered machine. emergency stop stop is activated ▪An audible alarm is sounded in the 2. Communicate with your is activated using the cab. supervisor or the ground staff to emergency stop ▪The tethered machine's travel drive address the cause(s) of the button on the is disengaged (if travel lockout is emergency. tethered fitted). 3. When it is safe to resume ▪The emergency brake is applied. operation, press and hold the machine's ▪The winch engine is shut down. joystick. Emergency Stop button for one second to reset the emergency stop and put the system back into a state of operation. 28 | Operator's Manual Alarm Problem System response SAFETY INSTRUCTIONS Remote engine The Winch ▪The winch brake is applied. 1. Stabilize the tethered machine. stop Assist's engine is ▪The winch engine is shut down. 2. If required, communicate with turned off using your supervisor or the ground the Engine Stop staff to address the cause(s) of button on the the engine shutdown. tethered 3. When it is safe to resume machine's display operation, start the engine. or key switch. Winch emergency The emergency ▪An on-screen alert is displayed. 1. Stabilize the tethered machine. stop stop is activated ▪An audible alarm is sounded in the 2. Communicate with your using the cab. supervisor or the ground staff to emergency stop ▪The tethered machine's travel drive determine and address the cause button on the is disengaged (if travel lockout is (s) of the emergency. Winch Assist fitted). 3. When it is safe to resume ▪The emergency brake is applied. operation, reset the emergency machine. stop. See Operator interface for more information. Winch machine The Winch Assist ▪An on-screen alert is displayed. 1. Stabilize the tethered machine. movement machine's ▪An audible alarm is sounded in the 2. Communicate with your detected movement switch cab. supervisor or the ground staff to is activated. ▪The wind-in function is disabled in determine and address the cause both winch mode and manual (s) of the emergency. mode. 3. Ensure that the Winch Assist ▪If you disable winch mode, the machine's movement switch is emergency brake is applied. anchored correctly and insert its actuator back into the actuator head when it is safe to resume operation. Refer to Safety features for more information. Note - Winch mode can only be re- engaged after the movement switch is reconnected. Winch overspeed The rope is Depending on the severity and 1. Reduce the travel speed of the unwinding off the duration of the situation, the system tethered machine until the drum drum too quickly. response takes place in the following speed is within the rated limits stages and the alarm stops. See General specifications for more ▪Stage 1 information. ▫An on-screen alert is displayed. 2. If a Stage 3 alarm has been ▫An audible alarm is sounded in triggered, the brakes may be the cab. damaged. ▪Stage 2 a. Stabilize the tethered machine. ▫An on-screen alert is displayed. ▫An audible alarm is sounded in b. Contact your Falcon Forestry Equipment authorized the cab. service technician. ▫The hydraulic tension is increased. ▪Stage 3 ▫An on-screen alert is displayed. ▫An audible alarm is sounded in the cab. ▫The tethered machine's travel drive is disengaged (if travel lockout is fitted). ▫The emergency brake is applied. Operator's Manual | 29 30 | Operator's Manual  CHAPTER 2 Specifications Dimensions⯇ General specifications⯇ Rigging specifications⯇ Base machine work modes⯇ Tightening torque specifications⯇ Gearbox oil specifications⯇ Operator's Manual | 31 Dimensions     A B C D 1163 mm 2048 mm 2550 mm 1223 mm (46 inches) (80 inches) (100 inches) (48 inches) 32 | Operator's Manual General specifications Winch unit weight (un-roped) 4400–4900 kg (9700–10,800 lb) Winch unit weight (roped) 6500–7000 kg (14,330–15,430 lb) Rope capacity 500 m Rated line pull 108:1 ratio gearbox 21 tonnes (23 US tons) 75:1 ratio gearbox 16.3 tonnes (18 US tons) Drum and line speeds (108:1 ratio gearbox) Max rated drum speed 22 rpm Rated line speed — bare drum 2.8 km/h (1.75 mph) Rated line speed — full drum 3.9 km/h (2.5 mph) Drum and line speeds (75:1 ratio gearbox) Max rated drum speed 32 rpm Rated line speed — bare drum 4 km/h (2.5 mph) Rated line speed — full drum 5.6 km/h (3.5 mph) Operating temperature -20 °C – 60 °C (-4 °F – 140 °F) Emergency arrest tension 21 tonne (23 US tons) Operator's Manual | 33 Rigging specifications See also: Rope inspection, Chain and rigging inspection WARNING It is recommended that you use replacement components that are supplied by Falcon Forestry Equipment for the ongoing safe operation of the Winch Assist system. If you are not using Falcon Forestry Equipment components, ensure that they meet or exceed specifications outlined in this manual. WARNING Ensure that the rigging is inspected by a trained professional before operation. WARNING Rope terminations are critical to the safe operation of the Winch Assist system. l Ensure that the rope terminations are installed by a trained professional, in compliance with best practices. l Ensure that the rope terminations are inspected by a trained professional before operation. Note - Due to the variations in wheeled tethered machines, the rigging for such machines is not specified in this manual. Contact your Falcon Forestry Equipment authorized dealer for more information.      34 | Operator's Manual  Component Type Size Load rating Safe working Minimum breaking load load q Rope Swaged 6 x 26 IWRC 28 mm (11/8 23,000 kg 69,000 kg inches) (50,700 lb) (152,000 lb) w Rope Spliced eye (three tucks on both – – – termination sides), or Open wedge socket, or Spelter socket e Rollover shackle Flush pin 38 mm (11/2 26,000 kg 126,000 kg inches) (57,300 lb) (277,000 lb) r Chain U3 stud link (6 m) 36 mm (17/16 26,000 kg 105,000 kg inches) (57,300 lb) (231,000 lb) t Swivel – – 22,000 kg 105,000 kg (48,500 lb) (231,000 lb) y Hammer lock Coupling link 26 mm (1 inch) 21,200 kg 84,000 kg shackle (46,700 lb) (185,000 lb) u Shackle Bow shackle 50 mm (2 25,000 kg 126,000 kg inches) (55,700 lb) (277,000 lb) Operator's Manual | 35 Base machine work modes Ensure that the base machine is set to the proper work mode for Winch Assist operation. Make Rev setting Work mode Komatsu 1500 P Sumitomo 1500 Pulveriser Hitachi 1500–1800 PWR Volvo G3 WINCH (attachment) Sany 1600 S Hyundai 1500 S Link-Belt 1500 P-Mode (attachment) Caterpillar 1500 High power 36 | Operator's Manual Tightening torque specifications CAUTION Use tools appropriate for the work to be done. Makeshift tools can create safety hazards. For loosening and tightening nuts and bolts, use correct size tools. Incorrectly sized tightening tools may slip, potentially causing personal injury. Note - Prior to assembly ensure bolts and nuts are clean; then lubricate all contact areas such as the threads and the underside of the bolt head or nut with anti-seize, unless Loctite is indicated. Note - These torques are not a substitute for manufacturers' specifications. Use manufacturers' specifications where available. Bolt types Tighten nuts or bolts correctly to torque specifications. Six different types and grades of bolt are employed. Make sure that you use the correct bolts and tighten them correctly when assembling the machine or components. Torque chart (metric) Bolt screw size Diameter (mm) Class 8.8 Class 10.9 Class 12.9 N m lb-ft N m lb-ft N m lb-ft M5 5 5 4 7 5 8 6 M6 6 8 6 11 8 14 10 M8 8 19 14 27 20 32 24 M10 10 38 28 54 40 64 47 M12 12 66 49 94 69 110 81 M14 14 106 78 150 111 176 130 M16 16 165 121 234 172 274 202 M18 18 226 167 323 238 378 279 M20 20 319 235 457 337 534 394 M22 22 435 321 624 460 728 537 M24 24 552 407 789 582 923 681 M30 30 1097 809 1570 1158 1834 1353 M36 36 1918 1415 2744 2024 3208 2366 Ref: DC000-PROC-A0006-3 Note - Reference torque values correspond to a clamp load of 75% of proof load for specified bolts. Operator's Manual | 37 Torque chart (imperial) Bolt screw size Class SAE Grade 5 Class SAE grade 8 Cap Screws UNC UNF UNF UNC UNF UNC N m lb-ft N m lb-ft N m lb-ft N m lb-ft N m lb-ft N m lb-ft 1/ 4 9 6 10 7 12 9 14 10 14 10 16 12 5/16 18 13 20 15 25 18 28 20 30 22 32 24 3/ 8 31 23 35 26 45 33 50 37 52 38 58 43 7/16 50 37 56 41 71 52 79 58 83 61 92 68 1/ 2 77 57 87 64 108 80 122 90 126 93 142 105 9/16 106 80 123 91 150 110 175 129 170 125 209 154 5/ 8 165 113 172 127 216 159 244 180 243 179 274 202 3/ 4 226 200 302 223 382 282 427 315 430 317 480 354 7/ 8 319 322 481 355 617 455 681 502 693 511 765 564 1 435 483 735 542 923 681 1037 765 1040 767 1166 860 Ref: DC000-PROC-A0006-3 Note - Reference torque values correspond to a clamp load of 75% of proof load for specified bolts. 38 | Operator's Manual Gearbox oil specifications Falcon Forestry Equipment specifications require gearbox oils that provide maximum protection to the hydraulic drive system, perform consistently over a wide temperature range, have a minimum viscosity index of N, and provide excellent resistance to oxidation, corrosion, foaming and aeration. Select oil for the range of temperatures that the machine will be operated at so that the most consistent temperature- viscosity characteristics are maintained. NOTICE Using unsuitable oil significantly reduces the product's service life. Only use oil that meets the required specifications for your location and application type. Operating temperature Minimum Maximum Oil grade -10 °C (14 °F) 30 °C (86 °F) ISO VG 150 -20 °C (-4 °F) 30 °C (86 °F) SAE 80W/90 -20 °C (-4 °F) 60 °C (140 °F) ISO VG 150-220 10 °C (50 °F) 45 °C (113 °F) ISO VG 220 SAE 85W/140 Common oils by grade Manufacturer Oil type ISO VG 150 ISO VG 220 ISO VG 150-220 SAE 80W/90 SAE 85W/140 AGIP Blasia 150 Blasia 220 Blasia SX 220 Rotra MP Rotra MP ARAL Degol BG 150 Degol BG 220 Degol PAS 150-220 Getriebeol HYP Getriebeol HYP BP Energol GR XP 150 Energol GR XP 220 Eversyn EXP 150-220 Hypogear EP Hypogear EP Castrol Alpha SP 150 Alpha SP 220 Alphasyn EP 150-220 Transmissiones EP Transmissiones EP CESPA Engranajes HP 150 Engranajes HP 220 Engranajes HPX 150- RPM Universal Gear RPM Universal Gear 220 Lubricants Lubricants Chevron N.L. Gear N.L. Gear Tegra Synthetic Gear Gear Oil GX Gear Oil GX Compounds EP 150 Compounds EP 220 EP 150-220 Esso Spartan EP 150 Spartan EP 220 Spartan EP 150-220 Pontonic MP Pontonic MP Fuchs Renolin CKC 150 Renolin CKC 220 Renolin Unisyn CKC Titan Super Gear Titan Super Gear 150-220 Kluber Kluberoil GEM1-150 Kluberoil GEM1-220 Klubersynt EG 4-150 / – – 4-220 Q8 Goya 150 Goya 220 El Greco 220 – – Mobil Mobilgear 600 XP Mobilgear 600 XP Mobilgear SHC XMP Mobilube HD Mobilube HD 150 220 150-220 Molycote L-0115 L-0122 L-2115 / L-2122 – – REPSOL Super Tauro 150 Super Tauro 220 Super Tauro Sintetico – – 150-220 Shell Omala EP150 Omala EP220 Tivela Oil S SPIRAXHD SPIRAXHD Total Carter EP 1500 Carter EP 2200 Carter SH 150-220 Transmission TM Transmission RS Operator's Manual | 39 40 | Operator's Manual  CHAPTER 3 Introduction About your Winch Assist⯇ Using your Winch Assist machine as an excavator⯇ Transporting your Winch Assist⯇ Operator's Manual | 41 About your Winch Assist The Winch Assist is designed to traction-assist a felling or shoveling machine on steep or slippery slopes where it would have difficulty gaining traction. When the machine is tethered to the Winch Assist it provides greater stability and safety for the operator. An electro-hydraulic control system enables the tethered machine operator to remotely control the automatic and manual functions of the winch over a zero-latency radio channel. In a typical forestry operation, the Winch Assist machine is set up on a flat pad adjacent to the slope that the tethered machine is to be working on and the two machines are then connected together with the wire rope tether system. The wire rope from the winch drum is wound or unwound in a controlled way through a system of rollers and sheaves on the Winch Assist base machine. Description q Hydraulic winch w Boom rollers e Fairlead r Dog bone sheave 42 | Operator's Manual Using your Winch Assist machine as an excavator When the winch system is turned off, the Winch Assist machine operates as a standard excavator. It may then be used for digging or loading logs and shoveling. Refer to the excavator's operation manual for more information. Note - Though the Winch Assist machine is slightly longer and higher, its weight and dimensions do not vary significantly from the manufacturer's specifications. Before using the Winch Assist machine as an excavator, do the following: l Set the local control in the Winch Assist machine to the off position. l Remove the rope from the dog bone sheave, the fairlead, and the boom rollers, wind it completely on the drum and securely fasten it to the drum. l Lock the dog bone sheave to the side using the locking pin. NOTICE Remove the aerial if you intend to operate the machine as an excavator for an extended period, to prevent it from damage. Operator's Manual | 43 Transporting your Winch Assist The Winch Assist is fitted to a conventional excavator (that is, the base machine). Although the dimensions vary by make and model of the base machine, the Winch Assist adds between 1.5 – 5 tonnes (1.6 – 5.5 US tons) to the weight and approximately 1 m (3 ft) to the height of the base machine. Follow these best practices when you transport the machine: l Weigh and measure the machine to ascertain its correct weight and dimensions with any additional components and attachments. l Ensure that the transport vehicle is suitable for the dimensions and weight of the machine. l When transporting the machine on public roads, ensure that you understand and follow all local laws and regulations. If required, disassemble the machine to bring it within the dimension and weight limits. l Refer to the base machine manufacturer's manual for instructions on loading, unloading, and securing the machine on the transport vehicle. Preparing for transport 1. Disconnect the Winch Assist machine from the tethered machine. 2. Disconnect the rigging from the end of the wire rope. The chain and other parts of the rigging may move unexpectedly when under tension. Ensure that the rope, WARNING rigging, and other parts of the system are in a zero-energy state before you start. 3. Secure the end of the wire rope to the boom using a light nylon rope that is sufficiently strong to bind it. Note - Ensure that there is enough slack in the wire rope to allow full movement of the boom and dipper. Additional disassembly (if required) If you need to reduce the height of the machine to meet the transport requirements, you may do the following: Lower the rope guides on the boom rollers 1. Remove the spring latch from the side of the rope guide. 2. Rotate the guide around and insert the spring latch to lock it in the lowered position. 44 | Operator's Manual Chain the dog bone sheave to the bucket 1. Use the travel lock pin to lock the dog bone sheave in place. 2. Run a chain of sufficient length around the sheave and lock it in place with a shackle, leaving the rest of its length hanging off the end. 3. Remove the top bolt from the dog bone sheave's base plate. 4. Curl the bucket in and towards the dipper arm until the bucket teeth are pointing away from the tracks. 5. Remove the top locking pin that connects the sheave assembly to the base plate and let the sheave assembly pivot on the bottom locking pin. 6. Curl the bucket out and bring the dipper arm to a vertical position so that the bucket teeth face the tracks. 7. Wrap the end of the chain around a tooth of the bucket. Note - Leave enough slack in the chain to curl the bucket. 8. Curl the bucket inwards and towards the dipper arm until the bucket teeth are pointing away from the tracks. 9. Fold the dipper arm inwards and towards the cab to minimize the dimensions of the machine as much as possible. Operator's Manual | 45 46 | Operator's Manual  CHAPTER 4 Setup Winch Assist machine setup⯇ Tethered machine setup⯇ Advanced setup⯇ Operator's Manual | 47 Winch Assist machine setup Select the anchoring location Select an anchoring site, taking into account the geography and conditions of the area. l Set up the Winch Assist machine on firm and level ground. l Avoid setting up the machine on areas of fill or on soil that has been dug up or moved as this may not offer sufficient stability to securely anchor the machine. l Ensure that the tethered machine does not pull the rope at a lead angle of more than 30°, horizontal to the central axis of the Winch Assist machine, on either side. l For a wheeled tethered machine, ensure that there is sufficient room to land the payload without exceeding a lead angle of 30°. Note - When landing the payload, the wheeled tethered machine may operate outside the 30° lead angle threshold and to a maximum of 70°, at low rope tension (that is, Tension Setting 2 and below). A large lead angle under low rope tension in some cases may result in damage to the rope from possible NOTICE unwinding. l Ensure that the tethered machine is always within line of sight of the Winch Assist's 900 MHz Wi-Fi directional aerial. For optimum communication, the tethered machine must be within the 60° beam width of the directional 48 | Operator's Manual  aerial. Dig-in the bucket 1. Rotate the tracks until they are at right angles to the boom. 2. Extend the boom and the dipper out and position the bucket over the dig-in spot. 3. Dig the bucket into the ground at a location that is well behind the bank of the slope. n Bucket teeth forward (recommended method). Operator's Manual | 49  a. Dig the bucket into the soil with its edge pointing away from the tracks. b. Continue digging the bucket in until it is at least 3/4 buried in the ground and the cutting edge is pushed forward so that it forms a wedge. TIP - Position the bucket behind a stump to further reduce the possibility of the machine sledging forward. n Bucket teeth back.  a. Dig the bucket into the soil with its teeth pointing towards the tracks. b. Continue digging the bucket in until it is at least 3/4 buried in the ground and its back is pushed up against the vertical back face of the hole. 4. Adjust the boom, dipper and bucket until the following conditions are met: n You can fully see the green strip of the angle indicator at the top of the dipper. n The top of the boom is above the level indicator on the window of the cab. Refer to Safety features for more information. n The angle between the dipper and boom (A) is greater than 110°. TIP - The greater the dipper arm angle, the longer the effective length of the machine and more stable the machine will be. Anchor the movement switch WARNING Incorrect installation of the anchor may prevent the movement alarm from functioning as intended. Movement of the machine may destabilize the system, resulting in the machine tipping over. 1. Remove the movement switch anchor plate from the small hatch at the rear of the Winch Assist. 2. Place the anchor plate on the ground at a position where the lanyard is no higher than 45° from the ground and stand on it to drive the spikes into the ground. TIP - You may hook the anchor plate spikes over a solid rock. Note - The lanyard should be loose enough to accommodate normal movement of the machine. 50 | Operator's Manual Operator's Manual | 51 Tethered machine setup Before you attach the Winch Assist system to the tethered machine, ensure that you are fully compliant with the following safety instructions. SAFETY INSTRUCTIONS ▪Ensure that the tethered machine meets the requirements and safety specifications for its intended use. Refer to Tethered machine safety information for more information. ▪Ensure that the Winch Assist machine is correctly set up. Refer to Winch Assist machine setup for more information. ▪Ensure that you can position the tethered machine in an area of the work zone where it can be operated stably and without the assistance of the Winch Assist machine. ▪Ensure that you can position the tethered machine in the work zone in compliance with the requirements for establishing an exclusion zone. Refer to Exclusion zones for more information. Attach the rigging SAFETY INSTRUCTIONS ▪Ensure that the Winch Assist machine and tethered machine are turned off. ▪Ensure that the point at which the rigging attaches to the tethered machine is at the center of the machine and is certified by a chartered professorial engineer. ▪Ensure that the rigging meets the requirements for its intended use. Refer to Rigging specifications for more information. WARNING An attachment point that is worn or structurally damaged may compromise the safety of the operator. Routinely inspected the attachment point for excessive wear or structural damage. 1. Attach the shackle on the rigging to the tow bar at the front of the tethered machine. 2. Securely fasten the shackle. Move the tethered machine into the work zone 1. Check that all the components or the rigging system are securely fastened. 2. Slowly walk the tethered machine away from the Winch Assist machine to take up the slack in the rope and chain. 3. Turn on the tethered machine's PLC. 52 | Operator's Manual 4. Observe the display to ensure that radio communication has been established between the two machines and there are no active alarms. If communication is not established follow the troubleshooting instructions in this manual. Refer to Troubleshooting for more information. Note - The system takes approximately 1–2 minutes to establish radio communication and register any alarms. Test the setup 1. Engage the Winch Assist brake. 2. For machines fitted with travel lockout, press and hold the Travel Lock Override button on the joystick. This will allow you to walk the tethered machine away from the Winch Assist machine while the brake is engaged. 3. Very slowly walk the tethered machine away from Winch Assist machine, watching the tension monitor as you do so. 4. Increase the tension to above 20% of the safe working load of the machine (for example, 25 tonnes for a 108:1 gearbox machine). Refer to General specifications for more information. Ensure that the rope tension does not exceed 35 tonnes. NOTICE When the rope is taut, even a small amount of machine movement will significantly increase the tension. CAUTION 5. Release the tension three times. 6. Once you have established that the Winch Assist machine is secure, slacken the rope by walking the tethered machine back towards the winch. Note - Ensure that the Winch Assist machine is anchored securely and has not moved. The soil adjacent to the bucket, should be inspected to ensure that there is no sign of instability of the soil. 7. Ensure that the movement anchor is in place and set up correctly. Refer to Winch Assist machine setup for more information. Operator's Manual | 53 Advanced setup This section describes how you may set up the Winch Assist system in environments and applications where normal setup is not possible. Bucket over the bank In certain situations it is not practical to set up the Winch Assist machine on a flat platform, for example, when operating off a road. In this situation, it is possible to dig the machine in with the bucket over the bank. 1. Select an appropriate anchoring location. Refer to Winch Assist machine setup for more information. 2. Rotate the tracks until they are at right angles to the boom. 3. Extend the boom and the dipper out and position the bucket over the dig-in spot. 4. Dig the bucket into the ground at a location that is well behind the bank of the slope. a. Dig the bucket into the soil with its teeth pointing away from the tracks. b. Continue digging the bucket in until it is at least 3/4 buried in the ground. Note - As it is highly likely for the soil of the bank to be loose and unstable, ensure that you dig the bucket in firmly before proceeding. 5. Adjust the boom, dipper and bucket until the following conditions are met: n You can fully see the green strip of the angle indicator at the top of the dipper. n The top of the boom is above the level indicator on the window of the cab. Refer to Safety features for more information. n The angle between the dipper and boom (A) is greater than 110°. TIP - The greater the dipper arm angle, the longer the effective length of the machine and more stable the machine will be. 54 | Operator's Manual  n There is adequate clearance between the bonnet and the rope (B). Note - The clearance between the bonnet and the rope will decrease as the rope pays out. Ensure that you account for this reduction. Binding (side-washing) In some situations, it is not possible to run the rope in a straight line between the Winch Assist machine and the tethered machine. In this situation it is recommended that an anchor block rated to the Safe Working Load (SWL) of the rope is used. Note - For small binding angles (less than 30°) it is acceptable to use suitable standing trees or stumps to bind around. NOTICE Binding around a tree or stump may cause increased rope tension due to friction and also damage the rope and rigging. Avoid binding around a tree or stump and, if necessary to do so, conduct a risk assessment before proceeding. Binding using a block l Use stumps or anchors that are set up to the correct local guidelines. l Ensure that the sheave of the anchor block is rated for 28 mm (1 1/8 inches) swaged rope and has a minimum working load limit of 21 tonnes (23 US tons). l Depending on the bind angle (A) select an appropriately rated anchor block for the anchor load (B) from the table below. WARNING The bind angle shall not exceed 60° as this may overload the anchor or block. Operator's Manual | 55 Angle of rope Load multiplication Anchor deflection (A) factor at anchor load* (B) (tonne) 15 0.3 5.5 30 0.5 10.9 45 0.8 16.1 60 1.0 21.0 * Values calculated for a line pull of 21 tonnes (23 US tons). Binding around trees WARNING The bind angle shall not exceed 30°. l Ensure that the tree size and soil conditions are sufficient for binding loads. l Frequently monitor the grooves in the trees caused by rope wear. l Regularly inspect the rope for damage caused by binding trees. l Use catching trees in case the first fails. l Use multiple trees to decrease the bind angle. 56 | Operator's Manual Actual line tension monitoring WARNING Additional tension, caused by friction of the bind will be seen in the lower section of the rope (that is, at the tethered machine end) during binding operations when the tethered machine is pulling out rope. As the tension meter is located on the Winch Assist machine, this additional tension is not reflected in the line tension readout on the tethered machine. Use the table below to calculate the actual line tension on the rope and ensure that you do not exceed the safe working load of the system. Tension monitor reading Actual line tension (tonnes) A = 10° A = 20° A = 30° 5 5.4 5.8 6.2 10 10.8 11.6 12.4 15 16.1 17.4 23.1 20 21.5 23.1 24.9 Uphill winch assisting l Use stump anchors that are set up to the correct local guidelines. l Use at least two separate blocks and anchors to reduce the load on the anchor and add redundancy. l Ensure that the sheave of the anchor block is rated for 28 mm (1 1/8 inches) swaged rope and the blocks are rated for a minimum working load limit of 21 tonnes (23 US tons). Operator's Manual | 57 58 | Operator's Manual  CHAPTER 5 Operation Operator interface⯇ Operator controls⯇ Pre-start inspection⯇ General operation⯇ Advanced operation⯇ Operator's Manual | 59 Operator interface The user interface to the Winch Assist system comprises of two programmable logic controllers (PLC) that are installed in the Winch Assist machine and the tethered machine. The PLCs enable touch button control of the winch while providing visual feedback and alerts to the operator. Winch assist PLC Main screen Item Description q System status Displays information about your Winch Assist system. w Override remote E-stop Tap this button to override an emergency stop that is engaged from the tethered (Only appears when machine. emergency stop is In some cases, when the tethered machine operator initiates the emergency stop activated from the function, winch functionality cannot be restored thereafter. In such cases, the tethered machine) emergency stop function remains activated in the Winch Assist and prevents it from operating. WARNING Overriding an alarm may have serious consequences for the operator and site personnel. Ensure that you follow all safety instructions before you do so. e Communication status Displays the status of the communication link between the Winch Assist machine and the tethered machine. r Data logger Tap RESET if the data logger does not start logging data within one minute after powering up the Winch Assist system. t System diagnostics Displays the state of the control system's switched inputs and outputs in real-time. y Setpoints configuration Enables you to configure the system's setpoints. Note - Access is password-protected. 60 | Operator's Manual  WARNING Correct Winch Assist settings are critical for safe operation. Only approved Falcon Forestry Equipment service technicians shall adjust these values. u Wire rope installation Enables you to remove old wire rope from the drum and install new wire rope in a bare drum. i Load cell calibration Enables you to calibrate the load cell i