PARTS BOOK

ATTACHMENT NAME POWER GRAPPLE GROUP No. 1362517B-B2A5ADBSERIAL No. E78432 and up MODEL No. HX30-RPGMT8.0

MACHINE MAKE MODEL No. DHSPSERIAL No. 2154LL

GIVE ABOVE INFORMATION WHEN ORDERING ORDER FROM YOUR LOCAL DEALER

CWS Industries (Mfg.) Corp. / IMAC

7622 18th Street, Edmonton, Alberta, Canada T6P 1Y6 Telephone: 780-469-9185 Fax: 780-469-9256

Toll Free: 888-848-8288 24-Hour Parts and Service Line: 780-446-0478

Visit CWS IMAC on the World Wide Web www.imac.ca

CWS Industries (Mfg) Corp.

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• DO NOT PROCEED WITH THE INSTALLATION, OPERATION OR MAINTENANCE OF THIS ATTACHMENT UNTIL YOU HAVE READ AND UNDERSTOOD YOUR MACHINE OWNER’S MANUAL AND THIS ATTACHMENT MANUAL. TO DO SO COULD LEAD TO SERIOUS INJURY OR DEATH OF THE PERSONNEL INVOLVED.

• INCORRECT OPERATION, LUBRICATION, MAINTENANCE OR REPAIR OF THIS ATTACHMENT CAN BE DANGEROUS AND MAY RESULT IN SERIOUS INJURYOR DEATH.

• If this attachment is equipped with hydraulic accessories, be aware of high pressure fluid hazards and take appropriate precautions.

• Secure all hydraulic hoses. Mismatched or incorrect hydraulic connections, fittings or adapters can result in possible injury, damage or attachment malfunction.

• Ensure that all ground personnel remain out of the machine operating envelope.

• Follow safe practices when servicing attachments: – secure all suspended parts – de-energize all hydraulic and electrical circuits – ensure all machine controls are locked out and that no personnel are in the cab

• Do not modify or weld on any area of this attachment without consulting CWS IMAC. Failure to do so will void any warrantees and may result in injury or death if any structural components are affected.

• A “Rated Loads” decal may be provided on this attachment. Failure to comply with these figures may result in product damage, personal injury or death. Some attachment load ratings may be higher than the capability of the machine on which they are mounted. Contact your dealer or reference your machine manual to calculate the safe working capacity of your machine. The attachment weight can be found on the serial number tag or “Rated Loads” decal. CWS IMAC cannot anticipate every circumstance that might involve hazards. The warnings in this product manual should not be considered a comprehensive safety

program. It is the responsibility of the owners and operators of industrial equipment to develop safety programs specific to their application and maintain current levels

of compliance to local Safety Codes.

Please contact your CWS IMAC Dealer if you require additional safety information about your attachment.

A good source for industrial equipment safety is: The Association of Equipment Manufacturers

Toll free: 1-800-AEM-0442 Web: www.aem.org

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THIS ATTACHMENT IS NOT A CERTIFIED OVERHEAD LIFTING DEVICE. ALL GROUND PERSONNEL SHOULD REMAIN FREE AND CLEAR OF ANY

SUSPENDED LOADS.

ALWAYS FOLLOW LOCAL RULES AND REGULATIONS FOR SAFE OPERATING PRACTICES. FAILURE TO DO SO CAN RESULT IN PROPERTY

DAMAGE, SEVERE INJURY OR DEATH.

• Ensure that the grapple installation checklist is completed before machine is put into service. Refer to the “Grapple Installation” section for safe installation, adjustment and “break-in” procedures.

• The owner of this attachment must develop a regular maintenance and inspection schedule to ensure the safe operation of the equipment. CWS IMAC recommends a minimum annual inspection for structural integrity using non-destructive testing methods equivalent to magnetic particle inspection. More frequent intervals should be used if site conditions are severe.

• Periodically check the grapple for signs of damage. (I.e. broken or worn pins, structural damage cut hoses etc.)

• This grapple is designed to handle balanced loads. Heeling the logs can cause damage to the grapple.

• Never use the grapple to “bulldoze” logs or push the machine as this may cause damage.

• Ensure ground personnel remain out of the operating envelope of the machine and drop zone of any loads.

• Do not stack materials, load or unload trucks near ground personnel. Do not lift or carry loads near ground personnel.

• Never attempt adjustments while the machine is moving.

• Never move an attachment that is not properly secured to the machine.

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Your grapple may be equipped with a lifting hook. (Optional)

• The hook itself is rated to lift up to 20,000 pounds. This may exceed the

capabilities of the machine. Contact your dealer or refer to machine manual to determine the safe working capacity of your machine. Remember to reduce the capacity by the weight of the attachment.

THIS ATTACHMENT IS NOT A CERTIFIED OVERHEAD LIFTING DEVICE. ALL GROUND PERSONNEL SHOULD REMAIN FREE AND CLEAR OF ANY

SUSPENDED LOADS.

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• Only qualified personnel should carry out service and repairs.

• Place attachment on ground and secure all suspended parts.

• Insure all hydraulic and electrical circuits are de-energized.

• Insure the machine controls are locked-out and that no personnel are in the cab.

GGGRRRAAAPPPPPPLLLEEE IIINNNSSSTTTAAALLLLLLAAATTTIIIOOONNN • For systems with PVG 32 valves, Sauer-Danfoss recommends the use of

mineral-based hydraulic oil containing additives: Type HLP (DIN 51524) or HM (ISO 6743/4).

• Filtration, a 10 µm nominal filter (or finer) or a 20 µm absolute filter (or finer) is

suitable.

CONTROL VALVE ADJUSTMENT

Figure 1

MAIN PRESSURE RELIEF SETTING

• Main pressure relief must be checked before grapple is put into service.

See parts book schematic for pressure setting.

• Install pressure gauge at port M shown above. • Ensure pressure of oil supplied to valve is higher than required pressure

setting of main pressure relief valve. To set relief pressure.

PORT B FLOW CONTROL

PORT A FLOW CONTROL

LS PRESSURE LIMITER

MAIN PRESSURE RELIEF

PRESSURE GAUGE PORT M MAY NOT BE EXACTLY AS SHOWN

PORT RELIEF NON-ADJUSTABLE

• Remove plastic cover from pressure relief valve.

• Fully open jaws and hold to get pressure reading • To adjust main relief pressure, turn inner cartridge using a 4mm hex key. Turn

clockwise to increase pressure. Turn counter-clockwise to decrease pressure.

• Turning set screw 360 degrees will adjust pressure by 1450 psi.

• Replace plastic cap

• Remove pressure gauge from port M and replace plug.

• Set oil supplied to valve back down to setting shown in schematic. NOTE: PRESSURE RELIEF VALVE MUST BE SET TO PRESSURE INDICATED IN SCHEMATIC OR DAMAGE TO ATTACHMENT MAY OCCUR.

Figure 2

ROTATE FUNCTION PRESSURE SETTING

• Rotate function pressure settings must be checked before grapple is put

into service. See parts book schematic for pressure setting.

• Install pressure gauge at LS Test Port on grapple bulkhead. See Figure 2 • Open jaws and press into ground to prevent grapple from rotating. • Activate grapple rotate function to send full pressure and flow to motors.

Check pressure in both directions. To set rotate function pressure.

• Remove plastic covers from LS pressure limiter.

• Turn inner cartridge using a 4mm hex key. Turn clockwise to increase

pressure. Turn counter-clockwise to decrease pressure.

• Turning screw 360 degrees will adjust pressure by 1450 psi.

• Replace plastic cap.

SAW FUNCTION PRESSURE SETTING (If applicable)

• Saw function pressure settings must be checked before grapple is put

into service. See parts book schematic for pressure setting.

• Install pressure gauge at LS Test Port on grapple bulkhead. See Figure 2 • Remove saw supply hose from grapple control valve (see piping kit in

replacement parts section of this manual for location).

• Plug port with a -10 orb plug. • Activate saw function to send full pressure and flow to saw. Check pressure.

To set saw function pressure.

• Remove plastic covers from LS pressure limiter. • Turn inner cartridge using a 4mm hex key. Turn clockwise to increase

pressure. Turn counter-clockwise to decrease pressure.

• Turning screw 360 degrees will adjust pressure by 1450 psi.

• Replace plastic cap.

INDIVIDUAL FUNCTION FLOW SETTINGS

• Individual function flow settings must be checked before grapple is put into service. See parts check list for cycle times.

• Loosen lock nut on flow control set screws using 10mm wrench. See Figure 1 • Turn set screw using a 3mm hex key. Turn clockwise to decrease flow, turn

counter-clockwise to increase flow.

Figure 3

HYDRAULIC MOTOR CROSS OVER RELIEF VALVE

• Cross over relief valve pressure setting is factory pre-set and should not

require adjustment. Cross over relief valve is bi-directional. A single cartridge controls both A and B ports.

To check cross over relief valve pressure.

• Install pressure gauge at port shown. See Figure 3.

• Adjust motor hydraulic LS pressure to 3500 psi. (See control valve

adjustments.)

• Adjust rotate function flow setting to achieve the following rotation speeds. (See individual function flow setting.)

• For 38-8 motors: single mcd drive 10-1/4 rpm, dual mcd drive 5-1/2 rpm. For 60-5 motors: single mcd drive 7 rpm, dual mcd drive 3-1/2 rpm.

• Open jaws and press into ground to prevent grapple from rotating.

• Activate grapple clockwise rotate function to send full pressure and flow to motors. Check setting on gauge.

• Pressure should be between 3000 psi and 3200 psi.

• Remove gauge, return rotate function flow to recommended setting.

To set cross over relief valve pressure.

• Remove cap on cartridge, use a 5mm hex key to adjust pressure setting.

• Turn clockwise to increase the setting. Turn counter-clockwise to decrease the

setting. Pressure will adjust by 493 psi per turn. • Re-test pressure setting in counter-clockwise rotation at second point as

shown.

• Replace cap on cartridge, reduce motor LS pressure to 2500 psi on control valve.

• Adjust rotate function flow to recommended setting.

CHARGE LINE RECOMMENDATION • Although not mandatory CWS IMAC recommends using a dedicated motor

charge line for rotating grapple products.

• To ensure the motors have a long working life and work within specifications, it must be full of hydraulic fluid at all times. If the motors are lacking in fluid or internal pressure is low two things can happen. 1. Cavitation can occur. The hydraulic motors turn into “pumps” every time

the grapple is stopped and without make-up fluid the motors can cavitate. This will cause gradual loss of power and speed, and allow the grapple to drift while holding the load at rest.

2. Free wheeling can occur if the motors become too low in fluid or severely

damaged by cavitation.

• A dedicated charge line:

1. Is not dependant on how the grapple is attached to the carrier 2. Is not dependant on another excavator function for pressure and flow 3. Is not dependant on any extra check valves in the system to have a low

cracking pressure

ROTATING GRAPPLE INSTALLATION REPORT CHECK PARTS MANUAL TO ENSURE ALL PARTS HAVE BEEN RECEIVED

MECHANICS NAME:

MODEL: DATE:

SERIAL NO:

IMPORTANT! This check must be made by the Mechanic before rotating grapple is put into service. CHECK PARTS MAUNUAL INSTALLATION / MAINTENANCE GUIDE TO CONFIRM ALL HYDRAULIC SETTINGS

ITEM Pressure (psi) Cycle time (s) / Flow (gpm)

1. Hydraulic Supply Check that the grapple is receiving min 30 GPM / max 40 GPM @ 4000 psi max as per parts manual.

(psi)

2. Tank Line Check the return line is always open to tank with max 250 psi back pressure as per parts manual. Check with grapple rotating and boom lowering at max speed.

(psi)

N/A

3. Charge line (recommended) Charge line must have min of 65 PSI to max 125 psi pressure @ 8 GPM as per parts manual.

(psi)

N/A

4. Drain Line Check that drain line has a max back pressure of 50 psi as per parts manual.

(psi)

N/A

CW CCW 5. Rotate Function Grapple rotation must be between 7 and 12 rpm. Check parts manual for required flow settings. Max pressure 2500 psi.

(psi) (rpm) (rpm)

OPEN CLOSE 6. Jaw Function, open and close. Check jaw open/close cycle time. Recommended 2.5 sec (21 GPM / 34 GPM). Max 5 sec. (10 GPM / 17 GPM), Min 2 sec. (25 GPM / 42 GPM). Max pressure 5000 psi.

(psi) (s) (s)

UP DOWN 7. Outrigger Function Check jaw open/close cycle time. Recommended 2.5 sec (21 GPM / 34 GPM). Max 5 sec. (10 GPM / 17 GPM), Min 2 sec. (25 GPM / 42 GPM). Max pressure 5000 psi.

(psi) (s) (s)

8. Saw Function (optional) Check saw flow and pressure. Max flow 35 GPM / min 29 GPM, recommended 35 GPM. Max pressure 4200 psi, min 3600 psi, recommended 4000 psi.

(psi)

9. Hydraulic Leaks Check all hydraulic connections for leaks and tighten if necessary.

IN OUT IN OUT 10. Tool cylinder pressure setting Tool cylinder pressure will vary depending on cylinder bore diameter see parts book schematic for required settings. Failure to follow these settings may result in damage to grapple.

(psi) (psi) (s) (s)

11. Break in for 'new' motors Run the rotate motors for 30 minutes with low load (30% max) and low speeds alternating directions. This will lap the faces and "wash" any contaminants to give a long service life.

Remarks:

(Mechanics Signature) (Date)

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• Proper lubrication of the mating surfaces of the pinion and bearing teeth is essential. A heavy duty gear lube will be sufficient. Rotate grapple at 90 degree intervals, grease at each interval. Interval: ONCE DAILY

Bearing grease point

Bearing / Pinion mating

Surfaces grease point

• Grease all points on the grapple. Interval: EVERY SHIFT

• Grease bearing with a lithium base “EP2” (extreme pressure) grease. Rotate grapple at 90 degree intervals, grease at each interval. This ensures proper distribution of grease around the bearing circle without blowing the seals. Interval: EVERY SHIFT

• Visually inspect for straightness and cracking or flaking paint, which may indicate of fatigue and imminent failure. Interval: INSPECT EVERY SHIFT

• Check torque on bearing bolts. Interval: AFTER FIRST 40 HRS OF USE AND EVERY 400 HRS THEREAFTER.

• Visually inspect bearing bolts. If bolts appear loose, clean all bolt circle holes and bolts with rustoleum natural degreaser, apply loctite #24231 and re-place with new bolts immediately. Refer to torque specification chart located in this manual for proper bolt torque settings. Interval: ONCE WEEKLY

• Inspect the cylinders for signs of leaking oil or excessive wear. If leaks are present, have the cylinder repaired by a qualified service facility. Interval: INSPECT EVERY 100 HRS OF USE

• Inspect all components and weld joints for signs of wear or cracking. Interval: INSPECT EVERY USE, NON-DESTRUCTIVE TEST YEARLY

• Maximum contamination for PVG 32 is 18/16/13 (see ISO 4406. Calibration in accordance with the ACFTD method).

Figure 4

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• CWS IMAC recommends chasing all bolt holes with a tap to remove any paint or debris from the threads. Clean threads are required to achieve correct torque and clamp loads.

• Standard torque specifications for Grade 8 bolts with dry threads.

• Standard torque specifications for common hydraulic fittings.

TORQUE Grade 8, Dry

BOLT SIZE (in) (ft-lb) (N-m) 1/2 - 13 119 160 9/16 - 12 160 215 5/8 - 11 230 310 3/4 - 10 380 515 7/8 - 9 600 815 1 - 8 900 1220 1-1/4 - 7 1430 1940

TORQUE ORB JIC (37o) ORF FITTING SIZE (ft-lb) (N-m) (ft-lb) (N-m) (ft-lb) (N-m)

-06 23 30 20 25 25 35 -08 40 55 40 55 55 75 -10 45 60 60 80 75 100 -12 75 100 80 110 130 175 -14 85 115 - - 170 230 -16 120 165 110 150 210 285 -20 155 210 130 175 250 340 -24 170 230 165 225 320 435

GGGRRRAAAPPPPPPLLLEEE OOOPPPEEERRRAAATTTIIIOOONNN • Continuous cyclic rotation of grapple through only 180 degrees clockwise

and counter-clockwise prevents flushing of oil through filter. This will reduce the life of the motors. When operating the grapple between cycles rotate grapple continuously in one direction for 3 to 5 rotations to “flush” contaminants out of the motor and motor lines into the filter.

• COLD WEATHER WARM UP. Do not immediately apply full pressure and

flow to control valve in cold weather or damage to valve will occur. Valve - in - head

• Follow machine Manufacturers warm up procedure before operating grapple. Cold fluid must be flushed from tank line by slowly “cycling” the rotate function. (Cycle by briefly pressing the rotate function and releasing, ¼ second on 2 seconds off.) Continue this for 3 to 5 minutes. Once cold fluid is flushed from tank lines warm up valve by operating all functions without load in both directions for 5 minutes.

Non valve - in - head

• Refer to valve manufacturers recommendations.

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Effective on sales after February 1, 1992

For products made and used in Canada. Other warranty conditions may apply for products made and used elsewhere in the world.

CWS Industries (Mfg.) Corp. warrants all attachments manufactured by CWS IMAC to be free from defects in material

and workmanship:

This warranty does not apply to any item which is warranted directly to the end user by its manufacturer. Warranty Period: The warranty period shall be 12 months starting from the date of delivery to the first user. CWS IMAC Responsibilities: If a defect in material or workmanship is found during the warranty period, CWS IMAC will, during normal hours and

at a place of business of a CWS IMAC dealer or other authorized source:

• Provide (at CWS IMACs' choice), new or remanufactured or CWS IMAC-approved, replacement parts to correct the

defect.

• Replace lubricating oil, filters, antifreeze and other service items made unusable by the defect.

• Provide labor needed to correct the defect except in the case of attachments installed by other than an authorized

dealer of heavy equipment. In that case labor is limited to repair only, and removal and re-installation is the user’s

responsibility.

Installer Responsibilities: The party who installs any CWS IMAC attachment on a machine is responsible for:

• Adjusting rollback and dump stops so that they contact the machine as prescribed by the machine manufacturer and

insuring the attachment clears the machine in all positions.

• Adjusting pressure settings both on the machine and on the attachment to insure normal operation of the attachment

and machine combination.

• Pressure testing all hydraulic connections and tightening where necessary.

• Checking and tightening all fasteners and pin locks once the attachment has been tested.

• Insuring that a warranty activation as provided is filled in and sent back to CWS IMAC.

User Responsibilities: The user is responsible for:

• The costs associated with transporting the attachment.

• Labor costs, except as stated under "CWS IMAC Responsibilities".

• Local taxes, if applicable.

• Parts shipping charges in excess of usual surface transportation cost as charged by scheduled carriers.

• Costs to investigate complaints unless the problem is caused by a defect in CWS IMAC material or workmanship;

subject to "CWS IMAC Responsibilities" above.

• Any costs resulting from failure to give CWS IMAC timely notice of a warrantable failure and promptly making the

product available for repair.

Limitations: CWS IMAC is not responsible for failures resulting from: and normal wear and tear or:

• Any use which CWS IMAC judges improper.

• Accessory, items, and parts not sold by CWS IMAC.

• Abuse, neglect, accident, changes to the product not authorized by CWS IMAC, and/or improper repair.

Miscellaneous: All notices given under or pursuant to this agreement shall be in writing and sent postage prepaid to CWS Industries (Mfg.) Corp., 7622 18th Street, Edmonton, Alberta, Canada T6P 1Y6. No terms or conditions, other than those stated herein and no agreement or understanding, oral or written, which in any way purports to modify this warranty, shall be binding on CWS Industries (Mfg.) Corp., unless approved in writing by an officer of the company.

Procedure: When a failure occurs you must notify CWS IMAC immediately to obtain authorization to carry out repair:

• Recommended repairs are to be discussed and agreed to by CWS IMAC.

• An estimate of repair hours and costs must be established.

• Repair parts will be ordered by customer purchase order at this time. Parts will be invoiced by CWS IMAC and

reimbursed under the terms of this warranty policy if applicable

Damaged Parts: All damaged parts must be returned prepaid to CWS IMAC unless directed otherwise by CWS IMAC.

• Damaged parts become the property of CWS IMAC.

Warranty Claim: Your warranty claim must contain the following:

• CWS IMAC attachment serial number.

• Model and Description of the CWS IMAC attachment.

• Machine serial number.

• Description of the machine.

• Date claim is prepared.

• Delivery date to the original user.

• Date of failure and repair.

• Hours of use on the attachment, (often the same as machine hour meter).

• Your internal reference or claim number.

• An accurate accounting of the work done. Photographs from before and after the repair are helpful in investigating

the failure and help expedite your claim.

• Your work order or other documentation to support your claim.

• A listing of parts and raw materials used in the repair. (Please note that we cannot reimburse for parts not purchased

from CWS IMAC.

THIS WARRANTY IS EXPRESSLY 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 LIMITED TO THE PROVISION OF MATERIAL AND LABOR, AS SPECIFIED HEREIN. CWS IMAC IS NOT RESPONSIBLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES.

CWS Industries (Mfg.) Corp. / IMAC, 7622 - 18th Street, Edmonton, Alberta, Canada T6P 1Y6

Phone: (780) 469-9185 Fax: (780) 469-9256 Website: www.imac.ca