Ozzie’s Pipeline Padder, Inc. Mini-padder

OZZIE’S PIPELINE PADDER, INC. 7102 West Sherman Street Phoenix, Arizona, 85043

Phone: (480) 585-9400 Fax: (480) 585-7977

Ozzie’s Pipeline Padder, Inc. Mini-padder

Operators Manual REV. A3

Page i Foreword

1 Foreword This manual contains information and instructional material pertaining to the safe and efficient operation and maintenance of Ozzie’s Mini-padder backfill separation Machines. The purpose of this manual is to promote the proper and safe operation and maintenance of Ozzie’s Padding Machines during operation and servicing. In addition to the information outlined in this manual, appropriate personal protection and equipment as described herein should be worn during operation and maintenance of Padding Machines in order to ensure optimum safety during operation and maintenance.

This manual should be read prior to commencing initial operation and maintenance procedures on Padding Machines. The manual should be kept available for reference by Machine operators and service technicians at all times. A copy of the manual should be stored on the Padding Machines in a secure designated location and remain with the Padding Machines at all times.

Operation and maintenance of earth moving equipment can be dangerous. Careless operation and maintenance practices can result in injury or death to the operator or maintenance and support personnel. Most accidents involving Padding Machine operation, maintenance and repair are caused by failure to apply and adhere to basic safety principles as outlined herein. All personnel must remain alert to potential hazards at all times and take appropriate precautionary measures to anticipate and avoid accidents before they can occur. Never operate or work on Padding Machines unless you have been properly trained and you are completely familiar with this manual. Read and understand all the instructions as well as all hazard and safety warnings outlined in this manual.

Some Figures in this manual may show details or attachments that differ from your specific unit. Some pictures show guards or covers removed for illustration purposes that may not need to be removed for routine maintenance of the Padding Machines.

Continuing improvement and advancement of product design may have resulted in changes and/or modifications to the Padding Machine which may not be covered in this manual. This manual is reviewed and updated on a regular basis in order to provide the most current information available for safe and efficient operation, maintenance and care of this Padding Machine.

Visit Ozzie’s Pipeline Padder, Inc. at the website address www.ozzies.com for the latest updates of this manual. Alternatively, contact one of our service technicians toll free at 1 800 758 6634 or contact our Phoenix Service Centre at 480 585 9400.

http://www.ozzies.com/

Page ii Table of Contents

2 Table of Contents 1 Foreword ................................................................................................................................................ i 2 Table of Contents .................................................................................................................................. ii

2.1 Table of Figures ............................................................................................................................ iv 2.2 Table of Tables ............................................................................................................................. iv

3 Introduction .......................................................................................................................................... 1 4 Machine Description ............................................................................................................................. 1

4.1 Specifications ................................................................................................................................ 1 4.1.1 Dimensions and Capacities ................................................................................................... 1 4.1.2 Attachment Serial Number ................................................................................................... 1 4.1.1 Loader/Engine Serial Number ............................................................................................... 2

4.2 Machine Orientation ..................................................................................................................... 2 5 Safety .................................................................................................................................................... 6

5.1 Terms and Signs ............................................................................................................................ 6 5.2 Lockout/Tagout Procedures .......................................................................................................... 6 5.3 Hazard Areas ................................................................................................................................. 7

5.3.1 Warning Zones ...................................................................................................................... 7 5.3.2 Caution Zones ....................................................................................................................... 8

5.4 Critical Safety Information ............................................................................................................ 8 5.4.1 General Safety Guideline ...................................................................................................... 8 5.4.2 Machine Maintenance Safety ............................................................................................... 9 5.4.3 Burn Prevention .................................................................................................................. 10 5.4.4 Cutting and Crushing Prevention ........................................................................................ 10 5.4.5 Electrical .............................................................................................................................. 11 5.4.6 Fire and Explosion Prevention ............................................................................................ 11 5.4.7 Hoses, Lines and Tubes ....................................................................................................... 12 5.4.8 Welding Safety .................................................................................................................... 12

5.5 Machine System Specific Safety Information ............................................................................. 12 5.5.1 Conveyor Safety .................................................................................................................. 12 5.5.2 Elevator Safety .................................................................................................................... 13 5.5.3 Vibrator Safety .................................................................................................................... 13 5.5.4 Loader Safety ...................................................................................................................... 13

5.6 Attachment Safety Signs ............................................................................................................. 14 6 Operation ............................................................................................................................................ 15

6.1 Before Operation ........................................................................................................................ 15 6.2 Mounting and Dismounting ........................................................................................................ 15 6.3 Operator Controls and Instrumentation ..................................................................................... 15

6.3.1 Attachment Controls ........................................................................................................... 15 6.4 Machine Start-Up Procedure ...................................................................................................... 18 6.5 Machine Operation ..................................................................................................................... 19

6.5.1 Initial Operation Setup ........................................................................................................ 19 6.5.2 During Operation ................................................................................................................ 20 6.5.3 Rocky Conditions ................................................................................................................. 21 6.5.4 High Moisture Conditions ................................................................................................... 21 6.5.5 Clearing Elevator Screen/Jams ............................................................................................ 21 6.5.6 Using the Dirt Deflector ...................................................................................................... 22

6.6 Machine Parking ......................................................................................................................... 23

Page iii Table of Contents

6.7 Machine Shutdown Procedure ................................................................................................... 23 6.8 Connecting/Disconnecting the Padder Attachment ................................................................... 23

7 Machine Maintenance ........................................................................................................................ 25 7.1 Loader Daily Inspections/Maintenance ...................................................................................... 25 7.2 Loader Scheduled Maintenance ................................................................................................. 25 7.3 Attachment Daily Inspection/Maintenance ................................................................................ 26 7.4 Attachment Scheduled Maintenance ......................................................................................... 27 7.5 Bearing Maintenance .................................................................................................................. 27 7.6 Elevator Screen Maintenance and Adjustments......................................................................... 28

7.6.1 Elevator Screen Inspection.................................................................................................. 28 7.6.2 Elevator Screen Installation ................................................................................................ 29 7.6.3 Elevator Screen Adjustment ............................................................................................... 31

7.7 Elevator Belt Maintenance and Adjustments ............................................................................. 34 7.7.1 Elevator Belt Inspection ...................................................................................................... 34 7.7.2 Elevator Belt Installation ..................................................................................................... 35 7.7.3 Elevator Belt Adjustment .................................................................................................... 38

7.8 Conveyor Belt Maintenance and Adjustments ........................................................................... 42 7.8.1 Conveyor Belt Inspection .................................................................................................... 42 7.8.2 Conveyor Belt Installation ................................................................................................... 42 7.8.3 Conveyor Belt Adjustment .................................................................................................. 43

8 Troubleshooting .................................................................................................................................. 46 8.1 All Attachment Functions are not Working ................................................................................ 46 8.2 An Attachment Function is Not Working .................................................................................... 46 8.3 Mechanical Systems .................................................................................................................... 46

8.3.1 Broken Keyway/Stripped Coupler ....................................................................................... 46 8.3.2 Test Motor Health ............................................................................................................... 46

8.4 Attachment Electrical System ..................................................................................................... 47 8.4.1 All functions not working .................................................................................................... 47 8.4.2 One function not working or intermittent functionality..................................................... 47 8.4.3 Blink codes .......................................................................................................................... 47 8.4.4 Calibration ........................................................................................................................... 48

Page iv Table of Contents

2.1 Table of Figures Figure 1: Machine Serial Number ................................................................................................................. 2 Figure 2: Machine Components .................................................................................................................... 3 Figure 3: Attachment Components (Right Side) ........................................................................................... 4 Figure 4: Attachment Components (Front View) .......................................................................................... 4 Figure 5: Attachment Components (ISO) ...................................................................................................... 5 Figure 6: ISO Danger Signage ........................................................................................................................ 6 Figure 7: ISO Warning Signage ...................................................................................................................... 6 Figure 8: ISO Caution Signage ....................................................................................................................... 6 Figure 9: ISO Caution Symbol ........................................................................................................................ 6 Figure 10: Lockout Symbol ............................................................................................................................ 7 Figure 11: Machine Hazard Areas ................................................................................................................. 7 Figure 12: Right Side Safety Signage ........................................................................................................... 14 Figure 13: Padder Attachment Controls ..................................................................................................... 16 Figure 14: Left Side Grease Locations ......................................................................................................... 27 Figure 15: Right Side Grease Locations ....................................................................................................... 28 Figure 16: Elevator Chain Orientation ........................................................................................................ 30 Figure 17: Elevator Screen Adjustor ........................................................................................................... 31 Figure 18: Loosening Elevator Screen Adjustment ..................................................................................... 32 Figure 19: Tightening Elevator Screen Adjustment .................................................................................... 32 Figure 20: Adjusting Elevator Screen Leftward ........................................................................................... 33 Figure 21: Adjusting Elevator Screen Rightward ......................................................................................... 34 Figure 22: Elevator Pulley Alignment .......................................................................................................... 36 Figure 23: Elevator Belt Adjustor ................................................................................................................ 37 Figure 24: Elevator Belt Lifting Technique .................................................................................................. 37 Figure 25: Elevator Belt Tension and Lacing Installation ........................................................................... 38 Figure 26: Tightening Elevator Belt Adjustment ......................................................................................... 39 Figure 27: Loosening Elevator Belt Adjustment .......................................................................................... 39 Figure 28: Elevator Belt Adjustment Measurement ................................................................................... 40 Figure 29: Elevator Belt Leftward Adjustment............................................................................................ 41 Figure 30: Elevator Belt Rightward Adjustment ......................................................................................... 41 Figure 31: Tightening Conveyor Belt Adjustment ....................................................................................... 44 Figure 32: Loosening Conveyor Belt Adjustment ........................................................................................ 44 Figure 33: Conveyor Belt Rearward Adjustment ........................................................................................ 45 Figure 34: Conveyor Belt Forward Adjustment .......................................................................................... 45

2.2 Table of Tables Table 1: Machine Specifications (Loader w/ Padder Attachment) ............................................................... 1 Table 2: Main Machine Components ............................................................................................................ 3 Table 3: Attachment Components (Right Side and Front) ............................................................................ 4 Table 4: Attachment Components (ISO View) .............................................................................................. 5 Table 5: Padder Attachment Control Descriptions ..................................................................................... 16 Table 6: Generic Loader Service Intervals ................................................................................................... 25 Table 7: Mini-padder Microcontroller Blink Codes ..................................................................................... 47

Introduction

3 Introduction The purpose of this manual is to provide Machine Operators and maintenance personnel with a concise overview of the safe care, operation and maintenance of the Ozzie’s Pipeline Padder, Inc. (“Ozzie’s”) Mini-padder backfill separation Machine (the “Machine(s)” or “Padding Machine(s)”). For the purposes of this manual “Attachment” shall be used to refer to the Ozzie’s Mini-padder head as a standalone unit. The term “Loader” shall refer to the equipment being used to power and operate the Mini-padder Attachment while the term “Machine” or “Padding Machine” shall be used to reference the complete unit of Loader and Attachment couple together.

This manual provides information and instructional material regarding proper operating and safety procedures for Ozzie’s Padding Machines. Reading this manual does represent qualification as a Machine Operator. This manual must be read in conjunction with job-site training from a qualified Ozzie’s Trainer before an individual can be certified as a qualified Operator (“Operator(s)”).

This manual is not to be considered a comprehensive maintenance manual. Contained within this manual is information pertaining to the general daily Preventative Maintenance (“PM”) procedures for Ozzie’s Padding Machines. Only properly trained technicians and/or qualified Machine Operators should perform this maintenance on the Machine, and always with the assistance of a helper (“Assistant/Oiler”).

It is the responsibility of the Operator to ensure the safe operation and daily maintenance of the Machine. It is the responsibility of the Oiler/Assistant to assist in the safe operation of the Machine through careful monitoring of the working environment and Operator blind spots. It is also the responsibility of the Oiler/Assistant to ensure the Machine is lubricated and assist with all daily PM schedules per the prescribed intervals contained within this manual.

Machine Description

4 Machine Description The Padding Machine has been designed to pick up and screen excavated material, separating out large rocks, hard lumps, cobble and/or sharp material and debris to produce a desired fine material for the use in bedding/padding of pipeline and/or electrical cable trenches.

Proper use of the Machine is limited to picking up, screening and/or placing material. These materials include previously excavated material, imported material, previously screened material, select fill, and/or sand. The Machine should never be used to excavate or push material, pull other equipment, transport personnel or for any use other than which it was designed.

For the purposes of this manual the front of the Machine will be identified by the forward facing direction of the operator’s cab or by the section of the Machine that the Mini-padding Attachment is coupled to. Right, left, front and rear directions are determined by facing the direction of the Machine in forward travel.

4.1 Specifications The following section contains general information and specifications for the individual Machine models covered within this manual. These specifications may vary depending upon specific Machine componentry and configuration.

4.1.1 Dimensions and Capacities Table 1: Machine Specifications (Loader w/ Padder Attachment)

Operating Parameter Specification [Units: U.S. (metric)] Weight 54,000 lbs (24,494 kg) Length 28 ft. 9 in. (8,763 mm) Width 12 ft. (3,658 mm) Height 10 ft. 10 in. (3,302 mm) Track Width 2 ft. 9 in. (850 mm) Engine Oil 5 US gal (18.9 L) Fuel Tank 95 US gal (562 L) Hydraulic Oil Tank 49 US gal (185 L) Ground Pressure*: 8.0 psi (55.2 kPa) *As a result of ongoing improvements and modifications, some machines may have a different ground pressure than listed above. Call Ozzie’s Pipeline Padder, Inc. for the most accurate ground pressure for your Machine.

4.1.2 Attachment Serial Number

The serial number for the Attachment is located on the side of the padder Attachment scoop as shown below in Figure 1. The serial number plate may be located on either the left or the right side depending on the year of manufacture and may not look exactly like the plate depicted below. Always include the complete serial number of your Attachment when ordering parts/components. Due to continuous improvements, some Attachments may contain different components. A separate parts manual is supplied with the Attachment for use when ordering replacement parts. Reference the supplied Parts Manual for detailed information regarding part numbering conventions and ordering practices.

Machine Description

Figure 1: Machine Serial Number

4.1.1 Loader/Engine Serial Number

The Loader serial number is located on the left hand side bucket arm of the Loader while the engine serial number plate is located on the engine of the Loader. These numbers are required for servicing or ordering Loader/engine parts. If either serial number plate is missing or has become illegible, contact Ozzie’s. Refer to the Loader manual directly for detailed information on serial number locations and any other Loader specific information.

4.2 Machine Orientation Figure 2, Figure 3, Figure 4 and Figure 5 below display the Machine in right side, Attachment right side, Attachment front and Attachment ISO views, respectively. Refer to these views to locate major Machine/Attachment components which are called out and labeled within the Figures. Machine component locations may vary depending on Machine models.

Machine Description

Figure 2: Machine Components

Table 2: Main Machine Components

# Part Name # Part Name # Part Name

1 Loader 4 Quick attach hitch 7 Microcontroller

2 Mini-padder Attachment 5 High pressure filter 8 Control box

3 Hydraulic Cooler 6 Electric/Hydraulic quick disconnect couplers

2

1

3

1

4

1

1

1

5

1

6

1

7

1

8

1

Machine Description

Figure 3: Attachment Components (Right Side)

Table 3: Attachment Components (Right Side and Front)

Figure 4: Attachment Components (Front View)


1 Hydraulic Valve stack 6 Stabilizer yoke 11 Conveyor

2 Hitch plate 7 Dirt deflector 12 Cutting Edge

3 Conveyor drive motor 8 Vibrator Motor 13 Scoop Wear Plate

4 Conveyor shift motor 9 Rock Guards 14 Lower elevator motor

5 Scoops 10 Elevator screen 15 Upper elevator motor

10

1

7

6

5

4

3

8

11

1

12 13

15

14

9

1

1

2

Machine Description

Figure 5: Attachment Components (ISO)

Table 4: Attachment Components (ISO View)


1 Upper elev. head pulley 5 Conveyor flashing 9 Lower elev. Head pulley

2 Vibrator rollers 6 Conveyor heady pulley 10 Elevator belt wiper

3 Vibrator isolators 7 Conveyor belt adjustor 11 Elev. idler pulley wiper

4 Elevator screen adjustor 8 Elevator belt adjustor 12 Elevator idler pulley

1 2

3

4

5

6

7 8

9

10

11

12

Safety

5 Safety Safety precautions and warnings are provided in this manual and on the Machine. Failure to adhere to signage and warnings could result in severe injury or death.

5.1 Terms and Signs Figure 6, Figure 7, and Figure 8 display the International Organization for Standardization (“ISO”) format signage for Danger, Warning and Caution respectively.

Figure 6: ISO Danger Signage

The “Danger” sign is used to indicate an immediately hazardous situation which, if not avoided, will result in death or serious injury. The use of “Danger” is limited to the most extreme situations.

Figure 7: ISO Warning Signage

The “Warning” sign is used to indicate a hazardous situation which, if not avoided, could result in death or serious injury.

Figure 8: ISO Caution Signage

The “Caution” sign is used to indicate a hazardous situation which, if not avoided could result in minor or moderate injury.

The ISO Caution Symbol shown in Figure 9 below will be used throughout this document and on the Machine to draw awareness to safety items of high importance.

Figure 9: ISO Caution Symbol

5.2 Lockout/Tagout Procedures Before performing any maintenance or repairs it is essential that the Machine be locked out and de-energized (“Lockout/Tagout”) in accordance with the approved manufacturers procedures for your specific Loader. Refer to Section 6.7 in this manual for recommended shut-down procedure and your Loader specific Operation and/or Maintenance Manual for individual Lockout/Tagout and shutdown procedures. Only properly instructed personnel should perform Lockout/Tagout operations.

The ISO “Lockout” Sign shown in Figure 10 below will be used throughout this document and on the Machine to draw awareness to operations requiring Machine Lockout/Tagout and the location of the Lockout/Tagout device on the Machine.

Safety

Figure 10: Lockout Symbol

5.3 Hazard Areas During normal Machine operation there are areas immediately surrounding the Machine that present different hazards. The areas in Figure 11 below highlighted in orange depict Waning areas, meaning that no personnel should enter these areas during normal Machine operation, doing so could result in serious injury or death. The areas highlighted in yellow depict Caution zones which require personnel to be trained and alert of the potential dangers in this area. Failure to wear proper PPE and be alert to potential hazards in this area could result in injury. The next sections of this manual highlight the specific dangers in each of the aforementioned zones.

Figure 11: Machine Hazard Areas

5.3.1 Warning Zones

The area immediately in front of the padder Attachment is a hazard are due to the presence of the elevator screen moving at a high rate of speed. Never contact the elevator screen while it is moving. The areas immediately to either side of the padding Attachment are also considered a hazard area due to the presence of moving motors and pulleys. Contact with any of these moving parts could result in serious injury. Never operate the Machine without proper guarding and never stick any foreign object or body part into a moving motor or pulley. The area to each side of the conveyor is a hazard area during normal operation as the operator may suddenly shift the conveyor in either direction. Standing in this area could result in being struck by a moving conveyor. The area between the rear of the padding attachment and the Loader is another hazard area due to the presence of flying debris and the potential for pinch points in the loader arms as well as crushing hazard by the loader itself. No personnel should be in this area during

Safety

normal operation. The area immediately behind the loader presents a hazard zone due to the presence of an Operator blind spot. During normal operation the Machine makes both forward and sudden reverse travel movements. Standing behind the Machine in the Operator’s blind spot could result in serious injury or death.

5.3.2 Caution Zones

A general three foot area surrounding the Machine and Warning zones has been identified as a Caution zone. Personnel should be particularly alert while in this zone as well as be aware and properly instructed of any potential hazards that exist while in this zone, including but not limited to:

• Moving mechanical parts;

• Loud noise;

• Flying debris;

• and, Sudden/erratic Machine movement.

For additional job site specific safety information, such as trench safety, contact your site specific safety representative.

5.4 Critical Safety Information The following sections identify general safety procedures and guidelines which must be followed when working on and/or around the Machine. Adherence to these procedures and guidelines, along with the use of the appropriate PPE, will ensure the safe care, operation and maintenance of the Machine. Failure to adhere to these procedures may result in severe bodily injury or death.

5.4.1 General Safety Guideline

Never allow unauthorized personnel on or around the Machine during operation, lubrication, servicing or maintenance. Refer to Figure 11 above for Machine operating clearances.

Always use proper Machine Lockout/Tagout procedures when performing maintenance or repairs. Lockout/Tagout procedures should be limited to properly instructed personnel only.

Always wear adequate Personal Protective Equipment (“PPE”), appropriate clothing and/or other safety equipment as required while operating or working on and around the Machine. Consult local safety representatives for site specific PPE regulations. While operating the Machine, at a minimum, steel toed safety boots, long pants, and a safety vest, should be worn at all times. While working on or around the equipment, at a minimum , steel toed safety boots, long pants, safety vests, hardhats, and eye protection should be worn at all times. Operators and Assistants/Oilers are required to wear proper PPE at all times while on the job site.

Use proper techniques for mounting and dismounting the Machine always maintaining three points of contact with the Machine (see Section 6.2 for specific mounting and dismounting information). Three points of contact can be defined as two hands and one foot or two feet and one hand. Never jump off the Machine to dismount, doing so can result in injury. Only mount and dismount the Machine at designated locations on the Machine.

Steps, ladders, platforms and handrails must be kept free from oil, grease, mud, snow and ice at all times and in good working condition. Damage to any of these components

Safety

should be repaired immediately as this may pose a serious safety hazard. Adhering to these preventative measures will minimize the risk of slips, trips, and falls.

Do not store rags that have oil or other flammable material on the Machine. Always dispose of them properly.

Exhaust from diesel engines contain byproducts of combustion, such as carbon monoxide, which may be harmful to your health. Never operate the Machine in areas without proper ventilation. Ensure exhaust gas is ventilated outside the working area if the Machine is operated in an enclosed area.

Never start or operate the Machine until you have done a complete walk around inspection. In an effort to alert nearby personnel, always honk the horn twice before starting the Machine.

To ensure safe operation of the Machine, immediately repair or service any defective parts/components. Do not operate the Machine until all defective parts have been repaired, doing so could result in further Machine damage or injury.

5.4.2 Machine Maintenance Safety

Never perform any maintenance or repairs for which you are not qualified to perform or do not have a complete understanding of the proper maintenance procedures. Always use the correct tools and approved safety devices (Cylinder Locking Devices and Conveyor Safety Chain) when performing maintenance and repairs.

Always follow the recommended Machine Lockout/Tagout procedures before performing maintenance or repairs. This will prevent injuries from unexpected/unauthorized introduction of energy into the system. Only properly instructed personnel should perform Lockout/Tagout operations.

Always wear proper PPE when performing repairs and maintenance on the Machine to prevent injuries. Consult the local safety representative for site specific PPE regulations.

Perform all maintenance, lubrication and inspections at the intervals listed in this manual. All maintenance, lubrication and inspections should be performed in accordance with in the safety guidelines specified in this manual.

Limit access of unauthorized personnel to the working during maintenance and repairs.

Perform all maintenance work with the Machine parked on firm level ground with the engine turned off and locked out unless otherwise specified in this manual.

Any safety devices removed during maintenance or repairs must be reinstalled and tested immediately after maintenance and/or repairs are completed.

Limit air pressure to 30 psi when cleaning with air. Always wear proper PPE when working with compressed air. Never point an air nozzle toward anyone.

Follow all manufactures’ product safety instructions and Safety Data Sheets (SDS) for use, handling and disposal of all maintenance and cleaning materials. Consult the local safety representative for site specific SDS information or call Ozzie’s for information on products supplied with the Padding Machine.

Clean surface areas and remove oil, fuel or other flammable liquids before performing any welding or flame cutting activities.

Use caution when removing filler caps, grease fittings and drain plugs. Cover the cap or plug to prevent being splashed or sprayed by liquids under pressure. These liquids may be

Safety

hot and can burn upon contact with skin. These liquids may be under pressure and have the ability to cut through PPE and skin. Always ensure all pressures have been relieved before servicing or maintenance operations are performed.

When lifting, always use proper lifting techniques and equipment rated for the work load. Do not try to lift heavy parts unassisted. Make sure all straps, belts, hooks or any other lifting aids have been inspected and are serviceable and have the proper lifting capacity for the parts being lifted.

Never stand under or allow others to stand under a supported and/or suspended load.

Regularly check all hydraulic lines, hoses and connections for leaks, wear or damage. Repair any problems immediately.

5.4.3 Burn Prevention

Portions of the Machine engine will become extremely hot during operation. Do not touch any part of an operating engine. Allow the engine to cool before any maintenance or repairs are performed on the engine.

Allow engine and hydraulic cooling system components to cool before draining any fluids or performing maintenance to the Machine. Any contact with steam, hot water or hydraulic fluid will result in severe burns.

Check the coolant level only after the radiator cap is cool enough to touch. Cover the cap with a rag and remove it slowly to relieve any pressure.

Relieve all pressure in air, oil, fuel, and/or cooling systems before any lines, fittings and/or related items are disconnected or removed.

Do not touch any hydraulic system components, including lines and fittings, at or near operating temperature. Allow the hydraulic system to cool to ambient temperatures before performing any maintenance or repairs.

Battery electrolyte contains acid and upon coming in contact with skin will result in severe burns. Avoid contact with skin and eyes. Use of gloves and safety glasses is recommended as a minimum when handling batteries and or battery acid.

Batteries can emit flammable fumes that have the potential to explode when exposed to an ignition source. Do not smoke, carry an open flame or provide any other source of ignition while checking battery electrolyte levels.

Always wear appropriate PPE, including safety glasses/goggles, protective face shield and gloves when working with batteries.

5.4.4 Cutting and Crushing Prevention

Stay clear of all moving and rotating parts. Machine guarding must be properly installed whenever maintenance is not being performed and the Machine is running.

Keep objects away from moving parts, such as fan blades, belts and chains. These moving parts may throw or cut objects that fall or are pushed into them.

Support the Machine at all times while performing any maintenance tasks beneath the Machine. Use only properly engineered load bearing stands that are rated to support the weight of the Machine. Do not use steel on steel contact to support the Machine. This creates a situation whereby the Machine has potential to slip from its supports. Never rely on hydraulic cylinders to hold Machine parts in a raised position.

Safety

Never perform maintenance under the Machine with the Attachment in the raised position unless it is properly blocked and supported with the provided Cylinder Locking Devices.

Wear safety glasses and a protective face shield when hammering on steel, drifts, punches or chisels. Never strike a punch, drift or chisel that has a mushroomed head. Chips can fly off these tools or the hammer and cause injury.

5.4.5 Electrical

Electrical repairs should be done by qualified personnel only.

Always follow the recommended Machine Lockout/Tagout procedures before performing electrical system maintenance and repairs. This will prevent injuries from unexpected/unauthorized introduction of electricity into the system. Only properly instructed personnel should perform Lockout/Tagout operations.

Disconnect battery before performing any electrical maintenance activities to the Machine to prevent the possibility of electrical shock.

5.4.6 Fire and Explosion Prevention

All fuels, most lubricants and some coolants and cleaning solutions are flammable. Check your site specific Safety Data Sheets (“SDS”) for information regarding the specific chemicals before all maintenance activities.

Fire may result from lubricating oil or fuel sprayed on hot surfaces causing personal injury and equipment damage.

Inspect all components, lines, tubes, and hoses for leaks and/or damage. Repair or replace damaged items immediately.

Make sure all clamps, guards and heat shields are properly installed to prevent vibration, rubbing and heat buildup.

Never smoke or use an open flame while refueling or in the vicinity of refueling areas, where batteries are being charged or any flammable materials are stored.

Never store or carry flammable fluids and/or rags soaked with flammable fluids on the Machine. Dispose of all contaminated rags and flammable materials using approved Health, Safety, and Environmental procedures.

Do not weld or flame cut on pipes, tubes or other materials that contain flammable liquids. Clean surfaces both inside and out thoroughly with nonflammable solvents before commencing any welding or flame cutting activities.

Batteries are to be kept clean with covers on all cells and recommended cables/connections used at all times. Ensure the battery box covers are installed at all times while operating the Machine.

Check the electrical system frequently for loose connections, frayed wiring, broken or damaged insulation and signs of corrosion. Wiring must be kept in good condition, properly routed and firmly attached. Damaged or improper wiring is a potential source of ignition and may lead to fire. Repair any issues/discrepancies to the electrical system immediately.

Consult the Machine specific electrical schematics or a trained Ozzie’s maintenance technician for information regarding wire gauges and fuse sizes. Do not use smaller gauge

Safety

wire or bypass fuses. Use of improperly rated wire will lead to overheating and create an additional source of potential ignition.

5.4.7 Hoses, Lines and Tubes

All hoses, lines, tubes and fittings must be inspected regularly for leaks and any visible defects. Replace or repair any damaged or leaky components immediately. Escaping oil has the potential to cut, burn or otherwise injure an individual. It also represents an additional ignition source for fire and is harmful to the environment.

Never check for leaks with your bare hands. Oil from a pinhole leak in a high pressure line can puncture or cut your skin. Use a piece of cardboard or other material to check for leaks.

5.4.8 Welding Safety

Always follow the recommended Machine Lockout/Tagout procedures before performing welding repairs. This will prevent injuries from unexpected/unauthorized introduction of energy into the system. Only properly instructed personnel should perform Lockout/Tagout operations.

Always disconnect the battery before performing welding operations on the Machine.

Always ensure the welding area is free of all flammable materials.

Identify the location of the nearest fire extinguisher. If a fire extinguisher is not readily available cease all welding activities until one can be located. Check the class of fire extinguished present and ensure it is rated for the maintenance activities you are about to perform. Ensure you have received instructions and training on the proper use of a fire extinguisher before commencing maintenance activities.

Always wear the proper personal protective equipment (flame resistant long sleeves and pants, welding mask, safety glasses, leather gloves, etc.) when welding. Wear approved welding respirator as necessary. Consult your site specific safety representative for respirator and fit test requirements. Only wear a respirator if you have gone through the necessary safety training.

Proper ventilation is required for all welding operations. When performing welding activities in an enclosed area ensure all welding fumes are vented to the outside environment.

5.5 Machine System Specific Safety Information

5.5.1 Conveyor Safety

Always perform proper Machine Lockout/Tagout procedures before attempting repairs or maintenance on the Machine conveyor assembly to prevent injuries from unexpected introduction of energy into the system.

Never perform maintenance on any vibrator system components unless the proper Lockout/Tagout procedure has been completed by a trained personnel.

Never reach into the conveyor system while the Attachment is energized.

Ensure locking devices and/or safety chains are installed when conveyor is in the raised position.

Never walk near or under the conveyor while it is in the raised position or when being raised or lowered.

Safety

Never step or stand on the conveyor or conveyor belt.

Relieve hydraulic tank pressure before performing maintenance on hoses, lines, fittings or hydraulic motors.

5.5.2 Elevator Safety

Always perform proper Machine Lockout/Tagout procedures before attempting repairs or maintenance on the Machine elevator assembly to prevent injuries from unexpected introduction of energy into the system.

Never perform maintenance on any elevator system components unless the proper Lockout/Tagout procedure has been completed by a trained personnel.

Never reach into the elevator system while the Attachment is energized.

Never step or stand on the elevator system or elevator screen unless the proper Lockout/Tagout procedure has been completed by a trained personnel.

Relieve hydraulic tank pressure before performing any maintenance on hoses, lines, fittings or hydraulic system components.

Elevator components are heavy, always use proper lifting techniques, lifting devices and approved straps/chains while handling elevator components.

5.5.3 Vibrator Safety

Always perform proper Machine Lockout/Tagout procedures before attempting repairs or maintenance on the Machine vibrator assembly to prevent injuries from unexpected introduction of energy into the system.

Never perform maintenance on any vibrator system components unless the proper Lockout/Tagout procedure has been completed by a trained personnel.

Never reach into the vibrator system while the Attachment is energized.

Relieve hydraulic tank pressure before performing any maintenance on hoses, lines, fittings or hydraulic system components.

5.5.4 Loader Safety

Always perform proper Machine Lockout/Tagout procedures before attempting repairs or maintenance on the Loader to prevent injuries from unexpected introduction of energy into the system.

Loader maintenance items are not covered in this manual. Refer to the Loader’s Operation and Maintenance Manual for specific maintenance information and safety items.

Safety

5.6 Attachment Safety Signs

Figure 12: Right1 Side Safety Signage

1 Identical to Left Side Safety Signage

1) ISO Pinch Point Hazard

Indicates pinch point presence. Keep all body parts and clothing clear of area. Failure to keep clear of this area could result in serious injury.

2) Moving Equipment

This area contains moving parts that may cause serious injury. Ensure that all body parts and loose articles of clothing are kept clear. Operate Machine only with proper guarding in place.

3) ISO Caution Triangle

General warning sign. Any messages following this sign should be obeyed to avoid a potentially dangerous situation.

4) Lift

This sign indicates a mandatory lifting action. Whenever lifting a Machine always do so from designated lifting points. Failure to do so could result in Machine Damage and/or serious injury.

5) Warning Stay Back 25 ft.

Moving Machine components present in this area may cause severe injury or death. All UNTRAINED personnel must maintain at least 25 feet of distance to avoid this hazardous area.

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Operation

6 Operation This Machine should only be operated by trained and qualified personnel. This section provides general information for the safe startup, basic operation, and shutdown of the Machine. Never operate the Machine in actual field conditions without proper training from an Ozzie’s qualified Operator.

6.1 Before Operation Before daily field operation, specific maintenance must be performed to help ensure safe Machine operation and performance. Refer to Section 7 of this manual for a detailed list of Attachment specific maintenance items. This maintenance should be completed daily at a minimum. Certain items may require additional attention throughout daily operation depending on environmental/working conditions.

6.2 Mounting and Dismounting Only mount and dismount the Machine at locations where proper foot and hand holds have been provided. The locations on the Machine intended for mounting and dismounting are at the Loader arms where both the hand railing and step are located. Access to the operator cabin is gained by walking on the Loader tracks to the door. Due to the presence of hydraulic/electric lines and other components on the right side of the Loader it is highly advised that access to the Loader is gained via the left side of the Loader. Loader access may vary with model. Please refer to your specific Loader’s Operation Manual for model specific instruction on proper methods of mounting and dismounting the Loader.

Prior to mounting the Loader, make sure the hand/foot holds and tracks are free of dirt, oil, and/or any other debris which may cause slipping. Inspect the hand and foot holds for structural damages/weaknesses and make any necessary repairs.

For proper Machine mounting and dismounting, face the Machine and maintain three points of contact with the Machine at all times. Three points of contact can be two feet and one hand or two hands and one foot.

Never mount or dismount a moving Machine. Never jump onto or off of the Machine while stationary or moving. Never attempt to carry tools or supplies while mounting or dismounting the Machine. Set items onto the platforms prior to mounting or dismounting, or use the assistance of another person or a hand line to pull supplies onto the Machine.

6.3 Operator Controls and Instrumentation The Machine is operated using both the stock Loader controls and the padder Attachment Control Box located inside the Loader cab to the right of the Operators seat. Travel, and boom/tilt functions for the Machine are controlled utilizing the stock Loader controls. For detailed instructions on the Loader controls refer to your Loader specific Operators Manual.

6.3.1 Attachment Controls

Operation of the padder Attachment is achieved utilizing the Attachment Control Box located within the Loader cabin. The Control box is located to the right of the Operator seat and is affixed using an adjustable mount for increased Operator ergonomics. Use caution when adjusting the position of the Control Box to ensure that the attached wiring harness does not become damaged or kinked.

Figure 13 and Table 5 on the next pages highlight the locations and explain the functionality of all controls/switches for the paddder Attachment control box.

Operation

Figure 13: Padder Attachment Controls

Table 5: Padder Attachment Control Descriptions

1) Elevator Reverse Switch

Momentary rocker switch

Pressing and holding the rocker switch will reverse the direction of the elevator screen travel. The chain will automatically ramp down speed and ramp up to a preset maximum speed regardless of the normal direction speed. Releasing the toggle causes the elevator to resume its normal direction of travel at its previously set speed.

2) Elevator Speed Control

Friction held proportional control knob (RPM: 0 = Stationary, 100 = Maximum)

This dial controls the relative speed of the elevator screen. The left most position is considered the zero or off position. Turning the dial to the right from the zero position will increase the speed of the elevator screen proportional to the amount the dial is turned. Maximum speed is achieved when the dial is turned all the way to the right most position.

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Operation

3) Hitch Pin Button: IN

Momentary pushbutton

Holding this button causes the quick-disconnect hitch solenoid to ENGAGE by extending the locking pins and securing the padding head.

4) Conveyor-Shift Toggle

Center spring two-direction toggle with a neutral center

Engaging the toggle in the left (negative x-axis) direction will shift the conveyor in the leftward direction. Engaging the toggle in the right (positive x-axis) direction will shift the conveyor in the rightward direction. In the absence of pressure applied being applied to the joystick, it will remain in the central neutral position and the conveyor will not shift in either direction. The conveyor shift should never be activated when the conveyor is in the folded position.

5) Hitch Pin Button: OUT

Momentary Pushbutton

Holding this button causes the quick-disconnect hitch solenoid to Disengage by retracting the securing pins and releasing the padder Attachment.

6) Conveyor Belt Speed Control


This dial controls the relative speed of the conveyor belt. The left most position is considered the zero or off position. Turning the dial to the right from the zero position will increase the speed of the conveyor belt proportional to the amount the dial is turned. Maximum speed is achieved when the dial is turned all the way to the right most position. The conveyor belt speed should never be activated when the conveyor is in the folded position.

7) ON/OFF (“Pause”) Button

Momentary pushbutton (Push-To-Toggle ON/OFF)

Enables/Disables all padder Attachment functions by suspending the controls at the Attachment’s microcontroller. Upon initial startup of the Machine depressing the button activates all Attachment controls at their respective settings as they are set via the individual controls. After initial startup depressing the button will pause all functions and will save the current settings for each function. Depressing the button again will resume Attachment functions at their previously set speeds. Elevator, conveyor, and vibrator as well as conveyor shift functions are deactivated while the Attachment is paused.

Note: It is important to turn all functions to their zero or neutral position when shutting the Machine down or leaving it unattended for any period of time. Doing so will prevent accidental startup of the padding Attachment when the Loader is turned on.

Operation

8) Vibrator Intensity Control


This dial controls the relative speed of the vibrating system. The left most position is considered the zero or off position. Turning the dial to the right from the zero position will increase the speed and thus frequency of vibration of the vibrator system proportional to the amount the dial is turned. Maximum speed is achieved when the dial is turned all the way to the right most position.

9) Conveyor Direction Switch

Two position friction held rocker switch

Activating the switch in the left direction will result in the conveyor belt rotating in the leftward direction at the speed specified by the conveyor speed potentiometer (see above). When the switch is activated in the right direction the conveyor will rotate rightward at the speed selected by the conveyor speed potentiometer.

10) Diagnostic Port This port is used to load program updates to the microcontroller and set maximum speeds and ramps. Use of a special program and cable are required. Contact your Ozzie’s service representative to make any kind of modifications to the Attachment programming.

6.4 Machine Start-Up Procedure To ensure safe Machine startup, proper procedure must be followed. Before mounting the operator cabin, the Operator must perform a safety walk around of the entire Machine to make sure that there are no personnel in the hazard areas of the Machine (see Section 5.3). This walk around should also be used to check for any Machine components that are damaged or missing that could cause unsafe conditions during startup and/or operation of the Machine. During the pre-startup walk around the Operator should ensure that all daily preventative maintenance has been done in accordance with Sections 7.1 and 7.3 in this manual. Any items found should be repaired/replaced before continuing with the startup procedure.

Upon completing the pre-startup walk around, mount the Loader to gain access to the Loader using the safe mounting practices outlined in Section 6.2 of this manual.

Once inside the operator cabin and situated in the seat it is essential to buckle up. Always wear a seat belt while operating the Machine.

Ensure all the Loader and Attachment controls are in the neutral or off position.

Refer to your specific Loader Operating Manual for proper startup procedure. The following procedure can be utilized as a general guideline when starting the Loader:

Turn the engine ignition switch to the “ACC” position and allow for instrumentation to turn on;

Honk the horn two times to signal the startup of the Machine to personnel nearby;

Start the Machine by turning the engine ignition key to “Start” and holding it there for several seconds, releasing it to the “On” position once the engine starts; and

Allow the engine to run at just above idle for at least 10 minutes to warm up fluids within the system. Check both hydraulic tank temperature and engine temperature to ensure that it is up to operating temperature before moving the Loader or starting the padding Attachment. In cold weather applications and temperatures the Machine may require more time for Machine warm up

Operation

Once the Loader has been started according to the procedure laid out in the Loader’s Operation Manual and all fluids are up to proper operating temperature, the Machine is ready for operation and the padder Attachment can be run.

6.5 Machine Operation After following the proper Machine start up procedure and observing the proper warm-up period the Machine is ready for operation.

6.5.1 Initial Operation Setup

Raise the padding Attachment slightly off the ground using the Loader boom controls.

Maneuver the Machine onto the spoil pile, using the Loader tracking controls, so that the Machine is centered on or straddling the middle of the spoil pile.

Note: Keep the padding Attachment as low to the ground as possible when moving the machine for increased stability.

Note: Ensure that the spoil pile is placed an adequate distance from the edge of the trench. Running the Machine too close to the edge of the trench could cause a cave-in and potentially cause bodily harm, injury or death to the Operator and/or ground personnel.

To enable the padder Attachment controls for operation, press the Control Box “On/Off” button (see Section 6.3.1). Pressing this button will enable all other buttons for operation. It is important to note that if any of the individual controls are not set to their zero or neutral position, when the “on/off” button is pressed, those functions will start at their set speeds. Be sure to check that all functions are in the zero or neutral position before turning the control box on.

Once the Control Box is energized you may operate the padding Attachment using the functions outlined in Section 6.3.1 as follows:

• To set the elevator speed turn the elevator speed control knob to the right until the desired elevator speed is achieved.

• Select the direction that you wish to discharge the screen material by pushing the conveyor direction rocker in the direction you wish the material to be discharged. Selecting the rocker to the left will discharge material to the left of the machine. Selecting the rocker to the right direction will discharge material to the right of the machine.

• To set the Conveyor speed turn the conveyor speed control knob to the right until the desired conveyor belt speed is achieved.

• To set the vibrator speed turn the vibrator control knob to the right until the desired vibrator intensity is achieved. The vibrator runs in one direction only. It may not always be necessary to run the vibrator to achieve optimal padding performance but it is highly recommended for most soil conditions.

• Shift the conveyor right or left using the conveyor shift toggle switch to aid in the placement of material in the ditch.

Once the initial speed settings are selected it is time to engage the padding Attachment into the spoil pile:

• Lower the Attachment into the spoil pile while moving the Loader slowly forward.

Operation

• Insert the leading edge of the Attachment into the spoil pile at a slight downward angle for ease of entry.

• Once the Attachment is engaged in the spoil pile, level the Attachment out to desired depth of pickup.

• Maintain a forward motion at all times to easily cut down into and through the spoil pile.

Do not use the Machine for any purpose other than which it was designed. Should you have any questions on Machine operations contact your Ozzie’s representative for further instruction.

6.5.2 During Operation

It may be necessary to adjust some or all of the padding functions during operation to achieve optimal padding efficiency and material placement. This includes:

• Adjusting the padding Attachment height – Adjusting the padding Attachment height will load the padding Attachment with more or less material. If the screen is becoming bogged down it may be necessary to take a smaller cut of the spoil pile. If there is not enough material being loaded onto the Attachment it may be necessary to take a larger cut.

• Adjusting the machine speed – Changing the Machine speed will alter the rate of material loading and speed of padding. Cut depth and Loader speed work hand in hand together to control the amount of material loaded and thus the rate of padding.

• Adjust the elevator speed – Changing the elevator screen speed will cause the Machine to load material faster or slower on the padding Attachment. Increasing the speed will move material across the screen quicker. If the elevator is set too fast it may not be able to process all of the fines and thus they are discharged over the back of the Attachment reducing padding efficiency. If the elevator speed is set too low the Attachment may not be able to move larger rocks up the inclined elevator screen and result in oversize rock accumulation on the screen and eventual stalling of the screen. In addition, if the elevator is set to low and a large cut is being taken the elevator screen may not have enough power to cut into the spoil pile also resulting in a stall situation. Some elevator screen jamming is normal, however, if the elevator screen is stalling excessively it may be necessary to increase the speed or adjust the padding Attachment height.

• Adjusting the conveyor speed – The conveyor speed can be adjusted as necessary to place the material in the exact desired location and to determine the speed at which material is being moved from the Machine. The primary function of the conveyor is to ensure all of the processed fines are discharged from the Attachment. If the conveyor is run too slowly, material may excessively pile up on the conveyor and spill over the edges, thus decreasing padding efficiency. This will also eventually result in a conveyor stall situation and plug the interior of the Attachment up with fine material. Always ensure the conveyor is running at an adequate speed to discharge the processed material and use the conveyor shift function in conjunction with the conveyor dirt deflector for accuracy of placement if necessary.

Operation

• Shifting the conveyor – Use the conveyor shift and/or conveyor speed functions to place material into the trench at the desired location. Utilizing the conveyor shift function is the preferred method to make finer adjustments to the location of material placement as there is a greater resolution of accuracy on that function. This function should be used in conjunction with the conveyor speed controls to find the optimal speed and distance to ensure accurate material placement is achieved.

6.5.3 Rocky Conditions

In excessively rocky conditions special care must be taken to ensure lasting Machine operation. Always remove all stones and debris that is larger than 8 inches in size. Failure to do so will result in premature component failure such as elevator screens and pulleys. During operation in excessively rocky conditions, excess oversize material may start to build up on the screen and not clear over the back. If this situation occurs stop forward travel of the Loader, then simultaneously raise the padder Attachment up slightly (approximately 12 inches) while tilting the Attachment back toward the Loader making the elevator screen more horizontal to the ground. This should allow all of the excessive rock buildup to be cleared safely off the back of the Attachment. Upon clearing the oversize off of the padding Attachment, reengage the spoil pile as outlined in Section 6.5.1. Repeat this clearing process as required throughout the day to prevent elevator jamming.

6.5.4 High Moisture Conditions

When dealing with high moisture content soil the Machine will experience reduced efficiency of padding due largely to material clumping and potentially clogging up screens. This is particularly more prevalent in soils with higher clay content. In the event that the screens are becoming clogged with material it is advisable to go to a larger screen aperture if allowed. This will prevent the screens from clogging up with material. In the event the screens continue to clog with material, use the approved cleaning method below.

If it is not possible to go to a larger screen size or if clogging persists contact an Ozzie’s representative for additional options for handling high moisture content material.

6.5.5 Clearing Elevator Screen/Jams

Should the elevator screen become clogged with material it will be necessary to clean the elevator screen before resuming padding operations. The easiest way to do so is using the reverse elevator direction rocker switch located on the Attachment control box.

Before engaging the elevator in reverse it is essential to move the Attachment such that it is no longer engaged in the spoil pile. Running the elevator in the reverse direction while the attachment is still engaged in the spoil pile could cause rocks to be jammed into the lower head pulley and cause further issues and potential damage to the Attachment. To remove the padding Attachment from the spoil pile, simply use the boom up function to bring the padding Attachment to a height of around two to three feet off the ground.

Before engaging the elevator reverse rocker switch to perform the cleaning process, ensure that no personnel are in front of the Machine as doing so will throw debris and rocks into the air in and around the front of the Machine. Once the areas is deemed to be clear, engage the elevator reverse rocker switch and hold it for as long as necessary to remove clogged material from the elevator screen. The reverse speed is pre-programmed

Operation

to a high velocity and should clear any material that is clogging the screen. Once the screen is clear of material, release the elevator reverse rocker and the Machine will automatically switch to the previous forward speed. Resume normal padding operations at this time.

If reversing the screen does not fully clear the clogged material it will be necessary to remove the machine from the spoil pile and park it in a safe location where there is enough room to remove the debris using hand tools.. Use the proper shutdown procedure outlined in Section 6.7 before beginning cleaning. Never perform cleaning operations using hand tools while the Machine is running.

If the elevator screen is experiencing a jam, use a similar method as to cleaning out the screen to remove the jammed object. The preferred method is to lift the Attachment up slightly off the ground and reverse the machine several feet. Any material cleared from the screen will fall in front of the Attachment, thus it is advisable not to dump it on the unprocessed spoil, but on the oversized material that has already been processed instead. Next, lift the Attachment up vertically using the boom function to a height of around 4 to 6 feet and then slightly tip the Attachment in the forward, or away from the Loader, direction in an effort to aid with removing any jammed rocks. Engaged the elevator reverse function as outlined above. If the screen remains jammed follow the manual cleaning method outlined above to free the jam.

NEVER use loader to raise/lower the head in a violent or jerky manor in an attempt to clean the screen or free a foreign object.

NEVER hit the padding Attachment against the ground or any other object in an attempt to clean the screen or free a foreign object. Doing so may cause severe damage to the Machine.

6.5.6 Using the Dirt Deflector

Due to various jobsite specific conditions including spoil pile location in relation to the trench, screen size, trench width, etc. it may be necessary to utilize the provided dirt deflector to obtain the desired padding results. The dirt deflector is typically required in conditions when it is necessary to operate the conveyor at a high speed to ensure all of the material being processed is discharged into the trench and does not spill off the conveyor but the trench is located close to the spoil pile resulting in the discharged material being deposited past the trench. Installing the dirt deflector at the end of the conveyor will allow the operator to run the conveyor at max speed while still controlling the discharge location of the processed material.

To install the dirt deflector, remove it from its storage location on the right hand side of the padding Attachment. Ensure the padding Attachment is turned off before removing the dirt deflector from storage. With the Attachment still off, insert the dirt deflector mounting rods into the securing tubes at either end of the conveyor. To adjust the distance that the material will be discharged from the end of the conveyor simply move the dirt deflector within the securing tubes. Once the desired location is selected, tighten down the screws located on the securing tubes. It is then necessary to secure the dirt deflector in place by attaching the chain located on the bottom of the dirt deflector plate to the slotted hole on the conveyor edge. To adjust the angel of the dirt deflector lengthen or shorten the chain as necessary.

Operation

It may be necessary to adjust the dirt deflector position and angle once padding has commenced. Never adjust the dirt deflector when the Attachment is running. Always turn off all Attachment functions before making any adjustments to the dirt deflector.

6.6 Machine Parking Prior to parking the Machine, ensure all padder Attachment controls are in the neutral or “Off" position and that none of the padder Attachment systems are still in operation.

To completely shut down the padder Attachment and disable the Attachment controls, press the Control Box “On/Off” button (see Section 6.3.1).

Always park the Machine on firm level ground. Never park the Machine in such a way that it interferes with job site traffic.

Always lower the Attachment and lightly anchor it in the ground by applying slight downward pressure. The Attachment is now anchored to the ground and inactive.

Do not attempt to move the Loader while anchored; doing so may damage the Machine.

Always ensure all joysticks, switches and controls for both the Loader and Attachment are in the neutral or off position and the hydraulic enable lever for the loader is in the off or position.

6.7 Machine Shutdown Procedure Ensure that the Loader throttle is idled down to the minimum setting prior to shut down. At a minimum, the Loader must be left running for one minute prior to turning the Loader off. Failure to do so will create a “hot shutdown” event and will result in premature engine failure. It is critical that the minimum idle period is observed prior to shutting the Loader off.

Once the minimum idle period has been observed, turn the key in the counterclockwise direction to the off position

Before leaving the Machine ensure that all keys have been removed and that all access to the operator cab is locked prior to leaving the Machine unattended.

6.8 Connecting/Disconnecting the Padder Attachment To disconnect the padder Attachment, park the machine as per the proper parking procedure outlined above in this manual. Dismount the machine and proceed to the hydraulic and electric quick couplers located on the right hand side loader arm. Start by first disconnecting the electrical plug. Doing so will relieve any trapped oil in the load sense line. Cap the electrical plug with the provided caps to ensure no moisture enters the plug and/or electrical harness while the Machine is decoupled.

After the electrical plug has been disconnected, start by removing the main hydraulic pressure line or 1 inch line. To remove the quick disconnect, loosen the outer sleeve by turning it in a counter clockwise direction. The sleeve is knurled to provide grip, however it is recommended to use a wrench to both tighten and loosen the outer sleeve. For the hydraulic return line a 2 3/8 inch wrench is required. Once the sleeve has been loosened, slide the sleeve up over the o-ring to hold it in place. The hydraulic hose can now be removed by pulling down in a direction parallel to the fitting.

Repeat the above procedure for the hydraulic return line or 1 ¼ inch line using a 2 5/8 inch wrench and then again for the case drain line or ½ inch line using a 1 ½ inch wrench. Finally disconnect the load sense line using a similar procedure noting that the coupler is reversed to that of all the others. This is done to ensure that the load sense and case drain lines do not become crossed as they use the same size quick coupler.

Operation

Once all electric and hydraulic couplers have been disengaged, remount the Machine and reengage the Loader hydraulic functions by placing the hydraulic control safety lever to the on position. Reactivate the padder Attachment controls by pressing the on/off button on the right side of the padder Attachment control box. Press and hold the “unpin” or red button on the control box for a period of three seconds, or until the pins are fully retracted, to disengage the hydraulic locking pins on the quick-attach. Have a spotter on the ground verify that the pins are fully retracted before attempting to uncouple the Attachment. If the pins did not disengage it may be necessary to unload the padder Attachment slightly from the ground or move the loader functions slightly to free up the pins while holding the unpin button. Do not lift the attachment off the ground while attempting to free the pins. Once you have verified the locking pins are retracted use the Loader bucket curl forward function to pull the bottom of the coupler free. Then lower the bucket boom the free the upper hooks. Once the quick-attach is free of the hooks you can reverse the Loader to completely decouple the Machine.

To connect the Attachment the same procedure is followed in reverse. Line the quick coupler up with the hooks on the padder Attachment. Use the bucket curl function to roll the top of the quick coupler forward and lower the Loader arms so that the top of the quick coupler clears underneath the padder Attachment hooks. Once the quick coupler has cleared the hooks, raise the loader arm until the quick coupler is engaged in the hooks and starts to lift the padder Attachment upward. Now, using the Loader bucket controls, curl the quick coupler back until the coupler hits the bump stops on the padder Attachment hitch plate. This should be evident as the front end of the padder Attachment will start to lift up. Use the on/off button on the right hand side of the padder Attachment control box to energize the control box. New depress the “Pin” or green button for three seconds or until the locking cylinders are fully engaged. Have a spotter on the ground verify that the locking cylinders on each side are fully extended into their respective holes on the padder Attachment hitch plate. It may be necessary to slightly agitate the bucket function on the loader while depressing the “pin” button to assist with the cylinders engaging the padder Attachment hitch plate. Once the padder Attachment is secure park the Machine using the aforementioned proper parking procedure in this manual.

Attach the hydraulic quick attach couplers, located on the right side Loader arm in the same manner as they were taken off starting with the load sense line. Although the quick couplers are knurled for hard grip it is advised that this is only used to hand tighten the fitting. It is necessary to use a wrench to tighten all hydraulic quick couplers to reduce the possibility of a coupler coming loose over time. After the load sense line is attached, move on to the case drain line again tightening with the 1 1/2 inch wrench. Next attach the hydraulic return line using a 2 5/8 inch wrench. It is critical that the return line is tightened securely. Should the return line become lose catastrophic failure to the valve stack will occur. Check the return line coupling periodically throughout the workday after newly coupling the Loader and padding Attachment. Finally install the high pressure line using a 2 3/8 inch wrench.

Once the hydraulic lines are attached the electrical connection can be hooked up. Always inspect the pins and electrical wires for frayed or loose connections prior to hookup. It is good practice to use dielectric grease on the electrical connection when the Loader and Attachment are being coupled. This will help prevent moisture from entering the plug and ensuring a good electrical signal to the padding Attachment. Do not pull the entire electrical cable by the plug end, doing so will result in the loosening of electrical connections over time. Always grab hold of the cable a couple feet down from the plug end.

Machine Maintenance

7 Machine Maintenance In order to maintain the Machine operating at a safe and efficient level, certain inspections and service items must be completed on a daily basis. This section is intended to provide service information primarily for the padder Attachment. For specific services on your Loader, refer to the Loader’s Operation and Maintenance Manual for maintenance information. In the absence of a Loader specific manual we have included some brief generic Loader services that are suggested at a minimum regardless of the make or model of your specific Loader.

7.1 Loader Daily Inspections/Maintenance Consult your Loader specific Operators and/or Maintenance Manual for the recommended daily inspections and preventative maintenance items.

As a general guideline or in the absence of a loader specific maintenance manual the following pre operation inspection should be adhered to as a minimum:

• Inspect engine oil level

• Inspect coolant level

• Inspect hydraulic oil level

• Inspect hoses and clamps

• Inspect engine belts

• Inspect horn and back up alarm are working properly

• Inspect seat belt

• Inspect fire extinguisher/first aid kit

• Inspect glass and wipers

Ozzie’s strongly recommends that the external engine air filter and cab air filters (when equipped) are blown out at a minimum frequency of twice daily. Depending upon environmental conditions the interval for cleaning the air filter may need to be reduced. Check air filters periodically throughout the day and clean as necessary.

Inspect the fire extinguisher and first-aid kit provided with the Machine to ensure that both are stocked and in good order. Should there be any defect or deficiency noted, replace immediately before operating the Machine.

7.2 Loader Scheduled Maintenance The Loader maintenance items specified in the Loader’s Operation and Maintenance Manual should be performed at the intervals specified. Consult your Loader specific manual for the exact service intervals. As a general guideline or in the absence of a Loader specific maintenance manual the following maintenance intervals should be adhered to as a minimum:

Table 6: Generic Loader Service Intervals

# 250 Hour Service # 500 Hour Service # 1000 Hour Service

1 Engine oil and filters 1 All 250 hour service items 1 All 250 hour service items

2 Primary fuel filter 2 Engine inner air filter 2 All 500 hour service items

3 Fuel water separator 3 Splitter box oil 3 Final drive oil

4 Engine outer air filter 4 Hydraulic oil filters 4 Attachment hydraulic filter

5 Engine crank case filter 5 Hydraulic return filters

6 Cabin air filter

Machine Maintenance

7.3 Attachment Daily Inspection/Maintenance Inspect all hydraulic components daily for leaks and damage. This includes all hoses, fittings, cylinders, pumps, motors, and filters. If any visible damage is detected, replace the component immediately. If any components are noted to be leaking, ensure that the leak is repaired immediately.

When inspecting hydraulic hoses look for the following to indicate that a repair is necessary:

• Damage on external cover that reaches through to the reinforcing wire;

• Excessive wear indicated by separation of layers, blisters or bubble formations; and

• Damage to hose ends/fittings, including corrosion and deformities.

Due to the vibration and movement of the Machine, bolts may become loose and/or fall out. Loose and/or missing bolts may cause the Machine to function improperly and/or result in damage and in extreme cases injury. Inspect all bolts to ensure that they are properly attached and have not been damaged. Tighten or replace bolts as required daily.

Inspect the Attachment and equipped mechanical components for damage, wear, and overall integrity. The following components should be checked, noting any damage or wear:

• Machine frame – Inspect the Attachment frame for any cracks or damage;

• Conveyor belt – Inspect for any holes, excessive wear or misalignment;

• Conveyor head pulleys – Inspect for degradation on vulcanized rubber and loose couplers;

• Conveyor idler rollers – Check that all pulleys move freely and that the bolts for the securing pins have not backed out;

• Elevator Flashing – Ensure there is a tight seal between the flashing and screen so oversized material does not get into moving components or contaminate the screened material;

• Elevator screen – See Section 7.6.1

• Elevator idler roller – Inspect the elevator idler pulley for excessive wear or grooves in the roller and for side to side alignment on the bearings;

• Upper elevator head pulley – Inspect the rubber lagging on the head pulley. Uneven or excessively worn lagging will cause the screen to run to one side consistently resulting in premature failure of the screen;

• Lower elevator heady pulley – Check lower elevator head pulley for side to side alignment on the bearing. Whenever the screen or belt is changed inspect the pulley for cracks around the end welds and center v-groove. Repair or replace the head pulley if cracks are detected;

• Motor Couplings – Check motor coupling alignment and grease.

• Bearings – Check bearings for seal quality, ease of movement and ensure that they are taking grease, see Section 7.5;

• Safety Devices. - Ensure that all safety devices and guards are securely fastened in place prior to operation; and

• Hydraulic quick-attach couplings – Inspect the couplings to ensure that none of the connections have become loose. Pay particular attention to the return line. Should the return connection come loose and the padder Attachment is activated catastrophic failure of the valve stack will result. Always tighten connections with a wrench, see Section 6.8.

Machine Maintenance

7.4 Attachment Scheduled Maintenance The majority of the maintenance required to the padding Attachment is done on an as needed basis following daily inspections with the exception of a couple of critical items.

Due to the ground engaging nature of this Machine it operates in an extremely dusty and dirty environment and as such the bearing on the Machine need to be greased multiple times throughout the day to ensure proper function and longevity. Please refer to the next section in this manual for all grease locations and recommended service frequency.

In addition to the bearings there is a high pressure filter for the Attachment circuit that is mounted on the right Loader arm. The purpose of this filter is to protect the padder Attachment hydraulics from any sources of contamination from the Loader itself. This filter should be serviced every 1000 HRS or if any contamination of failure in the hydraulic circuit is detected.

7.5 Bearing Maintenance The maintenance services in this section should be performed daily at a minimum in order to maintain safe operation and performance. Depending on working conditions some items may require attention at a higher frequency than daily, requiring two or more grease services per day. Check the bearings at multiple times throughout the day to ensure adequate grease is present. Frequent greasing will result in better performance and longer component life. Never substitute frequent greasing throughout the day for over greasing once a day. Over greasing will result in the bearing seals being pushed out leading to dirt contamination and premature bearing failure. Figure 14 and Figure 15 below shows all of the grease locations on the Mini-padder Attachment.

Figure 14: Left Side Grease Locations

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Figure 15: Right Side Grease Locations

7.6 Elevator Screen Maintenance and Adjustments

7.6.1 Elevator Screen Inspection

With all padder Attachment functions off, inspect the screen integrity. Advance and inspect the screen as required. Never leave the elevator function running and dismount the Machine to inspect the screen. It is highly recommended that two people be used at all times to preform inspections. One person to operate the machine and a second to perform the inspection.

Inspect the screen alignment by comparing the distance between the upper elevator head pulley guide/collar and the edge of the screen on both sides of the Attachment. The distances would be relatively consistent. At a minimum, ensure that the edge of the elevator screen is not riding against the guide/collar. If so, see the Section 7.6.3 for making adjustments to the alignment.

When running the screen, if there is the presence of a loud clanging noise, it is likely that the screen is too loose and is hitting the bottom skies. To resolve, increase the tension on the screen by means of extending the rear Elevator Slack Adjustors evenly. Alternatively, if the elevator screen is “rubber band tight” it will cause the screen to stretch too fast, resulting in failure as well as possibly cause damage to the lower elevator head pulley and/or the elevator belt idler pulley.

Common areas of screen wear include the following:

• Wear along the edges of the screen – This type of wear is usually a result of running the elevator screen against the upper head pullet guides/collar for a prolonged period of time. While okay for shorter periods of time, prolonged running of the edge of the screen against the guides will result in excessive wear of the screen edge welds causing the weave to come apart before the screen is fully worn. To avoid this, make the necessary adjustments to the screen to ensure center tracking.

• Broken links around the screen flights – The flights on the screen are designed to aid in moving oversized material off of the elevator screen and ensure efficient padding production. In especially rocky conditions the welds that attach the flights to the screen

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may become broken due to the increased stress put on the flights from the presence of excessive rock. To help minimize premature failure of the screen ensure any rocks with a diameter larger than eight inches is removed from the spoil pile. Doing so will help to increase the life of the screen.

Replace a damaged or worn screen as needed to prevent damage to the rest of the Machine and avoid additional down time. Detailed instructions on how to replace a damaged or worn screen can be found in the next section of this manual.

7.6.2 Elevator Screen Installation

To remove the elevator screen it is important to first relieve the tension on the screen. This is done via the left and right elevator screen tensioners located and the rear of the attachment frame. To loosen each adjustor first back off the locking jam nut using a 1 ½ inch wrench. Then turn the nut at the end of the adjustor bar in a counter clockwise direction using a 15/16 inch wrench until the bottom plate of the adjustor touches the guide tube. Repeat for the other side.

Note: The elevator Rock guards must be removed prior to replacing the elevator screen.

Once tension has been relieved, locate the master link and center it between the vibrator rollers aligned with the access cutout in the side of the padder Attachment frame. Cut the screen stay at each ends where it is welded to the elevator screen being careful not to cut the screen itself. Always wear proper PPE when performing metal cutting operations. Upon cutting the ends of the screen stay pull the rod out of the elevator screen in either direction. The elevator screen can now be removed by use of an approved lifting device and straps.

Alternatively, if the elevator screen has become significantly worn and it is not necessary to save it for future use, it may simply be separated using an oxy-acetylene torch. Ensure you use all proper PPE and follow onsite safety regulation regarding hot work before operating a cutting torch. Only do so if you are trained in using a cutting torch. Ensure the torch does not come in contact with any other Attachment components.

Once the elevator screen is removed inspect the elevator belt thoroughly, see Section 7.7.1 for detailed instructions on how to properly inspect the elevator belt. Having the elevator screen removed makes it easier to complete a detailed inspection of the belt. If the belt shows signs of wear it is advisable to replace the belt at this time. The Elevator screen can be replaced without removing the elevator belt but the opposite is not true, thus it is advisable to change the belt if it is beginning to show signs of wear when the elevator screen has already been removed. See Section 7.7.2 for complete instruction on how to change the elevator belt, then return to the next step to continue changing the elevator screen.

Note: The Elevator screen is directional. When installing a new elevator chain, make sure that the direction of the links runs with the forward motion of the elevator as shown in Figure 16 below. Improper directional installation can result in premature failure to the screen and other Machine components.

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Figure 16: Elevator Chain Orientation

To prepare the elevator screen for installation insert a rigid rod through the last chain loop at one end of the screen. Either install two small lifting shackles on the rod or feed the rod through two links of a lifting chain. Space the shackles/lifting chain out evenly so that the screen lifts level. At the other end of the screen install a similar steel rod with the provided rope in the same fashion as the other end of the screen. Check that you have setup the direction of the chain per the instructions above.

Using an approved lifting device, hoist the chain up vertically over the upper head pulley of the Attachment with the end to which the rope is attached facing down towards the padder Attachment. Ensure that the chain is centered on the upper head pulley. There should be an equal distance between the ends of the chain and the metal collars on each side. Feed the rope and screen down between the upper head pulley and the rear frame plate of the attachment. Next feed the rope and chain down around the lower elevator idler pulley. After the idler pulley, use the rope to feed the screen to the front of the padder Attachment in between the cutting edge and the lower head pulley. Once past the lower head pulley, feed the belt up and over the elevator belt and vibrator rollers. Pull the chain until the end lines up between the vibrator idler rollers. Release the other end of the screen from the lifting device. The ends of the elevator screen should be lined up with a small gap between them.

Using the modified C-clamps provided, tighten the screen until both ends of the screen are interlaced with the ends even on each side of the screen. Insert the straight master link through both ends of the screen, lacing the screen together. Once the master screen stay is installed and centered, bend the ends back at 90 degree angles. Once bent, weld the ends of the rod to the screen link to ensure the screen stay does not become loose during normal operation. Consult the safety section of this manual for welding related safety precautions. Always consult your site specific safety representative before performing any welding operations and to determine if a hot permit is required to perform welding operations. Always make sure the Machine is powered off and de-energized before performing any welding operations on the Attachment.

Once the retain clip has been installed, the elevator rock guards can be reinstalled on the Machine. With the guards in place, return tension to the elevator screen using the elevator screen slack adjustors on each side of the attachment frame. Evenly adjust out each adjustor at small intervals as not to stretch the screen unevenly. Proper screen

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tension is achieved when the screen is off the bottom skis and the elevator rock guard flashing is sealed on the screen. Always adjust a new elevator chain so that the adjustors are even. Due to wear on other components, such as the upper head pulley, it may be necessary to make immediate adjustments. See the next section of this manual for proper adjustment procedures.

7.6.3 Elevator Screen Adjustment

It is ideal for the elevator screen to run in the middle of the upper elevator head pulley to prevent excessive wear and premature failure of the screen. All elevator screens will stretch over time requiring additional tension be applied to the screen to maintain tension and proper alignment. Newly installed screens often require more attention than older screens. It is important to pay close attention to the alignment of a newly installed screen as unproportioned tension will result in a screen that is permanently out of alignment causing premature screen failure.

It is important to note that continual tightening of the screen to correct alignment and travel will result in excessive wear and reduced life of components.

The elevator screen should be adjusted with care. Minor adjustments will usually correct a poorly aligned screen. If the screen is over-adjusted it will stretch out too fast or track to one side causing premature screen failure. The screen will move to either side as you push against material, this is normal, do not be too quick to make adjustments.

Proper screen tension is achieved when the screen is off the bottom skis and the flashing is sealed on the screen. Adjust the screen tension through use of the elevator slack adjustors using the following procedure and as depicted in the following figures.

• Run the elevator to check alignment and tension.

• Run the elevator in the reverse direction to move the chain in the opposite direction to which it is running in the forward direction. If the chain is only slightly out of alignment this can be enough to make the chain re-center itself.

• The slack adjusters are adjusted by first loosening the lock nut (1 1/2”) located on the adjusting rod and then turning the adjustment screw (15/16”) in or out. Once the adjustment is complete ensure the lock nut is tightened again to hold the adjustment in place.

Figure 17: Elevator Screen Adjustor

Adjusting Screw

Lock Nut

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• The procedure displayed below in Figure 18, “loosens” or relieves tension on the elevator screen. To relieve the tension the adjusting screw should be turned in a counter-clockwise direction.

Figure 18: Loosening Elevator Screen Adjustment

• The procedure displayed below in Figure 19, “tightens” or increases the tension on the elevator screen. To increase the tension the adjusting screw should be turned in the clockwise direction.

Figure 19: Tightening Elevator Screen Adjustment

• It is necessary when first applying tension to a newly installed screen to make the same adjustments to each side of the machine, however, when adjusting the

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screen alignment it may be necessary to make adjustments to one side and not the other or to make the opposite adjustments on each side of the Machine to avoid overtightening the screen.

• The procedure displayed in Figure 20, where the right adjuster is tightened or extended and the left adjuster is loosened or retracted, adjusts the elevator screen to track further towards the left side of the Machine.

Figure 20: Adjusting Elevator Screen Leftward

• Conversely, tightening or extending the left adjuster and loosening or retracting the right adjuster adjusts the elevator screen to track further towards the right side of the Machine as depicted below in Figure 21.

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Figure 21: Adjusting Elevator Screen Rightward

• Make minor adjustments and let the machine cycle a few times after each adjustment. It may take time for the chain to correct itself. Be careful not to adjust the screen so that the difference in adjustor length is too much, doing so will result in the elevator belt being pulled from the v-groove and potentially causing damage and premature failure. If the chain will not center and there is a major difference in the amount of adjustment on each of the adjustors there is likely excessive wear elsewhere on the Attachment, such as the upper head pulley. If you are having trouble getting the elevator screen to track in the middle of the head pulleys contact an Ozzie’s service representative for further assistance.

7.7 Elevator Belt Maintenance and Adjustments

7.7.1 Elevator Belt Inspection

It is important to inspect the elevator belt on a daily basis as any rips or tears will adversely affect the amount of processed material that gets carried to the conveyor system. Visually inspect the belt for the following common wear issues:

• Holes are present in the belt – During normal operation, sharp material can become jammed in the elevator screen which when forced against the elevator belt as it travels around the lower head pulley can cause holes and rips in the belt. Holes will adversely affect production but poses not mechanical failure risk to the Attachment.

• Lacing is damaged – The lacing that holds the belt together can become damaged over time. In particular the retaining washers at the edge of the lacing kit may loosen up over time or become dislodged due to contact with foreign objects. It is important to inspect this retaining clip daily. If the retaining clip is missing, continued operation of the Attachment will result in severe damage to the rest of the elevator belt. Replace any missing retaining clips immediately.

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• Excessive side wear present on the belt – Check the edges of the belt for any signs of excessive wear in the form or rips or fraying of the belt and internal cords. The belts have a center v-groove that keeps them tracking straight. Any excessive side wear will be a result of the belt not running in its guide groove. Possible causes of this is that the elevator screen is not aligned and is pulling the belt out of alignment. Check elevator belt alignment and adjust accordingly. Alternatively the v-groove on the lower head pulley and/or elevator belt idler pulley may have become packed with dirt/debris forcing the belt out of alignment. There is a v-groove cleaner present on both pulleys that are designed to prevent this from happening and may become worn over time, requiring readjustment. If the v-groove is clogged it is necessary to remove the elevator chain and belt to properly clean the groove and readjust the v-groove cleaner. The v-groove cleaner should be within the envelope of the groove but not touching any of the sides or bottom of the pulley groove. See the following section for detailed instructions on aligning these cleaners.

7.7.2 Elevator Belt Installation

Before installing the elevator belt, it is essential to remove the elevator screen first. It is common practice to replace both the elevator screen and elevator belt at the same time but it is not always necessary, use the inspection instructions located in Section 7.6.1 to determine if the elevator screen needs replacing. See Section 7.6.2 for instruction in how to remove and replace the elevator screen.

Once the elevator screen is removed, the elevator belt can be removed. To remove the elevator belt the simplest method is to cut the belt on either side of the metal lacing using a belt cutter or razor knife. To better access the cutting area, center the belt lacing between the two elevator belt pulleys with the lacing facing upward. Always use caution when cutting a belt, the fabric inside is extremely durable and tough to cut. Always cut away from your body or away from other personnel in the area. It is possible to remove a belt by delacing it, however in most cases this proves to be extremely difficulty and time consuming with a high possiblity that the belt cannot be relaced again.

Remove the belt by pulling it out from the top using an approved lifting device. Once the belt has been removed perform inspections on the lower elevator head pulley, elevator belt wiper and elevator belt idler pulley. If either pulley is cracked or damaged, replace them at this time. For ease of maintenace it may be beneficial to remove the elevator belt wiper and both pulley cleaners when replacing each of the pulleys.

After replacing either pulley it is essential to realign them respective to the Attachment frame and each other to ensure proper operation. To properly align the pulleys start with the lower elevator head pulley and measure from the side of the padder Attachment frame to the end of the head pulley making sure the distance is the same on both sides of the pulley. Once this has been achieved lock down the set screws using red lock tight. This is a critical step, failure to use the proper lock tight will result in the set screw backing out and pulley misalignment, eventually causing premature component failure.

If the flashing on the elevator belt wiper is worn adjust and/or replace as necessary. There are two v-groove cleaners and scrapers, one for the lower elevator head pulley and one for elevator belt idler pulley that will require adjustment to ensure proper functionality of the v-groove cleaners. Install the wipers making vertical and horzonatal

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ajustments to ensure that the scraper is as close as possible to contacting each of the pulley drums without actually touching them and that the v-groove cleaners are within the envelope of their respective grooves but are not touching the sides or bottom of the groove.

Next with the belt wiper frame and wiper installed it is essential to align the elevator belt pulleys. Failure to align the two pulleys will cause the belt to pull out of the groove causing increased wear and premature failure. To set the alignment, place a 2”square with the short side against the bottom head pulley and the long on the belt wiper. Adjust the elevator belt idler pulley so that the edges of the v-groove on each pulley are aligned as depicted in Figure 22 below. Once the pulleys are aligned lock down the set screws on the elevator belt idler pulley, similar to that of the lower pulley using red lock tight.

Figure 22: Elevator Pulley Alignment

Before installing the new elevator belt, retract the belt adjusters all the way in using a 1 1/8” wrench. To do so, back the lock nut all the way out, then turn the threaded rod with the adjusting nut welded to the end in the clockwise direction until the adjustor becomes fully retracted. Repeat the process for the opposite side. When completely collapsed the adjustor should look similar to the one depicted in Figure 23 below.

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Figure 23: Elevator Belt Adjustor

The new elevator belt can now be installed. Hang the belt using a small chain and the master rod included in the kit to lace belt, see Figure 24. Slowly lower the belt over the top of the elevator idler pulley making sure to guide it down to the lower elevator belt head pulley and out the front, between the head pulley and the cutting edge. Then pull the belt around the lower elevator belt head pulley until it is approximately one foot over the top of the head pulley. Lower the belt down, the lacing kit should be centered at the top between the two elevator pulleys. Remove the installed rod and lifting chain.

Figure 24: Elevator Belt Lifting Technique

Adjusting Nut

1 1/8” wrench

Adjuster etracted

Lock Nut

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Once in place the new belt is ready to be laced together. Using a light duty ratchet strap can help to assist with the belt lacing process. Take the ratchet strap and feed it around both elevator pulleys on the outside of the belt and attached the ends of the strap to each other. Using the ratchet strap, tighten up belt until the lacing meets. Be careful not to over tighten the strap and place too much tension on the elevator pulleys. Too much tension could cause either elevator pulley to break at the v-groove. Using a light duty strap instead of a medium to heavy duty one will ensure that too much tension is not placed on the pulleys.

Reinstall the same rigid rod again connecting both ends of the belt. Now from the opposite side, install the cable stay, included with the new belt, pushing out the solid rod until the cable stay is sticking out evenly on both sides of the lacing, see Figure 25 below. Install the cable stay retainers on both sides of the cable and clamp down on the retainers using vicegrips to bend the retainers and hold them in place. Once the retainers are in place it is okay to remove the ratchet strap.

Figure 25: Elevator Belt Tension and Lacing Installation

Before the elvator belt can be ran it is important to tension the belt properly. To do so follow the Elevator Belt Adjustment instructions found in the next section of this manual.

Once the elevator belt is properly tensioned it is time to reinstall the elevator screen. Do so according to the instractions described in Section 7.6.2 of this manual.

7.7.3 Elevator Belt Adjustment

The elevator belt should be adjusted with care. Minor adjustments will usually correct a poorly aligned belt. The belt and rollers are outfitted with a v-groove system to aid with the alignment of the belt. If the belt is over-adjusted it will move out of the v-grooves and bind up on the Attachment side frame.

If this is the first time running a newly installed belt it is important to break the belt in evenly so that it does not become stretched unevenly. If a belt becomes stretched unevenly it will be harder to maintain good alignment in the future.

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There are two slack adjustors on either side of the Attachment frame that are used to put tension on the belt and make adjustments in alignment. The slack adjusters are adjusted by loosening the lock nut on the rear of the adjustor and then turning the adjustment screw, located at the end of the treaded rod, in or out. Once the adjustment is complete the lock nut must be tightened again to hold the adjustment in place.

The procedure displayed below in Figure 26, “tightens” or increases the tension on the elevator belt. To increase the tension the adjusting screw should be turned in the clockwise direction. When tightening the belt, adjust both adjustors out at the same rate.

Figure 26: Tightening Elevator Belt Adjustment

The procedure displayed below in Figure 27, “loosens” or relieves tension on the elevator belt. To relieve the tension the adjusting screw should be turned in a counter-clockwise direction. When loosening tension on the belt, adjust both adjustors in at the same rate

Figure 27: Loosening Elevator Belt Adjustment

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Due to the presence of the v-groove system when both adjustors are measured out at the same distance the belt should run straight. As a starting point new belts should be adjusted out to a distance of 28 ½” from the center of the lower elevator head pulley shaft to the center of the elevator belt idler shaft as depicted below in Figure 28.

Figure 28: Elevator Belt Adjustment Measurement

Making small adjustments to correct alignment still may be necessary in some instances. It may be necessary to make adjustments to one side and not the other or to make the opposite adjustments on each side of the Machine to keep the belt in alignment over time. Try not to make adjustments to one adjustor alone, this could result in over tightening and stretch the belt.

The procedure displayed in Figure 29, where the right adjuster is tightened or extended and the left adjuster is loosened or retracted, adjusts the elevator belt to track further towards the left side of the Machine.

28 ½”

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Figure 29: Elevator Belt Leftward Adjustment

Conversely, the procedure displayed in Figure 30, where the left adjuster is tightened or extended and the right adjuster is loosened or retracted, adjusts the elevator belt to track further towards the right side of the Machine

Figure 30: Elevator Belt Rightward Adjustment

Make only minor adjustments to the slack adjustors. Run the elevator in both directions for a short period after each adjustment to check alignment. Observe to see if the belt corrects itself before making another adjustment. It is important to note that if the adjustors are set at the same tension and the belt persist to become unaligned or come out of the v-groove the elevator screen may be pulling the belt out of alignment. Check the elevator belt alignment to ensure it is not running excessively to one side.

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7.8 Conveyor Belt Maintenance and Adjustments

7.8.1 Conveyor Belt Inspection

It is important to inspect the conveyor belt on a daily basis as any rips or tears will adversely affect the amount of processed material that gets deposited into the trench. Visually inspect the belt for the following common wear issues:

• Lacing is damaged – The lacing that holds the belt together can become damaged over time. In particular the retaining washers at the edge of the lacing kit may loosen up over time or become dislodged due to contact with foreign objects. It is important to inspect this retaining clip daily. If the retaining clip is missing, continued operation of the Attachment will result in severe damage to the rest of the conveyor belt. Replace any missing retaining clips immediately.

• Belt alignment – The conveyor belt comes with a rib on the underside that keeps the belt aligned via the v-grooves present in the conveyor head pulleys and idler rollers. Belt alignment can easily be measured by checking the distance between the edge of the belt and the end of the head pulley. The distance should be equal on each side of the belt. A properly aligned belt should show no signs of wearing on the sides. If the belt has become unaligned and both adjustors are even it is likely that the v-groove on the heady pulley has been clogged with material. It is necessary at this point to remove the belt and clean the v-groove out and readjust the v-groove cleaner.

7.8.2 Conveyor Belt Installation

To remove the existing conveyor belt, the simplest method is to cut the belt on either side of the metal lacing using a belt cutter or razor knife. To better access the cutting area, center the belt lacing on either of the conveyor head pulleys. Always use caution when cutting a belt, the fabric inside is extremely durable and tough to cut. Always cut away from your body or away from other personnel in the area. It is possible to remove a belt by delacing it in the event that it needs to be removed before it is completely worn. It should be noted however in most cases this proves to be extremely difficuly and time consuming with a high possiblity that the belt cannot be relaced again.

Once the belt is cut/delaced it have be removed by pulling it out from the side where the belt was cut/delaced. Once the belt has been removed perform inspections on both conveyor head pulleys along with all the interior idler pulleys and wipers. Check the head pulleys to ensure that the rubber lagging is in good condition and is not excessively worn. All idler pulleys should be inspected to ensure that they turn freely and that all of the v-grooves are aligned and centered within the conveyor frame. Replace any siezed rollers and relaign as necessary. Finally check that the head pulley cleaners are as close as possible, without touching, the head pulley and that the v-groove cleaners are centered and within the groove of their respective head pulleys. Make adjustments as necessary.

After replacing either pulley it is essential to realign them respective to the machine and each other to ensure proper operation. To properly align the pulleys/idlers measure from the side of the conveyor frame to the end of the head pulley making sure the distance is the same on both sides of the pulley. Once this has been achieved lock down the set screws using red lock tight. This is a critical step, failure to use the proper lock tight will

Machine Maintenance

result in the set screw backing out and pulley misalignment, eventually causing premature component failure.

Before installing the new conveyor belt, retract the belt adjusters all the way in using a 1 1/8” wrench. To do so, back the lock nut all the way out, then turn the threaded rod in the clockwise direction until the adjustor becomes fully retracted. Repeat the process for the opposite side.

Install the conveyor belt by feeding it through the underside of the conveyor around the opposite head pulley and back over top. It can be beneficial to use the solid chain stay provided with the lacing kit to attach a small chain or rope to the end of the belt to assist with feeding the belt across the padder Attachment.

The conveyor belt is now ready to be laced together. Reinstall the rigid stay through both ends of the lacing thus connecting both ends of the belt. Install the cable stay included with the new belt, by pushing it through the lacing and simultaneously pushing out the solid rod until the cable stay is sticking out on both sides of the lacing evenly. Install the cable stay retainers on both sides of the cable and clamp down on the retainers using vicegrips to bend the retainers and hold them in place

Before the elvator belt can be ran it is important to tension the belt properly. When adjusting a new belt it is best to start with even adjustment on each side of the belt. This can be achieved by measuring the distance of both the left and right adjustors and ensuring they are adjusted to the same measurement. A new belt requires extra attention while it runs in. On instructions how to make futher adjustments consult the next section of this manual.

7.8.3 Conveyor Belt Adjustment

The conveyor belt should be adjusted with care. Minor adjustments will usually correct a poorly aligned belt. This belt and rollers are outfitted with a v-groove system to aid with the alignment of the belt. If the belt is over adjusted it may move out of the v-groove and rub on the conveyor side frame.

There are two slack adjustors on either side of one end of the conveyor frame. These slack adjustors are used to put tension on the belt and make adjustments in alignment. The slack adjusters are adjusted by loosening the lock nut on the rear of the adjustor and then turning the adjustment screw in or out. Once the adjustment is complete the lock nut must be tightened again to hold the adjustment in place.

The procedure displayed below in Figure 31, “tightens” or increases the tension on the conveyor belt. To increase the tension the adjusting screw should be turned in the clockwise direction. When tightening the belt, adjust both adjustors out at the same rate.

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Figure 31: Tightening Conveyor Belt Adjustment

The procedure displayed below in Figure 32, “loosens” or relieves tension on the conveyor belt. To relieve the tension the adjusting screw should be turned in a counter-clockwise direction. When loosening tension on the belt, adjust both adjustors in at the same rate.

Figure 32: Loosening Conveyor Belt Adjustment

Due to the presence of the v-groove system when both adjustors are measured out at the same distance the belt should run straight. When adjusting a new belt, shift the conveyor to the leftmost position and measure the gap between the outside bottom idler roller located on the Attachment frame and that of the conveyor belt. The belt is properly tensioned when there is about a ¼ inch gap between the idler roller and the belt. If the belt is riding on the idler roller it is too loose and should be tightened. If the gap is larger than ½ inch the belt is too tight and needs to be loosened.

Making small adjustments to correct alignment still may be necessary in some instances. It may be necessary to make adjustments to one side and not the other or to make the opposite adjustments on each side of the conveyor to keep the belt in alignment over

Machine Maintenance

time. Try not to make adjustments to one adjustor alone, this could result in over tightening and stretch the belt.

The procedure displayed in Figure 33, where the front adjuster is tightened or extended and the rear adjuster is loosened or retracted, adjusts the conveyor belt to track further towards the rear of the Machine.

Figure 33: Conveyor Belt Rearward Adjustment

Conversely, the procedure displayed in Figure 34, where the rear adjuster is tightened or extended and the front adjuster is loosened or retracted, adjusts the conveyor belt to track further towards the front of the Machine

Figure 34: Conveyor Belt Forward Adjustment

Make only minor adjustments to the slack adjustors. Run the conveyor in both directions for a short period after each adjustment to check alignment. Observe to see if the belt corrects itself before making another adjustment.

Troubleshooting

8 Troubleshooting

8.1 All Attachment Functions are not Working Checking whether the problem is Electrical or Hydraulic should be first step.

Start the Machine and check the valve stack gauge on Mini padder Attachment.

If there is no pressure check the hydraulic quick coupler pressure and return couplers. If any of the couplers are loose, retighten the couplers and check the gauge for pressure again.

If there is still no pressure at the gauge, check with a different gauge that has been tested for functionality. If the problem persists contact an Ozzie’s service representative.

8.2 An Attachment Function is Not Working If there is pressure, attempt to manually activate the function on the Attachment that is not working using an end wrench or the provided control handle. Note: Stand clear from the conveyor and all other moving parts of the Attachment while operating any of the functions manually.

If the function that was not responding to electrical input works via manual override, the problem is in the electrical system. See Section 8.4 below for further help on electrical troubleshooting. If the function is still not operating after manual actuation consult Section 8.3 for further mechanical troubleshooting of the Elevator, Conveyor, Shift, and Vibrator systems.

8.3 Mechanical Systems

8.3.1 Broken Keyway/Stripped Coupler If the issue has been determined to be with the mechanical systems of the padder a quick visual inspection should be able to determine the source of the issue. Using a helper or spotter, activate the function in question and have a second qualified individual inspect the coupler or keyway between the motor and the pulley shaft. If the shaft of the motor is spinning and the pulley remains stationary it is likely that the coupler has become stripped or the keyway is broken. This is a common failure as they are designed to fail prior to any major components. Once the source issue has been identified, turn off all Machine function and replace the coupler or keyway and retest the function. Consult an Ozzie’s service representative for further instructions on how to replace couplers and keyways.

8.3.2 Test Motor Health With the Machine turned off, remove the case drain line from the motor for the function in question using a drain pan to catch any trapped oil in the hoses and motors. Place a drain pan under the open case drain port on the motor. Turn on the Machine and run the function via the manual controls, having a spotter watch the amount of oil that comes out of the motor case drain port.

A worn motor will have a lot of oil leakage from the case drain port. If there is a steady stream of oil coming from the motor case, it likely needs replacing. If there is very little oil that comes out of the case drain port consult an Ozzie’s service representative for further troubleshooting assistance. If there are two motors in the system for the function in question, test each of the motors separately.

Troubleshooting

8.4 Attachment Electrical System

8.4.1 All functions not working

First verify that the pause button on the Attachment control box has been pushed. After pushing the pause button, activate various Attachment functions. Check the micro controller, located in the right hand side Loader storage compartment, for flashing codes. If there are codes present refer to the Mini-padder Blink Codes table for further troubleshooting. If no codes are present, examine the electrical harness to the padder control box, as well as the quick coupler on the loader arm. If there is no obvious loose connection or damaged wiring, consult your local Ozzie’s service representative for further troubleshooting.

8.4.2 One function not working or intermittent functionality

Intermittent problems are often mechanical, first rule out any potential for mechanical issues with the function in question. If mechanical issues have been ruled out, check the micro controller, located in the right hand side Loader storage compartment, for flashing codes. If there are codes present refer to the Mini-padder Blink Codes table for further troubleshooting. If no codes are present, check the electrical connections at the valve stack for damaged or frayed wiring. If all wiring looks to be in good order and the problems are intermittent and persist call an Ozzie’s service representative.

8.4.3 Blink codes

Be aware if you unplug any part of the Micro Controller Electrical connections with the key switch on, recalibration of all of the controls will be required.

To locate the microcontroller, open the right side compartment under the cab. Inside to the left you’ll see the microcontroller mounted to the compartment wall. Look closely above the electrical connections and find the status light. This light will help to determine if there are any issues present with the microcontroller and or control box. Status for the control box is indicated as follows:

• Green light – There are no problems detected

• Flashing red light – There is a problem or problems detected

All codes are a two digit number. To determine what code is flashing use the following system of code definition system. The light will flash one after another and then pause, count the number of flashes until the pause occurs. The number of flashes is 1st number in the code. Then count next set of flashes until pause occurs, the number of flashes is 2nd Number. As an example: *** pause = 3, then ***** pause = 5. The active code would be 35. . Consult the following table to decode the active blink code.

Table 7: Mini-padder Microcontroller Blink Codes

BLINK CODE DESCRIPTION

21 CONV SHIFT A COIL DISCONNECTED BURNT OUT OR OVERDRIVEN

22 CONV SHIFT B COIL DISCONNECTED BURNT OUT OR OVERDRIVEN

23 CONV A COIL DISCONNECTED BURNT OUT OR OVERDRIVEN

24 CONV B COIL DISCONNECTED BURNT OUT OR OVERDRIVEN

25 ELEV A COIL DISCONNECTED BURNT OUT OR OVERDRIVEN

26 ELEV B COIL DISCONNECTED BURNT OUT OR OVERDRIVEN

27 VIB A COIL DISCONNECTED BURNT OUT OR OVERDRIVEN

Troubleshooting

28 VIB B COIL DISCONNECTED BURNT OUT OR OVERDRIVEN

32 CONV POT FAULT. OUT OF RANGE

33 CONV JOY FAULT. OUT OF RANGE

34 ELEVEVATOR POT FAULT. OUT OF RANGE

35 VIBRATOR POT FAULT. OUT OF RANGE

36 SENSOR POWER FAULT

37 CONV POT NOT CALIBRATED

38 CONV JOY NOT CALIBRATED

39 ELEV POT NOT CALIBRATED

41 VIB POT NOT CALIBRATED

8.4.4 Calibration

Before beginning calibration, make sure all the control knobs are at their zero position on control box. Use caution when turning knobs, turning the knobs with excessive force will DAMAGE potentiometer.

To perform calibration on the control box, reach into the right side under cab compartment located beneath the cabin door. There is one connection on the harness that will need to be disconnected. DO NOT DISCONNECT THE CONNECTIONS ON THE MICRO CONTROLLER. There are a couple of connections towards the back of the compartment, a three pin triangular Deutshce plug and a two pin rectangle Deutshce plug. The connection in question is the two pin rectangular plug. With key switch off, disconnect the two pin rectangle plug. Once unplugged, turn on the key switch and count to ten seconds. After the 10 seconds, plug the disconnected rectangle plug back in and immediately climb into cab and turn Elevator potentiometer clockwise until it stops (it’s right most position) and count five seconds. After the five seconds, turn the knob counterclockwise back to the zero or leftmost position and count to five again. After the five seconds, move onto the next function and repeat until all three knobs are finished. After calibrating all three pots, immediately move to the conveyor shift toggle lever and move the lever to the left side and hold it there for a period of five seconds. After five seconds let the toggle go and move the sift toggle to the right side and again hold for five seconds. At the end of the five seconds release the toggle back to the center position. All functions should be recalibrated at this time. There is no need to calibrate pin in, pin out, the pause button or the conveyor and elevator directional switches. To make the calibration process easier and to eliminate getting in and out of the Loader cabin, have a helper assist with calibration so that one person is on the ground at the electrical plug and the other is in the cabin.

Serial Number Reference Chart The following table has been provided for use as a quick reference guide for the Machine and Machine componentry serial numbers. This table is to be filled out and updated by the recipient of the Padding Machine.

Part/Component Manufacturer Serial Number Additional Notes Date

(example) Padder

(example) Ozzie’s

(example) OMP-2012-324

(example) Model OPP-300

(example) 9 July 2015

Mini Padder

Ozzie’s Pipeline Padder, Inc.

Mini-padder Operation Manual REV. A3 - 2017

Opening its doors in the 1980s, Ozzie’s delivered the first all-in-one padding machine to the world. Since then we have established ourselves as the premier source for pipeline padding equipment large and small, and continue to push the envelope in pipeline equipment engineering. Contact us today to see how we can help you.

Corporate Office ESI Energy Services Inc. Suite 500 727 - 7th Ave SW Calgary, AB T2P 0Z5 Canada T:+1 403.262.9344 F:+1 403.571.5191

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United States

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Chris Coffman – Parts Manager


+1 623.889.7955 +1 602.738.5714

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+1 623.889.7950 +1 602.300.5338

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Ozzie’s Pipeline Padder, Inc. Mini-padder

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