200 TR PARTS MANUAL Version 4-04 Ashland Industries Inc. 1115 Rail Drive P.O. Box 717 Ashland, WI. 54806 Ph: 877-634-4622 Toll Free Ph: 715-682-4622 Fx: 715-682-9717 www.ashlandind.
Model 1200 Trash Rake HOW TO ORDER PARTS: IMPORTANT Parts must be ordered through your local authorized ASHLAND dealer. Be sure to state MODEL and SERIAL NUMBER of your machine, PART NUMBER, DESCRIPTION and QUANTITY needed. Unless this is done, we cannot provide prompt service or assure shipment of the correct parts. INDEX Page 3. Page 4. Page 5. Page 6. Page 7. Page 8-9. Page 10. Page 11. Page 12. Page 13. Page 14. Page 15. Page 16-17. Page 18. Page 19. Page 20-21. Page 22. Page 23-40.
The Ashland trash rake is a knuckle boom device designed to reach into the depths of the water and engage the bottom or toe end of the trash rack bars. An articulate rake at the end of the boom sweeps the rack bars of any debris on its upward stroke. The debris may be dumped into the sluiceway at the top of the rack or may be lifted and swung over to either side and loaded onto a truck.
MAINTENANCE Basic maintenance practices are required to obtain the maximum life of the machine. Before initial operation, the oil level of the gearboxes and hydraulic reservoir should be checked and filled as needed. The swing bearing should be greased while slowly rotating the unit. All pivot points of the booms, cylinder pins, axles, chains and levers should be greased. All hoses and fittings should be inspected for leaks and replaced if leaks are found.
OPERATING INSTRUCTIONS A start-stop switch to control the electric motor is located in the cab. In cold weather, (below zero degrees centigrade), the motor should be allowed to run and circulate the hydraulic oil for five minuted or longer before operating the hydraulic control levers. The operator should remain in his seat while the motor is running. If temperatures below zero degrees centigrade are anticipated, the electric heater in the oil tank should be turned on twelve hours in advance of start-up.
LUBRICATION GUIDE 2 GREASE FITTINGS 2 GREASE FITTINGS ON CYLINDER 2 GREASE FITTINGS ON CYLINDER 2 GREASE FITTINGS ON STEM HEAD 2 GREASE FITTINGS ON CYLINDER On Thumb Pivot 2 GREASE FITTINGS ON CYLINDER 80W-90 GEAR LUBE 4 GREASE FITTINGS ON RAKE GREASE FITTINGS ON SWING BEARING GREASE DAILY OIL CHAINS GREASE 4 PILLOW BLOCKS 7
TROLLEY ASSEMBLY 5 7 8 8
Parts List - Trash Rake TROLLEY ASSEMBLY Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19A 19B 20 21 22 23 24 25 26 27 28 29 30 32 33 34 35 36 37 38 39 40 42 43 45 46 47 48 49 50 Req’d 1 4 8 8 3 2 8 2 8 2 2 1 4 6 10 10 1 1 6 4 16 16 1 1 2 3 1 1 1 44 1 1 2 4 16 16 8 4 1 1 1 1 1 1 1 1 Part No.
CAB ASSEMBLY ITEM 1 2 3 4 5 6 7 8 9 REQUIRED 2 1 1 1 1 1 1 2 2 PART NO 2P14022 1P13459 4F14032 3F14008 1P14033 10 DESCRIPTION Joy stick Windshield wiper Seat Heater Voltage converter Cab Cab Platform Foot Pedal Lights
END BOOM ASSEMBLY 14 15 19 1 18 20 21 17 6a 13 14 15 12 16 2 3 3 6 5 3 4 7 ITEM REQ’D PART NO 1 1 4F14114 2 2 2F12888 3 4 1P10271 4 1 2F14064 5 1 2F12890 6 1 2A14125 6a 1 2A14125 Spacer) 7 1 3F14112 8 1 1S12891 9 1 10 1 1P11742 11 4 1P14124 12 2 13 2 1P14130 14 3 1P10013 15 3 16 4 1P14029 17 1 4F14116 18 1 1F14129 19 1 1F14131 20 2 1P14068 21 1 1P10004 8 9 10 11 DESCRIPTION END BOOM PIN LOCKNUT 1-1/2 NF PIN PIN CYLINDER 3-1/2 X 7 (1” Spacer) CYLINDER 3-1/2 X 7-1/2 (1/2” RAKE PIN BOLT 1/2 NC X 4-1/
MAIN BOOM ASSEMBLY ITEM 1 2 3 4 5 6 7 8 9 11 12 REQUIRED 1 1 1 1 2 1 6 2 4 1 4 PART NO 4F14113 2A11650 2A14062 2F11072 1P10271 2F13473 1P10272 1P10273 1P11432 1P14030 12 DESCRIPTION Main Boom Cylinder, 5 x 28 Cylinder, 6 x 35 Pin Locknut, 1-1/2 NF Pin Ball Bushing, 1-3/4" Ball Bushing, 2" Grease Fitting Cushion Valve Pipe Clamp, 4-hole
MAIN BOOM CYLINDER 2A14062 (6” x 35”) ITEM 1 2 3 4 5 6 7 8 REQUIRED 1 1 1 1 1 1 1 2 PART NO 3F14060 1M11303 1S11304 1S11298 1M13222 3F14061 1A13236 13 DESCRIPTION Case Head Collar Nut Piston Rod Seal Kit Set screw, 3/8 NC x 3/8 long
END BOOM CYLINDER 2A11650 (5 x 28) ITEM 1 2 3 4 5 6 7 8 REQUIRED 1 1 1 1 1 1 1 2 PART NO 3F11651 1M11654 1S11655 1P11649 1M11653 2F11652 1P11657 14 DESCRIPTION Case Head Collar Nut Piston Rod Seal Kit Set screw, 3/8 NC x 3/8 long
RAKE AND THUMB CYLINDER 2A14125 (3-1/2 x 8) 11 ITEM 1 2 3 4 5 6 7 8 9 10 10 11 REQUIRED 1 1 1 2 1 1 1 1 1 1 1 PART NO 3F12009 2M11725 2S11592 1P11042 2F14123 2M12611 1P12731 1A11709 1S14138 1S14137 1P14124 15 DESCRIPTION Case Head Collar Set screw, 3/8 NC x 3/8 long Bushing Rod Piston Locknut Seal kit Spacer 1” (Rake Cyl) Spacer 1/2” (Thumb Cyl) Bushing
SWING & TRAVEL GEARBOX 1P14012 16
Parts List - Swing and Travel Gearbox ITEM 1A 1B 1C 1D 1E 1F 1G 1H 1I 1J 1J 1K 1Q 3A 3B 3C 3D 3E 3F 3G 3H 3 4 5 6 8 13 15 16 17 18 19 20 24 25 REQUIRED 1 1 1 1 1 1 1 1 1 1 2 2 1 1 6 84 3 3 3 3 6 1 1 2 1 1 1 4 2 8 4 4 1 1 2 PART NO 1P14036 1P14042 1P14038 1P14039 1P14040 1P14041 1P14037 1P14043 1P14035 1P14048 1P14046 1P14049 1P14050 1P14045 1P14051 1P14052 1P14047 1P14044 1P14056 1P14034 1P14059 1P14058 1P14057 1P14053 1P14054 DESCRIPTION Shaft Seal, lip Bearing, cup Bearing, cone Bearing, cup Bearing,
HYDRAULIC SWIVEL 1P14065 ITEM PART NO 1 2 3 1P14066 4 18 DESCRIPTION Housing Body Seals End Cap
HYDRAULIC HOSES (Parts Lists next page) 20
Parts List - Hydraulic Hoses Triangled Items ITEM SIZE DESCRIPTION Controls to valve bank 1 1/4" x 140" 4JIC 90 Sw X 4 JIC Sw 2 1/4" x 140" 4JIC 90 Sw X 4 JIC Sw 3 1/4" x 125" 4JIC 90 Sw X 6 JIC Sw 4 1/4" x 125" 4JIC 90 Sw X 6 JIC Sw 5 1/4" x 125" 4JIC 90 Sw X 6 JIC Sw 6 1/4" x 125" 4JIC 90 Sw X 6 JIC Sw 7 1/4" x 125" 4JIC 90 Sw X 6 JIC Sw 8 1/4" x 125" 4JIC 90 Sw X 6 JIC Sw 9 1/4" x 125" 4JIC 90 Sw X 6 JIC Sw 10 1/4" x 125" 4JIC 90 Sw X 6 JIC Sw 11 1/4" x 140" 4JIC 90 Sw X 4 JIC Sw 12 1/4" x 140" 4JIC 90 S
HYDRAULIC VALVE 2P14023 ITEM 3 MAIN BOOM ITEM 2 TRAVEL ITEM 4 THUMB ITEM 6 SWING ITEM 5 MIDEINLET ITEM 7 RAKE ITEM 8 JIB ITEM 9 OUTLET ITEM 1 INLET ITEM PART NO.
HYDRAULIC TROUBLESHOOTING GUIDE HYDRAULIC SYSTEMS CANNOT BE OPERATED AND MAINTAINED WITHOUT FOLLOWING CERTAIN GUIDELINES. WE HAVE TRIED TO COMPILE A LIST OF THE MOST COMMON PRECAUTIONS IN USE TODAY. THIS INFORMATION IS NOT REPRESENTED AS BEING ALL INCLUSIVE OF GOOD PRACTICES, BUT THE POINTS HEREIN SHOULD BE FOLLOWED TO EXPECT EQUIPMENT TO PERFORM PER SPECIFICATIONS.
INSTALLATION 1. THE MOST IMPORTANT PRACTICE TO OBSERVE IN ASSEMBLING HYDRAULIC SYSTEMS IS CLEANLINESS. SERIOUS DAMAGE CAN RESULT QUICKLY FROM FOREIGN MATERIAL IN THE SYSTEM. 2. WHILE IN TRANSIT OR DURING INSTALLATION, BOTH HYDRAULIC UNITS AND HYDRAULIC COMPONENTS MAY BE SUBJECT TO MANY USUAL CONDITIONS. ALWAYS INSPECT FOR DAMAGE OR CONTAMINATION (OPEN PORTS, CRACKED OR MISSING PLUGS, ETC). ALL HYDRAULIC UNIT OR COMPONENT PORTS MUST BE KEPT TIGHTLY PLUGGED UNTIL FINAL SYSTEM CONNECTIONS ARE MADE. 3.
11. WHEN USING PIPE SEALING COMPOUND, LEAVE THE FIRST TWO THREADS (INWARD) BARE TO KEEP SEALING MATERIAL FROM MIGRATING INTO THE SYSTEMS. 12. DO NOT USE PIPE COMPOUND ON STRAIGHT THREADS AS THESE TYPE FITTINGS DEPEND ON AN "O" RING FOR SEALING. 13. SELECT HOSES ADEQUATE FOR WORKING PRESSURES INVOLVED IN THE SYSTEM. REFER TO THE SCHEMATIC. HOSES SHOULD: - NOT BE BENT MORE THAN THE PUBLISHED MINIMUM BEND RADIUS FOR EACH STYLE.
START UP 1. FILL THE RESERVOIR WITH FLUID AS RECOMMENDED BY PUMP MANUFACTURER (SEE PUMP DATA), USUALL Y A PREMIUM GRADE HYDRAULIC FLUID WITH A VISCOSITY INDEX OF 90 OR HIGHER. FOR APPLICA TIONS WITH TEMPERATURES TO 130 DEGREES F, A FLUID VISCOSITY OF 150 SSU AT 100 DEGREES F WILL PROVIDE A MAXIMUM PUMP SERVICE LIFE. AUTOMATIC TRANSMISSION FLUID, DEXTRON TYPE D2, WILL USUALLY PROVE SATISFACTORY. THE RESERVOIR FILLING SHOULD ALWAYS BE DONE THROUGH A 10 MICRON FILTER OR FINER.
9. AFTER THE FIRST TWO HOURS OF SYSTEM OPERATION, INSPECT AND CLEAN OR REPLACE ALL FILTER ELEMENTS TO REMOVE ANY CONTAMINATION FLUSHED OUT OF SYSTEM COMPONENTS. REPLACEMENT ELEMENTS ARE READILY AVAILABLE FROM ACTIVATION. REPEAT THIS TASK EVERY TWO HOURS FOR THE NEXT EIGHT HOURS OF OPERATION, THEN AS NEEDED. (SEE SECTION ON OIL MAINTENANCE) IMPORTANT! FOR MOST APPLICATIONS, AN OPERATING TEMPERATURE OF 150 DEGREES F IS CONSIDERED MAXIMUM.
MAINTENANCE CHECKLIST HYDRAULIC SYSTEMS ARE PRECISION UNITS AND THEIR CONTINUED SMOOTH OPERATION DEPENDS ON PROPER CARE. KEEP THEM CLEAN, CHANGE THE OIL FILTER AT ESTABLISHED INTERVALS, AND FOLLOW PRESCRIBED MAINTENANCE. PERIODIC PROCEDURES ARE AS FOLLOWS: 1. CHECK THE RESERVOIR OIL LEVEL AND ADD OIL AS REQUIRED. THE LEVEL MUST BE MAINTAINED BETWEEN THE HIGH AND LOW MARKS ON THE SIGHT GAUGE. 2. CHECK THE OPERATING TEMPERATURE. 150 DEGREES F IS CONSIDERED MAXIMUM FOR MOST INDUSTRIAL APPLICATIONS. 3.
SAFETY PRECAUTIONS REQUIRED FOR HYDRAULIC MACHINERY OPERATION AND MAINTENANCE ALTHOUGH THE SCOPE OF THIS MANUAL COVERS ONLY THE HYDRAULIC OPERATION OF THE EQUIPMENT, THESE SAFETY PRECAUTIONS ALSO APPLY TO PNEUMATICALLY POWERED EQUIPMENT AND SHOULD BE OBSERVED WHERE APPROPRIATE.
7. IF HYDRAULIC SYSTEM HAS OIL ACCUMULATORS IN CIRCUIT, DRAIN PRESSURIZED OIL FROM ALL ACCUMULATORS (IF AUTOMATIC DRAINAGE IS NOT BUILT INTO CIRCUIT) AS SOON AS HYDRAULIC UNIT IS SHUT DOWN. IF ACCUMULATOR HAS A SHUT-OFF VALVE, CLOSE THAT VALVE ALSO. 8. SHUT DOWN HYDRAULIC UNIT AND RELIEVE PRESSURE FROM ALL PRESSURIZED ACCUMULATORS, ACTUATORS AND LINES BEFORE REMOVING, TEARING DOWN OR PERFORMING MAINTENANCE ON ANY REMOTELY LOCATED ACTUATORS, HOSES, FILTERS, VALVES, PIPING, ETC. 9.
OPERATING CONDITION. 17. IN PIPING THE HYDRAULIC SYSTEM ON THE EQUIPMENT, USE ONLY MATERIALS OF ADEQUATE SIZE AND STRENGTH TO SUIT THE FLOWS AND PRESSURES WHICH WILL BE PRESENT IN THE SYSTEM. IF A SCHEMATIC IS PROVIDED, IT PROBABLY SHOWS MINIMUM SUGGESTED LINE SIZES. LENGTH OF RUNS AND PRACTICAL EXPERIENCE MAY INDICATE USE OF LINE SIZES LARGER THAN SHOWN ON THE SCHEMATIC. USE SAFETY FACTORS IN SELECTING MATERIALS FOR STRENGTH TO AllOW FOR SHOCK AND OVER-PRESSURE CONDITIONS WHICH MAY OCCUR.
TROUBLE SHOOTING YOUR HYDRAULIC SYSTEM PROBLEM Failure of pump to deliver fluid Pump making a noise POSSIBLE CAUSES Low fluid level in reservoir REMEDY Add recommended oil and check level to be certain pump suction line inlet is submerged deeply enough to prevent air entering directly or by the formation of a vortex.
TROUBLE SHOOTING YOUR HYDRAULIC SYSTEM PROBLEM No pressure in the system POSSIBLE CAUSES Pump does not deliver pressure REMEDY Follow the remedies given for "Failure of Pump to Deliver Fluid". Bad pump-to-motor shaft connection Check pump/motor coupling for breakage. stripped key or keyway and replace or repair Relief Valve Malfunction 1) Incorrect valve setting 2) Valve leaking or by-passing 3) Valve spring broken Free re-circulation of oil to tank being allowed through system.
TROUBLE SHOOTING YOUR HYDRAULIC SYSTEM PROBLEM POSSIBLE CAUSES Excessive wear of pump Sustained high pressure parts above maximum pump rating Drive misalignment Check and correct Air recirculation causing chatter in system Check air problems in pump making noise Abrasive material in the oil Clean or replace filter and change oil Viscosity of oil too low at working conditions Check recommendations Breakage of inside pump Excessive pressure above housing pump rating External oil leakage around pump s
TROUBLE SHOOTING YOUR HYDRAULIC SYSTEM PROBLEM Solenoid valve problem POSSIBLE CAUSES Solenoid burned out REMEDY Replace solenoid coil. Check control voltage (High or low voltage will burn out oil) For double solenoid valves, check to see if both solenoids are being energized at the same time. Correct control circuit if this occurs. No pilot pressure for shifting main spool If valve is externally piloted, check pilot pressure source for adequate pressure.
TROUBLE SHOOTING YOUR HYDRAULIC SYSTEM PROBLEM POSSIBLE CAUSES Cylinder won’t develop Leaking piston packing full force or hold position when valve closes lines REMEDY Apply pump flow to one end and stroke cylinder until it bottoms out at end of stroke. Loosen return line at opposite end (from pressurized end) and measure leakage flow coming out. Any flow more than slow dripping requires new piston packing. Repeat for opposite end and stroke.
TROUBLE SHOOTING YOUR HYDRAULIC SYSTEM PROBLEM Excessive heating because of component conditions POSSIBLE CAUSES Relief valve set incorrectly REMEDY Readjust valve to system specifications pressure; usually 100 -150 psi above compensator setting Internal oil leakage (pump) Repair or replace pump Viscosity of oil too high Check recommendations to start-up information Leaking valves Repair or replace Improper functioning of oil cooler (if installed) Inspect cooler and see that it is working properly
ELECTRIC MOTOR TROUBLESHOOTING GUIDE PROBLEM Motor Runs Excessively Hot Won't Start (just hums and heats up) POSSIBLE CAUSES Overloaded REMEDY Reduce load or load peaks and number of starts in cycle Blocked Ventilation: Clean external ventilation system - check fan. a. TEFC's Blowout internal ventilation passages. b. O.D.P.’s Eliminate external interference to motor ventilation. High Ambient Temperature over 40°C (104°F). Reduce ambient temperature or provide outside source of cooler air.
ELECTRIC MOTOR TROUBLESHOOTING GUIDE PROBLEM Overload Relays Tripping Upon Starting Running Loaded Excessive Vibration (mechanical) POSSIBLE CAUSES Slow Starting (10- 15 seconds or more) due to High Inertia Load REMEDY Reduce starting load. Increase motor size if necessary. Low voltage at motor terminals. Improve power supply and/or increase line size. Overload. Reduce load or increase motor size Unbalanced Input Current.
ELECTRIC MOTOR TROUBLESHOOTING GUIDE PROBLEM Noisy Bearings (listen to bearings for the following) POSSIBLE CAUSES REMEDY Smooth Mid-Range Hum Normal Fit. Bearing OK. High Whine Internal fit of bearing too tight. Replace bearing -check fit. Low Rumble Internal fit of bearing too loose. Replace bearing -check fit. Rough Clatter Bearing Destroyed. Replace bearing -Avoid: a. Mechanical Damage. b. Excessive Greasing. c. Wrong Grease. d. Solid Contaminants. e. Water running into motor. f.
Limited Warranty Statement Ashland Industries Inc. warrants each new product to be free from defects in material and workmanship. This warranty is applicable only for the normal service life expectancy of the product or components, not to exceed six consecutive months from the date of delivery of the new Ashland Industries product to the original purchaser, or the date the product is first put into service via a rental agreement or other means, whichever occurs first. Genuine Ashland Industries Inc.
