Page 1
Operator's Technical Manual TimberRite™ X-20 Measuring System WA134818 18AUG21 (ENGLISH) COPYRIGHT® 2021 WARATAH NZ LIMITED Tokoroa, New Zealand All Rights Reserved LITHO IN NEW ZEALAND...
Page 2
Introduction Foreword This manual is written for an experienced technician; it identifies and recommends essential tools required for completing certain service work. Live with safety: read the safety messages in the introduction of this manual and the cautions presented throughout this text. Information is organized in groups, according to the various components requiring service instruction.
Page 3
We need your help to continually improve our technical publications. Please copy this page and FAX or mail your comments, ideas and improvements. SEND TO: Waratah New Zealand Limited PO Box 375 Attention: Product Support Group Tokoroa, 3444 NEW ZEALAND...
Contents Section 1—General Group 10—General Information Section 2—Safety Group 10—Safety: General Precautions Group 20—Safety: Operation Precautions Group 30—Safety: Signs and Labels Section 3—Maintenance Group 10—Welding Section 4—Hydraulic Installation Group 10—System Requirements Group 20—Hydraulic Installation: Circuits Group 30—Hydraulic Installation Kits Section 5—Electrical Installation Group 10—Electrical Installation Kit Section 6—Measuring System (Automation) Group 10—User Interface...
General Information This manual contains instructions for the installation of the specifications, instructions, etc. as required by ongoing Waratah felling heads with TimberRite™ X-20. If you have product improvements and updates. questions about the instructions, please consult your local All service and repairs should be carried out by qualified dealer for more detailed information.
(6) months, will be accepted during the Waratah, or 2) installation of the product on a machine warranty period. or by persons or firms not approved by Waratah, or 3) replacement parts that are not genuine Waratah parts. Validity: To validate this warranty, attachment installation...
Page 11
Section 2 Safety Contents Page Group 10—Safety: General Precautions General safety ..........2-10-1 Safety precautions........... 2-10-2 Operational safety ........... 2-10-3 Recognise safety information ......2-10-4 Operating precautions ........2-10-4 Prevent fires ............ 2-10-5 In case of carrier fires ........2-10-5 Group 20—Safety: Operation Precautions General safety ..........
Group 10 Safety: General Precautions General safety Ensure all operators read and understand this manual. If the manual is lost or damaged, you should replace it immediately. Operating, servicing, or adjusting a setting without fully understanding how the felling head works can have very serious implications for safety.
Safety: General Precautions Safety precautions IMPORTANT: The felling head must only be operated in a manner that prevents debris from hitting the cab. To support this operation, it may be necessary to replace the front window with the one capable of withstanding impacts from debris.
Safety: General Precautions Operational safety IMPORTANT: The felling head can fall unpredictably When working in a restricted area, check for interference when the engine is shut down. In the event of with cylinder rods, hydraulic hoses, and electrical cables, being unable to restart the engine, lower the etc.
Safety: General Precautions Recognise safety information This is the safety alert symbol. When you see this symbol, be alert for the risk of personal injury. Follow the precautions and safe operating practices highlighted by this symbol. A signal word — DANGER, WARNING, or CAUTION — is used with the safety alert symbol.
Safety: General Precautions Prevent fires Handle fuel safely: Store flammable fluids away from fire hazards. Never refuel a machine while smoking or when you are near sparks or flame. Clean the machine regularly: Keep trash/rubbish, debris, grease, and oil from accumulating: in the engine compartment;...
Group 20 Safety: Operation Precautions General safety NOTE: The locking-pin is retained at the Tilt Lock Cap Screw Storage Location. Understand all the control levers and their functions; note all safety devices on the felling head and ensure they are working properly.
Safety: Operation Precautions Avoid work site hazards Avoid contact with buried cables and gas/water lines: Before starting work, you should contact your local utility line location services to identify all underground utilities. Prepare the work site properly: Avoid operating near structures or objects that could fall onto the machine;...
Safety: Operation Precautions Prepare for service In order to prepare for carrying out service work, it is important you do the following: • Warn others of impending service work. • Lower the equipment to the ground before starting service work. •...
Group 30 Safety: Signs and Labels Safety Signs and Other Instructions TX1282849 Safety Signs and Other Instructions 1— WARNING, Pinch Area Keep 2— DANGER, Personal Injury or Away (4 used) Death May Occur (2 used) T7M7G6M,00001A2 -19-21NOV19-1/3 1. WARNING, Pinch Area Keep Away Pinch Area Keep Away These safety labels are located on the left and right...
Page 24
Safety: Signs and Labels 2. DANGER, Personal Injury or Death May Occur Rotating chain saw PERSONAL INJURY OR DEATH MAY OCCUR. Keep clear of chain saw. Service only when engine is stopped. This safety label is located on the right side of the attachment frame and on top of the chain saw guard.
Page 25
Section 3 Maintenance Contents Page Group 10—Welding Make welding repairs safely ......3-10-1 Remove paint before welding or heating............3-10-1 Welding on the carrier or felling head............. 3-10-2 Using booster batteries........3-10-3 WA134818 (18AUG21) Operator's Technical Manual 081821 PN=25...
Group 10 Welding Make welding repairs safely IMPORTANT: Disable electrical power before welding, and ensure you separate the harness connectors from the engine and vehicle microprocessors. Follow these instructions to facilitate completion of safe welding repairs: • Avoid welding or heating near pressurised fluid lines; flammable spray may eject and cause severe burns if pressurised lines fail as a result of heating.
Welding Welding on the carrier or felling head IMPORTANT: As an electrical welder current can damage the electrical system, always ensure you isolate the electrical components before welding. Failing to isolate this equipment will damage electrical components. Ensure you isolate the electrical equipment when performing any welding;...
Welding Using booster batteries Before boost starting, the machine must be properly shutdown to prevent unexpected machine movement when the engine starts. CAUTION: An explosive gas is produced while batteries are in use or being charged. Keep flames or sparks away from the battery area. Make sure that the batteries are charged in a well-ventilated area.
Page 31
Oil sample and flow test ........4-10-3 Group 20—Hydraulic Installation: Circuits Pilot valve ............4-20-1 System schematic ........... 4-20-2 Proportional pilot system schematic: Waratah manifold (Option)............4-20-3 Standard hydraulic system ......4-20-4 Rotator valve ........... 4-20-5 Group 30—Hydraulic Installation Kits Standard hydraulic installation kit ....
Group 10 System Requirements Install head on carrier – recommended hose When removing sequence to follow 1. Remove rotator guards. When installing 2. Remove the case drain hose. 1. Install the electrical cable hose in the junction box. 3. Remove the pressure hose and adaptor fitting. 2.
System Requirements Hydraulic oil: Supply Specification Pressure-rated filter: IMPORTANT: Install one of the two options of Pressure ............40 000 kPa filter warning systems to the hydraulic 400 bar system’s high-pressure filter. 5800 psi Pressure-rated filter: Ensure the supply line is 25.4 millimetres (one inch) in Flow rate ............
System Requirements Hydraulic system requirements Recommended supply pressure ............32 000 kPa IMPORTANT: Only connect the felling head to 320 bar the carrier once the Installation Test Sheet 4650 psi is complete; failing to do so may result in Return pressure ..........
Group 20 Hydraulic Installation: Circuits Pilot valve The pilot valve (1) is controlled by the felling head’s controller, which activates the carrier control valve according to the flow requirements of the selected function. The controller key-switch positions - ”Auto” and “Off”...
Proportional cartridges are fitted to the pilot isolation valve, which is controlled through the Waratah controller The proportional, reducing, and relieving valves are with a range of 0 — 100 per cent pulse width modulation designed to provide a proportional hydraulic signal, (PMW) signal.
Hydraulic Installation: Circuits Standard hydraulic system TX1064663 1— Carrier interlock isolation 6— Joystick handle (4 used) 12— P1 Signal 18— P2 signal valve 8— Felling head supply line 15— Pump 1 pilot control 19— Key-switch 2— From pilot pump 11— Pilot test point 16—...
Page 42
Hydraulic Installation: Circuits NOTE: Where an indexator rotator is used, the indexator Specification rotator valve must have a cross-over relief block that Rotator pressure ............8000 kPa is installed as closely as possible to the rotator. 80 bar 1160 psi The rotator valve requires a maximum flow specification at a specified pressure;...
Group 30 Hydraulic Installation Kits Standard hydraulic installation kit The WA105262 hydraulic installation kit is being revised. To ensure you get the correct parts, order them from the list below. Description Part Number Quantity WA100044 ½" hardened washer WA100162 1½" SAE seal WA100185 3/8"...
Hydraulic Installation Kits North American hydraulic installation kit The WA106199 hydraulic installation kit is being revised. To ensure you get the correct parts, order them from the list below. Part Number Quantity Description WA100207 ¼" BSP 5–7 psi check valve WA100904 Gritstop filter 1¼"...
Hydraulic Installation Kits South American hydraulic installation kit The WA109562 hydraulic installation kit is being revised. To ensure you get the correct parts, order them from the list below. Part Number Quantity Description WA100162 1½" SAE seal WA100565 1¼" Dowty washer WA100904 Gritstop filter 1¼"...
Group 10 Electrical Installation Kit General specifications CAN Network Supply voltage Nominal 24 V DC (24-28 V range) Approximately 10 amps continuous (depending on Supply current the felling head); a maximum current draw of 15 amps Operating -40 — 50°C temperature -40 —...
Page 52
Electrical Installation Kit XJ1290145 —UN—30DEC19 BASE AT422694 BASE MAIN PRESSURE (400 BAR) TO HEAD MAIN FILTER RETURN FILTER CASE DRAIN FILTER PUMP 1 PUMP 2 PUMP 3 STATUS STATUS STATUS 57M9957 57M10517 57M10517 57M10517 57M7796 WA101173 WA101173 WA101173 57M10615 SP_Z012_B [4 x 0.50] SP_Z013_B [4 x 0.50] 57M9956 57M13374...
Page 53
Electrical Installation Kit A1—Armrest Controller Left R3—CAN 2 TR1 B4—Case Drain Status Plug Y6— General Output 3 (ACL) R4—CAN 2 TR2 F1— Battery Fuse Y7— General Output 4 A2—Armrest Controller Right S2— Key Switch G1—Battery Y8— General Output 5 (ACR) S3 —...
Electrical Installation Kit Supplied parts The electrical installation is one of the most critical issues and associated systems. Following parts are supplied associated with the reliability of any electronic equipment in kit: Components supplied Continued on next page T7M7G6M,00001E0 -19-13JAN20-1/2 WA134818 (18AUG21) 5-10-7 Operator's Technical Manual...
Page 56
Failing to install the electrical components connect any equipment that is not part of the correctly will void the machine’s warranty. Waratah system into any terminal or connection. IMPORTANT: Always take the time to read, ensure The TimberRite™ X-20 electrical system kit also your comprehension, and follow the system’s...
Electrical Installation Kit Cab controller Mount the cab controller in the carrier cab, in an accessible, easy-to-work-on, position. NOTE: Mount the key-switch so it is forward of the operator’s shoulders. When cleaning the carrier, take care to ensure you do not allow water to come into contact with the controller and/or the wire connectors.
Electrical Installation Kit Display Unit Display Unit 1— Socket Head Screw 4— RAM Mounting Arm 7— Digital Display Unit 2— Flat Washer 5— Screen Mount Adapter 8— Mounting Bracket 3— Internal Lock Washer 6— Pillar Side Ball Mounting Bracket NOTE: When you install the display unit’s wire harness, and flat washers (2).
Page 59
Electrical Installation Kit Schematic: TimberRite™ TX-20 XJ1290146 —UN—27DEC19 PWR/IO CAN 1 (250 kbit/s) CAN 2 (250 kbit/s) CAN1 TR1 CAN2 TR1 ARMREST CONTROLLER LEFT (ACL) ARMREST CONTROLLER RIGHT (ACR) DOOR LH JOYSTICK (SG) RH JOYSTICK (SG) SWITCH Wire Styles GN/YE PWR/IO XJ1290146 TimberRite™...
Electrical Installation Kit A7—BCU S2— Key Switch Y6— General Output 3 Y9— General Output 6 F1— Battery Fuse Y4— General Output 1 Y7— General Output 4 G1—Battery Y5— General Output 2 Y8— General Output 5 G2—Battery S1— Battery Disconnect Switch T7M7G6M,000034B -19-16JAN20-6/6 Cinch connector Repairing Cinch™...
Page 70
Electrical Installation Kit 4. Without forcing it out, pull the terminal lock (A) out as far as it goes. A—Terminal Lock Terminal Lock T7M7G6M,00001EA -19-09DEC19-2/4 NOTE: The terminal extractor tool has two different sizes of pins: 0.6 for smaller, 20-gauge, holes (A); and 1.5 for larger, 16-, and 18-gauge, holes (B).
Page 71
Electrical Installation Kit 7. Remove the old terminal, and strip 4.85 millimeters (0.191 inches) of insulation from the wire. 8. Grip the terminal crimping tool (A) securely; then squeeze the ratcheting mechanism until it bottoms out. Then, allow it to open completely. 9.
Electrical Installation Kit Deutsch connector Replace Deutsch™ connector NOTE: Connector shown is the female half or a 4-pin square connector. Other similar styles of Deutsch® connectors can be serviced using the same procedure. 1. Pull connector (1) apart. Inspect and clean connector seal and contacts.
Page 73
Electrical Installation Kit Installing Deutsch™ connector 1. Strip 6 mm (1/4 in.) insulation from wire. 2. Adjust selector (A) on crimper for correct wire size. 3. Loosen lock nut (B) and turn in adjusting screw (C) until it stops. IMPORTANT: Select proper size contact sleeve or pin to fit connector body.
Electrical Installation Kit IMPORTANT: If all wire strands are not crimped into contact, cut-off wire at contact and repeat contact installation procedures. NOTE: Readjust crimping tool for each crimp- ing procedure. 8. Inspect contact to be certain all wires are in crimped barrel.
Page 75
Electrical Installation Kit 2. Push the wire into the ferrule until it stops. Bootlace crimp Wire inside ferrule Continued on next page T7M7G6M,00001EC -19-09DEC19-3/10 WA134818 (18AUG21) 5-10-27 Operator's Technical Manual 081821 PN=75...
Page 76
Electrical Installation Kit 3. Insert the metal pin part only into the tool and crimp. Phoenix contact crimper Crimping with crimper T7M7G6M,00001EC -19-09DEC19-4/10 4. Shorten the pins by clipping off 2 mm at the end and screw into the terminal. NOTE: Ensure that the seal nut, washer and rubber seal are strung onto the wire in respective order before termination.
Page 77
Electrical Installation Kit 5. Press the insert back into the cap until it clicks. When doing this ensure that the wire is out of the way of the screw insertion point to avoid damage. Plug assembling T7M7G6M,00001EC -19-09DEC19-6/10 6. Press the rubber seal into the cap. Rubber seal T7M7G6M,00001EC -19-09DEC19-7/10 7.
Page 78
Electrical Installation Kit 8. Screw the seal nut down with the 17 mm spanner. Seal nut tightened T7M7G6M,00001EC -19-09DEC19-9/10 9. Press in the screw and always fit the seal before screwing onto the solenoid. Solenoid connecting cap-screw T7M7G6M,00001EC -19-09DEC19-10/10 WA134818 (18AUG21) 5-10-30 Operator's Technical Manual 081821...
Page 79
Section 6 Measuring System (Automation) Contents Page Group 10—User Interface Startup and Shutdown ........6-10-1 Startup screen ..........6-10-1 User Interface Buttons........6-10-3 Icon Reference ..........6-10-4 Run Screen............6-10-9 Menu Screen ..........6-10-10 Menu Structure ..........6-10-11 Joystick Functions—Trigger Series Handle ............
User Interface Startup and Shutdown Startup: IMPORTANT: Always start the TimberRite X-20 Turn the key switch control to the ON position. Waratah measuring system after the carrier/base screen will appear as system starting up. machine is running. Starting the carrier/base machine’s engine during the TimberRite X-20...
Page 82
User Interface Handle Layout (Default) Screen • This is the handle layout (default) screen which appears NOTE: Menu button also works as enter. by pressing Menu/Enter button. T7M7G6M,000024D -19-16DEC19-2/2 WA134818 (18AUG21) 6-10-2 Operator's Technical Manual 081821 PN=82...
User Interface User Interface Buttons User Interface buttons to move between run screen and menus are as follows: • • Run Screen - returns to the run menu screen. Buttons LH Handle - default button layout for LH Handle • Button 1 and 2 - these buttons are not used.
User Interface Icon Reference Joystick Buttons User Interface Buttons Item Joystick Button FUNCTION General Output 3 XJ1290182 —UN—23DEC19 General Output 4 XJ1290185 —UN—23DEC19 General Output 5 XJ1290186 —UN—23DEC19 Continued on next page T7M7G6M,00002A3 -19-20JAN20-1/5 WA134818 (18AUG21) 6-10-4 Operator's Technical Manual 081821 PN=84...
Page 85
User Interface Item Joystick Button FUNCTION General Output 6 XJ1290187 —UN—23DEC19 Saw Mode Toggle XJ1290188 —UN—23DEC19 Saw Cut XJ1290189 —UN—23DEC19 Head Tilt Up XJ1290191 —UN—23DEC19 Head Tilt Down XJ1290192 —UN—23DEC19 XJ1290193 —UN—23DEC19 Continued on next page T7M7G6M,00002A3 -19-20JAN20-2/5 WA134818 (18AUG21) 6-10-5 Operator's Technical Manual 081821...
Page 86
User Interface Item Joystick Button FUNCTION L-10 XJ1290193 —UN—23DEC19 Head Dump XJ1290194 —UN—23DEC19 Generic Output 1 XJ1290195 —UN—23DEC19 Generic Output 2 XJ1290196 —UN—23DEC19 Fn Buttons* XJ1290197 —UN—23DEC19 Bar Extend XJ1290198 —UN—23DEC19 Continued on next page T7M7G6M,00002A3 -19-20JAN20-3/5 WA134818 (18AUG21) 6-10-6 Operator's Technical Manual 081821 PN=86...
Page 87
User Interface Item Joystick Button FUNCTION XJ1290193 —UN—23DEC19 Tree Counter Decrement* XJ1290202 —UN—23DEC19 Tree Counter Increment* XJ1290203 —UN—23DEC19 Grapple Closes XJ1290200 —UN—23DEC19 R-10 Grapple Open XJ1290199 —UN—23DEC19 Continued on next page T7M7G6M,00002A3 -19-20JAN20-4/5 WA134818 (18AUG21) 6-10-7 Operator's Technical Manual 081821 PN=87...
Page 88
User Interface Item NAME FUNCTION Run Screen Returns to the run menu screen XJ1290204 —UN—23DEC19 Back Button Moves back to the previous menu screen XJ1290205 —UN—23DEC19 Menu / Enter Button Main menu of software XJ1290201 —UN—23DEC19 NOTE: Menu button also work as enter. Up Button Up button used to scroll up.
User Interface Run Screen Run Screen • • The run screen is the normal operating screen. Felling Stem Count – ’0000’ is stem counter. The stem counter head operation is possible only within the run screen. is incremented after a felling cut or by pressing the •...
User Interface Menu Screen Menu Screen Main menu screen contains three basic functions:- 3. Setup 1. Operation 2. Diagnostics T7M7G6M,000029A -19-28JAN20-1/1 WA134818 (18AUG21) 6-10-10 Operator's Technical Manual 081821 PN=90...
The trigger series configuration is the same as the default TimberRite configuration for safety. Functions of the Operator functions of the TimberRite X-20 controller are trigger series Joystick buttons and preselect keypad are accessed via the joysticks. Button numbering is given as follows: in the diagram.
Group 20 Menus and Settings Grapple settings Grapple Settings • The grapple settings screen appears as above. NOTE: To save the setting value – hit Enter again before • Scroll up and down to the settings you want to change hitting back button to save the desired value.
Menus and Settings Head tilt settings Head tilt settings • The Head tilt settings screen appears as above. NOTE: To save the setting value – hit Enter again before • Scroll up and down to the settings you want to change hitting back button to save the desired value.
Menus and Settings Saw settings Saw Oiler Parameter Settings • The grapple settings screen appears as above. NOTE: Single press increases by 1% increments, long • Scroll up and down to the settings you want to change hold increases by 10% increments. and hit Enter.
Page 96
Menus and Settings Saw Bar Extend Delay Settings Saw Bar Extend Delay Settings T7M7G6M,00002AC -19-28JAN20-3/3 WA134818 (18AUG21) 6-20-4 Operator's Technical Manual 081821 PN=96...
Menus and Settings Head Settings Head Settings • The head settings screen appears as above. NOTE: To save the setting value – hit Enter again before • Scroll up and down to the settings you want to change hitting back button to save the desired value. Once and hit Enter.
Menus and Settings Output Port Settings Output Port Settings • The output port settings screen appears as above. NOTE: To save the setting value – hit Enter again before • Scroll up and down to the settings you want to change hitting back button to save the desired value.
Menus and Settings Monitor Settings Display Units Settings • The output port settings screen appears as above. NOTE: To save the setting value – hit Enter again before • Scroll up and down to the settings you want to change hitting back button to save the desired value.
Page 100
Menus and Settings Language Settings Language Settings T7M7G6M,00002AF -19-28JAN20-2/4 Brightness Settings Brightness Settings Continued on next page T7M7G6M,00002AF -19-28JAN20-3/4 WA134818 (18AUG21) 6-20-8 Operator's Technical Manual 081821 PN=100...
Group 30 Diagnostic Screens Diagnostic Screen Diagnostic Screen • The Diagnostic menu screen appears as above. NOTE: Any fault that occurs on the system, can be cleared Diagnostic screen contains three basic functions:- by power cycling the system using the key switch. 1.
Diagnostic Screens Diagnostic Codes Active And Stored Codes • Active and stored codes screen appears above. It 2. Stored codes 18 mainly contains :- 1. Active codes 2 T7M7G6M,0000275 -19-13JAN20-1/2 Active And Stored Codes Data • • Active and stored codes data screen appears above. Use the Scroll up and Scroll down button to scroll the next or previous active and stored codes data.
Page 105
Prepare for service safety ........2-20-3 Oil sample and flow test........4-10-3 Remove paint before welding or Proportional pilot system heating ............... 3-10-1 schematic—waratah manifold (op- Servicing and maintenance safety ....... 2-20-1 tion) ..............4-20-3 Safety—operation precautions Standard hydraulic system........4-20-4 Avoid work sight hazards ........