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COAST MACHINERY MARSH MASTER 2015, Operating & Maintenance Manual

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COAST MACHINERY MARSH MASTER 2015 Operating & Maintenance Manual Download Page 45

PROCEDURE TO REPLACE DRIVE SPROCKETS 

 

 

 

 

 

 

Using the jack plate at the center of the buggy, raise the buggy so that the tracks are clear 
off the ground, and clear of any other objects. 

 

 

Move the track until the front of the center belt is in line with the winch. 

 

 

Loosen the tension on the belt by unscrewing the bearing take-up nuts on the front 

idler shaft.

 

 

 

Remove the bolts that fasten the drive lugs attached to the front end of the belt. 

o

 

You will need to take note of which way the belts are meshed 

 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

 

The center belt should stay with the rear end of the track. 

 

 

With a little prying, the tracks should now be loose enough so that they fall on their own. 

o

 

You may want to tie a rope to the tracks so that you can let 
them down easily. 

 

THE TRACKS ARE HEAVY AND WILL FALL RAPIDLY! 

WARNING! 

SERIOUS INJURY CAN OCCUR! 

 

⚠ 

 

 

Summary of Contents for MARSH MASTER 2015

Page 1: ...http www marshmaster com MARSH MASTER OPERATING MAINTENANCE MANUAL COAST MACHINERY LLC 10012 UMBEHAGEN LANE BATON ROUGE LA 70817 225 753 1323 Rev 7 14 2015 ...

Page 2: ...he contents of this manual It contains instructions for the safe operation use and servicing of the machine The descriptions and specifications contained in this manual are subject to change Coast Machinery LLC reserves the right to modify specifications or design and to upgrade its equipment at any time as part of a continuing process of refinement Thank you for the confidence you have placed in ...

Page 3: ...limited to the replacement of the warranted part with no obligation to provide labor in installing such part ALL ABOVE WARRANTIES DO NOT COVER THE FOLLOWING Maintenance items adjustments or required maintenance as per written manuals or other instruction Transportation cost of machine for necessary repairs Repairs required as a result of failure due to normal wear accidents misuse abuse negligence...

Page 4: ...pen radiator cap or service cooling system until radiator and engine is cool to the touch Machine is unstable on jack Use jack on machine in designated locations ONLY Block machine up with jack stands Leaking hydraulic fluid under pressure can penetrate skin Severe infection or death can result Never use your hands to locate a leak Use cardboard to locate leak Battery acid causes severe burns Avoi...

Page 5: ...Y Prior to operating the machine become fully familiar with the controls and the function of each Turn the engine off when making any adjustments on the tracks control linkages or hydraulic components Do not operate the machine from any position other than the front seats Make periodic checks for hydraulic or fuel leaks Make sure all passengers are seated before putting the machine in motion Do no...

Page 6: ... machine in poorly ventilated areas Never run the machine in a closed building DO NOT ENCLOSE THE CAB OR ADD SEAT BELTS o The Marsh Master is an amphibious machine For this reason we strongly advise customers to not modify the cab by adding hard doors or seat belts o If the machine were to capsize an enclosed cab with hard doors or seat belts could cause the operator or passenger to become trapped...

Page 7: ...ta plate is for a standard base machine with a full capacity of diesel and hydraulic oil but with no options attachments or personnel aboard Any additional weight added to the base machine must be subtracted from the limit IT IS THE OPERATOR S RESPONSIBILITY TO STAY WITHIN THE CONFINES OF THE LOAD LIMIT STATED ABOVE If there are any questions regarding load limits contact Coast Machinery LLC LOAD ...

Page 8: ... be transported to the jobsite we recommend using a large John boat hull airboat hull barge type skid or multiple machines Trailers can be used in some situations if the area allows WHEN THE MACHINE IS BEING USED TO TRANSPORT PERSONNEL IN THE REAR BED AREA ANY REAR ATTACHMENTS SUCH AS THE ANCHOR MASTER BACKHOE CUTTER SPRAY RIG ETC SHOULD BE REMOVED THE OPERATOR IS RESPONSIBLE FOR ENSURING THAT THE...

Page 9: ...take a reading The instrument will alarm at 10 LEL lower explosion limit If you get an alarm or a reading above 2 percent LEL go to Step 4 If you get a reading of 0 or 1 the pontoon is safe to weld cut or drill Keep the instrument running at all times when welding THE HEAT FROM WELDING CAN GENERATE GAS FUMES STOP WELDING IMMEDIATELY IF YOU GET AN ALARM AND GO TO STEP 4 STEP 4 Purge the pontoon wit...

Page 10: ...this condition there is very little load on the undercarriage Don t be afraid of deep water the Marsh Master is very stable in the fully amphibious mode and is designed to seamlessly transition from land to water Water also keeps the tracks running clean and prevents mud from clogging the tracks The Marsh Master will not operate in sticky heavy clay soils This type of mud builds up on top the pont...

Page 11: ...BUTE TO A LOSS OF BALANCE OR AN UNSTABLE MACHINE TRACK CONTROL LEVERS The left lever controls the left track and the right lever controls the right track The drive system is in neutral when the levers are in the detent position To make the machine move forward slowly move both levers forward The farther the levers are advanced the faster the machine travels With the levers all the way forward you ...

Page 12: ... DAMAGE TO THE MACHINE OR INJURY TO THE OPERATOR OR PASSENGERS COULD OCCUR Control Lever Lockout THROTTLE The throttle controls the engine speed Normal operating speed ranges between 1800 to 2200 RPM When running a cutter 1800 2000 RPM is the recommended range WARNING SERIOUS INJURY CAN OCCUR ...

Page 13: ...gine s coolant temperature Normal engine coolant temperature ranges 180 220 F Temperature above 220 F indicates an overheating engine and at 230 F a warning light will come on Overheating may arise due to low coolant level clogged radiator a loose engine belt malfunctioning cooling fans or other engine malfunctions If overheating occurs shut the engine down and determine the cause Do not continue ...

Page 14: ...tor It is important to keep clean fuel in system and never allow fuel system to run dry Allowing a diesel to run dry will require priming the engine See engine section for instructions on priming and bleeding the injection system ...

Page 15: ...VERRIDE SYSTEM Marsh Master engines are equipped with a low oil pressure shutdown When oil pressure drops below 7 5 psi the engine will kill If this occurs the engine can be restarted by holding the auto override button down Continue to hold the override button down to keep the engine running This should be done only in emergency situations Low oil pressure can be caused by low oil level extreme o...

Page 16: ...LOADING UNLOADING THE BUGGY Make sure that the tilt pin has been removed from the trailer ...

Page 17: ...int tie down system o Always cross over the straps We recommend that you DO NOT use a trailer with steel ramps o There is very little friction between the aluminum cleats and the steel ramps o This may cause the machine to slide o Placing a strip of rubber between the tracks and the deck will help with this problem ...

Page 18: ...aight down the bank Both tracks should enter the water at the same time This allows both the left and right pontoon to provide equal flotation Avoid entering the water at an angle which puts much of the load on only one pontoon The load should be lightened before entering the water and the machine should be operated at slow speeds Avoid high banks with steep drop offs and select a suitable entry p...

Page 19: ...y one track runs up on the object then the machine will tilt at an angle If the angle becomes too great or the momentum of the tilting motion becomes too great the buggy can capsize For this reason the operator should not continue over such an object but slowly back off of it and find a way around If the operator is running the tracks too fast this tilting action can happen quicker than the operat...

Page 20: ...or is responsible for assuring the proper positioning and operation of machine to ensure safe operation when entering or exiting water SERIOUS INJURY OR LOSS OF LIFE COULD OCCUR IF THE MACHINE TURNS OVER WHEN ENTERING EXITING OR OPERATING IN WATER OVERLOADING IMPROPER LOAD DISTRIBUTION WRONG ANGLE OF ENTRY OR EXIT A LEAKING PONTOON OR FAILURE TO INSTALL DRAIN PLUGS COULD CAUSE THE MACHINE TO TURN ...

Page 21: ...n climbing a grade the machine should be operated at to full throttle but with very slow track speed for maximum torque and power Avoid turning the machine sharply when ascending descending or running along a side hill ditch bank or uneven ground Turn slowly to avoid plowing the downhill track SERIOUS INJURY OR LOSS OF LIFE COULD OCCUR IF MACHINE IS NOT OPERATED PROPERLY WHEN OPERATING ON A STEEP ...

Page 22: ...r or straddle Avoid thick stands of cypress knees that can bend or break track cleats and increase track throw probability In a situation when climbing over or straddling an obstacle avoid turning the machine until it has been crossed When you are on an obstacle the track is point loaded meaning that all of the weight of the machine is concentrated at one point This point is where the track is eng...

Page 23: ...e along to the outside end of a track cleat in front of the sprocket Attach the other hook to the outside end of a cleat on the other track o If the track is thrown to the inside Attach one hook of a come along to the inside end of a track cleat in front of the sprocket Attach the other hook to some object such as a tree or another buggy that can serve as an anchor o Avoid attaching the hooks to t...

Page 24: ...ay clear of the machine should this occur Special caution must be taken not to damage body or track parts when applying force If you do not have a come along then a long pry bar is an alternative to force the track back over o Be careful not to damage the pontoon with the pry bar o Use extreme caution when using the pry bar near the drive sprockets THE PERSON USING THE PRY BAR MUST USE CAUTION WHE...

Page 25: ...ition NOTE The selector valve handle MUST be up in the WINCH position if no tools are hooked up to the low flow auxiliary circuit or if the circuit is not in use If the handle is in the down position with no tools connected to the quick connects the fluid will dead head and trip an Off Loading Valve circuit breaker which prevents overload and overheating To reset the Off Loading Valve the handle m...

Page 26: ... please see the cutter manual for operating details If you are using the high flow circuit for tools other than the cutter follow these operating instructions Start the engine and set the engine speed at idle Push the control lever fully forward to lower the crank arms o This is a safety feature installed for the cutter system o Having the 3 point hitch at too high of a position will flip a switch...

Page 27: ... 3500 psi but do not let it run continuously if it reaches this point The MM 2C LH model does not have a 3 point hitch therefore it is not capable of running a cutter The cutter control box found in the above mentioned models is not found in the MM 2C LH model The key switch that controls the high flow circuit is located on the left side of the instrument panel Simply turn the switch to on to run ...

Page 28: ...cuit selector valve must be in the up WINCH position LETTING THE CABLE OUT When letting the winch cable out you have two options You can use the hydraulics to run the motor which is a two man operation or you can free spool the motor which is a single person operation When hydraulically releasing the cable always make sure that someone is pulling on the cable to create tension This tension is nece...

Page 29: ...AFE DISTANCE FROM THE WINCH AND WIRE ROPE WHILE UNDER LOAD Even though it is equipped with a brake the winch should not be used to lift or suspend people or heavy loads in the air It is to be used for recovery purposes only WINCHING IN THE CABLE AFTER USE When you are finished using the winch you need to pay attention to how the cable is reeled in Simply winching the cable in with no one to guide ...

Page 30: ...IN THE SPOOL OR OTHER MOVING PARTS USE A TOOL SUCH AS THE HANDLE OF A HAMMER TO KNOCK THE CABLE TO THE SIDE NEVER PUT YOUR HANDS IN THE SPOOL AREA WHEN WINDING OR UNWINDING THE CABLE NEVER GRAB THE CABLE BY THE STOP BLOCK OR ANY POINT BEHIND THE HOOK WARNING SERIOUS INJURY CAN OCCUR ...

Page 31: ...of extreme emergency Locate by pass valve on each side of hydraulic pump This is the bolt with a hole through the head See Sundstrand manual for details Back out 2 turns to open by pass Tow unit to suitable or safe work area Re tighten by pass valves before running machine ...

Page 32: ... which the Marsh Master is to be used 9 Have any potential hazards been identified and a plan made to deal with those hazards such as a rain swollen river with a strong current steep banks stumps logs 10 Do the operator and passengers have all their PPE 11 Are the operator and passengers wearing life jackets when operating in or near water 12 Is machine equipped with a fire extinguisher and first ...

Page 33: ... Engine Oil and Filter See Engine Manual EVERY 50 HOURS Check Pontoons for Leakage Remove Drain Plugs EVERY 300 HOURS Top Off Bogey Tubes with Fresh Oil Change Engine Oil and Filter See Engine Manual Change Hydraulic Filters Filters on all C models have a service indicator Check Oil in Rear Shaft for Moisture Shaft should be filled half way with oil EVERY 500 HOURS Change Bogey Tube Oil See mainte...

Page 34: ...rade 8 Zinc Plated BOGEY WHEEL NUTS NUT SIZE 7 8 9 TORQUE 100 ft lbs Material Stainless Steel Nylock IMPORTANT Use Never Seez on shaft thread to prevent stainless on stainless galling OTHER BOLTS All other fasteners on Marsh Masters are 18 8 Stainless Steel We recommend using Never Seez when using stainless fasteners and bolts in combination due to the tendency for stainless on stainless galling B...

Page 35: ...SERVICE POINTS Outside Front Track Bearing Daily Inside Front Track Bearing Daily Control Linkages Grease Monthly Lubricate with Light 3 in 1 Oil Monthly Rear Shaft Filled Halfway with 30 Weight Oil ...

Page 36: ...Engine radiator must be kept clean to prevent engine from overheating ...

Page 37: ...take a reading The instrument will alarm at 10 LEL lower explosion limit If you get an alarm or a reading above 2 percent LEL go to Step 4 If you get a reading of 0 or 1 the pontoon is safe to weld cut or drill Keep the instrument running at all times when welding THE HEAT FROM WELDING CAN GENERATE GAS FUMES STOP WELDING IMMEDIATELY IF YOU GET AN ALARM AND GO TO STEP 4 STEP 4 Purge the pontoon wit...

Page 38: ...t The leak may be in the bottom of the pontoon allowing the water to drain back out over time With the drain plug removed attach the pressure tester to the drain plug boss Attach an air hose to the tester Quickly open and close the ball valve putting no more than 2 psi of air into the pontoon o CAUTION More than 2 psi can damage the pontoon Let it sit for a few minutes while observing the gauge o ...

Page 39: ...URCE OF IGNITION PENETRATES THE PONTOON DO NOT CUT DRILL WELD OR PERFORM ANY HEAT OR SPARK GENERATING ACTIVITY UNTIL THE PONTOON CHAMBER ATMOSHPHERE HAS BEEN TESTED BY A COMPETENT PERSON USING A PROPERLY CALIBRATED EXPLOSIVE METER FLAMMABLE GAS DETECTOR Before doing any work on pontoon contact the manufacturer to review the work procedure planned WARNING SERIOUS INJURY CAN OCCUR WARNING SERIOUS IN...

Page 40: ...od 1 Primary Test Place jack at jack plate Jack up one side of machine until the track is off the ground Examine the track clearance between the bottom of the 5th bogey wheel and the top of the rubber belt The distance should be between 1 2 to 1 Method 2 Field Test Place your foot on the track in front of the buggy and apply pressure Properly tensioned tracks will spring back Improperly tensioned ...

Page 41: ...he bearing housing to the front of the bearing pad is the same on both sides of the track See pictures below Re lock the bearing take up nuts but do not over tighten them Outside Inside TRACK CLEAT REPLACEMENT When a track is bent it can usually be straightened in a hydraulic press The only time that it cannot be straightened is if the cleat is twisted or cracked Roll the cleat in need of replacem...

Page 42: ... Install the cleat tightening the bolts to 100 in lb OTHER TRACK MAINTENANCE ITEMS INCLUDE Check periodically for loose bolts or broken or bent cleats Replace or repair immediately Remove any wire fishing line grass or other materials which wind up on the sprocket shafts ...

Page 43: ...lts are either loose or have come out NOTE A bad bogey tube will squeak BOGEY TUBE SERVICE PROCEDURE Required every 500 hours Make sure the oil in the tubes is at least 70 F It is best to change the oil in the tubes when the machine is level Place a container to catch the oil under the tube and remove the bottom plug Remove the 1 8 pipe plug from the end of the shaft of the tube o Requires 3 16 Al...

Page 44: ...apa part 715 1016 o Coast part SPNL 0227 Use the Alemite Lever Operated Oil Gun Model 4035 to pump SAE 50 synthetic oil into the tube until oil comes out of the top vent o Typically 30 32 pumps 4 4 5 FL OZ per tube Once the tube is full remove the Alemite fitting and immediately insert the 1 8 pipe plug using Loctite 545 thread sealant Repeat this process for every tube on the machine ...

Page 45: ...the bearing take up nuts on the front idler shaft Remove the bolts that fasten the drive lugs attached to the front end of the belt o You will need to take note of which way the belts are meshed The center belt should stay with the rear end of the track With a little prying the tracks should now be loose enough so that they fall on their own o You may want to tie a rope to the tracks so that you c...

Page 46: ...unter clockwise 2 turns max See Sundstrand manual p 7 for details o Now the rear shaft will rotate freely by hand Remove the nylock nuts washers and bolts from the rear sprockets Remove the rear sprockets and rear shaft spacers o While the shaft is exposed inspect the sprocket bolt holes for wear and the weld along the rings for any cracks Install the new sprockets making sure the split in the spr...

Page 47: ...t shaft and against the angled face of the pontoon o This will hold the front end in place Before starting the machine close the bypass towing valve by turning the 5 8 hex head bolt clockwise until it bottoms out Lay the rear track back on the sprocket and use the engine to run the track back onto the pontoon Use C clamps to hold each end of the belt together Put the washers lock washers and bolts...

Page 48: ...drive lugs can be reassembled in the gap between the track and the pontoon at the front of the buggy Apply 2 drops of blue Loctite 242 to both inserts in each drive lug and reinstall o Torque to 100 in lb Use procedure for adjusting track tension found in a previous section of this manual to re tension the tracks ...

Page 49: ...olt connecting the control rod to the control arm 3 Loosen the nut on the rod end 4 Turn the rod end a Clockwise to shorten b Counter clockwise to lengthen 5 Tighten the jam nut on the rod end 6 Reconnect the control rod to the control arm by fastening the bolt and nut 7 Refasten the panel plate that was removed to access the control rods Neutral Band Adjustment If the Marsh Master veers to one si...

Page 50: ...eft control lever 9 Draw a line 10 Move the lever backward until the pump begins to engage and draw a line 11 Turn off the engine 12 Measure the distance between the front two lines and the back two lines a These two measurements should be the same If so move on to step 18 b If the front two lines are closer together than the back two then the control rod is too short and needs to be lengthened c ...

Page 51: ... close to the correct position The machine must now be field tested to check whether or not it is actually tracking straight Use the following procedure to finalize the adjustment 1 Start the engine and bring it up to 2000 rpm 2 Pick a straight flat path with no obstacles and make sure that the tracks are clear of anything 3 Push both control levers fully forward 4 Pick a point off in the distance...

Page 52: ...d replace oil filter Refasten oil pan drain plug Refasten plug on the bottom of the machine Fill engine with oil through filler cap located on top of valve cover NOTE Oil can be any SAE 15W 40 that meets API CD specifications Engine Oil Capacity 2 gallons use the dip stick to check for proper amount Oil Filter Donaldson P554770 or equivalent Primary Fuel Filter Racor R20P or equivalent Secondary F...

Page 53: ...leeder and the fuel primer knob and attempt to crank the engine o If the engine cranks then you are finished o If the engine does not crank after 10 seconds continue on to the next step Holding back up with a 14 mm wrench crack the 17 mm injector line closest to the radiator and turn the engine over for 5 6 seconds If the engine does not crank retighten the first injector and move to the next inje...

Page 54: ...odels are equipped with a hydraulically driven cooling fan This fan is mounted on the passenger side engine cover The hydraulic fan pulls a vacuum on the engine compartment so the hoods MUST BE KEPT SHUT to maintain proper cooling All air flow through the AKG radiator oil cooler is produced solely by this fan When the fan switch is on Hi mode the hydraulic fan runs at full speed This mode may be n...

Page 55: ...e speed to idle o The engine speed may need to be slightly above idle for some machines to fully switch from forward to reverse Flip and hold the switch to the Rev position Bring the engine speed up to 2000 rpm Hold for about 10 seconds Lower the engine speed back to idle Release the fan switch and set to auto This reversing process should be repeated every 30 minutes depending on the environment ...

Page 56: ...it is imperative to use a 4 wire 5000 psi hose with high pressure fittings that meets the SAE 100R13 standard It is also imperative to use all necessary precautions to keep contaminants from getting in the system Thoroughly clean the fittings off before disconnecting cap the hoses and motor fitting and blow out the new hoses with high pressure compressed air or wash out with soap and water before ...

Page 57: ... drain hose from the quick connects Pull the selector valve handle back to the up position Remove the main oil filter and replace with a new filter A Models Coast 2AH5 E Donaldson P16 4375 C Models Coast 2CH5 E Donaldson P16 4378 Coat the gasket with a thin coat of oil before screwing the filter on Remove drain plug at bottom of oil reservoir Drain remaining fluid Replace plug Use Loctite 545 thre...

Page 58: ...stem to the drive motor and the outlet hose to the drive hose o Make sure that the hose coming from the drive motor is the inlet hose to the filtration system o The filter will have an arrow to indicate the direction of flow If the tracks are still on jack the buggy up Run the track FORWARD for 5 10 minutes with the engine at 1800 rpm and the control lever fully forward Reattach the hoses taking e...

Page 59: ...nt parts WHEN ORDERING PARTS PLEASE FURNISH ALL OF THE FOLLOWING Machine Type Machine Model Number Machine Serial Number Date Manufactured Month and Year All of the above can be found on the machine date plate Also include o Company name o Shipping address o Billing address o Name of person ordering o Telephone number o Purchase order number o Part number description and quantity of each item ...

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