445 EX Operators Manual

Table Of Contents ...
Timbco
Introduction
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2
EXL Series Nomenclature (4-Way Cab Leveling) . . . . . . . . . . . . . . . . . 0.3
Important Model & Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.11
Group 1 - Safety
Section 1.1 - General Safety Information

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2
“Safety Alert” Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2
Understanding Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2
The Careful Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.3
Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.4
Emergency Escape Markers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.6
Asbestos Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.7
Personal Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.8
Mounting and Dismounting Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.9
General Operator Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.9
Operation Precautions:
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.9
Before Beginning To Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.10
During Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.10
Parking The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.10
Service and Maintenance Precautions:
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.12
Towing The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.14
Cooling And Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.14
Fluid Penetration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.15
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.15
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.16
Fire Prevention in the Field:
Fire Prevention Tips in the Field. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.17
Fire Prevention in the Shop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.18
T.1 Table Of Contents

Group 2 - Operating
Section 2.1 - Starting the Machine

Before Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2
General Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.2
Starting the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.3
Check for Proper Control Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.3
Adjust Operator’s Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.3
Cold Weather Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1.4
In-Tank Hydraulic Oil Heater Elements (Optional) . . . . . . . . . . . . . . . . . 2.1.4
Track Drive Charge Oil Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . 2.1.4
Section 2.2 - Pro-Heat Instructions
Auxiliary Heater System (PROHEAT)(Optional). . . . . . . . . . . . . . . . . . . 2.2.1
Section 2.3 - Jump Starting
Starting with Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1

Jump Starting a Stalled Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2
Engine and Hydraulic Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2
Warm-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2
Section 2.4 - Operating Track Drives
Controlling the Track Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1

Forward Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1
Reverse Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2
Steering Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2
Steering Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3
Spot Turns (Counter-Track Rotation) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3
Low Speed Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4
Track (Parking) Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4
Section 2.5 - Attachment Operation
Controlling the Implements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.1

Control Pattern Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.1
Tree Counter (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.1
Implement Control Movements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.7
Section 2.6 - General Operating Instruction
Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2

Cleaning the Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2
Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2
Table Of Contents T.2

Group 3 - Frame/Chassis
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.2
Frame Maintenance:
Checking the Swing Stop System . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.6
Leveling Frame Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.8
Adjusting the Slack Adjusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.9
Adjusting the Swing Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1.10
Group 4 - Cab Environment
Section 4.1 - General Information

Cab Door:
Opening Cab Door from Outside . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2
Opening Cab Door from Inside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2
Door Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2
Storage Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.2
Door Safety Interrupt Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3
Cab Door Closed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3
Cab Door Opened. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3
Up-Time Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.3
Emergency Cab Escapes:
Removable Rear Cab Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.4
Kick-out Front Cab Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.4
Adjustable Operator’s Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.5
Cab Air/Conditioner/Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.6
Cab Pressurization (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.8
Interior Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.9
AM/FM Radio/Cassette Player . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.9
Cab Interior Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.9
Sliding Rear Cab Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.9
Section 4.2 - Dash Panel

Engine Oil Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2
Engine Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2
Return Filter Back Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2
Hydraulic Oil Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2
Murphy Power View Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.4
Low Hydraulic Oil Level Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.4
Charge Filter By-Pass Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.5
Disc Saw Engaged Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.5
System Armed Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.5
Reversible Radiator Cooling Fan Switch . . . . . . . . . . . . . . . . . . . . . . . . 4.2.5
Arm System Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.5
Work Lights Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.5
Low Speed Lock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.5
Ignition Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.5
Throttle (Potentiometer) Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.5

Group 4 - Cab Environment (continued)
Auxiliary Oil Cooler (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.6

Auxiliary Cab Floor Heater (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.6
Charge Oil Heater (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.6
Disc Saw Engage Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.6
Disc Saw Disengage Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.6
Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.6
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.6
Section 4.2 - PowerView Display

Key Pad Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1
First Time Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1
Main Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.1
Engine Configuration Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.3
Faults and Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.4
Contrast Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.7
Select Units. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.8
Setup 1-Up Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.8
4-Up Display Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3.10
Section 4.3 - IQAN Master Display Module (MDM)

Sub Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.1
Browsing in the Menu System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.2
Mode Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.3
System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.4
Display Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.5
Changing Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.5
Changing Back Light Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.6
Changing Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.7
Sound Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.8
Setting Date and Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.9
Measuring Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.10
Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.12
PWM Function Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.15
Group 5 - Hydraulics
Section 5.1 - Hydraulic System Description
Types of Hydraulic Systems:

Implement Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.3
Hydrostatic Track Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.3
Hydrostatic Charge Pump System . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.3

Group 5 - Hydraulics (Continued)
Hydraulic System Cleanliness

Keeping Hydraulic Oil and System Clean. . . . . . . . . . . . . . . . . . . . . 5.1.4
Types of Contaminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.4
Sources of Contaminates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.4
ISO Code Rating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.4
Concerns When Adding Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . 5.1.5
Concerns When Replacing Hydraulic System Components . . . . . . 5.1.5
Concerns When Replacing Hydraulic Filter Elements . . . . . . . . . . . 5.1.5
Section 5.1.6 - Hydraulic Tank and Filters
Hydraulic Oil Filtration System

Return Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.7
How Oil Is Filtered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.7
Changing Return Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.7
Filter Bypass and Why it Should be Avoided . . . . . . . . . . . . . . . . . . 5.1.7
The Return Filer Back Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . 5.1.8
Pressurized Hydraulic Tank:
Hydraulic Tank Pressurization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.9
Releasing Hydraulic Tank pressure . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.9
The Importance of Hydraulic Tank Oil Level:
Hydraulic Tank Sight Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.11
Low Hydraulic Oil Level Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.11
Hydraulic System Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.11
IQAN Hydraulic Temperature Compensation System . . . . . . . . . . . . . . 5.1.11
Hydraulic Oil Type and Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.11
Hydraulic Tank Turbo Boost Regulator . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1
Hydraulic Tank Safety Relief Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.3
Oil Cooler Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.3
Oil Cooler Thermal Bypass Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.3
Section 5.3 - Valve Bank Pressure Adjustments
Differential Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2

Load Sense Maximum Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . 5.3.3
Feed Reducer Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.5
Main Control Valve Port Reliefs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.6
System Pilot Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.8
Section 5.4 - Disc Saw Pressure Adjustments
Disc Saw Pump Stand-by Pressure Adjustment . . . . . . . . . . . . . . . . . . 5.4.1

Disc Saw Pump POR Pressure Adjustment Procedure . . . . . . . . . . . . . 5.4.2

Group 5 - Hydraulics (Continued)
Section 5.5 - Implement Pump Pressure Adjustments
Implement Pump Stand-By Pressure Adjustment Procedure . . . . . . . . 5.5.1

Implement Pump POP Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.2
Auxiliary Implement Pump Pressure Setting . . . . . . . . . . . . . . . . . . . . . 5.5.2
Common Pressure Port Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.2
POR Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.3
Section 5.6 - Hydrostatic Pressure Adjustments
Charge Pressure Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.1

Hydrostatic Main Relief Adjustment Procedures . . . . . . . . . . . . . . . . . . 5.6.2
Hydrostat Begin of Stroke Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.3
Track Drive Pump Null Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.3
Section 5.7 - Emergency Towing Procedure
Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.1

Towing Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.2
Short Distances (Towing Reliefs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.2
Medium Distances (Disable Track Final Drives) . . . . . . . . . . . . . . . . . . 5.6.3
Group 6 - Electrical
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.2
Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.2
Points to Bear in Mind When Welding . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.3
Locating Electrical Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.3
Additional Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.3
Main Electrical Center, Cummins Engine . . . . . . . . . . . . . . . . . . . . . . . . 6.1.4
Main Electrical Center, SisuDiesel Engine . . . . . . . . . . . . . . . . . . . . . . . 6.1.5
Group 7 - Fire Extinguisher
Fire Extinguisher Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2

Recharging Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2
Fire Suppression System (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.3

Group 8 - Service & Maintenance
Section 8.1 - General
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.2
Special Component Break-In Schedule . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.4
Preventive Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.5
Lubrication Points Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1.6
Section 8.2 - Daily Maintenance
Visual Inspection:
Check for Loose or Missing Fasteners . . . . . . . . . . . . . . . . . . . . . . . 8.2.1
Check Track Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.1
Check Hydraulic Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.1
Clean Flammable Debris From Exterior Surfaces . . . . . . . . . . . . . . 8.2.3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.3
Component/System Checks:
Check Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.6
Drain Water/Sediment At Primary Fuel Filter . . . . . . . . . . . . . . . . . . 8.2.6
Check Engine Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.7
Adding Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.7
Check Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.9
Check Fuel Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.10
Check Fire Extinguisher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.11
Check Air Cleaner Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . 8.2.12
Check Hydraulic Oil Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2.13
Section 8.3 - Service as Required
Change Air Conditioner/Heater Unit Blower Filter . . . . . . . . . . . . . . . . . 8.3.1

Change Cab Pressurization Intake Filter (Optional) . . . . . . . . . . . . . . . . 8.3.2
Bleeding the High Pressure Track Drive Circuit . . . . . . . . . . . . . . . . . . . 8.3.3
Swing Bearing Service Tolerance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.4
Structural Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.6
Leveling Component Slack Adjusters . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.7
Section 8.4 - 50 Hour Checks
Test Door Safety Interrupt System Operation . . . . . . . . . . . . . . . . . . . . 8.4.1

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.2
Swing Bearing Race . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.2
Swing Stop Lead Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.2
Optional Cab Leveling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.2
Check Pump Drive Transmission Oil Level . . . . . . . . . . . . . . . . . . . . . . 8.4.3
Swing Gearbox Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.3
Track Final Drive Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.3
Torque Tapered Hub Retaining Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.4
Run Air Conditioner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.4
Check Cab Window Emergency Escapes . . . . . . . . . . . . . . . . . . . . . . . 8.4.4
Table Of Contents T.7 Table Of Contents

Group 8 - Service & Maintenance (Continued)
Check Engine Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.1

Check Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.2
General Inspection Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.2
Check Alternator Belt:
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.3
Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.3
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.3
Check A/C Compressor Belt:
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.3
Tension Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.3
Replacement & Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.3
Check Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.5
Change Engine Oil & Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.1

Change Fuel Filters:
Changing Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.3
Bleeding Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.3
Torque Specific Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.4
Swing Motor Mounting/Swing Bearing Mounting Bolts. . . . . . . . . . . . . . 8.6.4
Hydraulic Tank Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.5
Track Frame Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.5
Track Shoe Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.5
Track Rock Guard Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.6
Check Air Conditioner Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.6
Clean Air Conditioner Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.8
Check Engine Coolant Atifreeze Concentration . . . . . . . . . . . . . . . . . . . 8.7.1

Check Radiator Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.2
Change Air Cleaner Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.3
Change Hydraulic Oil Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.4
Return Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.4
Suction Strainers (Cleanable). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.7
Track Drive Charge Pressure Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.7
Check slack Adjusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.8
Secure & Clean Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.1

Change Pump Drive Transmission Oil . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.1
Change Swing Gearbox Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.3

Group 8 - Service & Maintenance (Continued)
Flush Track Final Drive Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.1

Flush Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.2
Draining The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.2
Flushing The Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.4
Filling The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.4
Clean Hydraulic Tank & Change Hydraulic Oil. . . . . . . . . . . . . . . . . . . . 8.9.4
Hydraulic System Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.8
Check Engine Valve Lash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9.8
Group 9 - Troubleshooting
Section 9.1 - General Troubleshooting Information
Troubleshooting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.2

Simplified Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.4
The 7 Step Troubleshooting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.4
Other Helpful Troubleshooting Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.5
Section 9.2 - Troubleshooting Track Drives
Track Drives Do Not Work Implements are O.K. . . . . . . . . . . . . . . . . . . 9.2.1

Track Drives Do Not Work And No Charge Pressure . . . . . . . . . . . . . . 9.2.2
Both Track Drives Slow or Sluggish in Both Directions . . . . . . . . . . . . . 9.2.3
One Track Drive Slow or Sluggish in Both Directions . . . . . . . . . . . . . . 9.2.4
One Track Drive Slow or Sluggish in One Direction . . . . . . . . . . . . . . . 9.2.6
Track Drives Lose Pressure When Running Hot . . . . . . . . . . . . . . . . . . 9.2.7
Machine Creeps in Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.8
Not Tracking Straight in Both Directions . . . . . . . . . . . . . . . . . . . . . . . . 9.2.9
Not Tracking Straight in One Direction . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.10
Track Drive Brakes Will Not Release . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.11
Track Brakes Slipping or Will Not Hold . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.12
Track Brakes Slow to Apply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.12
Low Speed Lock Will Not Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.13
Low Speed Lock Slow or Sluggish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2.14
Section 9.3 - Troubleshooting Engine Starting
Engine Stalls at Start Up or Turns Over Hard . . . . . . . . . . . . . . . . . . . . 9.3.1

Engine Stalls Easily During Normal Operation . . . . . . . . . . . . . . . . . . . . 9.3.2
Engine Loses Power After Running for a Short Time . . . . . . . . . . . . . . 9.3.3
Engine Surges or “Hunts” Even When Not Operating a Function . . . . . 9.3.4

Group 9 - Troubleshooting (Continued)
Section 9.4 - Troubleshooting Electrical
Engine Will Not Start and No Electrical Will Work . . . . . . . . . . . . . . . . . 9.4.1

Engine Will Not Start, Other Electrical O.K. . . . . . . . . . . . . . . . . . . . . . . 9.4.2
Starter Turns, But Engine Does Not . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4.3
Starter Motor Continues to Run After Engine Starts . . . . . . . . . . . . . . . 9.4.4
Noisy Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4.4
Lights Do Not Work, All Other Electrical O.K. . . . . . . . . . . . . . . . . . . . . 9.4.5
Electrical Oil Fill Pump Will Not Work. . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4.6
Section 9.5 - Troubleshooting Air Conditioning/Heater
Both Air Conditioner and Heater Will Not Work . . . . . . . . . . . . . . . . . . . 9.5.1

Air Conditioner Works, But No Cold Air Comes Out . . . . . . . . . . . . . . . 9.5.1
Heater Works But No Warm Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5.3
Section 9.6 - Troubleshooting Disc Saw Attachment
Disc Saw Will Not Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6.1

No Stand By Pressure, No Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6.2
Disc Saw Circuit Will Not Produce Full Pressure . . . . . . . . . . . . . . . . . . 9.6.3
Disc Saw Circuit Loses Pressure When Running Hot . . . . . . . . . . . . . . 9.6.4
Poor or Erratic Performance of Disc Saw. . . . . . . . . . . . . . . . . . . . . . . . 9.6.5
Disc Saw Blade Rotates When Shut Off . . . . . . . . . . . . . . . . . . . . . . . . 9.6.5
Section 9.7 - Troubleshooting Implement Circuit
No Implement Functions Work, Track Drives O.K.. . . . . . . . . . . . . . . . . 9.7.1

Implement Function Slow and No Power, Track Drives O.K.. . . . . . . . . 9.7.2
Implement Functions Not Smooth, “Jerky” . . . . . . . . . . . . . . . . . . . . . . . 9.7.3
Single Function Slow or Sluggish in Both Directions . . . . . . . . . . . . . . . 9.7.4
Electric Operated Function Will Not Work . . . . . . . . . . . . . . . . . . . . . . . 9.7.6
Electric Operated Function Slow or Sluggish in One Direction . . . . . . . 9.7.7
Cab Level Cylinder Retracts Without Control Input . . . . . . . . . . . . . . . . 9.7.8

Appendix A - Machine Specifications
Engine Identification & Specifications. . . . . . . . . . . . . . . . . . . . . . . . A.2

Engine Oil & Coolant Information . . . . . . . . . . . . . . . . . . . . . . . . . . . A.6
Hydraulic Oil Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.8
Track Final Drive Oil Information . . . . . . . . . . . . . . . . . . . . . . . . . . . A.11
Machine Dimensional Specifications . . . . . . . . . . . . . . . . . . . . . . . . A.12
Boom Sweep Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.18
Implement Circuit Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.22
Undercarriage Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.27
Upper Structure Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.30
Cylinder Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.31
Operator’s Environment Information . . . . . . . . . . . . . . . . . . . . . . . . . A.32

Chapter 0 - Introduction
EX/EXL Series Feller-Buncher

(EXL Includes 4-Way Cab Leveling)
Komatsu Forest
* 1075 Airport Road / P.O. Box 516

Shawano, WI 54166 USA
Tel +715.524.2820
Fax +715.526.2347
Introduction The instructions and procedures in this manual
cover the basic machine model furnished with the
The purpose of this manual is to familiarize the new most commonly used options. Pictorial information
owner/operator with the many features of the in some areas may vary slightly from the actual
EX/EXL Series Feller Buncher (EXL Includes the machine on hand. This variation, however, does
4-Way Cab Leveling option) so that they may not have any impact on the accuracy of the written
become proficient in safe operation and periodic information.
maintenance of the machine. This manual
provides detailed safety information, operating and The information contained in this manual is current
maintenance instructions, and equipment data. at the time of publication, however, continuing
product improvement may result in changes to the
Throughout this manual, references are made to machine which are not covered. Should you require
the front, rear, left and right sides of the machine. information regarding such changes or any other
Consider the sprocket end of the tracks as the rear information on the machine, please contact your
of the machine. Determine the left and right sides servicing dealer.
when sitting in the operator’s seat facing away from
the track sprockets.
Rear
Front
Track
Sprocket
Left Right
Feller-Buncher Nomenclature (4-Way Cab Leveling)
Hydraulic Oil Tank
Operator’s Cab
(ROPS/FOPS/OPS/WCB)
Main Boom
Stick Boom
Fuel Tank
Undercarriage
Main Boom
Operator’s Cab
(ROPS/FOPS/OPS/WCB)
Engine Compartment
Emergency
Escape Hatch
Hydraulic Oil Tank
Pump Compartment
Track Motor
Compartment Swing Bearing
Figure 2: General Nomenclature (Typical)

Return Filter Guard (Removed) Radiator Fill Spout Access Cover (Open)
Engine Compartment
ROPS Panel
Hydraulic Air Cleaner

Oil Tank / Muffler Area
Louvered Swing-Out Radiator Guard (Open)
Swing
Motor
Swing Bearing
Engine Pivot Guard (Open)
Figure 3: Upper Turntable Nomenclature - Side View (Less Cab and Booms)
Chapter 0 - Introduction Page 0.1.4

Engine Compartment
ROPS Panel
Hydraulic
Engine and Pump Access Doors (Closed) Oil Tank
Boom Side
Pump Panel
Swing
Motor
Main Boom
Pivot Point
Swing Bearing Upper Turntable

Perforated Swing-Out Engine Guard (Open)
Base Plate
Swing-Out Pump Access Guard (Open)
Figure 4: Upper Turntable Nomenclature - End View (Less Cab and Booms)
Page 0.1.5 Chapter 0 - Introduction

Air Conditioner Drier Inspection
Cover (Open)
Optional Skylight
Fire Suppression System Mounting Position

(Optional)
Front
Mount
Exterior
Lights
Door
Latch
Fuel
Tank
Flush Mount
Flush Mount Cab Exterior Lights
Exterior Light Door
Figure 6: Cab Nomenclature - Side View

Air Conditioner Condenser Access
Cover (Open)
Rear Mount
Exterior Lights
(Standard)
Lift Eye
Emergency Escape Hatch

Oil Cooler Swing Out (Covered for shipping)
Door Latch
Swing Out Auxiliary Oil Cooler
Auxiliary Oil Cooler

(Opened)
Hydraulic Control Valve Location
Figure 6: Cab Nomenclature - End View

Boom Elbow Boom Elbow
Hose Guard Pivot
Main Boom
Stick Boom
Main Boom
Lift Eye
Main Boom
Tube lines
Stick Boom
Lift Eye
Tool Tilt
Stick Boom Cylinder
Cylinder
4-Bar
Linkage
Main Boom
Cylinder
Stick Boom
Tube lines
Main Boom
Pivot Point
Cutting Attachment
(Optional Bar Saw
Attachment Shown)
Figure 6: Boom Nomenclature

Lower Turntable
(Casting)
Track Motor Compartment Cover (Open)

Intermediate
Leveler
Level
Cylinder (2)
Fuel Tank
Fill
Track Motor Fuel Tank

Compartment
Frame Clean
Level out
Cylinder
Anchor
Figure 7: Frame & 4-Way Leveling Nomenclature

Replaceable
Slider Track Tensioner Cover (Open)
Track
Idler
Lower Track
Rollers
Track Sprocket
& Final Drive
Track Rock
Guard
Track Chain
Assembly
Track Shoe
Figure 9: Undercarriage Nomenclature

Important Model
& Serial Numbers
For quick reference, use the lines provided below
each illustration to record important manufacturer,
model and serial number information for your
Feller-Buncher and its major components. These
serial numbers will allow your dealer to correctly
identify your machine and its components when
filling replacement parts orders or providing service
information.
Engine (Typical)
Manufacturer:__________________________________
Model:________________________________________
S/N#:_________________________________________
Feller-Buncher
Model:________________________________________
S/N#:_________________________________________
Implement Pump (Typical)

NOTE: The “CE” certification marking is located on Manufacturer:__________________________________
the machine serial number placard.
Model:________________________________________
S/N#:_________________________________________
See your cutting attachment

manufacturer’s manual
Cutting Attachment
Manufacturer:__________________________________
Model:________________________________________ Track Drive Pump (Typical)
S/N#:_________________________________________ Manufacturer:__________________________________
Model:________________________________________
S/N# (Left):____________________________________
S/N# (Right):___________________________________

Disc Saw Pump (Optional) Undercarriage (Typical)
Manufacturer:__________________________________ Manufacturer:__________________________________
Model:________________________________________ Model:________________________________________
S/N#:_________________________________________ S/N# (Left):____________________________________
S/N# (Right):___________________________________
Swing Motor
Manufacturer:__________________________________ Track Final Drive (Typical)
Model:________________________________________ Manufacturer:__________________________________
S/N#:_________________________________________ Model:________________________________________
S/N# (Left):____________________________________
S/N# (Right):___________________________________
Swing Motor Gearbox
Manufacturer:__________________________________
Track Motor (Typical)
Model:________________________________________
Manufacturer:__________________________________
S/N#:_________________________________________
Model:________________________________________
S/N# (Left):____________________________________
S/N# (Right):___________________________________

Chapter 1 - Safety
Safety
General Safety Information

Safety Decals On Machine
Safety Rules & Precautions
Fire Safety
General Understanding Signal Words
Our policy is to produce products that are safe In this manual and on the safety decals installed
and reliable. However, even when using well on the machine, the “Safety Alert” symbol is always
engineered equipment, there will always be an accompanied by a signal word to identify the haz-
element of risk in heavy equipment operation. ard level. Understand the signal words DANGER,
WARNING, and CAUTION.
Most accidents involving heavy equipment
operation, maintenance or service result from
failure to follow basic safety rules and precau-
tions. To minimize the risks and promote safety at Identifies the most serious safety hazards
all times, the safety group in this manual details a where failure to follow the safety message
number of safety rules which should always be would result in high probability of death or
followed and obeyed. serious personal injury.
Study all the safety messages carefully, remember

them and apply them when operating, maintaining
or servicing this machine.
Identifies that a safety hazard exists where
“Safety Alert” Symbol failure to follow the safety message can
result in death or serious personal injury if
proper precautions are not taken.
Identifies that a hazard exists where failure

to follow the safety message can result in
personal injury or equipment damage if the
proper precautions are not taken.
The signal words DANGER, WARNING and

CAUTION are used to identify personal safety
hazards and some equipment cautions. In this
manual, the signal word NOTICE is also used to
Figure 1 - Safety Alert Symbol identify hazards that may damage the machine or
its components.
The “Safety Alert” symbol is used where appli-
cable throughout the text and on the machine to
indicate important personal safety measures and
equipment cautions. Carefully read, understand Follow procedures outlined to avoid damage to
and follow these instructions to prevent hazardous the machine or its components as a result of
situations, possible injuries to personnel or damage use or improper procedures.
to the machine.
Chapter 1 - Safety Page 1.1.2

The Careful Operator
The careful operator is one who studies,
remembers, and applies the basic safety rules
and all safety messages found in the manuals and
on the equipment being operated, maintained or
serviced. This person also has the required
training, skills and tools to operate this machine
and/or perform the required maintenance and
service procedures.
The factory cannot anticipate every possible

circumstance where a potential hazard may exist.
Therefore, the safety messages and equipment
cautions found in this manual and on the
machine are not all inclusive. If an operating
technique, maintenance or service procedure, tool,
etc... not specifically recommended by the factory is
used, it is your responsibility to insure it is safe for
yourself and others. You should also be sure the
machine will not be damaged or made unsafe by
the operation, maintenance procedures or service
procedures you choose.
WHEN IT COMES TO SAFETY, NOTHING WILL

EVER REPLACE A CAREFUL OPERATOR.
SAFETY FIRST !
Page 1.1.3 Chapter 1 - Safety

Safety Decals
There are a number of specific safety decals
installed on the machine. The location and safety
message of each is reviewed here. Study and
remember the locations of all safety messages.
All safety and equipment caution decals should be

kept clean and readable. Clean decals with a mild
detergent and water only. Never use solvents to
clean decals or damage to the decal will result.
For your own safety and the safety of others

it is your responsibility to replace any missing,
damaged or otherwise unreadable safety or Located on the cab door interior panel.
equipment caution decals. If a component with a
decal is replaced, be sure a new decal is installed.
Full rotation lateral tilt heads are capa-

ble of endangering the machine opera-
tor as well as persons on the ground.
Follow all safe operation and maintenance

procedures found in owner’s manuals when
inspecting, maintaining, and operating these
types of heads. Do not allow discharged
debris to be projected towards the cab.
Thoroughly inspect the disc, saw teeth,

tooth holders, and mounting hardware regu-
larly. Any damage should be repaired before
work begins. Also inspect the front window
Located on left side of cab weldment near swing motor
for scratches that reduce the strength of the
(shown), at all pivot points of the frame and, when
equipped, at all cab leveling component pivots. window. Replace front window if scratched.
Operate full rotation lateral tilt heads with

extreme caution. Death or serious injury
can result.
CRUSH ZONE. Keep clear to avoid personal

injury or death.

Located on hydraulic tank fill spout guard Located behind operators seat.
Check operation of emergency escape

The hydraulic tank is under pressure.
hatch every 50 hours. Loosen the star knob
2-3 turns and push/pull on escape hatch.
Vent tank before removing fill cap or Serious
The hatch should not stick. If hatch sticks,
personal injury could result.
remove it completely and apply “anti-seize”
to rubber seal. Re-install and tighten the
star knob.
Located on upper right horizontal member inside the cab
Located on upper left horizontal member inside the cab
When fueling, servicing or repairing, set

booms on ground and shut down engine.
Never operate the machine without the Use of this ROPS in a damaged, modified
door closed and seat belt fastened. or abused condition or with prior overturn
is unsafe and the operator protection is
QUALIFIED OPERATORS ONLY. Study no longer suitable and must be replaced.
Operator’s Manual. Injury or death can Any alterations, modifications, add-ons
result from untrained operation. or repair without the written consent of the
company will void the product’s warranty,
liability and certification.

Located in several places around engine fan shroud Located on the side of the hydraulic tank near the boom
Fan guard must be bolted in place before Do not remove the tank support with the
operating unit. hydraulic tank installed.
If the tank support must be swung out of

the way, be sure the hydraulic tank is sup-
ported by other means.
Serious personal injury or damage to the

equipment could result.
Emergency Escape Markers
Located in several places around engine fan shroud
Keep clear of all moving parts. Serious per-

sonal injury could result.
Located above the removable rear window

outside and inside the cab. Also located above the
kick-out front window inside the cab

Asbestos Information
The track system used on your Hydro-Buncher, and Use caution to avoid breathing asbestos dust
factory approved replacement parts, are asbestos that may be generated by handling components
free. We recommend the use of only genuine OEM containing asbestos fibers. If asbestos dust
replacement parts in the track system. If non-OEM is inhaled, it can be hazardous to your health.
replacement parts containing asbestos are used, Aftermarket (non-OEM) components that could
the procedure must comply with all applicable rules be installed in Hydro-Bunchers that may contain
and regulations for the work place and environment asbestos fibers include track brake pads, brake
such as (in USA) OSHA requirements as set forth band and lining assemblies and some gaskets. The
in 29 CFR 1910.1001 plus the following guidelines asbestos in these components are usually bound in
should be used when handling these parts and a resin or sealed in some way. Normal handling is
asbestos debris. not dangerous as long as airborne dust which con-
tains asbestos is not generated.
If dust which can contain asbestos is present, there

are several common sense guidelines that should
be followed:
The procedure must comply with all applicable rules

and regulations for the work place and environment
such as (in the U.S.A.) OSHA requirements as set
forth in 29 CFR 1910.1001.
Never use compressed air for cleaning asbestos

containing materials.
Avoid brushing or grinding of asbestos containing

materials.
For clean up, use wet methods or a vacuum equipped

with a high efficiency particulate air (HEPA) filter.
Use exhaust ventilation on permanent machining

jobs.
Wear an approved respirator if there is no other way

to control the dust.
Follow environmental rules and regulations for

disposal of asbestos.
Avoid areas where asbestos particles might be in

the air.

Personal Precautions
Keep a comprehensive and complete first aid kit

in an easily accessible place on the machine at
all times.
Use recommended protective clothing and safety

devices such as gloves, safety boots, safety hat,
reflective vests and eye, ear and respiratory
protection as required by job conditions.
Avoid loose fitting clothing, loose or uncovered long

hair, jewelry and loose personal articles.
Do not rush. Walk, do not run.

Maintain a charged fire extinguisher on the
Use only approved signaling practices. Only accept machine AND KNOW HOW TO USE IT.
signals from one designated person.
General Operator Precautions

Carry no passengers. The machine is provided and
approved with seating for the operator only.
Keep floors, steps and running boards clean and free

of oil, ice, mud and loose objects.
Properly secure all loose items not part of the machine

such as tools, maintenance items, and lunch boxes.
Inspect the machine daily for signs of damage, unusu-
al wear, fluid leaks or faulty operation.
Clean out debris from high heat areas, such as the

engine compartment, frequently during the working
Comply with the instructions in this manual and shift and always after quitting operations for the day.
your company’s regulations for the operation of
this machine.
Never remove any element of the engine’s exhaust
YOU MUST BE FULLY TRAINED to operate this system or any safety covers or devices from the opera-
machine and its felling attachment.
tional machine.
Danger:
Get to know the capabilities and limitations of the
All operators must read and understand the machine and learn the most efficient operating
content of this manual and the manual for safe techniques.
operation of any attachment before operating
the machine.

Mounting And Dismounting EMERGENCY ESCAPE: An emergency escape is
Precautions provided on all Hydro-Bunchers. See Section 2.2 for
additional information.
Use tread plates and handles provided with at
least three points of support (two hands and one Report all required repairs.
foot or two feet and one hand) when mounting and
dismounting the machine. Do not climb, mount or
dismount machine in any other fashion. Before Starting Engine
Always face machine when mounting and

dismounting.
NEVER attempt to mount or dismount a moving

machine.
NEVER jump from the machine.
Do not use the controls or operator’s seat armrest

as a hand hold when mounting or dismounting the
machine.
Do not carry tools or other materials with you as you Diesel exhaust fumes contain elements that are
mount or dismount the machine. Get assistance or hazardous to your health. Always run engine in
use a hand line to raise and lower materials. a well ventilated area. If in an enclosed space,
vent exhaust to the outside.
Operation Precautions
Be sure no one is working on, underneath or close
General to the machine. KEEP ALL PERSONNEL CLEAR.
Check the machine to insure that all doors, pan-

els, and access covers are installed and properly
secured.
Start machine ONLY from the operator’s seat.

Never short across the starter terminals or
batteries.
Adjust the operator’s seat correctly. Full foot pedal

travel must be obtained with your back firmly against
the seat back.
If working conditions require lighting, be sure

machine is adequately equipped with lighting and
that it is in good working condition.
The operator’s seat is equipped with a seat belt.
Use this belt at all times when operating the When ready to start engine, be sure all controls
machine. are positioned as specified in the engine starting
instructions in Section 4.1.
Operate the machine controls only from a seated
position in the operator’s seat. When the engine is running, allow no personnel
in the areas of the machine where they may be
Operate the machine only when physically fit and crushed by moving components.
not under the influence of alcohol or drugs.

Before Beginning To Work
Fasten safety belt.
Full rotation lateral tilt heads are capable of
endangering the machine operator as well
Always allow for adequate warm-up of the engine
as persons on the ground.
and hydraulic oil, particularly when ambient
o o
temperature is below 32 F (0 C). Refer to cold
Follow all safe operation and maintenance
weather starting instructions in Section 4.1.
procedures found in owner’s manuals
when inspecting, maintaining, and operat-
ing these types of heads. Do not allow
discharged debris to be projected towards
Check operation of emergency escape
the cab.
hatch every 50 hours. Loosen the star
knobs 2-3 turns and push/pull on escape
Thoroughly inspect the disc, saw teeth,
hatch. The hatch should not stick. If hatch
tooth holders, and mounting hardware
sticks, remove it completely and apply
regularly. Any damage should be repaired
“anti-seize” to rubber seal. Re-install and
before work begins. Also inspect the
tighten all star knobs.
front window for scratches that reduce the
strength of the window. Replace front win-
Check all controls for proper operation. If a control
dow if scratched.
is malfunctioning, stop immediately and have the
problem corrected before resuming work.
Operate full rotation lateral tilt heads with
extreme caution. Death or serious injury
Be aware of all obstacles and hazards around you; can result.
stumps, slopes, ditches, overhead wires, etc.
Maintain a safe operating distance between the
Before moving the machine, check position of machine and other equipment and personnel.
tracks. Normal forward travel is with the idlers in
front of the cab and sprockets to the rear. When the NEVER swing the boom or felling attachment above
cab is turned such that the sprockets are in front of the heads of bystanders.
the cab, forward actuation of the pedals will cause
the direction of movement to be over the operator’s When moving the machine, watch that enough
shoulder. clearance is available on both sides and above
the boom. Extra clearance may be required
During Machine Operation particularly where ground is uneven.
Adhere strictly to all regulations at the work site per- Maintain a safe operation distance from hazards
taining to the operation of this machine. such as steep drop-offs, deep ditches and areas
where the ground may be unstable and allow the
Know the capacities and limitations of the machine machine to slide or tip.
and DO NOT exceed them. Lift capacity decreases
as the load moves away from the machine. Drive machine with care and at speeds compat-
ible with job conditions. Use extra care on rough
If a failure occurs that causes the loss of imple- ground, slopes and when turning the machine.
ment control, steering, brakes or engine, stop
machine motion as quickly as possible, lower felling
attachment to the ground and shut down machine.
Leave machine parked until repairs can be made or
the machine can be towed.
Keep eye contact on the felling attachment and its

immediate surroundings at all times when cutting
and handling a tree.

Keep felling attachments close to ground level, Parking The Machine
approximately 15” (40 cm), while traveling.
When parking the machine, select a spot where
the ground is level. Do not park on a hillside or an
Keep loads close to the machine when traveling or
incline.
swinging.
When in freezing conditions, planks can be placed
Avoid conditions and operating practices that may
under the machine to prevent the tracks from
lead to tipping or overturning the machine.
freezing into the ground.
On steep slopes, travel as straight up and down as
Lower cutting felling attachment to the ground and
possible and always carry any tree load as upright
shut down the engine. Remove ignition key and
(vertical) as possible.
place in safekeeping.
Always lower the booms so that the felling
If the machine is to be parked for a greater length
attachment rests on the ground whenever
of time, such as overnight, switch off the master
operation is stopped; regardless if the engine is
electrical disconnect or disconnect the positive
running or not.
(+) battery cable.
Use a recommended vehicle when transporting the
machine between job sites.
When transport of machine is required, make sure

that it is adequately secured to the vehicle. Even
though the machine’s track parking brakes are fully
engaged, block the tracks to prevent movement
during transport.
When transporting the machine, know and use

the signaling devices required by the machine.
Provide an escort for transporting the machine
when required.

Service And Maintenance
Precautions
General
Keep your head, hands, and feet clear of all

moving parts.
Before performing maintenance or repairs on the

machine, consult this manual and follow the
recommended procedures.
Unless otherwise specified, all maintenance or

repair procedures should begin as follows:
1) Position machine on level ground.
2) Lower felling attachment to the ground.
3) Shut down engine. Remove ignition key

and place in safekeeping. Keep yourself, all objects and tools away from
moving fan blades. Fan blades will cut or throw
4) Switch off master electrical disconnect or any object dropped or pushed into them.
disconnect the positive (+) battery cable.
Run the engine only when it is required for test or

adjustment purposes.
Support components when working beneath

them. Do not depend on hydraulic cylinders for
Diesel exhaust fumes contain elements that are support. A component may fall if a control is
hazardous to your health. Always run engine in moved or a hose breaks.
a well ventilated area. If in an enclosed space,

Always use the proper tools for the job. Repair or
replace any broken or damaged tools, including
lifting equipment, immediately.
When servicing or replacing hardened steel pins,

use a brass drift or other suitable material between
the hammer and pin if it must be driven into the
pivot. Use safety glasses or other suitable eye
protection.
DO NOT make adjustments while the machine is

moving or the engine is running unless otherwise
specified to do so.
DO NOT remove the tank support with the
hydraulic tank installed. If the tank support must
be swung out of the way, be sure the hydraulic
DO NOT change the pressure setting on any
tank is supported by other means. hydraulic valve without authorized instruction.
Check electrical connections daily. Have any loose

connections or damaged wiring tightened, repaired
or replaced immediately.
Use all cleaning solutions with care. Avoid

breathing vapors and contact with eyes and skin
Keep all fuels and maintenance items in properly

marked containers.
Place all fuel or oil soaked rags, waste material,

debris and other flammable items in a properly
marked protective container stored in a safe place.
At operating temperature, the engine, exhaust
system components, cooling system Inspect the machine for missing, unreadable or
components and hydraulic system components damaged safety decals. Keep safety decals clean.
are HOT. Any contact can cause severe burns.
The maximum allowed air pressure used for

cleaning purposes should not exceed 30 psi
(205 kPa).
Always disconnect both the positive RED and

negative BLACK battery cables before welding
on the machine to protect sensitive electrical
components.
In addition to the battery also disconnect the fol-

lowing:
• IQAN control box and MDM module
• Maxi control computers (If equipped)
Pressurized air can cause personal injury. • Pro-Heat (Optional engine heater)
When using pressurized air for cleaning, wear
protective clothing, face shield and shoes. • Fire Suppression Control Box (Optional)

Towing The Machine Check coolant level only with the engine shut down
and the radiator cap cool enough to remove with
If it becomes necessary to tow the machine, do not your bare hand.
exceed recommended towing speed. Be sure the
towing equipment has sufficient braking capacity to
Anti-freeze solutions used in the cooling system
stop the towed load. If the towed machine cannot
may contain alkali that can cause personal injury.
be braked, a tow bar must be used or two towing
Avoid contact with skin, eyes and mouth.
machines must be used - one in front pulling, and
the other in the rear retarding. Avoid towing over
long distances. See Section 4.5 for additional Do not bend or install bent or damaged hydraulic
information. hoses and tube lines.
Do not strike hydraulic hoses or tube lines.

Cooling And Hydraulic System
Be sure all hose clamps, guards and protective
wrapping is installed correctly to prevent vibration
and rubbing which could lead to hose failure.
Evidence of Kinking
Chaffing or Cuts, or Crushing
Wire Exposed
Damaged or
Leaking Fitting
Pressure can be maintained in system circuits

long after the engine and pumps have been shut
down. Release trapped pressure in hydraulic,
fuel, and cooling system lines before performing
Localized
any maintenance or repair procedures. Ballooning
Check hoses carefully. Do not use your

bare hands to check for leaks. See “Fluid
Penetration”. Tighten all connections to recom-
mended torque. Replace if any of the following
are found:
- End fittings damaged or leaking.
- Outer covering chafed or cut and wire

reinforcing exposed.
- Outer covering ballooning locally.
- Hose shows evidence of kinking or crushing.
At operating temperature, the radiator and

hydraulic tank are HOT and under pressure.
Allow these components to cool to the touch
before servicing.
Loosen radiator cap slowly to release pressure.
Release pressure from hydraulic tank at the turbo

boost release valve before opening fill spout.

Fluid Penetration Maintain control of the hose nozzle when filling the
fuel tank. Do not allow fuel to spill. Clean up spilled
fuel immediately. Dispose of clean up materials
properly.
Do not fill fuel tank to capacity. Allow room for fuel

expansion.
Tighten the fuel cap securely. If the fuel cap is lost,

replace only with original equipment or a factory
approved equivalent.
Do not use diesel fuel for cleaning purposes.
Use the correct grade of diesel fuel for the operating

season.
Hydraulic oil under pressure can penetrate body
tissue causing serious injury and possible death.
When troubleshooting a hydraulic system for

leaks, always use cardboard or other material as
a deflector. DO NOT USE YOUR HANDS.
If you are injected with hydraulic oil or any other

fluids, seek treatment by a doctor familiar with
this type of injury immediately.
Track tension adjustment grease is under high

pressure. Grease exiting the track tension
adjustment relief valve under pressure can
penetrate the body causing serious injury or
death. Do not watch the relief valve when adjust-
ing track tension. Watch the track or track tension Fuel spilled or leaked onto hot surfaces or
adjustment cylinder to see if the track is being electrical components can cause a fire.
loosened. Do not loosen the relief valve more than
one full turn.
Diesel Fuel
All fuels, most lubricants and some coolant

mixtures are flammable. Do not smoke while
refueling while near refueling operations. Keep
all fuels, lubricants and coolant mixtures away
from open flames.

Batteries Use jumper cables with care when attempt-
ing to start a machine with dead batteries. See
Section 2.3.1 for additional information.
Always disconnect both the positive RED and

negative BLACK battery cables before welding
on the machine to protect sensitive electrical
components.
In addition to the battery also disconnect the fol-

lowing:
• IQAN control box and MDM module
• Maxi control computers (If equipped)
Do not smoke while checking battery electrolyte
• Pro-Heat (Optional engine heater)
(acid) level. Keep open flames or sparks away
from batteries and where they are stored or • Fire Suppression Control Box (Optional)
charged. Battery fumes are flammable and can
explode
Always wear protective clothing and suitable

eye, face and hand protection when working with Always wear proper eye and face protection
batteries. when working with jumper cables. Batteries can
explode.
Battery electrolyte (acid) is highly corrosive.

Avoid contact with eyes, skin and clothing.

Maintain a charged fire extinguisher on the
machine AND KNOW HOW TO USE IT.
Fuel spilled or leaked onto hot surfaces or

Fire Prevention In The Field electrical components can cause a fire.
Forest debris alone may cause a fire, however,
when mixed with fuel, oil, or grease in a hot con-
Always clean up excess accumulations or spillage
fined space, the danger of fire is much higher.
of grease, hydraulic oil, engine oil, etc. immedi-
ately. KEEP A CLEAN MACHINE and use only
nonflam-mable solutions for cleaning the machine
or machine components.
In particular, keep flammable forestry debris
and other trash from collecting around the turbo
and exhaust areas, and from around the engine
pre heater (if equipped). These areas are the
hottest and are most susceptible to starting
fires. KEEP THESE AREAS CLEAN!
Most forestry equipment fires originate from very

flammable forest debris collecting around an
engine’s exhaust and turbocharger areas, and from
around the engine pre heater (if equipped). Once
ignited, the sparks can be fanned by the engine fan
and blown into other areas of the machine where
there may be additional flammable material. All fuels, most lubricants and some coolant
mixtures are flammable. Do not smoke while
refueling while near refueling operations. Keep
Fire Prevention Tips In The Field all fuels, lubricants and coolant mixtures away
from open flames.
Forest debris such as brush, leaves and needles
can easily collect in and around the machine. This Make sure the battery hold down bracket is kept
is not only an eyesore, but a very real fire hazard. snug against the batteries so there are no loose
Clean away all forest debris and any oily rags electrical connections during operation.
or other trash that may accumulate around the
machine, especially around the engine’s exhaust Do not store oily rags or other combustible material
and turbo areas, and from around the engine pre used for cleanup, etc. in the machine.
heater (if equipped). These areas are the hottest
and are most susceptible to starting fires. KEEP Take precautions when refueling equipment in the
THESE AREAS CLEAN! field. Keep fuel spillage away from hot areas and
electrical components.
Inspect the machine daily for potential fire hazards
and make repairs immediately. Check hydraulic Never smoke while refueling or performing other
and fuel system hoses, fittings and connections. in-field service work on the machine.
Also check electrical wiring and connections.

Before performing repair work such as welding, cleaned of all debris and a fire extinguisher posi-
the area surrounding the repair location should be tioned close by.
Do not smoke while changing ether cylinders or

Fuel spilled or leaked onto hot surfaces or where ether cylinders are stored. Keep ether cyl-
electrical components can cause a fire. inders away from open flames.
All fuels, most lubricants and some coolant

mixtures are flammable. Do not smoke while Discard spent ether cylinders per manufacturer’s
refueling while near refueling operations. Keep instructions. Do not puncture or burn. Ether cyl-
all fuels, lubricants and coolant mixtures away inders can burst causing serious personal injury.
from open flames.
Fire Prevention In The Shop

Take precautions when refueling equipment, even
in the shop. Keep fuel spillage away from electrical
components and areas that may become hot during
operation.
Do not smoke while refueling or performing other

service work on the machine.
Before performing repair work such as welding,

the area surrounding the repair location should be
Do not smoke while checking battery electrolyte cleaned of all debris and a fire extinguisher posi-
(acid) level. Keep open flames or sparks away tioned close by.
from batteries and where they are stored or
explode Do not use diesel fuel for cleaning purposes.

THIS PAGE LEFT BLANK FOR NOTES

CHAPTER 2 - OPERATING
Operating
Starting the Machine Page 2.1.2
Pro-Heat Instructions Page 2.2.1
Jump Starting Page 2.3.1
Engine and Hydraulic Warming Page 2.3.2
Operating Track Drives Page 2.4.1
Attachment Operation Page 2.5.1
General Operating Instruction Page 2.6.1

Before Starting The Engine
You must read and understand the safety signs and

safety messages found in Group 1 of this manual
before performing any operation or maintenance
procedures.
Keep a comprehensive and complete first aid kit in an eas-

ily accessible place on the machine at all times.
Use recommended protective clothing and safety devices Maintain a charged fire extinguisher on the machine AND
such as gloves, safety boots, safety hat, reflective vests KNOW HOW TO USE IT.
and eye, ear and respiratory
protection as required by job conditions.
General Pre-Start Inspection
Always perform a general pre-start inspection before
starting the machine.
Check around and under the machine for oil or coolant

leaks, worn or damaged components and loose bolts or
fasteners. Clean up accumulated debris, especially in
the engine, pump and exhaust areas where fires are most
likely to start.
Check engine oil, hydraulic oil, coolant and fuel

levels. When in cold weather conditions, make
Comply with the instructions in this manual and your sure the engine oil and hydraulic oil are the correct
company’s regulations for the operation of this machine. viscosity, the coolant is the correct mixture and
the diesel fuel is the proper grade for cold weather
YOU MUST BE FULLY TRAINED to operate this
machine and its felling attachment.
operation. Refer to the “Lubricant & Fill Capacities”
chart in Appendix A.
See “Daily Machine Walk-Around Inspection” in Chapter

8.2, Servicing, for detailed daily inspection information.
Chapter 2 - Operating Page 2.1.2

Starting the Machine Starting
Before the machine can be started, the “Master Electric Dis-
connect” switch must be turned to the on position. The switch 1. Set the throttle control to the idle position by turning
is located behind the perforated swing-out engine door on the
the control knob all the way counter-clockwise.
left side of the machine. The switch is mounted on the battery
hold down bracket. Turn the switch clockwise so the long part
of the switch handle is pointing to the on portion of the decal.
2. Turn the ignition key clockwise to the first or “Run”

position, the warning alarm will sound continuously
until the engine is started. (This is normal.)
3. Wait for the “WAIT-TO-START” light to go out,

and then turn the ignition key clockwise to the end or
“Start” position.
Check for Proper Control Positions

Be sure that all of the foot pedals and hand controls are in the To prevent damage to the starter, Do Not engage the starting
centered “neutral” position. Check by moving each control motor for more than 30-seconds. Wait 2-minutes between
slightly and then releasing it. The control should return to the each starting attempt.
centered “neutral” position on its own when released.
Check the positions of the dash panel rocker switches. All 4. When the engine starts, release the ignition key. It
rocker switches should be in the “OFF” position. A quick will automatically go back to the “Run” position.
check is that all of the black portions of the switches are in the
down position.
Adjust Operator’s Seat

Adjust the operator’s seat and seat belt correctly before start- If the red “Engine Stop” light stays on there is a potentially
ing the machine. Full foot-pedal travel must be obtained with damaging condition in the engine. SHUT DOWN THE
you back firmly against the seat back. See Chapter 4, Cabin, ENGINE IMMEDIATELY. Determine the problem
for further information on adjusting the seat. before attempting to restart the engine.
Check the seat belt. Replace any worn or missing compo-

nents. Tighten or replace loose seat belt mounting hardware.
If the yellow “Engine Service” light stays on, there is an active

engine fault code stored in the computer.
For more information see Chapter 5 - Engine.
Do not allow the engine to run at low idle for long periods.
Long idle time (10-minutes+) can cause the combustion
chamber temperature to drop low enough so fuel does not
burn completely allowing carbon build up around the injec- 5. Allow the engine to idle for 3 – 5 minutes before oper-
tors and piston rings which may cause valves to stick. ating with a load.
6. Increase the engine speed (RPM) slowly to provide

adequate lubrication to the bearings and allow the oil
pressure to stabilize
Page 2.1.3 Chapter 2 - Operating

Cold Weather Starting
When weather conditions are below freezing (32ºF / 0ºC),
make sure the engine oil and hydraulic oil are the correct vis-
cosity, the engine coolant is the correct mixture, and the fuel is
the proper grade for cold weather operation. Refer to Appendix
A - Servicing for more detailed information.
There are several available factory installed options that are

offered for starting your machine in cold climates. Please
check with your servicing dealer before installing any other
types of systems.
In-tank hydraulic oil heater elements. (Cover removed)

Never Use Ether! Track Drive Charge Oil Heater (Optional)
Electronically governed engines are equipped with air intake An optional track drive charge oil heater is available for help-
grid heaters. Serious personal injury or death, and damage ing to speed-up hydraulic system warm up in colder climates.
to the engine may result from using ether. This option consists of a block containing a fixed orifice that
is bolted to the forward face of the track drive charge pres-
sure filter manifold. A switch on the dash actuates a solenoid
Wet Kit (Optional) coil that forces the track drive charge oil to pass through the
A warm water circulation kit (wet kit) is available to pre-heat orifice and generate heat. The heated oil is then vented to the
the engine block before starting. The wet kit allows an exter- hydraulic oil reservoir where it mixes with the colder oil, thus
nal warm water source (a properly equipped service vehicle, warming the entire oil supply.
portable propane water heater, etc.) to be circulated through
the machine’s cold engine for easier starting.
The external source for warm water must have the same
coolant type and mixture as that of the machine. Coolants
Orifice
containing different additives or mixture ratios may result in
chemical imbalance and possible engine damage.
For temperatures below 0ºF / -18ºC additional pre-heating

equipment may be required when starting the machine. Such
equipment could include an engine block heater, diesel fuel Press the red side of the switch to activate the heater.
heater, coolant heater, or extra battery capacity.
Avoid unnecessary engine idling. Long idling periods can

cause rapid wear of engine parts. Maintain 1000 RPM or
more if prolonged idling is necessary. All machine control functions are disabled when the charge
oil heater is activated.
In-Tank Hydraulic Oil Heater Elements (Optional) DO NOT leave the charge oil heater on for extended
The optional in-tank hydraulic oil heater elements operate the periods as overheating damage to the hydraulic system may
same as the optional wet kit. An assembly of four elements is result.
installed into the hydraulic tank. Quick-disconnect hook-ups
are provided to allow warm water from an external source When the charge oil heater is activated, the IQAN control sys-
(properly equipped service vehicle, portable propane heater, tem blocks operation of all control functions. This is done to
prevent system damage from overheating if the machine was
etc.) to be circulated through the cold hydraulic tank. A bolt
operated with the charge oil heater engaged.
on cover is installed over the elements for protection.
The operator must monitor the hydraulic temperature when
the charge oil heater is engaged. If the charge oil heater is
left on for extended periods (40+minutes) overheating of the
hydraulic system is possible. The charge oil heater option is
not equipped with an automatic shut-off.

To Set Clock - Time & Day
When warming hydraulic oil, you MUST stop and cycle

all functions every 5 minutes of warming. This is to en-
sure that all functions warm evenly.
Failure to cycle all functions could result in the control

spool sticking in a valve bore and causing serious
damage.
1. Press & hold “Clock”.

2. Press “�” or “�” to set “ON” time.
3. Press “Day” to set day.
Auxiliary Heater System (PROHEAT)(Optional) 4. Release “Clock”.
The auxiliary diesel fuel fired heater option warms the engine
coolant and hydraulic system simultaneously by heating the Note: 12 or 24 hour option is set using Dip switch #1 on back
engines coolant and pumping it through the engine, tubes of the Timer.
in the hydraulic tank, as well as the cabins heater core. The On = 12 hour mode
unit can be programmed to start at any time you wish so that Off = 24 hour mode
the engine is ready to start, the hydraulic warm up period is
(Factory preset: 12 hour mode)
reduced, and the windows are defrosted and the cabin is warm
To Set Timer (Single Timer Mode)
when you arrive on the job. The unit can also be used as a
supplemental heating system.
General Description
1. Press & hold “Timer”.

3. Press “Day” to set day.
4. Release “Timer”. (Green light and “T1” will remain lit to
indicate active timer.)
Timer set in the single timer mode only will allow you to set
one “ON” time. With the T1 time activated, the Timer will go
“ON” at the preset time, and will be de-activated at the end of
its duration time. To re-activate the Timer press “Timer”.
The Teleflex 7-Day Digital Timer can be preset for a single
start time, one day at a time or two programmed start times per Note: When the time is reached, heater switches on. Red and
day constantly activated for multiple days of the week. The green lights are on.
clock can be preset for 12 or 24 hour time display. The heater
run time duration can be preset for 1 or 3 hours. The manual 1 or 3 hour duration option is set using Dip switch # 2 on back
button can be used to override the program and run the heater of the Timer.
indefinitely until it is switched off. ON = 3 hour duration
OFF = 1 hour duration
Note: If power to the Timer is interrupted, the display will (Factory preset: 3 hour duration)
flash “12:00 am MON” in 12 hour format or “00:00 MON” in
24 hour format. Stored programmed times will remain set in
memory.

To Set Timer (Dual Timer Mode) Manual & Timed Heater Operation
The “Manual” button is used to turn the heater on and of when
desired.
In the dual timer mode setting you can program your Timer to
come “ON” daily. Mon thru Fri, Mon thru Sat, or Mon thru
1. Press “Manual” to activate the heater. (Red light will go on
Sun. It also has a built in repeat function so that you do not
and the heater will operate indefinitely.)
have to pre-activate the Timer after every duration.
2. Press “Manual” again to de-activate the heater. (Red light
will go out and the heater will turn off.)
1. Press & hold “Timer”.
Note: “Manual” & “Timer” cannot be active at the same time.
3. Press “Day” to set day(s). If “Manual” is active and “Timer” is pressed, the heater will
4. Release “Timer”. (Green light and “T1” will remain lit to turn off and the red light goes out.
indicate active T1 program.
If “Timer” is active and “Manual” is pressed, “Timer” is de-
activated and the green light goes out.
When the heater has been turned on by the “T1 Timer” in

single timer mode, the heater can be turned off by pressing
either “Manual” or “Timer”. Both red and green lights will go
out.
If the heater has been turned on by the “T1 or T2 Timer” in

dual timer mode, pressing “Manual” will turn the heater off
but leaves the Timer(s) activated. Pressing “Timer” will turn
5. Press & hold “Timer”. off the heater and de-activate the Timer(s).
7. Press “Day” to set day(s).
8. Release “Timer”. (Green light and “T2” will remain lit to
indicate active T2 program.)
9. Press “Timer” once more to activate both “T1” & “T2”.
(“T1” and “T2” will remain lit to indicate active T1 and T2
programs.
Note: Timer will repeat each set day until switched off.
Dual Timer Mode is recommended for extremely cold cli-

mates so you can have the heater warm the system late at night
and again early in the morning. The Timer will repeat each
cycle each week until it is switched off. In the above example,
the heater will start at 6:00am and run through its duration,
then shut off. The heater will start again at 11:00 p.m. and run
through its duration and then shut off.
Note: In Dual Timer Mode you can set T1, T2 or both T1 and
T2. Timer mode option is set using Dip switch # 3 on back of
the Timer. ON = single timer (T1 only), OFF = dual timer (T1
& T2). Factory preset is T1 only.

Starting With Jumper Cables
Make sure the master electrical disconnect switch on the

stalled machine is in the “ON” position before attach-
ing the jumper cables to prevent damage to the electrical
circuits on the stalled machine.
Batteries give off flammable fumes that can explode!

- Do not allow ends of jumper cables to touch
each other.
- Always connect the battery positive (+) to
battery positive (+) and battery negative (-)
to battery negative (-).
- Jump only with a battery of the same voltage.
- Turn off all lights and accessories on the stalled
machine; otherwise, they will operate when the
jump source is connected.
Do not smoke while checking battery electrolyte (acid)
level. Keep open flames or sparks away from batteries Note: This machine has a 24 volt DC starting system. Use
and where they are stored or charged. Battery fumes are of a different voltage boost source will damage the electrical
flammable and can explode. circuits on this machine.
Battery electrolyte (acid) is highly corrosive. Avoid

contact with eyes, skin, and clothing.
When jump starting from another machine, make sure they

do not touch. This will prevent damage to engine bearings
and electrical circuits.

Jump Starting a Stalled Machine Engine and Hydraulic Warming
1. Determine cause of start failure.
2. If possible, lower booms or other implements to the When the ambient temperature drops below freezing, machine
ground. warm-up may require 1⁄4 to 1 hour before full speed operation
3. Make sure the engine on the stalled machine has been can begin.
shut down and all electrical accessories have been
turned off.
4. On the stalled machine, turn the master electrical dis- Operating the engine at full throttle when cold can damage
connect switch to the “ON” position, if equipped. the piston rings and increase wear on all engine parts. Al-
5. Move the boost machine close enough for the jumper low the engine to warm-up before operating at full throttle.
cables to reach, but, do not allow the machines to
touch.
6. Shut down engine on boost machine.
7. Make sure battery caps are in place and tight on both
machines. Make sure battery on stalled machine is
not frozen or low on electrolyte (acid). Cavitation and extreme damage to piston pumps and motors
may result from operating the hydraulic system at full capac-
8. Connect positive (+) red jumper cable to the positive
ity when the hydraulic oil is too cold to flow easily. Warm
(+) battery post on the stalled machine.
up the hydraulic system before operating at full capacity.
9. Connect the other end of the positive (+) red jumper
cable to the positive (+) battery post on the boost
machine.
10. Connect the negative (-) black jumper cable to the
negative (-) battery post on the boost machine. Variable displacement hydraulic pumps only pump oil
11. Connect the other end of the negative (-) black jumper when a control is activated. Simply letting the engine idle
cable to the frame of the stalled machine away from will not warm the hydraulic oil.
the batteries, fuel lines, hydraulic lines, or moving
parts. Do not connect the negative (-) black jumper
cable to the negative (-) battery post on the stalled
Warm up the engine at low idle for at least 5-minutes. Slowly
machine.
operate the implement functions to help speed the warm-up of
12. Start the engine on the boost machine. the hydraulic system.
13. Wait a minimum of 2 minutes for the batteries of the
stalled machine to partially charge. Warm-Up Procedure
14. Attempt to start the stalled machine. 1. Begin the procedure with the engine running at low idle.
Check the system monitoring gauges and warning lights fre-
15. Immediately after the stalled machine starts, remove
quently throughout the procedure.
the jumper cables in reverse order.
16. Complete a starting failure analysis of the stalled 2. Move all implement functions slowly to maximum position
machine and make the necessary repairs. and back again to minimum position for several cycles. Watch
the return filter pressure gauge and warning light. If the alarm
sounds, slow down the operation of the functions.
Do not allow the positive (+) cable clamps to touch any 3. Once you can begin to achieve full control movement with-
metal other than the positive (+) battery terminal. out setting off the alarm, repeat the procedure with the engine
at a higher throttle setting.
Warm up all functions evenly, not just a single function.

4. Use the boom to lift a set of tracks off the ground. Cycle
the track forwards and backwards, starting slowly and speed-
ing up the operation as the system warms. Repeat for the
other track.
5. Only when the return filter back pressure gauge reaches its
normal operating range of 5 - 15 psi (35 - 105 kPa) and the
hydraulic oil temperature gauge begins to rise can the machine
be operated at full speed operation.
An internal by-pass is provided on the oil cooler to help speed

the warm-up of the hydraulic oil and prevent high case pres-
sure in the pumps during start-up. If the return oil pressure
through the oil cooler exceeds 50 psi (345 kPa), or return oil
temperature is below 120 - 140ºF (50 - 61ºC), a relief valve in
the oil cooler opens and diverts the oil directly to tank. As the
oil warms and resistance through the oil cooler becomes less,
the relief will close and oil will go through the oil cooler.

Forward Travel
procedures.
Controlling the Track Drives
Normal track drive operation is with the

track sprockets at the rear of the machine and the
track idlers at the front of the machine under the
cab. If the sprockets are at the front of the machine
under the cab, the track drive controls will work in
reverse.
At maximum speed the system pump is fully

stroked. When more power is desired for a steep
climb or sharp turn, you must let up on the pedals
and implement functions to allow for less displace-
ment and therefore, less flow or speed.
Do Not operate the track drives at high speed

for more than 30 minutes. Overheating of the
track final drives can result. When operated at
prolonged high speed, stop the machine in Figure 1: Forward Travel
regular intervals and operate the implement func-
tions to allow the track final drives to cool before To go FORWARD, push down on the tops of both foot
continuing. pedals with your toes. See Figure 1. Forward travel will
always be towards the track idlers.
The cab door must be fully closed when operating the
machine. All TIMBCO Hydro-Bunchers are equipped Track speed is determined by how far the pedals are
with an interrupt that automatically shuts off pilot pres- pushed. The farther down the pedals are pushed, the
sure to the controls and electrical signal to the IQAN faster the track speed.
when the door is opened.
Return the pedals to the center “neutral” position to stop.
Track brakes are applied automatically when the pedal is
in the centered “neutral” position.

Reverse Travel Steering Left
Figure 2: Reverse Travel Figure 3: Steering Left

(FORWARD LEFT turn shown)
To go in REVERSE, push down on the bottoms of both To steer the machine to the LEFT, operate the right track
foot pedals with your heels. See Figure 2. Reverse travel at a higher speed than the left track. See Figure 3.
will always be towards the track sprockets.
The greater the difference between left and right
Track speed is determined by how far the pedals are track speed, the sharper the turn. The machine
pushed. The farther down the pedals are pushed, the can be pivot turned to the LEFT by operating the
faster the track speed. right track at full speed while leaving the left track
stationary.
Return the pedals to the center “neutral” position to stop.
Track brakes are applied automatically when the pedal is
in the centered “neutral” position.

Steering Right Spot Turns (Counter-Track Rotation)
Figure 4: Steering Right Figure 5: Spot Turns

(FORWARD RIGHT turn shown) (RIGHT counter-track rotation shown)
To steer the machine to the RIGHT, operate the left track To turn the machine on-the-spot, operate one track for-
at a higher speed than the right track. See Figure 4. ward at full speed while operating the other in reverse at
full speed. See Figure 5.
The greater the difference between right and left
track speed, the sharper the turn. The machine
can be pivot turned to the RIGHT by operating the
left track at full speed while leaving the right track
stationary.

Track (Parking) Brakes
Low Speed Lock
There are disc brakes located between the track drive motor
and final drive of each track. The brakes are set by spring pres-
sure. Hydraulic pressure must be applied against the spring to
release the brakes.
The track brakes are set automatically by the IQAN control

system which monitors foot pedal movement. When a foot
pedal is actuated, IQAN energizes the track brake solenoid coil
which allows hydraulic pressure to release the track brakes.
When the foot pedal is released, IQAN de-energizes the track
brake solenoid coil which blocks hydraulic pressure and allows
the spring pressure to re-apply the track brakes. The IQAN
system uses a time delay when re-applying the track brakes to
prevent damage to the motors.
The machine must come to a smooth stop which is de-

termined by the time delay programmed into the IQAN
control system. The time delay function is dependent
on operating conditions and the operator. Contact your
Note: Shown in low speed locked position. servicing dealer if the machine stops too aggressively.
Do not operate the track drive low speed lock control

while the machine is moving. Sudden changes in track
speed may cause the machine to become unstable. Seri-
ous personal injury could result from sudden changes
in machine stability.
The track drive motors are equipped with an auto-shift feature

that automatically shifts the motor between high displacement
(low speed) and low displacement (high speed). The shifting
of the motor is determined by pressure in the drive circuit.
Low speed provides the greatest drawbar pull and more

precise control of the track drives. The track motors can be
locked in low speed by activating the low speed lock switch in
the dash. Push down on the top of the switch (green icon side)
to allow the track motors to shift automatically. Push down on
the bottom (black side) of the switch to lock the motors in low
speed.
It is recommended to use low speed lock when doing the fol-

lowing:
- Starting the machine.
- Traveling over soft or rough ground.
- Working on slopes.
- Unloading or loading the machine for transport.
Note: Always use low speed lock when traveling downhill to

prevent track motor overspeed.

You must read and understand all the safety signs and If equipped with a tool tilt function, do not forcefully
messages found in this manual as well as those posted on extend the tool tilt cylinder until it bottoms out. This will
the machine before performing any operation or mainte- cause damage to the rod and piston. When felling, always
nance procedures. release the tree before it over-extends the tool tilt cylinder.
Controlling The Implements Since there are a wide variety of attachments that can be used
on this machine, we recommend reading the attachment man-
ufacturer’s operation manual for correct operating procedures
for the attachment.
The control patterns shown in this manual and on any
decals found on the machine reflect the control configura- Control Pattern Diagrams
tion as installed at the factory. Any changes to the control
configuration of this machine become the sole responsibil- The implement control pattern can vary depending upon the
ity of the owner.
way the control pilot lines are connected at the main control
valve and how the rocker switches are wired at the electri-
cal box behind the cab. See your servicing dealer for control
The cab door must be completely closed and the IQAN sys- changes.
tem armed before the machine will operate. The machine is
equipped with an interrupt switch at the base of the cab door There are several standard control configurations available at
that automatically shuts down the controls if the door is open. the factory level:
A) U.S. Bar Saw - See Figure 1.

B) SAE Bar Saw - See Figure 2.
C) U.S. Disc Saw - See Figure 3.
D) SAE Disc Saw - See Figure 4.
E) Canadian SAE - See Figure 5.
The control pattern of the machine when shipped from the factory
appears on a decal located above the dash panel. Occasionally,
a machine is shipped from the factory with a special control
pattern resulting from a custom attachment
installation or special owner request. These
machines have a control pattern decal completed
by hand or they are shipped with a blank control
pattern decal for the owner to complete.
Press the green portion of the Arm System switch located on
the dash panel to arm the system.
Tree Counter (Optional)
An optional tree counter is available with the IQAN system.

Do not attempt to change the control pattern of the machine The counter switch is programmed into an available button on
on your own, contact your servicing dealer if changes are one of the joystick hand controls. The tree counter location
required. The control pattern decal in the machine MUST
varies from machine to machine; see the control pattern decal
match the control pattern of the machine. Do not operate
for the location in your machine if so equipped.
the machine unless the control patterns match.
The tree count is read on the IQAN system MDM screen. To

advance the counter, push the counter button. To reset the
counter, press and hold the tree counter button for 4 seconds.

Figure 1: U.S. Bar Saw Control Layout

Figure 2: SAE Bar Saw Control Layout

Figure 3: U.S. Disc Saw Control Layout

Figure 4: SAE Disc Saw Control Layout

Figure 5: Canadian SAE Control Layout

Implement Control Movements
Stick Boom IN
Main Boom DOWN
Figure 8: Knuckle Stick Boom In
Figure 6: Lower Main Boom Move the control handle to this position to knuckle the
stick boom in. See Figure 8.
Move the control handle to this position to lower the
main boom. See Figure 6.
Stick Boom OUT
Main Boom UP
Figure 9: Knuckle Stick Boom Out
Figure 7: Raise Main Boom Move the control handle to this position to knuckle the
stick boom out. See Figure 9.
Move the control handle to this position to raise the main
boom. See Figure 7.

Swing LEFT Tool Tilt FORWARD
Figure 11: Swing Upper Turntable Left Figure 12: Tilt Cutting Attachment Forward
Move the control handle to this position to tilt the cutting

attachment forward. See Figure 12.
Move the control handle to this position to swing the
upper turntable to the left. See Figure 10. IMPORTANT: Do not forcefully extend the tool tilt
cylinder until it bottoms out. This will damage the rod
and piston. When felling, always release the tree before
Swing RIGHT it over-extends the tool tilt cylinder.
Tool Tilt BACK
Figure 10: Swing Upper Turntable Right
Move the control handle to this position to swing the

upper turntable to the right. See Figure 11.
Figure 13: Tilt Cutting Attachment Back
Move the control handle to this position to tilt the cutting

attachment back. See Figure 13.

Cab Level FORWARD Cab Level LEFT
Figure 14: Cab Level Forward Figure 16: Cab Level Left
Press switch to level the cab forward. See Figure 14. Press switch to level the cab to the left. See Figure 16.
Cab Level BACK Cab Level RIGHT
Figure 15: Cab Level Back Figure 17: Cab Level Right
Press switch to level the cab to the rear. See Figure 15. Press switch to level the cab to the right. See Figure 17.

Cutting Attachment Clamp Arms OPEN Cutting Attachment Accumulator Arm OPEN
Figure 18: Open Cutting Attachment Clamp Arms Figure 20: Open Cutting Attachment Accumulator Arm
(TIMBCO Bar Saw Shown) (TIMBCO Bar Saw Shown)
Press switch to open the cutting attachment clamp arms. Press switch to open the cutting attachment accumulator
See Figure 18. arm, when equipped. See Figure 20.
Cutting Attachment Clamp Arms CLOSE Cutting Attachment Accumulator Arm CLOSE
Figure 19: Close Cutting Attachment Clamp Arms Figure 21: Close Cutting Attachment Accumulator Arm
(TIIMBCO Bar Saw Shown) (TIMBCO Bar Saw Shown)
Press switch to close the cutting attachment clamp arms. Press switch to close the cutting attachment accumulator
See Figure 19. arm, when equipped. See Figure 21.

Bar Saw CUT Cutting Attachment Lateral Tilt LEFT (Optional)
Figure 22: Bar Saw Cut Figure 24: Tilt Cutting Attachment to the Left
Press switch to begin the bar saw cut, when equipped. Press switch to tilt the cutting attachment to the left,
See Figure 22. when equipped. See Figure 24.
Bar Saw RETRACT Cutting Attachment Lateral Tilt RIGHT (Optional)
Figure 23: Bar Saw Retract Figure 25: Tilt Cutting Attachment to the Right
Press switch to retract the bar saw after the cut, when Press switch to tilt the cutting attachment to the right,
equipped. See Figure 23. when equipped. See Figure 25.

Operating The Machine Frozen Ground Conditions
General

procedures.
Figure 1: Freeing The Tracks From Frozen Ground
Free the tracks from frozen ground before operating the

track drives. Use the boom’s lifting power to free the
tracks.
1. Swing the boom to the idler end of the machine and

place the cutting attachment on the ground. See
Figure 1.
2. Use the Main boom DOWN function to lift and free

The operator’s seat is equipped with a seat belt. Use this the idler end of the machine.
belt at all times when operating the machine.
3. Swing boom around to the sprocket end of the

machine. Repeat boom lifting procedure to free the
Stay in control of the machine at all times.
sprocket end of the machine.
Do not shift track drive speed when traveling up or down
When parking the machine in freezing conditions, planks
a grade. Use “LOW” speed when traveling on grades.
or forest debris can be placed under the machine to pre-
vent the tracks from freezing into the ground. Also place
Use “LOW” speed when working in soft ground condi- planks or forest debris under the cutting attachment to
tions. prevent it from freezing into the ground.
Reduce speed when working in tight quarters or when

breaking over a rise.
When traveling, always keep the boom as low as possible

to the ground for maximum stability.
Changing Direction Forward And

Reverse
Forward and reverse directional changes at full throttle
are possible. However, for operator comfort and maxi-
mum service life of the drive train components, reduc-
ing engine speed is recommended.

Parking The Machine
When parking the machine, select a spot where the

ground is level. Do not park on a hillside or any
incline.
When freezing conditions are expected, do not park

machine in loose or wet soil which could freeze in
the tracks.
1. Select a level spot to park the machine. If it is nec-

essary to park on an incline, the tracks must be
blocked securely. Figure 3: Lifting The Machine To Clean the Tracks
2. Use the Main boom DOWN function to lift the track

After each day/shift’s operation, dirt and debris off the ground. See Figure 3.
should be cleaned from the tracks. See “Cleaning
the Tracks” before continuing.
3. Run the track in both directions to shed the maxi-
mum amount of mud, dirt and debris.
2. Reduce engine speed to low idle.
4. Lower the track to the ground. Repeat
3. Lower the cutting attachment to the ground and procedure for the other track.
apply slight down pressure.
5. Clean in and around the top and bottom rollers.
Cleaning The Tracks
It is a good practice to clean the tracks at the end of the Stopping The Engine
day or shift’s operation. This will increase the service
life of the track components by making it such easier to
inspect for leaks or other damage that could lead to pre-
mature component failure. Stopping the engine immediately after it
has been working under load can result in
overheating and accelerated component wear.
Allow engine to cool down while running at low
idle before shutting down.
1. With the machine parked, run the engine at low

idle for a few minutes to allow it to cool down.
Stopping the engine immediately after working
under load can result in overheating and
accelerated component wear.
2. Turn the ignition key to the OFF position. Remove

the ignition key and place in
6 ft.
(183 cm) safe-keeping.
3. If the machine is to be parked for a greater length

Figure 2: Positioning The Boom To Lift the Machine of time, such as overnight, switch off the master
electrical disconnect or disconnect the positive (+)
1. Swing the boom to one side of the machine and posi- battery cable.
tion the cutting attachment approximately 6’ (183
cm) from the tracks. See Figure 2.


Chapter 3 - Frame / Chassis
Frame / Chassis Component Adjustments

Frame Maintenance Page 3.1.6
Swing Stop Box Page 3.1.7
Leveling Frame Adjustments Page 3.1.8
Slack Adjusters Page 3.1.9
Swing Bearing Adjustment Page 3.1.10

FRAME / CHASSIS
Description
The frame / chassis are divided into two main parts, the upper and lower units. The upper unit contains the turntable
along with the cabin and engine housing. The lower unit consists of the frame and track drive units.
The two halves of the machine are connected via a swing bearing and can be a leveling or non-leveling configuration.
Depending upon the options, the leveling version may have continuous rotation or it may be limited to 270 degrees or 3/4
swing rotation in each direction from the forward neutral position. The non-leveling variation has continuous rotation.
Upper Frame (Typical)
Engine Compartment
Frame
Swing Motor Mount
Crane Mount
Upper Turntable
Chapter 3 - Frame / Chassis Page 3.1.2

Lower Frame Unit (Typical)
Page 3.1.3 Chapter 3 - Frame / Chassis

Intermediate Section (Non-Leveling)(Typical)

Intermediate Section (Leveling)(Typical)

FRAME MAINTENANCE
The swing bearing ring gear is provided with a grease cup located in the cab. Pump 5 – 6 strokes of grease into the cup, then rotate
the machine 90° and pump another 5 – 6 shots of grease, continue for a complete revolution. The swing bearing should be greased
according to the lubrication chart found in the service & maintenance section of this manual.
Checking the Swing Stop System
Machines that are not equipped with a continuous rotation swing system are equipped with a mechanical / electric swing stop that will
automatically stop the swing travel after 270° or 3⁄4 revolution from the forward (neutral) position. Once the swing stop is actuated the
swing will only work in the opposite direction.
1. Position the machine in neutral swing with the booms directly over the fuel tank with no twist in the hoses.
2. Slowly operate the swing left function. The upper turntable should stop automatically after 270º or 3⁄4 of a revolution. If the
upper turntable swings beyond a 3⁄4 revolution, the swing stop must be adjusted or replaced.
3. Slowly operate the swing right function. The upper turntable should stop automatically after 270º or 3⁄4 of a revolution. If the
upper turntable swings beyond a 3⁄4 revolution, the swing stop must be adjusted or replaced.
The major swing stop adjustment is made before the swing stop box was installed. The vertical moving arm is moved up and down by
turning on the pinion gear. The vertical moving arm must be positioned so that the contact points are of equal distance to both swing
stops switches. If there is a slight adjustment to be made, it should be done by loosening the adjustment screws on the swing stop
switches and sliding the switch.
If the swing stop system must be replaced, be sure the vertical moving arm is centered between the two swing stop valves and the
boom is positioned directly over the fuel tank with no twist in the hoses when the new swing stop box is installed.

Swing Stop Box
Swing Stop Switch
Loosen the screws to adjust.
Vertical Moving Arm
Swing Stop Switch

Loosen the screws to adjust.
Lead Screw Pinion

Leveling Frame Adjustment
Leveling machines are equipped with true 2-cylinder, 4-way cab leveling. In order to achieve this, there has to be a certain amount of
tolerance built into the leveling system components for assembly purposes.
The 3⁄4” (19 mm) diamond shaped slack adjusters (shims) are provided in the main front-to-back and side-to-side pivots. The purpose
of the slack adjuster is to prevent side movement of the leveling component across the pin during operation.
Each slack adjuster is provided with two set-screws and jam-nuts. As the pivot wears, the un-wanted side movement between leveling
components is removed by repositioning the slack adjusters with the set-screws.

Adjusting the Slack Adjusters
The slack adjusters are located in the main front-to-rear and side-to-side pivot points. As these pivot points wear, the resulting
increase in tolerance between the leveling components must be removed. This is done by re-positioning the slack adjusters.
1. Position the machine on a level surface.
2. Level the upper turntable.
3. Tighten the set screws on the front and right side slack adjusters to take the excess tolerance out of the leveling components.
4. After excess slack has been removed, back all set-screws off 1⁄2 turn and tighten the jam-nut.

Adjusting the Swing Bearing
Periodically, the Rotek swing bearing service tolerance may need to be checked. A service tolerance of up to 0.095” is acceptable. To
check the bearing tolerance you will need two dial indicators with magnetic bases.
1. Torque all bearing mounting bolts to specification before beginning procedure.
2. Position a dial indicator with its magnetic base affixed to the lower turntable weldment and the indicator pointer against the outer
race of the bearing. Position a second dial indicator on the opposite side of the bearing.
• Position the dial indicators as near as possible to the center line of the bearing (looking towards the bearing from the sides of
the machine).
• Be sure the magnetic base is fixed to a smooth flat surface and it has firm contact with the lower turntable.
3. Start the engine. Position the boom at full extension over one side of the machine with the cutting attachment a few inches off the
ground. Shut down the machine.
4. Zero both dial indicators.
5. Start the engine. Lower the cutting attachment to the ground, then use the main boom down function to continue putting down
pressure on the boom until the track on the boom side begins to lift off the ground.
6. Shut down the engine. Record both dial indicator readings. The indicator readings should be within 0.002” of each other. If not,
it could indicate loose bearing mounting bolts that may be allowing the bearing to flex slightly.
7. Re-position the dial indicators to the front and rear of the machine. Perform steps 3 thru 6 with the boom extended over the front
of the machine.
• Position the dial indicators as near as possible to the center line of the bearing (looking towards the bearing from the sides of
the machine).
• Be sure the magnetic base is fixed to a smooth flat surface and it has firm contact with the lower turntable.
8. A new machine at the factory has approximately 0.020 – 0.024” of bearing tolerance (this is actually bearing tolerance plus other
inherent tolerances found in the machine assembly). The difference between “new” and your readings is the bearing’s service
tolerance.

Chapter 4 - Cabin
Cab Environment
General Information 4.1.2
Dash Panel 4.2.1
Power View Display 4.3.1
IQAN MDM Display 4.4.1

Cab Door Door Stop
Opening Cab Door From Outside The cab door is equipped with a door stop latch that allows the
door to be secured in an open position, however, the controls
will not operate with the cab door open. To close the door, lift
the “T” handle until it clears the slide bar and allows the door
to be closed.
Lift and turn the large “D” ring handle to the left to release the
cab door latch. After opening the cab door, return the “D” ring
handle tot he recessed position for protection.
The cab door can be locked for security by inserting the key
and turning counter-clockwise. To unlock, insert the key and
turn clockwise. The door key number is stamped on the lock.
If additional keys are required, they can be ordered by the
number on the lock. Storage Tray
The cab door is equipped with a storage try to place small
Opening Cab Door From Inside tools, cleaning supplies, a lunch box, etc..
Pull the handle downward to release the cab door latch.
Chapter 4 - Cabin Page 4.1.2

Door Safety Interrupt Switch “Up-Time Kit”
DO NOT BY-PASS, remove, or tamper with the door

safety interrupt system. Serious personal injury could
result while operating the machine with the cab door
open or a faulty door safety interrupt system.
A normally-open electrical switch is located at the base of the

cab door. This door-actuated switch is part of a safety inter-
rupt system used to signal the IQAN control system when the
cab door is open. The IQAN control system will only allow
operation of the machine when the cab door is closed.
The door safety interrupt switch is wired into a dedicated sig-

nal loop circuit. The IQAN control system continuously sends
an electrical signal through the circuit whenever the ignition
switch is in the RUN position.
The Manual Pack (which includes the Spare Parts Manual,

Operator’s Manual, and Electrical and Hydraulic Schematics
for the machine) are placed inside the cab door or under the
seat.
Optional “Up-Time Kits” that are purchased seperately, are

packaged in a large cardboard container and placed in the cab
behind the seat when the machine leaves the factory.
The exact contents of the “Up-Time Kits” will vary depending

upon the type of engine, main control valve, and cutting attach-
ment the machine is equipped with when it leaves the factory.
Cab Door Closed

When the cab door is closed the electrical signal passes
through the switch and back to the IQAN control system. As
long as the signal loop remains closed the IQAN control sys-
tem will supply electrical power to the system arming switch
which allows machine operation when activated.
Cab Door Open

When the cab door is open the electric signal cannot pass
through the normally-open switch and return to the IQAN
control system. When this happens the IQAN control system
blocks power to the system arming switch which stops or
prevents machine operation. Machine operation will continue
only after the cab door is closed and the arming switch is re-
activated.
Page 4.1.3 Chapter 4 - Cabin

Emergency Cab Escapes Kick-Out Front Cab Window
Removable Rear Cab Window

The kick-out front cab window and its guard weighs
The entire rear cab window and its guard can be removed from Approximately 150 lbs. (68 kg).
either inside or outside the cab for use as an emergency escape
route.
The entire front cab window and its guard can be removed
from the inside of the cab for use as an emergency escape
route.
The rear cab window and its guard weighs approximately
57 lbs. (26 kg). 1. Loosen the four star knobs, one at each corner of the front
window guard.
From Inside The Cab:

1. Fold the seat back all the way forward.
2. Remove the star knob.
3. Using the hand-holds, lift the rear cab window guard away
from the opening and place it behind the operator’s seat.
2. Swing the star knobs inward to release the window and

frame.
From Outside The Cab:

1. Remove the star knob.
2. Grab hold of the wire mesh guarding and push the window
inward.
3. Push or kick the window forward.

Figure 1: Adjusting the Operator’s Seat (Standard)
Adjustable Operator’s Seat (See LUMBAR ADJUSTMENT - Turn the knob

clockwise for firmer lumbar support. Turn
Figure 1) the knob counter-clockwise for softer lumbar
Adjust the operator’s seat correctly. Full foot pedal support.
travel must be obtained with your back firmly against
the seat back. BACKREST ANGLE ADJUSTMENT - Turn
the knob clockwise to tilt the backrest back.
HEIGHT ADJUSTMENT - Lift lever and Turn the knob counter-clockwise to tilt the
adjust seat to desired height. Release lever to backrest forward.
lock seat in position.
RIDE ADJUSTMENT - Turn the knob

clockwise for a softer ride. Turn the knob
counter-clockwise for a firmer ride.
SEAT FORE & AFT ADJUSTMENT - Pull

the lever to the left and slide seat (including
the armrests and joystick controls) forward
or back as desired.
JOYSTICK FORE & AFT ADJUSTMENT

- Turn the knob clockwise to release bracket
and position as desired. Turn the knob coun-
ter-clockwise to lock bracket in position. 00014
ARMREST ADJUSTMENT - Turn the knob The operator’s seat is equipped with a seat belt. Use
clockwise to raise the armrest. Turn this belt at all times when operating the machine.
the knob counter-clockwise to lower the
armrest.

Cab Air Conditioner / Heater
Figure 3: Cab Air Conditioner / Heater Control Unit Installation (Typical)
The air conditioner/heater is mounted in the roof

with the controls and air outlets located on the
angled part of the roof just behind the skylight. See
Figure 3. The ignition key switch must be in the During seasons when the heater will not be used,
“RUN” position for the air conditioner/heater to close the shut-off valves in the hot water supply
operate. and return lines to the control unit. The shut-off
valves are located on the engine.
Air Conditioner
1. Select “A/C” at the mode select switch.
2. Select fan speed at the fan speed select switch.
3. Adjust temperature of air flow at the thermostat

knob .
4. Position the vents on the control unit for

desired air flow direction.

Heater
Be sure the shut-off valves in the hot water

supply and return lines to the control unit are
open. The shut-off valves are located on the
engine.
Figure 4 - The auxiliary unit is located on the floor behind

the operator’s seat. A fresh air duct is connected to a filtered
intake via a flexible hose.
1. Select “HEAT” at the mode select switch.
2. Select fan speed at the fan speed select

switch.
3. Position the vents on the control unit for

desired air flow direction.
Cab Floor Heater (Optional)

When equipped, The optional cab floor heater is
attached to the rear of the operator’s seat mounting
brackets. See Figure 4. The heater is designed to
direct heat across the floor of the cab and keep the Figure 5: Cab Floor Heater ON/OFF Switch
operator’s feet warm.
The heater’s ON/OFF switch is located in the dash

panel. See Figure 5. The ignition key switch must
be in the “RUN” position to turn on the cab floor
heater.

Cab Pressurization (Optional)
Figure 7: Water Shut-Off Valve On Engine (Typical)
engine. See Figure 7. This prevents warm water

Figure 6: Optional Cab Pressurization System Intake
from circulating through the cab floor heater.
The optional cab pressurization system works with Normally, the water shut-off valves are closed in
the optional cab floor heater to bring an increased warm weather to operate the cab air conditioner.
volume of air into the cab interior. The increased air
volume creates a positive pressure within the cab that Remove the 8 screws that hold the louver in place to
helps keep dust out of the cab and reduces condensa- clean or replace the filter.
tion build-up on the windows in cold weather.
The cab pressurization system air intake is located

on the right side of the cab under the window. See
Figure 6. A replaceable filter element is located
behind the louvered panel. Simply remove the panel
to gain access to the filter element for routine service
and maintenance.
A simple vent at the auxiliary floor heater unit allows

any combination of inside/outside air mixture.
The cab floor heater must be running for the cab

pressurization system to work. The ignition key
switch must be in the “RUN” position to turn on
the
cab floor heater.
The cab pressurization system is operated in warm
weather by closing the water shut-off valves at the

Interior Dome Light
Figure 8: Interior Dome Light Figure 10: Cab Interior Fan
The interior dome light is located directly above the

operator’s seat. See Figure 8. The dome light is
Cab Interior Fan
turned on by a small rocker switch on its left side. The cab interior fan is located in the upper left
The power supply to the dome light comes from the corner of the front window. See Figure 10. The fan’s
air conditioner/heater electrical circuit so the igni- ON/OFF toggle switch is located at the base of the fan.
tion key switch must be in the “RUN” position to The ignition key switch must be in the “RUN” posi-
turn on the dome light tion to operate the cab interior fan.
AM/FM Radio/Cassette Player The cab interior fan is mounted on a swivel base so
it can be used as a front window defroster in colder
The AM/FM radio/cassette player is located at the weather or as a cooling fan for the operator in warm-
rear of the cab above the operator’s head. See Figure er weather.
9. The radio and cassette player controls are self-
explanatory.
Sliding Rear Cab Window
The rear cab window is fully guarded and features
a sliding glass window for additional cab ventilation.
See Figure 11.
Figure 9: Optional AM/FM Radio/Cassette
Figure 11: Opening Rear Cab Window

Dash Panel
Murphy Link
Power View Display
Engine Coolant
Temperature Gauge
Engine Oil Pressure Gauge
Hydraulic Oil
Temperature Gauge
Return Filter Back Pressure Gauge
Audible Warning Alarm

For Mechanical
Gauges

Engine Oil Pressure Gauge
Return filter bypass will cause contamination of the
entire hydraulic system. Contamination in the hydrau-
lic system will cause catastrophic damage to hydraulic
system components. Never operate the machine in filter
Operating the machine with low engine oil pressure will
bypass condition.
cause severe damage to the engine.
Excessive return oil back pressure is the result of dirty filters
or cold oil being forced through the filters. Change return
filters according to the preventive maintenance schedule found
The engine oil pressure gauge monitors engine lubricating oil in this manual.
pressure.
Always change return filters after a major component failure,
Since the oil pressure varies between different engine manu- such as a hydraulic pump failure.
facturers and models, please refer to the engine owner’s
manual for your specific engine requirements. During cold starts, always allow the machine to reach normal
Normal gauge readings will vary with engine temperature. operating temperatures before running at full throttle. Follow-
Shut down engine immediately if engine oil pressure drops. ing these simple rules will help prevent costly down-time and
Have the machine inspected and get the problem corrected increase the life of your equipment.
before re-starting the engine.
Engine Water Temperature
Hydraulic Oil Temperature Gauge
Gauge
The engine water temperature gauge monitors the engines The hydraulic oil temperature gauge monitors the temperature
cooling system temperature. of the hydraulic oil in the tank.
Normal operation is 160° - 210°F (70°- 99°C). Normal hydraulic oil temperature should be no higher than
Warning Alarm is triggered at 210°F (99° C). +100°F (38°C) above the ambient (outside air) temperature.
If the engine water temperature gauge sounds an alert, return The warning alarm varies depending upon the ISO rating of
the engine to an idle until it cools down. the hydraulic oil.
If engine overheating is a re-occurring problem, check the ra- ISO 32.....................................170° F (77° C)
diator / oil cooler fins for debris. Keep the area in front of the ISO 46.....................................190° F (88° C)
radiator / oil cooler clean for maximum cooling air flow. ISO 68.....................................210° F (99° C)
Return Filter Back Pressure
The gauge is factory set for the ISO rating of the oil shipped
Gauge in the machine. When changing oil, be sure the gauge is set
The return filter back pressure gauge monitors return oil back correctly for the new ISO rating (available from your oil dis-
pressure above the three in-tank return filters. tributor). To adjust the gauge, use a 1/16” hex tool to turn the
screw in the center of the gauge face.
Normal operation is 5 - 15 PSI (35 - 105 kPa)
Warning alarm is at 23 PSI (160 kPa) If high hydraulic oil temperature is a re-occurring problem,
check the radiator / oil cooler fins for debris or look for a pos-
Return oil back pressure is dependent on hydraulic oil tem- sible pump or valve relief set too low that is allowing oil to
perature. dump over it and create excessive heat.
The return filters will go into bypass when back pressure

reaches 35 PSI (240 kPa). Preventing return filter bypass is
extremely important. Unfiltered oil bypassing the return filters
will enter the main hydraulic tank and begin to contaminate
the entire hydraulic system.
Incorrect cold weather operating procedures can force

return filter bypass. Follow the Machine Warm-Up Proce-
dures found in this manual.

Hydraulic Oil Level
Warning Light
Disc Saw Engaged Warning Light
Charge Filter By-Pass
Warning Light
System Armed Warning Light
Arm System Switch
Work Lights Switch
Low Speed Lock Switch Note: The black portion of the switch = OFF.
All switches are shown in the off position.
Ignition Switch:
Position 1 = Accessory
Position 2 = Stop / Off
Position 3 = Run
Position 4 = Start
Throttle Knob:
Clockwise = Increase RPM
Counter Clockwise - Decrease RPM
Note: The black portion of the switch = OFF.

All switches are shown in the off position.
Auxiliary Oil Cooler Fan ON/OFF Switch (Optional)
Cab Floor Heater Fan ON/OFF Switch (Optional)
Charge Oil Heater ON/OFF Switch (Optional)
Disc Saw Engage Switch
Disc Saw Dis-engage Switch
Fuel Transfer Pump ON/OFF Switch

(Not on all models)

IQAN - Master Display Module (MDM)
Manual Override Switch for Reversing Engine Fan
Audible Alarm -
CAN Bus System (Murphy Link)
Machine Hour Meter
Dash Panel Component Description
Murphy Power view Display
The Power View System is a multifunction tool that enables

equipment operators to view many different engine or trans-
mission parameters and service codes. The system provides
a window into modern electronic engines and transmissions.
Low hydraulic oil level can expose suction filters to air
The Power View includes a graphical backlit LCD screen. The
and cause catastrophic damage to the pumps.
display can show either a single parameter or a quadrant dis-
Keep the hydraulic oil level in the green zone of the sight
play showing 4 parameters simultaneously. Diagnostic capa- gauge at operating temperature.
bilities include fault codes with text translation for the most
common fault conditions.
Low Hydraulic Oil Level Warning

It is very important that a safe level of oil is maintained in the
The machine is equipped with a sensor which monitors hydrau- tank at all times. The operator will be alerted if the oil level
lic oil level in the tank. The low hydraulic oil level sensor is in the tank drops below a safe level. Always use the hydraulic
designed to protect the machine in the event of a hose failure or oil level sight gauge mounted on the tank to determine a safe
rapid oil loss. You must shut down the machine immediately if oil level. The sight gauge can be seen from the operator’s seat.
the low hydraulic oil level warning light signals the alarm. The It is always a good policy for the operator to check oil level
warning light is RED colored. frequently throughout the working shift.

Charge Filter By-Pass Warning Light Arm System Switch
The machine is equipped with a sensor which monitors the Press the green portion of the switch to arm the hydraulic
track drive charge filter bypass. The charge filter bypass sen- system. No machine control functions are allowed to work
sor is designed to protect the hydrostatic travel circuit from oil until the door is closed and the arm system switch has been
contamination damage. Shut down the machine immediately if pressed. If the door is opened and than closed again, the arm
the charge filter bypass warning light signals an alarm. Change system switch must be pressed again before the machine can
the filter element or allow the machine to warm up before con- be operated.
tinued operation. The warning light is YELLOW colored.
Work Lights Switch
Press the icon portion of the switch to turn on the machine work
lights. Press the black side of the switch to turn the lights off.
Charge filter bypass will allow unfiltered oil into the hy-
drostatic track drive circuit where it will contaminate the Low Speed Lock Switch
rest of the track drive system. The track drive motors are equipped with an auto-shift feature
that automatically shifts the motor between high displacement
(low speed) and low displacement (high speed). The shifting
of the motor is determined by pressure in the drive circuit.
Press the icon portion of the switch to enable auto-shift. Press
the black side to “Lock” the track drive motors in low speed.
A dirty charge filter element leads to charge filter bypass
and hydrostatic drive system contamination. Change the Ignition Switch
charge filter element according to the preventive mainte- The ignition switch is a 4-position switch used to start the
nance guidelines, or sooner if required. machine and activate power to functions in the run position.
Position 1 - Auxiliary Supplies power to computer

and other accessories, engine
is off.
Incorrect cold weather operating procedures can force Position 2 - Off Turn the key to this position
charge filter bypass. Follow the “Machine Warm-Up to shut down the engine. In-
Procedures” as described in this manual. sert and remove the key from
this position. No power
output.
Disc Saw Engaged Warning Light Position 3 - Run The ignition key will auto-
The machine is equipped with a warning light to remind you matically return to this posi-
that the disc saw is live whenever the disc saw engage switch is tion when it is released after
pressed. Never operate the machine with the disc saw engaged starting the engine. Supplies
when people are within the safety zone around the machine. power for all machine func-
tions.
The warning light is YELLOW colored.
System Armed Warning Light Position 4 - Start Turn the key all the way
The machine is equipped with a warning light to alert you clockwise to crank the en-
whenever the hydraulic system is live. As a safety feature gine. Release the key when
in the IQAN control system, you must press the arm system the engine starts. Do not
switch to bring the control levers to life. crank the engine for more
than 30 seconds if it does
Reversible Radiator Cooling Fan Switch
not start. If the engine fails
By pressing the button, you can manually reverse the direction
to start, return the key to the
of the radiator cooling fan so that it blows out instead of suck- “OFF” position for about 2
ing in. This feature allows the operator to blow the debris off minutes before trying to start
of the radiator screens throughout the day, thus reducing the again.
frequency of manual cleaning.
Throttle (Potentiometer) Knob
The radiator fan will reverse every 30 minutes for a time period Turn the throttle potentiometer all the way counter-clockwise
of one minute and will then switch back. for idle. Turn the throttle potentiometer all the way clockwise
for maximum throttle position. The throttle potentiometer is
infinitely adjustable between idle and maximum positions.

Auxiliary Oil Cooler (Optional)
Press the BLUE icon portion of the switch to activate the elec-
tric fan motor in the auxiliary oil cooler assembly mounted on
the swing out valve cover directly behind the cab. Press the
black portion of the switch to turn off the electric motor.
Auxiliary Cab Floor Heater (Optional)

Press the “BLUE” icon portion of the switch to activate the
optional floor heater located behind the operator’s seat. Press
the black portion of the switch to turn off the heater.
Charge Oil Heater (Optional)

Press the red portion of the switch to activate the optional
charge oil heater. When the charge oil heater is activated the
IQAN control system blocks operation of all control functions.
This is done to prevent system damage due to overheating if
the machine was operated with the charge oil heater engaged.
The charge oil heater is designed to help warm up the hydrau-
lic oil during cold weather machine warm-up. Press the black
portion of the switch to deactivate the charge oil heater.
Disc Saw Engage Switch

If the machine is equipped with a disc saw, press the
“YELLOW” icon portion of the switch to engage the disc saw.
Once pressed, a “YELLOW” warning light appears on the dash
panel as a reminder to be very cautious and watch that there are
no bystanders within your work zone.
Disc Saw Disengage Switch

Press the “YELLOW” icon portion of the switch to disengage
the disc saw.
Fuel Transfer Pump (Not on all models)

Certain models of machines have two fuel tanks, one in the
lower unit and one in the upper unit. Press the “YELLOW”
portion of the switch to activate the fuel transfer pump to move
fuel from the lower tank to the upper tank.
Hour Meter
The hour meter records the actual hours the machine has been
operated. Do not disconnect the hour meter for any reason. All
recommended preventive maintenance procedures are based on
the hour meter reading.

Key Pad Functions Preview Menus
1. Display First Time Start Up

2. Menu Key 1. When power is applied to the Preview the “Logo Screen”
3. Left Arrow Key will be shown followed by the “Software Version Screen”.
4. Right Arrow Key
5. Enter Key
6. Bezel
2. The “Wait to Start” message will be displayed for engines

with a pre-startup sequence. Once the “Wait to Start” message
is no longer displayed the operator may start the engine. Note:
Displays only when SAE J1939 message is supported by
engine manufacturer.
Keypad Functions
The keypad on the Preview is a capacitive touch sensing

system. There are no mechanical switches to wear or stick,
and the technology has been time proven in many applications. 3. Once the engine has started the display will show the single
It operates in extreme temperatures, with gloves, through ice, engine parameter display.
snow, mud, grease, etc.., and it allows complete sealing of the
front of the Preview. The ‘key is pressed’ feedback is provided
by flashing the screen. The keys on the keypad perform the
following functions:
– Menu Key - The Menu Key is pressed to

either enter or exit the menu screens.
– Left Arrow - The Left Arrow Key is

pressed to scroll through the screen either
Main Menu Navigation
1. Starting at the single or four engine parameter display,
moving the parameter selection toward the
depress the “Menu Button”.
left or downward.
– Right Arrow - The Right Arrow Key is

pressed to scroll through the screen either
moving the parameter selection toward the
right or upward.
– Enter Key - The Enter Key pressed to

select the parameter that is highlighted on
the screen.

2. The first seven items of the “Main Menu” will be displayed.
3. Depressing the “Arrow Buttons” will scroll through the

menu selections.
4. Pressing the right arrow button will scroll down to reveal

the last items of “Main Menu” screen highlighting the next
item down.
5. Use the arrow buttons to scroll to the desired menu item or

press the “Menu Button” to exit the Main menu and return to
the engine parameter display.

Engine Configuration Data
1. Starting at the single or four engine parameter display press

the “Menu Button”.
6. Press the “Menu Button” to exit the Main menu and return
to the engine parameter display.
2. The main menu will pop up on the display. Use the

“Arrow Buttons” to scroll through the menu until the “Engine
Configuration” is highlighted.
Stored Fault Codes

1. Starting at the single or four engine parameter display
3. Once the “Engine Configuration” menu item has been

highlighted press the “Select Button” to view the engine
configuration data.
2. The main menu will pop up on the display. Use the “Arrow
Buttons” to scroll through the menu until the “Stored Fault
Codes” is highlighted.
4. Use the “Arrow Buttons” to scroll through the engine

configuration data.
3. Once the “Stored Fault Codes” menu item has been

highlighted press the “Select Button” to view the “Stored Fault
Codes”.
5. Press the “Menu Button” to return to the main menu.

4. If the word “MORE” appears above the “Arrow Buttons”
there are more stored fault codes that may be viewed. Use
the “Arrow Buttons” to scroll to the next “Stored Diagnostic
Code.
2. The PVA Series of auxiliary gauges can be attached to

the Preview. These auxiliary gauges communicate with the
Modbus master PVA Series gage via a daisy-chained RS-485
port. If at any time during system initialization or normal
operation an auxiliary gauge should fail the single of four
5. When the arrow appears to the right of the word “MORE” parameter screen will be replaced with the “MLink Gage
continue to scroll to the right to see more “Stored Diagnostic Fault” message. The screen title “MLink Gage Fault” will
Codes”. If the arrow shifts to the left side of the word flash.
“MORE” the end of the stored codes has been reached. Press
the left “Arrow Button” to review the stored codes.
3. To acknowledge and “Hide” the fault and return to the

single or four parameter display press the “Select Button”.
4. The display will return to the single or four parameter

screen.
Faults and Warnings
Auxiliary Gage Fault

1. During normal operation the single or four parameter
screen will be displayed.

5. Pressing the “Select Button” will re-display the hidden 4. When the arrow appears to the right of the word “MORE”
fault. Pressing the “Select Button” once again will hide the continue to scroll to the right to see more “Active Fault
fault and return the screen to the single or four parameter Codes”. If the arrow shifts to the left side of the word
display. NOTE: The fault can only be cleared by powering the “MORE” the end of the active codes has been reached. Press
system down, removing or replacing the auxiliary gauge. the left “Arrow Button” to review the active fault codes.

Active Fault Codes single or four parameter display press the “Select Button”.
1. During normal operation the single or four parameter
screen will be displayed.

display, but the display will contain the flashing “Active
2. When the Preview receives a fault code from an engine Fault”warning icon.
control unit the single or four parameter screen will be
replaced with the “Active Fault Codes” message. The screen
title will flash between the two messages “Active Fault Codes”
and “Warning!”.
7. Pressing the “Select Button” will re-display the hidden
3. If the word “MORE” appears above the “Arrow Buttons”

there are more active fault codes that may be viewed. Use the
“Arrow Buttons” to scroll to the next “Active Fault Code”.
8. Pressing the “Select Button” once again will hide the fault
and return the screen to the single or four parameter display.
NOTE: Ignoring active fault codes can result in severe engine
damage.

5. Pressing the “Select Button” will re-display the hidden
Shutdown Codes
1. During normal operation the single or four parameter 6. Pressing the “Select Button” once again will hide the fault
screen will be displayed. and return the screen to the single or four parameter display.
NOTE: Ignoring the Shut Down message could lead to serious
engine damage.
2. When the Preview receives a severe fault code from an

engine control unit the single or four parameter screen will be
replaced with the “Shutdown!” message. The screen title will
flash the message “Shutdown!”. Back Light Adjustment

single or four parameter display press the “Select Button”.
2. The main menu will pop up on the display. Use the
“Arrow Buttons” to scroll through the menu until the “Adjust
Backlight” is highlighted.

display, but the display will contain the flashing “Shut Down”
icon.
3. Once the “Adjust Backlight” menu item has been
highlighted press the “Select Button” to activate the “Adjust
Backlight” function.

Buttons” to scroll through the menu until “Adjust Contrast” is
highlighted.
4. Use the “Arrow Buttons” to select the desired backlight

intensity.
3. Once the “Adjust Contrast” menu item has been

highlighted press the “Select Button” to activate the “Adjust
Contrast” function.
4. Use the “Arrow Buttons” to select the desired contrast

intensity.
Contrast Adjustment
depress the “Menu Button”. 6. Press the “Menu Button” to exit the Main menu and return

Select Units 6. Press the “Menu Button” to return to the main menu.
2. The main menu will pop up on the display. Use the arrow to the engine parameter display.
buttons to scroll through the menu until the “Select Units” is
highlighted.
Setup 1-Up Display

1. Starting at the single engine parameter display press the
3. Once the “Select Units” menu item has been highlighted “Menu Button”.
press the “Select Button” to access the “Select Units” function.
4. Use the arrow keys to highlight the desired units. “English” Buttons” to scroll through the menu until the “Setup 1-up
for Imperial units i.e. PSI, ºF or Metric for IS units i.e. KPA, display” is highlighted.
ºC.
3. Once the “Setup 1-up Display” menu item has been

highlighted press the “Select Button” to access the “Setup 1-
5. Press the “Select Button” to select the desired units or
up Display” function.
CANCEL to exit.

4. Three options are available for modification of the 1-Up 8. Pressing the “Select Button” will display a list of engine
display. parameters.
a.) Use Defaults – This option contains a set of engine
parameters: Engine Hours, Engine RPM,
System Voltage, % Engine Load at Current
RPM, Coolant Temperature, Oil Pressure, Etc. The
factory default has all available engine parameters
available for display.
b.) Custom Setup – This option contains a list of engine
parameters. Engine parameters from this list
can be selected to replace any or all of the
default parameters. This option can be used to limit
the number of parameters available for scrolling in 9. Use the “Arrow Buttons” to scroll to and highlight the
the 1-Up Display. “Clear All Parameters” from the menu. NOTE: Highlighted
c.) Automatic Scan – Selecting the scan function will parameters were previously selected.
because the 1-Up Display to scroll through the
selected set of parameters one at a time, momentarily
pausing at each.
5. Use Defaults - To select “Use Defaults” use the arrow

buttons to scroll to and highlight “Use Defaults” in the menu
display.
10. Press the “Select Button” to clear previously selected

parameters.
6. Press the “Select Button” to activate the “Use Defaults”

function. This action will reset the unit to the factory default
with all parameters available for scrolling from the 1-Up
Display.
11. Use the “Arrow Buttons” to scroll to and highlight the

desired parameter. Press the “Select Button” to select the
parameter for inclusion in the 1-Up Display.
7. Custom Setup - To perform a custom setup of the 1-

Up Display use the arrow buttons to scroll to and highlight
“Custom Setup” on the display. Two methods may be used:
Build a list by individually selecting parameters or “Select All
Parameters” then de-select those parameters not desired.

12. Continue to scroll through and select additional
parameters for the custom 1-Up Display.
13. Automatic Scan - Selecting the scan function will

cause the 1-Up Display to scroll through the selected set of
parameters one at a time. Use the “Arrow Buttons” to scroll to
the “Automatic Scan” function.
4-Up Display Setup

1. From the single or four engine parameter display press the
“Menu Button”.
14. Pressing the “Select Button” toggles the “Automatic

Scan” function on.
Buttons” to scroll through the menu until the “Setup 4-Up
Display” is highlighted.
15. Pressing the “Select Button” again toggles the “Automatic

Scan” function off.
3. Once the “Setup 4-Up Display” menu item has been

highlighted press the “Select Button” to activate the “Setup 4-
Up Display” menu.
16. Once the “Use Defaults”, “Custom Setup” and

“Automatic Scan” functions have been set press the “Menu
Button” to return to the main menu.
4. Use the “Arrow Buttons” to select one of the four engine

parameter display locations.

5. Pressing the “Select Button” will bring up a list of engine 10. Use the “Arrow Buttons” to scroll to and highlight the
parameters. desired parameter.
6. Use the “Arrow Buttons” to scroll through and highlight 11. Pressing the “Select Button” will place the selected
the desired engine parameter. parameter in the pre-selected 4-Up Display Location.
7. Pressing the “Select Button” will place the selected 12. Repeat the parameter selection process until all spaces are
parameter in the pre-selected 4-Up Display Location. filled.
NOTE: The parameters in any of the four display locations
may be edited and saved without affecting the other display
locations.
8. Use the “Arrow Buttons” to select the next parameter

display location.
9. Press the “Select Button” to view the engine parameter list.

IQAN Master Display Module (MDM)
The MDM is a user friendly computer module that allows the

user to make adjustments and troubleshoot the machine from
the operator’s seat. The MDM is set up with only 5 sub-menus,
therefore, you do not need to be a computer whiz to use the
system.
Sub-Menus:
1. Mode – Allows for 4 different operator settings which

are selected in the MODE screen. This means MODE On the display there are three function buttons [F1], [F2],
1, day shift operator, can tune the machine with differ- and [F3]. These are used to select different functions in the
ent maximum speeds and ramps on the outputs for the system’s submenus. Above every function button, there will
system. A 2nd shift operator can be MODE 2 which be an informative tab for the current function.
may be set a little slower or have smoother ramping
than the day shift operator. MODE 4 is generally The MDM also has an UP/DN button. The UP/DN button is
reserved for factory default settings and no changes used to increase or decrease values in the system wherever you
can be made to this MODE. see a ± or to browse a list whenever up and down arrows are
shown in the upper right of the display.
2. Information – Gives information on the Application,
including serial number identification and comments Use the escape [ESC] button to access the menus and to return
from the manufacturer. Also, all information on the to the previous menu or operating screen.
module communication and status is displayed in the
INFORMATION screen. This allows review of each
module of the system to determine if components are
on line and enabled.
3. Settings – The changes on this area are for informa-

tional configuration for the operator of the machine.
Changes include Light and Contrast adjustments, abil-
ity to change from the primary language to a second-
ary language (such as English to French), set warning
alarm volume, and date and time on the clock.
4. Measure – The measure menu allows the operator

to monitor all inputs or outputs of the IQAN system.
This feature when used is one of the most powerful
aspects for the machine control system. A malfunc-
tion or performance variance can easily be viewed
from the screen. This has several modes including %
signal monitoring, millivolt or milliampere monitor-
ing, or as a rudimentary oscilloscope.
5. Properties – The properties menu allows the operator

to set the adjustable parameters for inputs or outputs
as determined by the manufacturer of the machine.
This allows operator 1 to set the minimum and maxi-
mum current to a valve which can control minimum
and maximum flow of a function. The start ramp and
stop ramp for extending and retracting a cylinder as
well as the ability of fine control to make the joystick
work to the operator’s advantage.

Browsing in the Menu System:
Use the ESC button to go to the menu system and also when
you want to return to the operational position. (To return to
the operational position, you must be on the first menu level.)
To browse between the different menus, use the UP/DN - but-

ton to the right of the character window.
In the sub-menus, use the ESC button to return to the previous

menu level.
Menu System:
The system consists of five menus and their sub-menus.

• Mode
• Information
• Settings
• Measure
• Properties
The different menus are characterized by their own icon which

is shown before the menu name.

Mode Setting:
In this menu, you can switch between up to four different

operators and copy values from on mode to the active mode.
The current mode is always shown in the character window’s
upper right corner.
To select a mode:
• Press the [F1] button to select the function
SELECT MODE.
• Browse with the UP/DN button and press [F1] key
to save. (An informative tab OK will be
displayed above the [F1] button.
• If you press CANCEL [F2] or press ESC, the
display returns tot he previous menu without
changing mode (operator) settings.
Copying settings from another mode:
Such as if you add another machine operator.

• Press the [F2] COPY to select the function
COPY FROM MODE.
• Browse to the desired mode using the UP/DN
button and press [F1] OK. The display shows
copying.... and returns to the previous menu.
• Press [F2] CANCEL or ESC to return the
display to the previous menu without copying
the mode settings.
• Press [F3] to reset to the actual factory pre-set
values.

System Information
This menu contains functions for showing information about

the application hardware and software including modules.
It may be helpful in certain cases to write down the information

found under system information to give to your service techni-
cian when calling for service work.
To show application information:
• Press APPLIC. [F1] to show information regarding

the application.
• The first screen shows the application description fol-

lowed by the version number.
• Press MORE [F1]
• The first line will show the date and time of the latest
change.
• The last line will show the latest change.

Display Settings:
This menu contains functions to change the display’s contrast

and light, change language on the menu texts, set the volume
for the buzzer, change button sound, and set the date and
time.
There is not enough space in this menu for all function tabs in
the character window. Using the MORE [F3], you can switch
between the different tabs.
Changing Contrast:
• Press LCD [F1] to select the function LCD

SETTINGS.
• Press CONTRAST [F1] to select the function LCD

CONTRAST.
• Change to the desired contrast by pressing the UP/DN

button and then press OK [F1] to save the setting and
return to the previous menu.
• CANCEL [F2] or ESC returns to the previous menu

without saving changes.
• The RESET [F3] resets the contrast to the factory pre-

set setting.

Changing Back Light Settings:
• Press LCD [F1] to select the function LCD

SETTINGS.
• Press LIGHT [F2] to select the function LCD

LIGHT.
• Change the desired light level using the UP/DN

button and press OK [F1] to save the setting and
• CANCEL [F2] or ESC returns to the previous
menu without saving changes.
• RESET [F3] resets the light to the factory pre-set
setting.

Changing Language:
• Press LANGUAGE [F2] to select the function

LANGUAGE SETTINGS.
• Use the UP/DN button to select the language and

press the OK [F1] key to save the changes and
• CANCEL [F2] or ESC returns to the previous
menu without saving changes.
Note: This changes the language in all menus.

Sound Settings:
In this menu you can select the sound level for the keys and
also for the warning alarms.
Note: The warning alarms should be set loud so that it can

alert an operator of a problem.
• Press MORE [F3] to get to the sound tab.
• Press SOUND [F1] to select SOUND SETTINGS

menu.
• Press ALARM [F1] or BUTTON [F2] to select

which sound level you wish to change.
• Adjust the sound level using the UP/DN button.
Up increases the volume and down decreases
the volume.
• Press OK [F1] to save the setting and return to the

previous screen.
• CANCEL [F2] or ESC to return to the previous
screen without saving.
• Press RESET [F3] to apply the factory pre-set
values.

Setting Date and Time:
• Press MORE [F3] to get to the sound tab.
• Press SET CLOCK [F2].
• Use the UP/DN button to choose the functions

of year, month, day, hour, and minute.
• Press SELECT [F1] to make any changes.
• Press OK [F1] to save the changees and return to

the previous menu.
• Press CANCEL [F2] or ESC to return to the
previous menu without saving changes.

Measure:
This function is used for measuring on different channels or

functions. You can measure voltage, digital, and frequency of
inputs to the IQAN as well as current and digital outputs from
the IQAN. These functions are primarily used in troubleshoot-
ing to find an open or short circuit or possibly a faulty sender.
Measuring Inputs:
Input functions are measured the same way for voltage, digi-
tal, and frequency.
• Press INPUTS [F1].
• Use the UP/DN button to find the type of input you

wish to check; voltage in, frequency in, or digital in.
• The first line gives you information on the channel

type and PIN number.
• The second line gives you the channel (function)

name and the measured value.
• Press the [F1] button to choose how you want the

measured value displayed, scaled or voltage.
• Press SCOPE [F3] to get the channel’s value pre-

sented in a graph form to be able to read an historic
trend.
• To the left of the graph, the channel’s minimum and

maximum values are shown. The graph is drawn from
left to right. After 30 seconds, the curve is drawn
from the left again.
• To return to the previous menu, press ESC.

Measuring an output current:
• Press OUTPUTS [F2].
• Press the UP/DN button to choose between current out

or digital out, and press the SELECT [F1] button.
• Use the UP/DN button to select the function you wish

to test, shown in the lower left of the display.
• The first line shows the channel type and PIN num-
ber.
• The second line shows the channel (function) name

and measured value.
• Select SCOPE [F3] to view the output in a graph

form.

Properties:
The properties menu allows the operator to set the adjust-

An output will continue to move after a signal is ended.
able parameters for inputs and outputs as determined by the
This could be hazardous based on the machine function.
manufacturer of the machine. This allows operator 1 to set the
minimum and maximum current to a valve which can control
minimum and maximum flow to a function. It is also possible
to set start and stop ramps on certain functions which enable a
Fine Control: Fine control allows for an operator to set the
function to start and stop smoothly.
output to be very small for a movement of a joystick. For
example, if you set the Fine Control at 25% then the valve will
It is adjusted at CURRENT OUT and PWM OUT. see 25% of maximum current for 50% of the joystick handle
movement. The last 75% of the current would occur in the last
Minimum Current: Is the setting that determines at what 50% of the handle movement. This feature allows for excel-
point a function begins to move. If set too low, the joystick lent creep controls near the center of the joystick. This feature
could move an excessive amount before the function begins to should be adjusted by the operator to see what fits them in their
move. If set too high, the function may start abruptly when the application.
joystick is moved a short distance or may stop with a jerk as
opposed to a nice ramping.
Maximum Current: Is the setting that determines the maxi-

mum speed for a function. The lower the setting, the slower
the function will move. This can be used in conjunction with a
MODE setting to allow for instance MODE 1 (operator 1) to be
fast, but MODE 2 (operator 2) can be a creep setting.
Start Slope: This is the ramp up of a function from the stopped

condition to the full on condition. For example, if an operator
moves a joystick rapidly to full on, this Start Slope will ramp
the signal to the valve to ensure elimination of a jerky start.
Stop Slope: This is the ramping down of a function from the

on condition to the stop condition. For example, if you were to
suddenly let go of a joystick from the full on position the func-
tion would ramp down to the stop instead of quickly stopping
and causing a jerk.

Properties:
• Press OUTPUTS [F2].
• Press SELECT [F1] to select current out.
• Use the UP/DN button to select the function you wish

to adjust. The function name is in the lower left of the
display.
• Press [F1] or [F2] to adjust the direction of the func-

tion you want to adjust.
Note: You can move the function and the mA will show a + or
– number. This tells you which one to select.
• Use the UP/DN button to choose what adjust-

ment you wish to make; MIN CURRENT, MAX
CURRENT, STARTSLOPE, STOPSLOPE, OR
FINE CONTROL.
• Press the SELECT [F1] key.

• Use the UP/DN button to adjust the current.
• Test drive the function to be sure it works how you

want it.
• Press OK [F1] to accept the new setting or press

CANCEL [F2] or ESC to exit to the previous menu
without saving the changes.

PWM Function Adjustments
Properties: Press F2 to get to Current Out.
Press the UP/DOWN button to get to PWM OUT.
Press Select, F1.
Use the UP/DOWN button to select the function you wish to

adjust.
Press F1 or F2 to select which direction you wish to adjust.
Use the UP/DOWN button to select either MIN MR, MAX

MR, STARTSLOPE, STOPSLOPE, or FINE CONTROL and
press the F1 [OK] button.
Use the UP/DOWN button to make the adjustment and press

the F1 [OK] button to accept the change or press ESC to exit
back to the previous screen without saving the change.

Chapter 5 - Hydraulics
Hydraulic
Section 1
Hydraulic System Description Page 5.1.3
Hydraulic Tank & Filters Page 5.1.6
Section 2
Hydraulic Tank Pressurization Page 5.2.1
Oil Cooler Page 5.2.4
Section 3
Valve Bank Pressure Adjustments Page 5.3.1
Section 4
Disc Saw Pressure Adjustments Page 5.4.1
Section 5
Implement Pump Pressure Adjustments Page 5.5.1
Section 6
Hydrostatic Pressure Adjustments Page 5.6.1
Section 7
Emergency Towing Procedure Page 5.7.1
You must read and understand the warnings and basic safety Unexpected track movement can result in serious
rules, found in Chapter 1 of this manual, before performing personal injury or death. Pin the tracks to prevent
any operation, test, or adjustment procedures. movement during testing and adjustment procedures.
At operating temperature, the engine, exhaust system

components, cooling system components, and hydraulic
system components are HOT. Any contact can cause Diesel exhaust fumes contain elements that are hazard-
severe burns. ous to your health. Always run engine in a well ventilated
area. If in an enclosed space, vent exhaust fumes to the
outside.
Sudden movement of any machine part can cause

serious bodily injury or death. Make sure there is
nobody within the danger zone of the machine when
performing tests or making adjustments.
Pressure can be maintained in system circuits long

after the engine and pumps have been shut down.
Release trapped pressure in hydraulic, fuel, and cool-
ing system lines before performing any maintenance
or repair procedures.
Chapter 5.1 - Hydraulic Page 5.1.2

Hydraulic Systems tracking functions. The track drive system used is a
“closed-loop hydrostatic” system consisting of the track
drive pumps and motors. Each track has its own separate
Types Of Hydraulic Systems Used in circuit. This gives the machine high tractive effort that is
independent of the implement functions.
Your Feller-Buncher
There are actually three types of hydraulic systems used “Closed-loop hydrostatic” means that the pump directly
on the machine: drives the motor without valves being required to divert
oil flow.
Implement Hydraulic System - The implement
hydraulic system controls the boom, cab leveling and Hydrostatic Charge Pump System - Each hydrostatic
cutting attachment functions. The implement hydraulic track drive system is charged by a common gear pump.
system is a “closed-center, variable displacement, load The charge oil system also incorporates a filter/manifold
sense” system. The major components consist of the assembly equipped with a relief valve to maintain a set
implement pump, main control valve and the various pressure in the system. The charge oil system supplies
motors and cylinders that do the work. cool oil to the track drive hydrostatic loops and also to
operate the track brakes and track motor shift function.
“Closed-center” means that when the main control
valve spools are in the centered (neutral) position there is
almost no oil flowing through the system.
“Variable displacement” means the implement pump

has the ability to vary its oil flow output to match the
demands of the system.
“Load sense” is how the system tells the pump to vary

its oil flow output. This is usually done with a pressure
signal sent from the main control valve to the pump.
Hydrostatic Track Drive System - The track drive

hydraulic system controls the forward and reverse
Page 5.1.3 Chapter 5.1 - Hydraulic

Hydraulic System Cleanliness moisture, chemicals, etc. Whenever a hydraulic
system component is removed, especially
hoses, contaminates can enter the system. Even
Keeping Your Hydraulic Oil And changing filter elements can allow contaminates
to enter the system.
System Clean
The hydraulic system uses piston pumps and 4) Produced internally: component wear, hydraulic
motors that operate at pressures as high as oil or hose breakdown as a result of overheat,
6500 PSI. These state-of-the-art components must be rust, oxidation, etc.
manufactured with very tight tolerances to provide high
performance and efficiency. The tighter the tolerances, ISO Code Rating
the more damage contamination will cause.
Cleanliness of hydraulic oil is rated on an
ISO Code scale. An ISO Code rating is made up of
Types Of Contaminates
two numbers that reference the approximate number of
There are many types of contaminates. The most particulate contaminates, by size, that can be found in a
common are: fixed volume (1 ml) of hydraulic oil.
1) Particulate (dust, dirt, sand, fibre, rust, For example: ISO Code 17/14 - This is the cleanliness
rubber, paint chips, metal flakes, etc.) required by the manufacturer of the pumps and motors
Particulates are referred to by their size in used in your Feller-Buncher’s hydraulic system.
“Microns”.
The lower the ISO Code numbers, the cleaner the oil is.
For example: Generally, the only time you will see an ISO Code rating
is on an oil performance specification sheet or an oil
Grain of table salt . . . . . . . . . . . . . 100 microns sample test results sheet. Because an ISO Code rating is
Human hair diameter . . . . . . . . . . . . 70 microns based on particles you cannot see with the naked eye, it
Limit of visibility . . . . . . . . . . . . . . . 40 microns is difficult to use the ISO Code rating unless it references
White blood cell . . . . . . . . . . . . . . . . 25 microns test results.
Talcum powder . . . . . . . . . . . . . . . . 10 microns
Red blood cell . . . . . . . . . . . . . . . . . . 8 microns A better example, or reference, may be this:
Bacteria . . . . . . . . . . . . . . . . . . . . . . . 2 microns
ISO Code 14/10 - Cleanliness required by most hydraulic
2) Water servo-type systems.
3) Sealants (Teflon, etc.) ISO Code 17/14 - Cleanliness required in the your Feller-
Buncher’s hydraulic systems.
4) Sludge (result of hydraulic oil breakdown)
ISO Code 21/19 - Generally, the cleanliness of “new”
Sources Of Contaminates hydraulic oil shipped in the drum.
Contaminates can get into a hydraulic system in several
On the ISO Code rating scale, a 14/10 rating is 10X
ways:
cleaner than a 17/14 rating, and... a 21/19 rating is 10X
dirtier than a 17/14 rating. This is why it is so important
1) Un-clean “new” hydraulic oil: Hydraulic oil, as
to only add pre-filtered oil to your hydraulic system.
it is packaged by the manufacturer, is not clean
enough to use in a hydraulic system without
filtering.
2) Inherent: Component storage, Manufacturing

Process, Assembly, etc.
3) Ingested from the environment: dust, dirt,

Concerns When Adding Hydraulic Oil 4) Always bleed the hydraulic circuit, especially
hydrostatic drive circuits, of air after replacing
Each machine is equipped with an electrical hydraulic a component or hose. Air in the system can
oil fill pump which should be used to add oil to the damage pumps and motors.
hydraulic tank. The fill pump pushes the oil being added
across the return filter system to reduce the likelihood
of contamination. NEVER pour unfiltered hydraulic oil Concerns When Replacing Hydraulic
into the hydraulic tank. Oil companies typically do not Filter Elements
filter their oil before packaging. Replacing hydraulic filter elements can also allow
contaminates into the system, especially the return filters
Concerns When Replacing Hydraulic System in the hydraulic tank.
Components
Replacing hydraulic system components, especially
hoses, is a big potential source of contamination. When
replacing a component, be sure to do the following:
1) Thoroughly clean the area around the component

before removal.
2) Always cap or plug disconnected hoses

immediately. Do not leave hoses or ports open to
atmosphere unless specifically required by a test
procedure.
3) Use only replacement hose assemblies

that have been flushed and capped. An un-
flushed hose is full of contaminates from when
the hose was cut.

Filter Head Cover
Return Oil
Flow
Filter Head
Filter Canister
Hydraulic Oil
Filter Element
Filter Element Tank
Diffuser Tube
Implement Pump
Suction Strainer
Auxiliary Suction
Strainers
Figure 3: Exploded View - Hydraulic Tank Filters & Strainers

Hydraulic Oil Filtration System IMPORTANT: When changing a filter element, inspect
the oil around the element for metallic flakes before
Good hydraulic oil filtration is one of the most important removing it. If metallic flakes can be seen, or if there
factors in the good operation and long service life of your has been a pump or motor failure recently, you should
hydraulic system. Filters and strainers catch and retain not remove the filter element. Doing so will allow the
harmful contaminates that can damage the system. contaminated oil around the element to drain directly
into the main tank. In this case, the entire filter assembly
Return Oil Filters must be removed before the element can be changed.
There are three canister-type filters installed through the There is also a decal located just above the dash panel
top of the hydraulic tank that filter return oil. See Figure that explains how to change return oil filters. Return
3. All return oil must pass through one of these filter oil filters should be changed after every 500 hours of
assemblies before entering the main tank. operation.
NOTE: The filter assembly furthest from the boom is for
Filter Bypass And Why It Should Be Avoided
case drain oil.
How Oil Is Filtered

Each filter assembly has a removable element. Hydraulic
Return filter bypass allows unfiltered oil into the
oil is filtered in the following manner:
main tank where it begins contaminating the rest of
the hydraulic system. Prevent return filter bypass.
1) Oil enters the filter assembly at the
filter head. See Figure 3.
The hydraulic return oil filter assemblies are equipped
with a bypass valve that prevents the filter element from
2) From the filter head, the oil flows down into
rupturing or collapsing if the filter canister back-pressure
the canister between the canister wall and filter
gets too high. This bypass valve is located where the
element.
filter head cover seals the top of the filter element. See
Figure 3 Inset.
3) Oil if then filtered by passing from OUTSIDE
the filter element to INSIDE the filter element.
The filter bypass valve cracking pressure is preset to
prevent the filter element from collapsing. Bypass can
4) Filtered oil can now enter the main tank through occur for several reasons:
a diffuser at the bottom of the canister. The
diffuser reduces turbulence
1) The filter element is plugged.
in the oil.
2) The hydraulic oil viscosity is too heavy for
Changing Return Oil Filters ambient conditions.
Return filter elements are changed by removing the filter
head cover and removing the element. 3) The hydraulic oil is too cold to flow easily
through the filter element.
Avoiding filter bypass is very important because it allows

unfiltered oil to return directly into the main tank. The
debris resulting from a catastrophic pump or motor failure
can quickly plug a return filter causing it to bypass and
sending more debris into the rest of the hydraulic system
which can cause more severe damage.

The Return Filter Back Pressure Gauge During a cold start always allow the oil to warm to
operating temperature before running the engine at full
speed. Following these simple rules will help prevent
costly downtime and greatly increase the service life of
your equipment.
Suction Strainers
Individual suction strainers made of 100-mesh
screen are installed in all pump suction lines.
See Figure 3.
The primary purpose of a suction strainer is to prevent

“vortexing” or “swirling” of the oil as it enters the pump
suction line. Water draining from a sink is a good visual
example of a “vortex” condition. It is important to
Figure 4: Return Filter Back Pressure Gauge prevent “vortexing” because it can cause cavitation and
damage the pump.
The other purpose of a suction strainer is to stop large

particles from entering the suction line. The suction
stainers will not protect the hydraulic system if the return
Dirty Filters lead to return filter bypass and possible filters go into bypass and contaminate the tank.
hydraulic system contamination. Change filters
according to preventative maintenance guidelines, IMPORTANT: A suction strainer is not a filter.
or sooner if required. A 100-mesh screen will pass a 149-micron size particle,
a little larger than a grain of salt, that will damage a
pump.
Incorrect cold weather starting can force return Suction strainers should be removed and cleaned at least
filter bypass and possible hydraulic system every 2000 hours, or once a year.
contamination.
The machine is equipped with a gauge in the dash which

monitors back pressure in the return filter canisters. See
Figure 4. The operator will be alerted with a warning
light and buzzer if return filter back pressure reaches 30
psig (210 kPa); indicating that a return filter is nearing
the bypass setting [normal operating back pressure is 10 -
15 psig (70 - 105 kPa) depending upon oil temperature].
Excessive back pressure is usually the result of dirty

filters in need of changing, or in the case of a cold
start, cold oil being forced through the filters. Return
filters must be changed per the preventive maintenance
schedule or earlier if the back pressure reaches 30 psi on
the return filter back pressure gauge at normal hydraulic
oil operating temperature above 120F.

Pressurized Hydraulic Tank Releasing Hydraulic Tank Pressure
The hydraulic tank must be pressurized because
most pumps, especially piston pumps, cannot
“suck” oil. Oil must be forced into the pump’s inlet.
Piston pumps can cavitate, and be damaged, if the Hydraulic oil tank is under pressure.
suction inlet pressure drops below 1 psi (7 kPa). Escaping oil can cause serious injury. Vent
tank before removing cap or servicing the
hydraulic system
Figure 5: Hydraulic Tank Turbo Boost Regulator

(Typical)
Hydraulic Tank Pressurization Figure 6: Turbo Boost Release Valve
The hydraulic tank is pressurized to 5 psig (35 kPa)

using turbo boost from the engine. See Figure 5. Before adding oil or opening the tank for any
The engine is capable of producing up to 25 psi reason, boost pressure must be released by
(172 kPa) boost pressure, therefore, a pressure opening the turbo boost pressure release valve.
regulator is required to maintain the required 5 psig See Figure 6.
(35 kPa) boost pressure.
It is also good practice to release boost pressure
A check valve is located between the turbo boost from the tank before performing any maintenance
line and tank to prevent oil from getting into the on the hydraulic system. Many lines are common to
turbo. the tank. Releasing the boost pressure will prevent
oil from escaping under force when loosening
The tank is also equipped with a 13 psi (90 kPa) fittings.
safety relief cap to protect the system in the event
the pressure regulator would malfunction. The drain
hose from the relief cap is routed down through the
turntable base plate.

Oil Return
Oil level going up a 27° slope
while at low oil level warning. Suction
strainers will be exposed to air.
Keep oil in
green zone
of sight gauge
when hot
Low Oil
Warning
Level
Main Tank
Return
Filter
Implement
Suction
Strainer
Auxiliary
Suction Strainers
Figure 7: The Effects Of Low Hydraulic Oil Level
The Importance of Hydraulic Tank Catastrophic failures result in very large amounts of
contamination being dumped into the hydraulic system.
Oil Level This will often result in the additional failure of other
The level of hydraulic oil in the tank is very important major components. In many cases the complete hydraulic
in any hydraulic system. If the oil level drops too low, system and its components must be thoroughly flushed to
the suction strainers for the pumps can be exposed to air. remove all contamination before returning to work.
Exposing a suction strainer to air will allow the air to
enter the pump where it will cause catastrophic damage. To prevent cavitation, the hydraulic oil level in the tank
This is called “cavitation”. must be kept at the level indicated on the tank’s sight
gauge.
When air mixes with oil in the suction line it forms
bubbles. These bubbles are drawn into the pump and
are very tightly compressed by the pump’s piston rotary
group. As the compressed air bubbles leave the rotary
group, they expand very rapidly, like tiny explosions.
These tiny explosions deteriorate the brass surface of
the piston shoes and valve plate and will very quickly
destroy the pump.

Hydraulic System Overheating
Preventing hydraulic system overheating is another
important factor in the good operation and long service
life of your hydraulic system. Hydraulic system
overheating can damage the system in many ways such
as breakdown of the hydraulic oil producing “sludge”,
deterioration of hose linings releasing rubber particles
into the system, and increased formation of acids that can
begin to corrode components. Correct any overheating
problems as soon as possible.
IQAN Hydraulic Temperature

Compensation System
Figure 8: Hydraulic Oil Sight Gauge The IQAN system monitors hydraulic oil temperature
and adjusts function outputs for hot or cold oil. To
Hydraulic Tank Sight Gauge reduce heat input, when the oil temperature exceeds 190F
the machine functions will automatically begin to slow
On most models, the hydraulic tank sight gauge can be down. The hotter the oil, the greater the reduction in
easily viewed from the operator’s seat when the main output speed until at 210F machine functions are reduced
boom is raised. See Figure 8. It is usually located near to 50% of normal speed. To protect the pumps from
the air cleaner canister. Always be sure that the hydraulic cold start cavitation, the same control reduces machine
oil level remains in the green zone of the sight gauge functions when temperatures are below 50F.
decal when the oil is at operating temperature. Keeping
the hydraulic oil at this level will prevent the suction
strainers from being exposed to air when positioned on a Hydraulic Oil Type & Viscosity
slope. See Figure 8. The selection of hydraulic oil type and viscosity plays
a major role in the maximum allowable operating
IMPORTANT: Always check oil level when it is at temperature of the hydraulic system. For instance, a
operating temperature. As oil warms it will expand. winter grade hydraulic oil such as ISO 32 can not operate
Filling the tank to the green level when the oil is cold will at temperatures over 165F without damaging hydraulic
result in over filling. An over filled tank will purge oil out components. The operator must know the temperature
the safety relief and contaminate the environment. limitations of the oil in his machine. Always be sure
the hydraulic oil viscosity is correct for the ambient
It is a very good policy for the operator to visually check conditions. Detailed information on hydraulic oil type
the sight gauge frequently throughout the working shift. and viscosity can be found in Appendix A.
As added protection, a low hydraulic oil level warning
system is standard on every machine.
Low Hydraulic Oil Level Warning

A fluid level sensor is installed in the tank that warns
the operator with an indicator light and buzzer if the
hydraulic oil drops too low. See Figure 8.
This warning system should not replace a visual check by

the operator. It is designed only to alert the operator if
there was a rapid loss of oil like a ruptured hose, etc.

Hydraulic Tank Turbo Boost Tools Required:
Regulator • 1/2”, 9/16”, 5/8” & 11/16” wrenches
• 0 - 30 psi (200 kPa) gauge
• Air supply
Specification:
You must read and understand the warnings and
basic safety rules, found in chapter 1 of this 5 - 7 psig (34,5 - 48,2 kPa)
manual, before performing any operation, test or
adjustment procedures. Procedure:

system components, cooling system
components, and hydraulic system components are Figure 9: Turbo Boost Release Valve
HOT. Any contact can cause severe burns.
1. Release turbo boost pressure at the turbo boost
release valve. See Figure 9.

down. Release trapped pressure in hydraulic, fuel,
and cooling system lines before performing any
maintenance or repair procedures.
Figure 10: Hydraulic Tank Turbo Boost Regulator
(Typical)
2. Open the perforated swing-out engine guard to

access the turbo boost release valve and turbo boost
regulator. See figure 10.
3. Disconnect and remove the turbo boost regulator

from the engine intake manifold.
Page 5.2.1 Chapter 5.2 - Hydraulics

6. Record original reading.
Adjuster 7. Pull adjuster knob out from lock position and set the
Knob
turbo boost regulator to specification.
Inlet Port To increase pressure setting, turn the adjuster knob

in clockwise. To decrease the pressure setting, turn
the adjuster knob out
counter-clockwise.
Auxiliary
Gauge Port NOTE: Always start with a pressure reading lower
then specification and bring adjustment up to
Outlet Port specification, otherwise pressure creep will occur.
8. Push the adjuster knob in to lock and then

Figure 11: Turbo Boost Regulator
re-install the turbo boost regulator.
4. Install pressure gauge on the outlet port of the turbo 9. Close the turbo boost release valve, then close and
boost regulator. See Figure 11. secure the perforated swing-out engine guard.
5. Attach an air supply with a shut-off valve to the

inlet port of the turbo boost regulator.
Chapter 5.2 - Hydraulics Page 5.2.2

Hydraulic Tank Safety Relief Cap Tools Required:
Coolant cap tester
Specification:
14 psig (96,5 kPa)
You must read and understand the warnings
and basic safety rules, found in Group-1 of this Procedure:
adjustment procedures.
Figure 12: Turbo Boost Release Valve

system components, cooling system 1. Release turbo boost pressure at the turbo boost
components, and hydraulic system components are release valve. See Figure 12.

long after the engine and pumps have been shut Figure 13: Hydraulic Tank Safety Relief Cap
down. Release trapped pressure in hydraulic, fuel,
and cooling system lines before performing any 2. Remove the hydraulic tank safety relief cap.
maintenance or repair procedures.
3. Install the cap on a tester.
4. Pump the tester until the cap relieves. Record the

pressure at which the cap relieves. Replace the cap
if it does not meet specification.
5. Re-install the hydraulic tank safety relief cap.

Oil Cooler Performance Test Standards:
• Hydraulics must be a minimum of 165°F to ensure
thermal bypass valve is closed.
• Engine at full throttle.

and basic safety rules, found in Group-1 of this
• Oil flow across cooler.
Procedure:
1. Ensure machine meets test standards.
2. Open the louvered swing-out radiator guard.
3. Start engine and run at full throttle.
4. Cycle the boom up and down.
5. Measure the temperature at the top and bottom oil

cooler. Record measurements.
6. Subtract the top temperature from the bottom

At operating temperature, the engine, exhaust temperature to obtain the temperature differential
system components, cooling system (³T).
components, and hydraulic system components are
Tools Required:
Temperature Probe or gun
Specification:
• ³T < 12°F (7°C) - Scaled (internal) or dirty
oil cooler (external)
• ³T 12 - 16°F (7°C - 9°C) - Normal cooler

temperature differential
• ³T > 20°F (11°C) - Failed thermal bypass valve or

internally plugged oil cooler

Oil Cooler Thermal Bypass Valve Procedure:

NOTE: This test can be used if an accurate closing

temperature of the thermal bypass valve is needed
or if the thermal bypass valve is to be tested
before installation. Otherwise, use the oil cooler
performance test.
1. Release turbo boost pressure at the turbo boost

release valve. See Figure 14.

components, and hydraulic system components are
Tools Required: Figure 15: Oil Cooler Thermal Bypass Relief Location
• 1-3/4” wrench 2. Open the perforated swing-out engine guard to

• Steel Pot access the thermal bypass valve at the top of the oil
• Heat source cooler. See figure 15.
• 0 - 200°F (0 - 93°C) Temperature probe
• Length of mechanics wire 3. Remove the thermal bypass valve from the oil
cooler.
Specification:
4. Set up steel pot and heat source. Fill the steel pot
120 - 140°F (49 - 60°C) Closing
with oil.
Test Standards: 5. Ensure the thermal bypass valve is below 100°F

Valve must be below 100°F (37°C) prior to starting (37°C) then insert a length of mechanics wire
test. between the valve’s copper heat sink and spring
cage.

6. Immerse the thermal bypass valve in the oil by
hanging it from the side of the steel pot with the
mechanic’s wire.
NOTE: Ensure the thermal bypass valve is not

touching the bottom of the steel pot otherwise an
incorrect test will result.
7. Insert the temperature probe in the oil. Do not let

it contact the bottom of the pot otherwise incorrect
temperature reading will occur.
8. Heat the oil until the thermal bypass valve slides

off the wire. Read and record temperature that this
occurred at. The thermal bypass valve cannot be
adjusted so replace the valve if the test specification
is not met.
9. Re-install the thermal bypass valve in the oil cooler.
10. Close and secure the perforated swing-out engine

guard.

Figure 18: Test Port Manifold 445EXL (Typical)
Figure 19: Main Control Valve (Typical)

Differential Pressure Adjustment
The adjustment procedure is to turn the adjustment screw in until it bottoms out. (See figures 20 & 21)
This will result in a 500-530 psi (34.5-37.5 bar) differential pressure.
The differential pressure acts as a safety relief for the system. The load sense signal is additive to this adjustment. (Example: The
differential pressure will always be 500-530 psi (34.5-37.5 bar) higher than the highest load sense signal.)
Figure 20: Differential Pressure Adjustment Screw Location (K220 Valve)
Note: There are two differential pressure adjustments if you have the K220 pressure port separate from the L90LS pressure port. One
pump supplies the K220 sections and another pump supplies the L90LS sections. The adjustment procedure is the same for both.

Figure 21: Differential Pressure Adjustment Screw Location L90LS Valve (Typical)
Load Sense Maximum Pressure Adjustment
Adjustment Procedure:
1. Install a 6000 psi (414 bar) gauge into the Implement Pump test port on the centralized manifold. (See figures 17 & 18)
2. Start the engine and set the throttle to 1500 rpm.
3. Have another person bottom out a boom function while you read the POR (Pump Over Ride) pressure.
It should read 3800 psi (262 bar).
4. Start turning the Implement Pump POR adjustment screw clockwise to increase the pressure. The pressure will increase until you
reach the load sense maximum pressure setting, 4200 psi (290 bar). If the pressure is correct, reset the Implement Pump POR
pressure to 3800 psi (262 bar). If the pressure is incorrect, adjust the load sense maximum pressure adjustment clockwise to
increase the pressure or counter-clockwise to decrease the pressure. (See figures 22 & 23)
5. Reset the Implement Pump POR pressure to 3800 psi (262 bar).

Figure 22: Load Sense Maximum Pressure Adjustment Screw Location (K220 Valve) (Typical)
Figure 23: Load Sense Maximum Pressure Adjustment Screw Location (L90LS Valve) (Typical)

Feed Reducer Pressure Adjustment
There are two types of Feed Reducer sections used:

1. If the section has two Feed Reducers installed, you can adjust the pressure for “A” and “B” ports independently.
Example: Clamp pressure for “A” port is set at 3000 psi (207 bar).
Clamp pressure for “B” port is set at 2000 psi (138 bar).
2. If the section has one Feed Reducer installed, it will adjust the pressure on both “A” and “B” ports identically.
Example: Lateral tilt pressure for “A” and “B” ports are set at 3000 psi (207) bar.
Adjustment Procedure:
1. Install a 6000 psi (414 bar) gauge in the Implement Pump test port. (See figures 17 & 18)
3. Have another person bottom out the attachment function you need to adjust and set the pressure to the attachment manufacturer’s
suggested setting. Turn the Feed Reducer clockwise to increase the pressure or counter-clockwise to decrease the pressure.
(See figures 24 & 25)
Figure 24: Feed Reducer Adjustment Screws K220 Valve (Typical)

Figure 25: Feed Reducer Adjustment Screw L90LS Valve (Typical)
Main Control Valve Port Reliefs

The main control valve port reliefs are NOT adjustable.
The main control valve port reliefs are designed to protect the system from hydraulic spikes or damage as a result of a malfunctioning
POR valve.
Port relief settings can be checked by running the engine at idle while bottoming out each implement function in both directions. If
the engine pulls down or labors when the function is bottomed our, the port relief for that function may be faulty and will require
replacing. (See figures 26, 27 & 28)

Figure 26: Port Relief Location “A” Port K220 Valve (Typical) Figure 27: Port Relief Location “B” Port K220 Valve (Typical)
Figure 28: Port Relief Location “A” Port L90LS Valve (Typical)

System Pilot Pressure
The system pilot pressure is NOT adjustable.
System pilot pressure is controlled by a regulator spool and preset spring found in the inlet section. If there is a problem with pilot
pressure, check for contamination in the regulator spool or broken or weak regulator spring.
Pressure Check Procedure:

1. Install a 600 psi (42 bar) gauge in the PS port on the inlet section. (See figure 29)
3. Have another person activate a boom function so a pressure reading can be taken. Pilot pressure should be 507 psi (35 bar).
Figure 29: Pilot Pressure Port (PS)

Disc Saw Pump Stand-By Pressure Adjustment Procedure:
1. Lock the disc saw blade with the bolt or lock device according to the disc saw manufacturer so the blade will not turn.
2. Be sure the Disc Saw Switch on the dash is in the OFF position so that the disc saw blade does not start during the procedure.
(See figure 30)
4. Read the disc saw pressure gauge mounted in the cabin. (See figure 31)
The disc saw stand-by pressure should be 200 psi (13-14 bar).
5. If adjustment is required, turn the adjustment screw counter-clockwise until the gauge reads about 100 psi (6-7 bar), then turn the
adjustment screw clockwise until the gauge reads the correct pressure of 200 psi (13-14 bar). (See figure 32)
Figure 30: Disc Saw Switches on Dash Panel Located in Cabin.

(Switches shown in OFF position)
Figure 31: Disc Saw Pressure Gauge Location (Typical)

Figure 32: Disc Saw Pump Stand-By Pressure Adjustment Location (Typical)
Disc Saw Pump POR Pressure Adjustment Procedure:

1. Lock the disc saw blade with the bolt or lock device according to the disc saw manufacturer so the blade will not turn.
2. Be sure the Disc Saw Switch on the dash is in the OFF position so that the disc saw blade does not start during the procedure.
(See figure 30)
3. Start the engine and increase the throttle to full engine rpm.
4. Turn the Disc Saw “ON” switch to the “ON” position to signal the disc saw to come on stroke. (See figure 30)
5. Read the pressure gauge. (See figure 31) The disc saw POR pressure should be at 4000 psi (275 bar).
6. If adjustment is required, turn the POR adjustment screw counter-clockwise until the gauge reads about 3200 psi (220 bar), then
turn the adjustment screw clockwise until the gauge reads 4000 psi (275 bar). (See figures 33 & 34)
Flying objects and moving parts can cause serious personal

injury or death. Keep clear of the disc saw cutting attach-
ment when in operation.

Figure 33: Disc Saw Pump POR Adjustment Screw Location (Behind Implement Pump on some models.)
Figure 34: Disc Saw Pump POR Adjustment Screw Location (Behind Track Drive Pump)

Implement Pump Stand-By Pressure Adjustment
Procedure
Note: Do not connect the 600 psi (41 bar) pressure gauge until
the engine is running.
1. Disconnect the load sense line from the hydraulic pump and
plug the hose end. Leave the pump vented. (See figure 35)
2. Start the engine and run at low idle.
3. Connect the 600 psi (41 bar) pressure gauge to the centralized
pressure manifold. (See figure 36)
4. Increase engine speed to 1500 rpm.

Figure 36: 445 EXL Test Port Manifold (Typical)
5. Read and record the stand-by pressure. Pressure should be set
at 425 psi (30 bar).
6. If adjustment is required, adjust at the stand-by adjustment

screw on the implement pump clockwise to increase pressure
or counter-clockwise to decrease the pressure. (See figure 37)
7. Stop the engine.
8. Re-connect the load sense line when completed.
Figure 37: Stand-By Pressure Adjustment Screw Location
Figure 35: Load Sense Line at Implement Pump (Typical)

Implement Pump POR Pressure
1. Connect a 6000 psi (414 bar) pressure gauge on the

centralized test port manifold. (See figure 36)
2. Start the engine and increase engine speed to 1500 rpm.
3. Have another person bottom out an implement function

while you read the pressure gauge.
4. Read and record the pressure setting. Implement pump

POR pressure should be 3800 psi (262 bar).
5. If adjustment is required, turn the POR adjustment screw

clockwise to increase the pressure or counter-clockwise to
decrease the pressure. (See figure 38) Figure 39: Common Pressure Port
Figure 38: POR Adjustment Screw Location Figure 40: Separate Pressure Ports
Auxiliary Implement Pump Pressure Setting Common Pressure Port Adjustment Procedure:
Stand-by Pressure Adjustment
There are two ways the Auxiliary Implement Pumps are 1. Disconnect the load sense lines on both implement pumps
connected: and plug the hose ends. Leave the pumps vented.
1. Common pressure port - The main implement pump flow (See figure 35)
goes to the Inlet section of the K220 section and the Auxiliary
Pump flow goes into the side cover of the L90LS section 2. Start the engine and run at idle.
through a check valve. (See figure 39)
3. Connect a 600 psi (42 bar) gauge to the test port on the
2. Separate pressure ports - The main implement pump flow Auxiliary Pump. (See figures 41 & 42)
goes to the Inlet section of the K220 section and Auxiliary
Pump flow goes to the Inlet section of the L90LS section 4. Increase engine speed to 1500 rpm.
above the Differential Pressure Adjustment. (See figure 40)
5. Read and record the stand-by pressure. Should be 425 psi
Note: The pressure adjustment procedures are different for the (30 bar).
Common and Separate pressure port installations.
6. If adjustment is required, turn the stand-by pressure
Note: There are also two different size Auxiliary Pumps used, adjustment screw clockwise to increase the pressure or
however, the pressure adjustment procedure is the same: counter-clockwise to decrease the pressure.
1. A10V - 45cc (See figures 41 & 42)
2. A10V - 71cc
7. Stop the engine.
8. Re-connect the load sense lines and remove the pressure

Gauge.

POR Pressure Adjustment (Common Pressure Port) Separate Pressure Port Adjustment Procedure
1. Connect a 6000 psi (414 bar) pressure gauge to the test port
on the auxiliary pump. (See figures 41 & 42) Stand-by Pressure Adjustment
1. Disconnect the load sense lines on both implement pumps
2. Start the engine and increase to 1500 rpm. and plug the hose ends. Leave the pumps vented.
(See figure 35)
3. Have another person bottom out an implement function while
you read the pressure. 2. Start the engine and run at idle.
4. Record the pressure, should be 3600 psi (248 bar). 3. Connect a 600 psi (42 bar) gauge to the test port on the
Auxiliary Pump. (See figures 41 & 42)
clockwise to increase the pressure or counter-clockwise to 4. Increase engine speed to 1500 rpm.
decrease the pressure.
5. Read and record the stand-by pressure. Should be 425 psi
(30 bar).
6. If adjustment is required, turn the stand-by pressure

adjustment screw clockwise to increase the pressure or
counter-clockwise to decrease the pressure.
(See figures 41 & 42)
7. Stop the engine.
8. Re-connect the load sense lines and remove the pressure

Gauge.
POR Pressure Adjustment (Separate Pressure Port)

1. Connect a 6000 psi (414 bar) pressure gauge to the test port
Figure 41: A10V - 45 cc Auxiliary Pump on the auxiliary pump. (See figures 41 & 42)
2. Start the engine and increase to 1500 rpm.
3. Have another person bottom out an implement function on the

L90LS valve while you read the pressure.
4. Record the pressure, should be 3800 psi (262 bar).

clockwise to increase the pressure or counter-clockwise to
decrease the pressure.
Figure 42: A10V - 71cc Auxiliary Pump

Charge Pressure Relief Adjustment
1. Start the engine and set the throttle just above idle.
2. Install a 600 psi (42 bar) pressure gauge in the charge pressure
test port. (See figure 43)
3. Read and record the pressure. Should be 375 psi (26 bar).
4. Increase engine to 1500 rpm. Charge relief [sequence valve]

should read 475 psi (33 bar).
5. Shut off engine.
6. Turn the Charge Pump Relief adjustment screw counter-

clockwise (CCW) about 3 turns. (See figure 45) Figure 44: High Track Pump Pressure Test Ports
7. Move the pressure gauge from the charge pressure test port to
either the right or left track pump test port. (See figure 44)
NOTE: DO NOT STROKE PUMP
9. Adjust the charge pump relief to 475 psi (33 bar) by turning
the adjustment screw clockwise. (See figure 45)
10. Remove gauge from high-pressure test port.
Figure 45: Charge Pump Pressure Adjustment Screw
Figure 43: Charge Pressure Test Port Location
Figure 46: Track Drive Charge Pressure Adjustment

Hydrostatic Main Relief Adjustment Procedures
1. Install track pins for safety. (See figure 47)
2. Start engine and set throttle just above idle.
3. Install a 10,000 psi (690 bar) pressure gauge at the right track
drive test port. (See figure 48) The pressure for reference
should be 5500 psi (380 bar). Destroke Pump.
4. To set the main relief valves - have pump destroked, first turn
POR valve out (CCW) to lower pressure. (3500 psi / 241 bar)
(See figure 49)
5. Adjust main relief valves A and B (CW) inward, to a higher

setting or until the stop. (See figure 50) Figure 49: POR Adjustment Screw
6. Stroke pump to about 20%. Reading the gauge - adjust

pressure to 6000 psi (413 bar) by turning POR (CW) or
inward. (See figure 49)
7. Back off main relief valve adjustment screw CCW. Reading

pressure gauge, adjust pressure to 6000 psi (413 bar). (See
figure 50) [Stroke pump in opposite direction to set the other
main relief.]
8. Stroke pump to about 20%. Lower POR adjustment (CCW) to

3500 psi (241 bar). Then adjust POR (CW) back to 5500 psi
(380 bar). (See figure 49)
9. Repeat for the left track pump. (See figure 51)
Figure 50: High Pressure Relief Valve Adjustment Screws A & B
Figure 47: Track Lock Pin Installation
Figure 51: Left Track Pump Pressure Test Port
Operating the track drives over relief produces extreme heat

that can seriously damage hydraulic system components.
Expedite all pressure readings and adjustments.
Figure 48: Right Track Pump Pressure Test Port

Hydrostat Begin of Stroke Adjustment
1. Install a 10,000 psi (690 bar) pressure gauge in the right track
pump test port. (See figure 48)
2. Install a 10,000 psi (690 bar) pressure gauge in the “M1” port
of the right track motor. (See figure 52)
3. Disconnect the pilot line to the “X” port on the motor and plug
the line. Leave the “X” port on the motor open to atmosphere.
4. Apply locking pins in the tracks. (See figure 47)
5. Run engine at low idle.
6. Set POR on pump at the same pressure you want the motor Figure 53: Begin of Stroke Adjustment Screw Location
setting to be, i.e set POR at 3500 psi (241 bar) if you want the
motor to shift at 3500 psi (241 bar). Track Drive Pump Null Adjustment
7. While watching the gauge in “M1”, loosen the lock nut on the 1. Ensure the hydraulics are at the correct operating temperature.
motor begin of stroke adjustment and adjust pressure to obtain
1⁄2 the pressure of the pump, i.e. with pump at 3500 psi 2. Open the swing-out pump guard to access the track drive
(241 bar) adjust until you read 1750 psi (121 bar). pumps.
(See figure 53)
3. Install track pins. (See figure 47)
8. Repeat steps 1 - 7 for the left track motor.
4. Using a 3/16” allen wrench, remove the plugs from ports “X1”
9. After setting the two motors, reconnect the “X” port pilot lines and “X2”. Install a #6 ORBM - #4 JICM adapter in each port.
and set the pump pressure back up the 5500 psi (380 bar). (See figures 54 & 55)
10. Remove gauge in “M1” port and re-install plugs. 5. Connect a 24” (61 cm) jumper hose between ports “X1” and
“X2”.
6. Connect a 6000 psi (414 bar) pressure gauge on the Right

Track Pump test port. (See figure 48)
7. Start the engine and run at idle speed.
8. Using a 24 mm wrench and a 8 mm allen wrench, loosen the

jam nut and adjust the setscrew in and out to find the lowest
pressure reading. (See figure 56)
Note: The lowest pressure reading indicates when the control
piston is in the centered ‘Null’ position.
9. Remove the 6000 psi gauge and replace it with 600 psi
(41 bar) pressure gauge.
Figure 52: Port “M1” Location
10. Repeat step 8 to make the final adjustment and lock the jam
nut.
11. Stop the engine.
12. Remove the jumper hose and adapters and re-install the plugs
into “X1” and “X2”.
13. Replace the 600 psi gauge with the 6000 psi gauge.

14. Start the engine and run at idle.
15. The ‘Hydraulic Null’ adjustment is made using a 13 mm

wrench and a 4 mm allen wrench, loosen the jam nut and
adjust the setscrew in and out to find the lowest pressure.
(See figure 57)
Note: The lowest pressure reading indicates when the
control spool is in the centered ‘Null’ position.
16. Remove the 6000 psi gauge and replace it with the 600 psi
gauge.
17. Repeat step 15 to make the final adjustment and lock the jam
nut.
18. Stop the engine. Figure 55: Install Jumper Hose Between X1 and X2.
19. Repeat procedure for the left track pump.
Figure 56: Mechanical Null Adjustment Screw Location

Figure 54: Jumper Hose
The hydraulic null adjustment is made with an eccentric pin

and should not be turned more than 90° from center (as indi-
cated by a notch on the adjustment screw), otherwise damage
to the eccentric pin could result.
Unexpected track movement can result in serious

personal injury or death. Pin the tracks to prevent
movement during testing and adjustment procedures.
Figure 57: Hydraulic Null Adjustment Screw Location

Important Information These instructions are for moving a disabled machine a
short distances, no faster than 1.2 mph, to a convenient
location for repair. These
instructions are for emergencies only. Always haul the
machine if long distance moving is required.
Personal injury or death could result when
towing a disabled machine incorrectly. Shielding must be provided on the towing machine to
protect the operator if the tow line or bar should break.
Block the tracks to prevent movement before
releasing the track brakes. The machine can roll DO NOT allow an operator on the machine being towed
free if the tracks are not blocked. unless the operator can control the steering and/or brak-
ing.
Follow the recommendations below to
properly perform the towing procedure. Before towing, be sure the tow line or bar is in good
condition and has enough strength for the towing situ-
Relieve the hydraulic tank and line pressure ation involved. Use a towing line or bar with a capac-
before any disassembly. Removing the plugs ity at least 1.5 times the gross weight of the towing
from the brake cover without first releasing machine, for a disabled machine stuck in mud or when
the internal pressure will cause hydraulic oil to towing on a grade.
stream out.
Attach towing cable to towing hook found on either end
of the machine.
DO NOT use a chain for pulling. A chain link can break

causing possible personal injury. Use a wire rope cable
Even after the machine has been turned off, the with loop or ring ends. Use an observer in a safe posi-
hydraulic oil can still be hot enough to burn. tion to stop the pulling procedure if the cable starts to
Allow the hydraulic oil time to cool before break or unravel. Stop pulling
draining. whenever the pulling machine moves without
moving the towed machine.
Keep the tow line angle to a minimum. DO NOT

o
exceed a 30 angle from the straight ahead
To tow the machine, both final drives must be dis- position.
engaged.
Quick machine movement could overload the tow
Do not operate the track drive motors with the line or bar and cause it to break. Gradual and smooth
final drives disengaged. Damage could result. machine movement will work better.
Clean the track drive motor and nearby areas Normally, the towing machine should be as large as the
before releasing the track brakes. disabled machine. Satisfy yourself that the
towing machine has enough brake capacity, weight and
Dirt can damage the track drive motor and reduce power to control both machines for the grade and dis-
performance or cause machine tance involved.
malfunctions.
To provide sufficient control and braking when
moving a disabled machine downhill, a larger machine
or additional machines connected to
the rear could be required. This will prevent the
disabled machine from rolling uncontrolled.

All the different situation requirements cannot be given, Short Distances (Towing Reliefs)
as minimal towing machine capacity is required on
smooth level surfaces to maximum on inclines or poor
surface conditions.
A towed machine, when loaded, must be

equipped with its own brake system operable from the
operator’s compartment.
Consult your dealer for towing a disabled machine.
Towing Instructions

Hydraulic oil tank under pressure. Escaping Allow these components to cool to the touch
oil can cause serious injury. Vent tank before before servicing. Loosen radiator cap slowly to
removing cap or servicing the hydraulic system. release pressure.

Without the spur shaft in place, the brakes are boost release valve before opening fill spout.
not effective. Provide other means to hold or stop
the machine.
Hydraulic oil tank under pressure. Escaping

oil can cause serious injury. Vent tank before
Even after the machine has been turned off, the removing cap or servicing hydraulic system.
hydraulic oil can still be hot enough to burn.
Allow the hydraulic oil time to cool before The track drive pumps are equipped with a towing relief
draining. feature which allows the machine to be towed short
distances up to 600 feet (550m) in emergencies.
1. Release boost pressure from the tank.
To tow the machine, both final drives must be

disengaged.
Do not operate the track drive motors with the final

drives disengaged. Damage could result.
Clean the track drive motor and nearby areas before

releasing the track brakes.
Dirt can damage the track drive motor

and reduce performance or cause machine
malfunctions.
See Figure 58. This must be done before working

on the hydraulic system.

2. Operate the track drive foot pedals back and forth
several times with the engine shut down to relieve Grease Gun filled
with clean, filtered
any pressure in the pilot control system. hydraulic oil
1/8” NPT to 1/
4” NPT Swivel
Connector
1/4” NPT
Street Tee
1000 (100 Bar)
Pressure Gauge
1/4” NPT to 1/4” ORS

Hose Assembly
Figure 59: Activating The Towing Relief Feature

1/4” ORS
3. Activate the towing relief feature on the track Connector
drive pumps. Use a 4 mm allen wrench to turn

the setscrew at the top of the track drive pump
directional relief out two turns CCW.
See Figure 59.
Figure 60: Typical Grease Gun Modification
Do this to both reliefs on both track drive pumps.
NOTE: To avoid changing the relief setting, only

turn the setscrew with the 4 mm allen wrench. You
do not need to use a hex wrench anywhere on the
relief.
4. Use a modified grease gun, See Figure 60, or other

pressure source to pressurize the track brake signal
line to at least 400 psi (2,76 Mpa). This will release
the track brakes.
NOTE: When towing the machine in this fashion,

limit speed to 1 mph (1,6 km/hr) to avoid internal
heat damage to the track drive pumps.
5. When towing is completed, de-activate the towing

relief feature by turning the setscrew in CW until it
bottoms out.

Medium Distances
(Disable Track Final Drives)
Figure 61: Track Final Drive Cross-Section (Typical)
1. Thoroughly clean the area around the final drive 7. Remove the planetary gear spur shaft (4). Removing
including the track shoes above the final drive. this shaft will disable the drive.
2. Drain the final drive oil into a suitable NOTE: The final drive may be equipped with a
container. nylon thrust button (5) that is located between the
cover and spur shaft. Be sure this thrust button is
3. Remove all but 2 of the cover bolts (1) retaining the also removed with the spur shaft.
final drive cover. See Figure 61.
8. Re-install final drive cover using all of the cover
4. Remove one track shoe to provide access to the bolts removed previously.
parting face between the final drive cover (2) final
drive housing (3). 9. Fill the final drive with clean oil.
NOTE: Be sure area around the final drive cover 10. Repeat this procedure for the other final drive.
is clean to prevent debris from falling into the final
drive housing.
5. Using a hammer and wedge, or other suitable tools,

separate the final drive cover from the housing.
6. Remove remaining the 2 cover bolts and final drive

cover.



Chapter 6 - Electrical
Electrical
General Information Page 6.1.2
Welding Pre-cautions Page 6.1.3
Electric Center Description Page 6.1.4
Fuses / Relays Locations Page 6.1.6

SERVICING ELECTRICAL EQUIPMENT If batteries are properly looked after, the engine will start even
under difficult conditions. Always keep the level of electrolyte
1cm above the plates. The checking interval depends on several
Batteries
factors, including ambient temperature, age of batteries and oper-
ating hours per day. Determine the checking interval on the basis
of experience. Use only distilled water to top up the batteries.
You must read and understand all of the safety warnings
Keep the terminals clean. Avoid oxidation by coating the termi-
and regulations found in Chapter 1, Safety, of this manual
nals with dielectric grease.
before attempting any service to the electrical system of
this machine.
Charging
• Batteries, battery cables and cable lugs must be checked
regularly. The poles of the battery must be thoroughly
cleaned and the cable lugs must always be tightened and well
greased to prevent open circuits. There must not be any loose
connections.
• Do not confuse the positive and negative terminals of the

battery when installing.
• If you need to make repairs to the alternator equipment,

always disconnect the battery cables first. If rapid charging
of batteries is to be done, also disconnect the battery cables
first.
• Disconnect the positive cable from the battery to the main

Always wear the proper protective clothing for the task at hand. switch before charging.
The electrolyte in the battery contains corrosive sulfuric acid.

Always keep a stocked first aid kit on hand. Immediately remove any electrolyte spilled on the skin. Wash
the affected area with plenty of water and soap. If electrolyte
gets into the eyes or on any other sensitive part of the body,
rinse immediately with plenty of water and seek medical at-
tention without delay.
Never smoke or allow open flame near a battery.
Risk of explosion is present when jumping batteries,

always wear face and eye protection.
Chapter 6 - Electrical Page 6.1.2

The most important service action for the electrical system is Locating Electrical Faults
to maintain proper belt tension for the alternator. Refer to the
operator’s manual for the engine for proper tensioning procedure If an item of electrical equipment does not work, the first step is
for your engine. to check the fuse. If the fuse is in order, check the circuit for the
relevant function against the schematic.
Points To Bear In Mind When Welding
If the fuse has blown, open all switches. Install a new fuse as
1. Switch off the main electric power at the master switch. listed in the fuse list. Switch on the functions one by one and
(See figure 1) check which function causes the fuse to blow. When the fault has
been located, open the main switch before carrying out the repair.
2. If equipped with an automatic fire suppression system,
unplug the connection to the central unit. If the fault is in the circuit of the starter motor or the alternator,
disconnect the battery earth cable before doing any repair work.
3. Disconnect the earth cable between the battery and chassis. The earth leads of the cab, engine and chassis must always be
connected when the electrical system is operating, since poor
4. Disconnect the positive cable of the alternator (B+). earthing increases the risk of fire.
5. Disconnect charging lamp wire (D+). Additional Connections

6. Unplug connectors to all computers. If additional electrical equipment is installed later, the connec-
tion arrangement must be approved by the manufacturer of the
7. Connect the earth cable of the welding set as close to the machine.
welding point as possible, so that the welding current does
not damage the bearings of the machine.
Figure 1: Master Switch
Page 6.1.3 Chapter 6 - Electrical

MINI FUSE A FUNCTION LIST MINI FUSE B FUNCTION LIST
A 7.5A A39 BATTERY + A 10A LEFT VISOR LITE
B VACANT B 7.5A CHARGE HEAT SWIT. PWR.
A B C D C VACANT A B C D C 15A IGNITION "BATT"
D VACANT D 10A LEFT FOPS LIGHT WT92200-C FUSE LEGEND
E 7.5A LIFT PUMP RELAY E 10A RIGHT VISOR LITE
F VACANT F 10A A/C-HEATER MAIN ELECTRICAL CENTER W/CUMMINS ENGINE
E F G H G VACANT E F G H G 2A DOME LIGHT
H VACANT H 10A RIGHT FOPS LIGHT
I 5A A40 BATTERY+ I 5A FRONT LOWER LITES

J VACANT J 3A AUX. FLOOR HEATER MAXI FUSE BANK A
I J K L K VACANT I J K L K 3A ENGINE HOUSE WORK LITE
L VACANT L 10A FUEL PUMP RELAY
50A HYD. FILL PUMP RELAY
M 7.5A A50 BATTERY + M 3A RIGHT UPPER SIDE LITE 50A VISOR LITE RELAY
N VACANT N 3A DEFROST FAN
M N O P O VACANT M N O P O 2A REAL TIME CLOCK 20A HDLT #1 RELAY
P VACANT P 3A RADIO
40A CONDENSER FAN RELAY
Q 10A A38 BATTERY + Q 5A REAR UPPER LITES 50A +ENGINE SUPPLY
R VACANT R 10A SISU GRID HTR CONT. RELAY
Q R S T S VACANT Q R S T S 10A XPO (+BATT-A) & MDM 30A BATTERY +
T VACANT T 5A 12V-5A ACCESSORY
30A 24-12V CONVERTER #1
U 5A VEHICLE KEY SWIT. INPUT U 3A RIGHT LOWER SIDE LITE 50A FOPS HELLA LITE RELAY
V VACANT V 2A FUEL PUMP LATCH RELAY
U V W X W VACANT U V W X W 10A XP1 (+BATT-A)
X VACANT X 5A 12V-5A ACCESSORY AN14066 PLACARD
Y 5A VEHICLE KEY SWIT. INPUT Y 10A FUEL PUMP

Z 20A REVERSE FAN/ACCESSORY Z 20A CONDENSER FANS MAXI FUSE BANK B
Y Z AA BB AA VACANT Y Z AA BB AA 10A XPO + XP1 (+BATT-B) XS
BB VACANT BB 1A DIODE
50A IGNITION POWER RELAY
30A HYD. FILL PUMP
20A HDLT #2 RELAY

MINI FUSE BANK A MINI FUSE BANK B
50A IQAN RELAY
B
C
B
C
40A AUX. OIL COOLER RELAY
D
D
A
A
7.5A
10A
7.5A
15A
10A
VACANT
50A START SIGNAL RELAY
H
H
E
E
7.5A
10A
10A
2A
10A
30A REV. FAN/ACCES. RELAY
L
L
I
I
AN14062 PLACARD
5A
5A
3A
3A
10A
M
P
M
P
3A
3A
3A
2A
7.5A
Main Electrical Center, W/Cummins Engine
NOTE: SISU 24V CONVERTER NOTE: AUXILLIARY OIL
T
T
Q
Q
SECONDARY FUSE MOUNTED COOLER FUSE NOW MOUNTED

5A
10A
10A
5A
10A
REMOTELY NEAR IQAN CONN. REMOTELY NEAR BATTERY +
REMAINS VACANT STUD (ATO 15).
U
X
U
X
3A
2A
10A
10A
5A
NOTE:
ORIENTATION
Y
BB
Y
BB
5A
20A
10A
20A
10A
OF DIODE IS
EXTREMELY
Z
Z
AA
AA
IMPORTANT!!!
Page 6.1.4
AN14065 PLACARD AN14064 PLACARD
MINI FUSE A FUNCTION LIST MINI FUSE B FUNCTION LIST
A 10A +12V CONT. BOSCH RELAY A 10A LEFT VISOR LITE
B VACANT B 7.5A CHARGE HEAT SWIT. PWR.
Page 6.1.5
A B C D C VACANT A B C D C 15A IGNITION "BATT"
D VACANT D 10A LEFT FOPS LIGHT WT92200-S FUSE LEGEND
E 10A LIFT PUMP RELAY E 10A RIGHT VISOR LITE
F VACANT F 10A A/C-HEATER MAIN ELECTRICAL CENTER W/SISU ENGINE
E F G H G VACANT E F G H G 2A DOME LIGHT
H VACANT H 10A RIGHT FOPS LIGHT
I 5A +12V CONT. EEM I 5A FRONT LOWER LITES

J VACANT J 3A AUX. FLOOR HEATER MAXI FUSE BANK A
I J K L K VACANT I J K L K 3A ENGINE HOUSE WORK LITE
L VACANT L 10A FUEL PUMP RELAY
50A HYD. FILL PUMP RELAY
M VACANT M 3A RIGHT UPPER SIDE LITE 50A VISOR LITE RELAY

N VACANT N 3A DEFROST FAN
M N O P O VACANT M N O P O 2A REAL TIME CLOCK 20A HDLT #1 RELAY
P VACANT P 3A RADIO
40A CONDENSER FAN RELAY
Q VACANT Q 5A REAR UPPER LITES VACANT
R VACANT R 10A SISU GRID HTR CONT. RELAY
Q R S T S VACANT Q R S T S 10A XPO (+BATT-A) & MDM 30A BATTERY +
T VACANT T 5A 12V-5A ACCESSORY
U VACANT U 3A RIGHT LOWER SIDE LITE 50A FOPS HELLA LITE RELAY
V VACANT V 2A FUEL PUMP LATCH RELAY
U V W X W VACANT U V W X W 10A XP1 (+BATT-A)
X VACANT X 5A 12V-5A ACCESSORY AN14061 PLACARD
Y 5A VEHICLE KEY SWIT. INPUT Y 10A FUEL PUMP

Z 20A REVERSE FAN/ACCESSORY Z 20A CONDENSER FANS MAXI FUSE BANK B
Y Z AA BB AA VACANT Y Z AA BB AA 10A XPO + XP1 (+BATT-B) XS
BB VACANT BB 1A DIODE
50A IGNITION POWER RELAY
30A HYD. FILL PUMP
20A HDLT #2 RELAY

MINI FUSE BANK A MINI FUSE BANK B
50A IQAN RELAY
B
C
B
C
40A AUX. OIL COOLER RELAY
D
D
A
A
10A
10A
7.5A
15A
10A

50A START SIGNAL RELAY
H
H
E
E
10A
10A
10A
2A
10A
30A REV. FAN/ACCES. RELAY
L
L
I
I
AN14062 PLACARD
5A
5A
3A
3A
10A
M
P
M
P
3A
3A
3A
2A
Main Electrical Center W/SisuDiesel Engine
NOTE: SISU 24V CONVERTER NOTE: AUXILLIARY OIL
T
T
Q
Q
SECONDARY FUSE MOUNTED COOLER FUSE NOW MOUNTED

5A
10A
10A
5A
REMOTELY NEAR IQAN CONN. REMOTELY NEAR BATTERY +

(ATO 25) NOTE: STUD (ATO 15).
U
X
U
X
3A
10A
2A
5A
ORIENTATION
OF DIODE IS
Y
BB
Y
BB
EXTREMELY
5A
20A
10A
20A
10A
IMPORTANT!!!
Z
Z
AA
AA
AN14063 PLACARD AN14064 PLACARD
Maxi Fuse Bank - B
Maxi Fuse Bank - A
Mini Fuse Bank - B
Mini Fuse Bank - A
Electrical Center Fuse Location (Typical)
Chapter 6 - Electrical Page 6.1.6

Reverse Fan Relay
Sisu Grid Heater Control Relay
Fuel Pump Relay
Sisu Lift Pump Relay (12V)
Fuel Pump Latching
Disc Saw Latching Relay Relay
Condenser Fans Relay Auxiliary Oil Cooler

Relay
Headlight Circuit #1 Relay
Headlight Circuit #2
Relay
Dash Connector
Engine Harness
Visor Light Relay Connector
FOPS Panel
Light Relay
IQAN Relay
Ignition Power Lower Cab Harness

Relay Connector
Hydraulic Return PSI
Hydraulic Fill & Hydraulic Temp.
Pump Relay (Non-IQAN)
Upper Cab Harness Hydraulic Fill Pump

Connector
Start Signal
IQAN Connector
Auxiliary Oil Cooler
Start Signal Relay
24-12V Converter, 24V
Supply
Sisu 24-12V Converter

24V Supply
Electrical Center Description (Typical)
Page 6.1.7 Chapter 6 - Electrical

Chapter 7 - Fire Extinguisher
Fire Extinguishing
Fire Extinguisher Location Page 7.1.2
Recharging Fire Extinguishers Page 7.1.2
Fire Suppression System Page 7.1.3

Fire Extinguisher
Maintain a charged fire extinguisher on the machine

AND KNOW HOW TO USE IT.
Figure 2: Fire Extinguisher Charge Level Indicator

The fire extinguisher is located to the left and rear of the oper-
ator’s seat. (Figure 1) Read and understand the manufacturer’s Recharging Fire Extinguishers
instructions printed on the fire extinguisher for its proper use Fire extinguishers may only be recharged by an authorized
before operating the machine. service company.
Check a minimum of monthly that the lead seal on the extin-

guisher is unbroken and that the pressure gauge needle is in the
green field. (Figure 2) The pressure in the container changes
with the ambient temperature, so the needle will be close to the
red field when the extinguisher is cold and close to the white field
when it is warm.
Figure 1: Fire Extinguisher Location
Remember the word: P A S S

Pull the pin at the top of the extinguisher that keeps the handle
from being accidently pressed.
Aim the nozzle toward the base of the fire.
Squeeze the handle to discharge the extinguisher.
Sweep the nozzle back and forth at the base of the fire.
Remember that most hand held fire extinguishers are effective

only up to about 8 feet (2.4 meters). Also, watch carefully after
the fire is extinguished as it may re-ignite.
Chapter 7 - Fire Extinguisher Page 7.1.2

Note: See the manufacturer’s manual for the fire
suppression system supplied with the machine for
Never try and extinguish a fire unless
you have a clear escape path.
proper operation and test procedures.
Fire Suppression System (Optional)

When equipped with the optional fire suppression system, the
in-cab manual actuator and system operation test box are located
directly below the right side of the operator’s seat and directly
below the right side window. (Figure 3)
It is the owners responsibility to keep the fire suppression
system in working order. We recommend having the system
inspected at least once per year by an authorized agent of
the fire suppression system manufacturer.
Figure 3: Manual Actuator (In-Cab Location)
A second manual actuator is mounted behind the cab on the main

boom mounting near the boom pivot. (Figure 4)
Figure 4: Manual Actuator (Outside Location)
Page 7.1.3 Chapter 7 - Fire Extinguisher

Chapter 8 - Service & Maintenance
DAILY . . .
50 HRS . . .
100 HRS . . .
250 HRS . . .
500 HRS . . .
1000 HRS . . .
2000 HRS . . .
Preventive Maintenance
Section 1
Preventive Maintenance Chart Page 8.1.4
Lubrication Chart Page 8.1.6
Section 2
Daily Maintenance Page 8.2.1
Section 3
Service as Required Page 8.3.1
Section 4
50 Hour Checks Page 8.4.1
Section 5
Section 6
Section 7
Section 8
Section 9
General

manual, before performing any operation or
maintenance procedures.
For additional engine maintenance guidelines,

see the manufacturer’s manuals provided with
the machine.
Diesel exhaust fumes contain elements that are
hazardous to your health. Always run engine in
Use recommended protective clothing and safety

devices such as gloves, safety boots, safety hat,
reflective vests and eye, ear and respiratory Keep your head, hands, and feet clear of all
protection as required by job conditions. moving parts.
Before performing maintenance or repairs on the

machine, consult this manual and follow the
recommended procedures. Keep yourself, all objects and tools away from
any object dropped or pushed into them.
Chapter 8.1 - Preventive Maintenance Schedule Page 8.1.2

Support components when working beneath any maintenance or repair procedures.
them. Do not depend on hydraulic cylinders for
support. A component may fall if a control is
moved or a hose breaks.

before servicing.
components and hydraulic system components Loosen radiator cap slowly to release pressure.
Pressurized air can cause personal injury.

When using pressurized air for cleaning, wear
protective clothing, face shield and shoes.
Page 8.1.3 Chapter 8.1 - Preventive Maintenance Schedule

10

10
Page 8.1.5 Chapter 8.1 - Preventive Maintenance Schedule

Lubrication Points Diagram
Hour
# Fittings Lubricant Interval
1) Main Boom Cylinder Base End Pivot 2 Lubriplate #176 10
2) Main Boom Pivot 2 Lubriplate #176 10
3) Main Boom Cylinder Rod End Pivot 1 Lubriplate #176 10
4) Stick Boom Cylinder Base End Pivot 1 Lubriplate #176 10
5) Stick Boom Pivot 2 Lubriplate #176 10
6) Stick Boom Cylinder Rod End Pivot 1 Lubriplate #176 10
7) Tool Tilt Cylinder Base End Pivot 2 Lubriplate #176 10
8) Tool Tilt Cylinder Rod End Pivot 1 Lubriplate #176 10
9) 4-Bar Linkage Pivots 5 Lubriplate #176 10
10) Cutting Attachment (See Manufacturer's Manual) ----- -------------------- ------
11) Cutting Attachment Pivot 2 Lubriplate #176 10
12) Swing Bearing Ring Gear 4 Lubriplate #176 10
13) Swing Bearing Race 1 Lubriplate #176 50
14) Swing Stop Lead Screw 1 Lubriplate #176 50
15) Cab Level Cylinder Rod End Pivots 2 Lubriplate #176 50
16) Cab Level Cylinder Base End Pivots 2 Lubriplate #176 50
17) Lower Turntable Pivots 4 Lubriplate #176 50
18) Intermediate Leveler Pivots 6 Lubriplate #176 50
19) Thottle Cable & Linkage ----- Light Oil 250
Use a good quality grease containing at least 5-6% Molybdenum Disulfide by volume at all lubrication points
unless otherwise specified. TIMBCO recommends using Lubriplate #176.

You must read and understand the warnings and basic safety
rules, found in Chapter 1 of this manual, before performing
any operation or maintenance procedure.
For additional engine maintenance guidelines, see the

manufacturer’s manuals provided with the machine.
Figure 2: Pin Retainer (Typical)

It is extremely important to perform a daily walk-around inspec-
tion of the machine before beginning to work. All preventive
maintenance, especially a simple daily inspection, will help
ensure trouble-free operation and a long service life for your
equipment.
The daily preventive maintenance can be divided into three

groups: Visual Inspection, Lubrication, and Component/System
Checks.
Visual Inspection
A general visual inspection of the machine should be the first
procedure performed before the start of the workday or shift.
Check for leaking fluids, damaged or loose components, unusual
wear, accumulation of flammable debris, etc. Specific examples
are given below.
Figure 3: Access Panel Under The Turntable Plate (Typical)
Check For Loose Or Missing Fasteners
Inspect for any loose or missing bolts. Especially the tapered
hub retaining bolts, pin retaining bolts, and the bolts securing the
access panels under the engine and pump compartments. Replace
any missing bolts immediately.
Figure 1: Tapered Hub (Typical)
Page 8.2.1 Chapter 8.2 - Service & Maintenance

Check Track Components
Figure 6: Track Shoe Bolts (Typical)

Figure 4: Check For Track Chain Wear
Look for loose or missing track shoe bolts and broken track
Inspect for unusual wear, especially on the track chain, that may shoes. Correct any problems before beginning to work.
indicate track tension is too tight.
Check Hydraulic Hoses
Hydraulic oil under pressure can penetrate body tissue

Figure 5: Roller Hubs (Typical) causing serious injury and possible death.
Inspect for leaks at the upper roller (when equipped), lower roller, When troubleshooting a hydraulic system for leaks, al-
and idler assembly hubs. Leaks from the oil filled hubs can fore- ways use cardboard or other material as a deflector. DO
warn of a pending component failure. NOT USE YOUR HANDS.
If you are injected with hydraulic oil or any other fluids,

seek treatment by a doctor immediately.
Chapter 8.2 - Service & Maintenance Page 8.2.2

Lubrication
Chaffing or Cuts, Evidence of Kinking
Exposed Wires or Crushing
Use a good quality grease containing at least 5-6% Molybdenum
by volume, at all lubrication points. Lubriplate #176 is recom-
Damaged or mended. Grease meeting the above requirement has a higher
Leaking Fitting rated load pressure than a typical multi-purpose EP grease.
Add grease at the following points until it appears at the pivot

area.
Localized Ballooning
or Blistering
Check hoses carefully. Do not use your bare hands to check

for leaks. Tighten all connections to recommended torque.
Replace if any of the following are found:
- End fittings damaged or leaking.
- Outer covering chafed or cut and wire reinforcing is exposed.
- Outer covering ballooning.
- Hose shows evidence of kinking or crushing.
Figure 7: Main Boom Cylinder Base End Pivot (2 fittings)
Inspect hydraulic hose assemblies for leaks, damaged fittings
and worn exterior. Do not use your hands to check for hydraulic
leaks. A hydraulic oil stream from pressure can penetrate body
tissue and cause serious injury or possible death. Use a piece of
cardboard or other material as a deflector to detect leaks. Replace
any problem hose before beginning work.
Clean Flammable Debris From Exterior Surfaces
Keep flammable forest debris and other trash from collect-

ing around the turbo and exhaust areas, and from around
the engine preheater (if equipped). These areas are the
hottest and are most susceptible to starting fires.
KEEP THESE AREAS CLEAN!
Forest debris such as brush, leaves, and needles can easily collect
in and around the machine. This is not only an eyesore, but a Figure 8: Main Boom Pivot (2 fittings)
very real fire hazard. Clean away all forest debris and any oily
rags or other trash that may accumulate around the machine,
especially around the engine’s exhaust and turbo areas, and
from around the engine preheater (if equipped). These areas are
the hottest and are the most susceptible to starting fires. KEEP
THESE AREAS CLEAN! KEEP A CLEAN MACHINE and
use only non-flammable solutions for cleaning the machine and
machine components.

Figure 9: Boom Grease Points (7 fittings) Figure 11: 4-Bar link yoke to “Dog Bone” pivot
(2 fittings)(Paddle link shown)
On the underside of the stick boom there is a group of grease fit-
tings that are for the following points:
- Main boom cylinder rod end pivot
- Stick boom cylinder base end pivot
- Stick boom cylinder rod end pivot
- Stick boom pivot (2 fittings)
- Tool tilt cylinder base end pivot (2 fittings)
Figure 12: 4-Bar link yoke to attachment pivot

(1 fitting)(Paddle link shown)
Figure 10: Tool tilt cylinder rod end pivot

(1 fitting)(Paddle link shown)

Figure 13: 4-Bar link “Dog Bone” Pivot
(2 fittings)
Figure 15: Swing bearing ring gear
(1 fitting)
The swing bearing ring gear is provided with a grease cup located
in the cab. Pump 5 - 6 strokes of grease into the cup. To ensure
uniform distribution of grease, rotate the cab (bearing) 1/4 turn
and repeat greasing. Repeat this procedure for a complete
revolution.
Figure 14: Cutting attachment pivot

(3 fittings)

Component / System Checks Drain Water / Sediment At Primary Fuel Filter
Check Engine Oil Level
Dipstick
Oil Fill
Figure 17: Fuel System Water/Sediment Drain

(SisuDiesel engine shown)
Figure 16: Engine Oil Check & Fill Location
(SisuDiesel engine shown) The water/sediment drain valve is located on the primary fuel
filter found on the left side of the engine.
1. Shut down the engine.

Never operate the machine with the engine oil level below
or above the “FULL” range on the dipstick as engine dam- 2. Holding a catch pan under the primary fuel filter, turn
age could result. the drain valve slowly counter-clockwise by hand until
fuel begins to drain. Drain fuel until it flows clear.
3. Turn drain valve clockwise by hand to close. Do not

Engine oil check and fill points are located on the left side of the
use tool to tighten the drain valve. Hand-tighten only to
engine behind the perforated swing-out engine door. Oil level
prevent damage.
should be within the “FULL” range on the dipstick. Add oil if
required (See the engine manual for capacities and oil recommen-
4. Dispose of waste fuel properly.
dations).
Position the machine on level ground for the most accurate mea-
surement. Shut down the engine and wait at least 5 minutes, to
allow oil to drain into the pan, before checking the oil level.

Check Engine Coolant Level
Skin contact with used antifreeze can cause skin disor-

ders or other personal injury.
Wait until the engine coolant temperature drops below

120°F (50°C) before removing the radiator cap. Hot
coolant released under pressure can cause serious per-
sonal injury.
Do not fill the overflow tank.
The coolant volume will expand as the engine reaches

operating temperature.
Figure 18: Radiator Overflow Tank Sight Glass Location
For the most accurate measurement, check coolant level

with the engine cold.
Coolant level is checked at a sight gauge in the radiator overflow

tank. The sight gauge can be viewed from the cab on most mod-
els. Coolant level should be in the middle of the sight gauge. If
required, add appropriate coolant.
Adding Engine Coolant
Avoid skin contact with used antifreeze.
Figure 19: Radiator Fill Spout Access Cover

(Typical)
1. Allow the cooling system to cool down.
2. Locate the radiator fill spout and remove cap slowly to

allow any trapped pressure to escape.
3. Prepare a mixture of 50% low silicon ethylene glycol

base antifreeze and 50% distilled water. [If distilled
water is not available, use clean tap water. (A rule of
At operating temperature, the radiator is HOT and under thumb about water cleanliness: Do not add water to
pressure. Allow these components to cool to the touch your cooling system that you would not drink yourself.)]
before servicing.
Note: Check the engine manufacturer’s manual
Loosen the radiator cap slowly to release pressure. for special instructions regarding coolant mixture
and additives.
4. Add coolant mixture until level is in the middle of the

overflow tank sight gauge. Reinstall the radiator cap.

Fire Hazard! Do not use diesel fuel or gasoline to clean
parts. Use compressed air or a water soluble cleaning
agent only.
The machine is equipped with a “sucker” type of engine fan

and has a screen installed behind the radiator guard to fur-
ther protect the radiator, oil cooler, and air cooler fins. DO
NOT operate the machine without this screen.
Figure 22: Radiator Screen Opened
1. Open the swing-out radiator door and open the screen.
2. Check radiator/oil cooler/air cooler fins for debris. If

required, clean the fins with compressed air. Comressed
water or steam can also be used.
Never exceed 30 psi (205 kPa) of pressure to clean the

radiator. Damage to the cooling fins could result.
3. Clean the debris off the screen using compressed air,

Figure 20: Radiator/Oil Cooler/Air Cooler Assembly water, or steam.
The radiator/oil cooler/air cooler fins must be kept clean to pre- 4. Close the screen and the swing-out door.
vent engine and hydraulic system overheat problems.
Figure 21: Radiator Swing-out Door Screen Latch
To open the radiator swing-out door screen, move the thumb

latch up.

Check Track Tension
Properly adjusted track tension will increase the service life of

the tracks and drive components.
1. Place a straight edge on the track which is long enough

to reach between the return roller and the track idler.
2. Measure the maximum amount of track sag between the

bottom of the straight edge and the highest point of the
lowest grouser. Correct track tension should have
between 1” and 1-1/2” (25mm - 40mm) of sag.
Adjusting Track Tension
Track tension adjustments are made by either adding or releasing Figure 23: Checking Track Tension
grease from a tensioner cylinder. A fill valve and relief valve are
located behind the small access cover on the track side frame.
To increase track tension, add grease through the fill valve fitting
until the correct track tension is reached. A difference in track
tension should be noticed after 4 or 5 strokes of grease. If a
change in track tension is not noticed, check the idler unit slides
for wear or contamination.
To decrease track tension, loosen the relief valve one turn only to
allow grease to escape.
Figure 24: Track Tension Fill Valve and Relief Valve Location
Figure 25: Adjusting Track Tension

Check Fuel Level
All fuels, most lubricants and some coolant mixtures

are flammable. Do not smoke while refueling or near
refueling operations. Keep all fuels, lubricants, and
coolant mixtures away from open flames.
Figure 28: Fuel Cap (Typical)
1. Clear all dirt and debris from around the fuel filler neck
so that contamination is not accidently knocked into the
tank.
2. Lift the handle on the fuel cap to remove.
3. Lift the dipstick to check fuel level. (Figure 29)
4. Add fuel as required.
Fuel spilled or leaked onto hot surfaces or electrical

components can cause a fire.
Figure 29: Fuel Tank Dipstick
Figure 26: Fuel Tank Fill Spout (Typical)

(May be in a different location on some models.)
Check Fire Extinguisher
Maintain a charged fire extinguisher on the machine

Figure 30: Fuel Strainer and KNOW HOW TO USE IT.
5. Before replacing the cap, check the strainer in the fuel

filler neck, clean if required.
6. If the strainer requires cleaning, remove the four 1/2”
bolts securing the access cover to which the fuel neck is
mounted. Lift the access cover clear being careful not
to knock dirt and debris into the open tank.
7. Remove the snap ring holding the strainer to the access
cover. Clean the strainer with compressed air. Do not
use water or steam.
8. Re-install all components in reverse order. Make sure
the cover’s o-ring is seated properly.
9. Install fuel cap.
Figure 31: Fire Extinguisher
Check the charge condition of the fire extinguisher. The charge

indicator gauge pointer should be in the green zone. If not, have
the fire extinguisher recharged or replaced before beginning
work.

Check Air Cleaner Restriction Indicator
Service the air cleaner only when the engine is shut down.
Dirt and debris can enter the engine and cause damage if
the engine is operated with the air cleaner filters removed.
Figure 34: Primary Air Cleaner Filter
Figure 32: Air Cleaner Restriction Indicator Location
The air cleaner restriction indicator is visible from the operator’s

seat with the main boom raised. The air cleaner filters need
replacing if the indicator’s colored piston has popped out and is
visible when the engine is running at high idle.
Replacing Air Cleaner Filters

1. Shut down the engine. Figure 35: Secondary Air Cleaner Filter
2. Loosen the wing nut securing the air cleaner canister
cover and remove the cover. (Figure 33) 6. The secondary (inner) air filter can generally be used
longer before replacement than the primary (outer)
air filter. Inspect the secondary filter and replace it
if required.
7. Uncover the engine air intake and install new filters
in reverse order. Finger tighten the wing nuts, do not
use a wrench as damage to the seals could result.
8. Reset the air filter restriction indicator by pushing
the reset button. (Figure 36)
Press Button to reset
Colored Piston
Figure 33: Removing Air Cleaner Canister Cover
Figure 36: Reset Air Filter Restriction Indicator
3. Remove the wing nut securing the primary filter.
Remove the filter from the air cleaner housing. 9. Start the engine and run at high idle. If the filter
(Figure 34) restriction indicator’s colored piston pops out and is
4. Remove the wing nut securing the secondary filter. visible again, or exhaust smoke is still black, shut
Remove the filter from the air cleaner housing. down the engine and replace the secondary filter.
(Figure 35)
5. Cover the engine air intake opening and wipe away
any dust from inside the housing and cover.
Check Hydraulic Oil Level
Hydraulic oil tank is under pressure!

Low hydraulic oil level can expose suction filters to air and
Escaping oil can cause serious injury. Vent the tank
cause catastrophic damage to the pumps. Keep hydraulic oil
before removing cap or servicing the hydraulic system.
level in green zone of sight gauge at operating temperature.
Position the machine on a level surface for the most

accurate measurement.
Hydraulic oil straight from the drum may contaminate the

hydraulic system resulting in possible pump failure.
Use pre-filtered hydraulic oil only.
Added hydraulic oil must pass through the return filters.

If not filtered, hydraulic system contamination and
possible pump failure may result. Never add oil through
the hydraulic tank access cover.
Release pressure from the hydraulic tank by opening the turbo

boost pressure release valve. (Figure 38) This must be done
before adding oil or working on the hydraulic system.
Turn the petcock counter-clockwise to open the valve. Turn the

pet cock clockwise to close the valve.
Figure 37: Hydraulic Oil Sight Gauge
The hydraulic oil tank is equipped with a sight gauge that is vis-
ible from the operator’s seat with the main boom raised. The oil
level should be kept within the green zone of the sight gauge at
operating temperature, and within the yellow zone when cold.
Add oil if required.
Adding Hydraulic Oil
Figure 38: Turbo Boost Relief Valve
At operating temperature, the hydraulic tank is under

pressure.
Release pressure from the hydraulic tank at the turbo boost

relief valve before opening fill spout.

Hand Pump - Hydraulic oil can be added with a hand pump at Electric Fill Pump (Optional) -
a quick coupling provided on the return oil manifold located on An electric fill pump is available as an option. To add oil using
the left side of the engine. (Figure 39) The mating female quick the electric fill pump, place the fill pump’s suction hose (figure
coupling is shipped with the machine in the Up-Time Kit located 40a) into a container filled with pre-filtered hydraulic oil. Press
under the operator’s seat. Add oil until level in the tank is within and hold the pump actuation button located behind the perforated
the green zone of sight gauge at operating temperature or within engine swing-out door. (Figure 40) Add oil until the level in the
the yellow zone when cold. tank is within the green zone of the gauge at operating tempera-
ture or within the yellow zone when cold.
Figure 39: Quick Connect Location for Hand Pump

Figure 40: Electric Fill Pump Switch Location
Figure 40a: Electric Fill Pump Suction Hose

Check Instrument Panel Gauges
With the engine running at operating temperature, check that all

system monitoring gauges are working properly. Standard machines are not equipped with continuous rota-
tion swing. To swing more than two complete revolutions
Determine the cause of any problems and correct them before in either direction would cause severe damage to the hoses
operating. running through the center of the machine.
Check operation of the swing stop system daily to prevent a

hose wind-up hazard.
There is an audible warning alarm that will sound an

Note: Neutral position is with the boom positioned directly over
alert if systems monitoring gauge reads a possible system
the fuel tank with no twist in the hoses.
problem, or if the hydraulic level drops below the oil level
sensor in the hydraulic tank.
Swing Stop Check
Check Swing Stop System 1. Position the machine in the neutral position.
Some models of machines are equipped with continuous rota- 2. Slowly operate the swing left function.
tion and others are equipped with a swing stop system to protect The rotation of the upper turntable should stop
against a potentially dangerous hose wind-up situation. automatically after 270° or 3/4 revolution, the swing
stop system should be adjusted or replaced, if required.
Machines equipped with the swing stop mechanism will automat-
ically stop swing travel after 270° (3/4 revolution) in direction 3. Return the machine to the neutral position.
from the forward or neutral position. When stopped, the swing
will only work in the opposite direction of travel. 4. Slowly rotate the swing right function.
The rotation of the upper turntable should stop
The swing stop mechanism is located behind the operator’s seat automatically after 270° or 3/4 revolution, the swing
on the left side. (Figure 41) stop system should be adjusted or replaced, if required.
Swing Stop Adjustment
The major swing stop adjustment is made before the swing stop
box was installed. The vertical moving arm is moved up and
down by turning on a pinion gear. (Figure 41) The vertical mov-
ing arm must be positioned so that the contact points are of equal
distance to both swing stop switches. If there is a slight adjust-
ment to be made, it should be done by loosening the adjustment
screws and slightly moving the switch location, away from center
for more travel or toward center for less travel.
If the swing stop system must be replaced, be sure the vertical

moving arm is centered between the two swing stop switches and
the machine is in the neutral position when the new swing stop
box is installed.
Figure 41: Electric Swing Stop

This Page Left Blank For Notes

Change Air Conditioner
/Heater Unit Blower Filter
The air conditioner/heater control unit is equipped
with an intake filter for the blower fan. The filter
is located directly above the operator’s seat. See
Figure 3. If air flow from the blower vents has
degraded, remove and service the filter.
1. Turn off the air conditioner/heater control unit.
2. The filter is held in place by small clips. Pull

the clips back and remove the filter.
3. Clean the filter per instructions on it’s Figure 3: Air Conditioner / Heater Unit Blower Filter
aluminum housing. If the filter requires Removal & Installation
replacement, it can be ordered from your
servicing dealer.
4. Install filter so the airflow arrow on the housing

points towards the blower vents.
5. Secure filter in place with the clips.

Cab Floor
Heater Unit
Seat Mounting
Bracket
Filter Element
Louvered Panel
Protective
Metal Screen
Figure 5: Cab Pressurization System
Change Cab Pressurization

Intake Filter (Optional)
The cab pressurization system is equipped with an
intake filter for the blower fan. The filter is located
behind a louvered panel on the right side of the cab.
See Figure 6. If air flow from the cab floor heater
vents has degraded, remove and service the filter.
1. Turn off the cab floor heater control unit.
2. Remove the eight(8) bolts securing the

louvered panel to access the filter. See Figure
6.
3. Remove and clean the protective metal screen. Figure 6: Optional Cab Pressurization System Intake
If damaged, it can be ordered from your
servicing dealer. See Figure 5. 5. Reinstall protective metal screen and
louvered panel.
4. Remove the filter element and replace with
new filter element which can be ordered from
your servicing dealer.

Bleeding The High Pressure Track
Drive Circuit
If the high pressure track drive circuit is not bled properly
when a pump, motor, hose, drive line swivel, etc... is
replaced, severe damage to the pump or motor can
occur from air trapped in the circuit. Proper bleeding
procedures must be used every time the hydrostatic
high pressure track drive circuit is opened.
1. Open the perforated swing-out engine guard to gain Figure 8a: Sisu Engine Fuel Shut Down Solenoid
access to the engine oil fill. See Figure 7.
Figure 8b: Cummins Fuel Shut Down Solenoid
6. Re-connect the fuel shut-off solenoid power wire.
7. Do a few short starts and stops, then crack the high

Figure 7: Swing-Out Pump Access Guard
pressure lines again to allow any remaining trapped
2. Locate and disconnect the fuel shut-off solenoid’s air to escape.
power wire. See figure 8.
8. Close and secure the perforated swing-out engine
NOTE: The fuel shut-off solenoid power wire must guard.
be disconnected to prevent the engine from starting
during the first steps of the bleed procedure. 9. Start the engine and run at a low idle.
3. Be sure the high pressure lines between the track 10. Swing the booms to the side and lift the track in the
drive pump and motor are full of oil and there is air (as if cleaning the track) that corresponds to the
sufficient hydraulic oil in the tank. circuit being bled. See Figure 9.
NOTE: If this bleeding procedure is being done

after a track motor replacement, be sure to fill
the case of the track drive motor completely with
hydraulic oil before continuing. Fill the track drive
case through the case drain hose to be sure the
track motor case is completely full.
4. Crack the high pressure lines that are to be bled at

the track drive pump outlets.
5. Turn the engine over to let trapped air escape. Do

this several times until no more air is released, then
tighten the high pressure lines.
Figure 9: Lifting The Machine as if To Clean the Tracks

11. With the engine at low idle, slowly move the
track forward and reverse a few pads at a time.
Swing Bearing Service
Gradually increase the amount of track moved Tolerance
but do not increase the speed.
12. After the track has been moved several

rotations forward and reverse with the engine
at low idle, increase engine speed to 1/3
throttle. Continue with the same forward and
manual, before performing any operation, test
reverse movement while slowly lowering the
or adjustment procedures.
track to touch the ground to increase the load
on the circuit.
13. With the engine still at 1/3 throttle, slowly walk

the machine forward and reverse in low gear to
purge any remaining air trapped in the circuit.
14. Shut-down the engine.
15. Procedure complete.
Diesel exhaust fumes contain elements that are


components and hydraulic system components

Periodically, the swing bearing service tolerance 5. Start the engine. Lower the cutting attachment
may need to be checked. A service tolerance of up to the ground, then use the main boom down
to 0.095” is acceptable. function to continue putting down pressure
on the boom until the track on the boom side
1. Torque all bearing mounting bolts to begins to lift off the ground.
specification before beginning procedure.
6. Shut down the engine. Record both dial
indicator readings. The indicator readings
should be within .002” of each other. If not,
it could indicate loose bearing mounting bolts
that may be allowing the bearing to flex slightly.
7. Re-position both dial indicators to the front and

rear of the machine. Perform steps #3 thru #6
with the boom extended over the front of the
machine.
- Position the dial indicators as near as

possible to the center line of the bearing
(looking towards the bearing from the front
and rear of the machine).
Figure 10: Positioning The Dial Indicator
- Be sure the magnetic base is fixed to a
2. Position a dial indicator with its magnetic base smooth flat surface and it has firm contact
affixed to the lower turntable weldment and with the lower turntable.
. . . . . . . . . . . . .the indicator pointer against
the outer race of the bearing. See Figure 10. 8. New machine bearing tolerance at the
Position a second dial indicator on the opposite factory is approximately .020-.024” (this is
side of the bearing. actually bearing tolerance plus other inherent
tolerances found in machine assembly). The
- Position the dial indicators as near as difference between “new” and your readings is
possible to the center line of the bearing the bearing’s service tolerance.
(looking towards the bearing from the sides
of the machine).
- Be sure the magnetic base is fixed to a

smooth flat surface and it has firm contact
with the lower turntable.
3. Start the engine. Position the boom at full

extension over one side of the machine with
the cutting attachment a few inches off the
ground. Shut down the engine.
4. Zero both dial indicators.

Structural Points
Figure 11: Patented Tapered Hub Pin Retainer (Typical)

Patented Tapered Hub Pin Retainers The minimal amount of clearance necessarily inherent in all
machined components for manufacturing and accumulated
All critical pivot points are equipped with a tapered hub pin clearance from normal wear can be largely eliminated with the
retainer. (See figure 11) patented tapered hub pin retainers.
The tapered hub pin retainer was developed as a means to The tapered hub principle is very simple. As the tapered hub
provide a solid pin retaining system with as little clearance as retaining bolts are tightened, the tapered hub is drawn into a
possible to minimize the amount of free-play between compo- tapered pin bore causing the hub to clamp around the pin. The
nents. This is especially important in the optional cab leveling result is the pin being firmly secured equally on all sides. This
system where excessive free-play will significantly reduce the also results in much better transfer of load stresses across the
operating life of the swing bearing. pin mounting area.

Leveling Component Slack Adjusters
Figure 12: Level System Slack Adjusters (Typical)

Leveling Component Slack Adjusters Each slack adjuster is provided with two setscrews and jam
nuts. Normal pivot wear causes unwanted side movement
The machines can be equipped with the optional 2-cylinder, between leveling components and can be removed by reposi-
4-way cab leveling system. In addition to the tapered hub pin tioning the slack adjusters with the setscrews.
retainers, slack adjusters have been developed to minimize the
side movement of the leveling components down the length of
the pin during operation.
The inherent manufacturing clearance in the machined level-

ing components and accumulated clearance from normal wear
can be minimized with the slack adjusters.
3⁄4” (19 mm) diamond shaped slack adjusters (shims) are pro-
vided in the main front-to-back and side-to-side pivots.
(See figure 12)


6. Slowly operate one of the hand controls. The controls
should not respond with the cab door closed until the
IQAN control system has been armed.
You must read and understand the warnings and basic
safety rules, found in Chapter 1 of this manual, before If the controls respond without first arming the IQAN
performing any operation or maintenance procedures. control system, STOP and have the door safety interrupt
system repaired before operating the machine.
For additional engine maintenance guidelines, see the
manufacturer’s manuals provided with the machine. 7. With the cab door closed, arm the IQAN control system.
The “System Armed” light should illuminate to indicate
Perform the following maintenance items after every 50 hours or the machine is ready for operation. Open the door, the
machine operation. “System Armed” light should go out and none of the
controls should work.
Test Door Safety Interrupt System Operation If the “System Armed” light stays on and/or any of the
controls stay active after opening the door, STOP and
have the door safety interrupt system repaired before
operating the machine.
DO NOT bypass, remove, or tamper with the door
safety interrupt system.
Serious personal injury or death could occur while

operating the machine with the cab door open or with
a faulty door safety interrupt system.
A normally open electrical switch is located at the base of the cab

door. (Figure 1) This switch is part of the door safety interrupt
system used to monitor the cab door. The IQAN control system
will only allow operation of the machine when the cab door is
closed.
Use the following procedure to test the door safety interrupt

system:
1. Sit in the operator’s seat and fasten the seat belt. Figure 1: Door Safety Interrupt Switch
2. Be sure the cab door is fully open and the door safety
latch is in the locked position. (Figure 2)
3. Start the machine and try arming the IQAN control
system. The “System Armed” light should not
illuminate.
If the “System Armed” light illuminates with the cab

door open, STOP and have the door safety interrupt
4. Slowly operate one of the hand controls. The controls

should not respond with the cab door open.
If the controls respond with the cab door open, STOP

and have the door safety interrupt system repaired
before operating the machine.
Figure 2: Door Safety Latch
5. Close the cab door but do not arm the IQAN control
(Shown in the Un-locked Position)
system. The “System Armed” light should not be
illuminated.
To lock, open the door all the way and the “T”-handle will drop
into a cut out in the slide bar.
If the “System Armed” light illuminates by only closing
the cab door, STOP and have the door safety interrupt

Lubrication
Use a good quality grease containing at least 5-6% Molybdenum

by volume, at all lubrication points. Lubriplate #176 is recom-
mended. Grease meeting the above requirement has a higher
rated load pressure than a typical multi-purpose EP grease.
Swing Bearing Race
Figure 4: Lubricate Swing Stop Lead Screw
Optional Cab Leveling Components
When equipped, on either side of the track motor compartment

in the car body there are a group of grease fittings that are for the
following points: (See figure 5)
LH Side
Figure 3: Lubricate Swing Bearing Race - Lower turntable front pivot
(1 fitting in cab, 3 auxiliary fittings around diameter of bearing) - Lower turntable slack adjuster
- LH Intermediate Pivot (3 fittings)
The swing bearing ball race is provided with one grease fitting in - LH Cab level cylinder rod end pivot
the cab and three auxiliary grease fittings around the diameter of -LH Cab level cylinder base end pivot
the bearing. (Figure 3)
RH Side
Begin greasing with the boom directly over the fuel tank. While - Lower turntable rear pivot
applying grease, slowly swing to the right until the swing stop is - Lower turntable slack adjuster
reached, then back left until the swing stop is reached. Applying - Intermediate slack adjuster (2 fittings)
grease throughout the swinging motion insures an even distribu- - LH Intermediate Pivot
tion of grease around the bearing. - RH Cab level cylinder rod end pivot
- RH Cab level cylinder base end pivot
The auxiliary grease fittings around the diameter of the bearing
can also be used, however, applying grease from the cab fitting is Add grease to these fittings until it appears at the pivot area.
preferred. Greasing at both the cab and the auxiliary fittings is a
very good idea as a little extra grease will not harm anything.
Swing Stop Lead Screw
The swing stop lead screw is provided with one grease fitting in
the vertical moving arm that is accessed through the hole located
in the cover of the swing stop box. (Figure 4) Only one stroke of
grease is required to properly lubricate the lead screw.
Figure 5: Cab Leveling Grease Points

(14 fittings, 7 each side of carbody)(RH Side shown)

Check Pump Drive Transmission Oil Level
1. Open the swing-out pump compartment guard to gain

access to the pump drive transmission. (Figure 6)
2. Locate the pump drive transmission oil level dipstick

where the left rear engine mount attaches to the pump
drive transmission housing.
The oil level should be within the FULL range on the

dipstick. If required, add SAE 75W-90 synthetic oil
that meets MIL-L-2105 specifications. Add oil through
the fill port located just above the dipstick. (Figure 7)
Figure 8: Swing Motor / Gearbox (Typical)
Track Final Drive Oil Level
Overfilling the track final drive will cause the track motor
seals to allow hydraulic oil or water to enter and contami-
nate the drive.
1. Position the machine on level terrain so that the LEVEL

port in the final drive cover is at the 3:00 position.
(Figure 9)
Figure 6: Swing-out Pump Access Door (Typical) 2. Remove the plug in the LEVEL port. Oil level should
be even with the bottom of the LEVEL port opening.
3. If required, add oil until it reaches the bottom of the
LEVEL port opening. See appendix A for approved
oil specifications.
4. Clean the LEVEL port plug. Inspect the o-ring seal
and replace if damaged.
5. Install the plug.
6. Repeat procedure for the other final drive.
Level
Figure 7: Pump Drive Transmission Dipstick and Fill Port

(Typical)
Swing Gearbox Oil Level

Drain
Locate the swing gearbox oil level dipstick(s). Some machines
are equipped with 2 swing motor/gearbox units. (Figure 8)
The oil level should be within the FULL range on the dipstick Figure 9: Final Drive Level Check Positioning
for each unit. If required, add oil through the dipstick port. See
appendix A for approved oil specifications.

Torque Tapered Hub Retaining Bolts Run Air Conditioner
It is recommended that the air conditioner be run for at least 5

minutes per week year around. Regular operation of the Air Con-
Severe structural damage can occur if tapered hub ditioner keeps the compressor seals lubricated with oil to prevent
assemblies are not kept tight. them from drying out.
See Chapter 4, Cabin, for Air Conditioner operation.
Check Cab Window Emergency Escapes
Keep cab window emergency escape hatches easily

removable. Serious personal injury or death could
result if the rear window guard can not be removed in
an emergency.
The cab window emergency escape hatches must be easily

Figure 10: Tapered Hub (Typical) removed in order to be effective. Do not allow the weather
stripping to become stuck to the cab or the star knob(s) to
Tapered hub pin retainers are used at the pivot between the main become bound or difficult to remove.
boom and upper turntable and in the cab level component pivots.
Torque all tapered hub retaining bolts to 100 ft. lbs. (135 Nm). Do not use grease to lubricate the rear window guard
(Figure 10) weather stripping or star knobs. In cold weather grease can
become hard and cause the weather stripping to stick or
It is recommended that the tapered hub retaining bolts be tight- bind the star knobs.
ened in the pattern as a seen in Figure 11.
The rear cab window and its guard weighs approximately
57 lbs. (26 kg). The front cab window and its guard weighs
approximately 200 lbs. (91 kg).
The cab window emergency escape hatches should be checked at

least once a week.
1. Remove the star knobs securing the hatch. If they did
not turn freely, coat the threads with anti-seize
compound (such as Loctite 765-1151).
2. Push / pull the escape hatch away from the opening.

The escape hatch should be free to move. If not, remove
the escape hatch and apply anti-seize compound (such as
Loctite 765-1151) to the weather stripping.
3. Re-install the escape hatch and hand tighten all star

knobs.
Figure 11: Tapered Hub Torque Pattern

and basic safety rules, found in Group 1 of this

the machine.
Perform the following maintenance items after every

100 hour interval of operation.
Check Engine Fan Figure 3: Remove Radiator Shroud (Typical)
1. Shut down engine before working near the 2. Open the perforated swing-out engine guard
engine fan and belts. and pivot the engine pivot guard forward to
access the engine fan and belts.
See Figures 1 & 2.
3. Remove engine fan shroud. See Figure 3.
Cracks or Fan
Blade Damage
NOT O.K.
REPLACE FAN
Figure 1: Perforated Swing-Out Engine Guard
Figure 4: Check Engine Fan (Typical)
4. Remove engine fan. Inspect blades and hub

for cracks or other damage. See Figure 4.
Replace engine fan if required.
NOTE: If also checking engine belts, leave the

engine fan removed until all the belts have been
inspected. If an engine belt must be replaced,
the engine fan would have to be removed in
order to replace the belt.
5. Install engine fan in reverse procedure order.

Figure 2: Engine Pivot Guard
Use Loctite 242 on engine fan mounting bolts.

Check Belts
Lengthwise Cracks,
Intersecting Cracks,
or Belt Damage
NOT O.K.
Cracks
REPLACE BELT Across
Width
O.K.
Keep your head, hands, and feet clear of all Figure 1: Ribbed Serpentine Belt Inspection - General
moving parts.
All Cracking
NOT O.K.
REPLACE BELT
Figure 2: V-Belt Inspection - General

Keep yourself, all objects and tools away from
any object dropped or pushed into them. Any cracking on a V-belt is not acceptable. Replace
any V-belt that has cracking. See Figure 2.
General Inspection Information
Any ribbed belt or V-belt showing signs of wear
Keep engine and accessory belts properly or that has material missing should be replaced.
tensioned for maximum engine performance and When a belt is replaced, check its tension again
fuel economy. Proper belt tension minimizes after 30 minutes of operation. New belts will stretch
slippage and increases belt life. with use.
Belts that are too loose see excessive vibration and

increased wear. Belts that are too tight produce
wear on both the belt and the bearings of the pul-
leys it travels around.
Check ribbed serpentine belts for intersecting

cracks. Cracks across the width of a ribbed belt are
acceptable. Cracks along the length of a ribbed belt
are not acceptable. Ribbed belts with cracks along
their length should be replaced. See Figure 1.

Check Alternator Belt Check A/C Compressor Belt
Inspection Inspection
Visually inspect the ribbed serpentine alternator
belt according to guidelines under “Check Engine
Fan & Belts.” If a belt requires replacement, see
instructions below.
Tension Check
The engines are equipped with an automatic
tensioner for the alternator belt. No manual
adjustment is required.
Replacement
1. Remove engine fan. See procedure under
“Check Engine Fan & Belts.”
Figure 8: A/C Compressor Belt Guard (Typical)
1. Remove A/C compressor belt guard. See

Figure 8.
2. Visually inspect the A/C compressor V-belt

according to guidelines under “Check Engine
Fan & Belts.” If the belt requires replacement,
see instructions below.
Tension Check
Figure 7: Lifting Automatic Tensioner (Typical)
2. Raise the automatic tensioner to release

the old belt and install the new belt. See
Figure 7.
3. When replacing the alternator belt, it is a good

idea to check the tensioner capscrew torque.
Torque should be 32 ft.lbs (43 Nm). See
Figure 7.
4. If no other belts are to be inspected, reinstall

the engine fan. See procedure under “Check Figure 9: Check A/C Compressor Belt Tension
Engine Fan & Belts.”
Check the adjustment of the A/C compressor belt by
applying 25 lbs. (110 N) of force to the belt midway
between the pulleys, The belt should deflect 1/2”
- 3/4” (13mm - 19mm). See Figure 9. Adjust belt
tension or replace belts if required.
If the belt does not require adjustment, reinstall the

A/C compressor belt guard.

2
Figure 10: A/C Compressor Belt Adjustment

Cummins (Typical)
Replacement & Adjustment

1. Loosen A/C compressor mounting bolt (1) and
adjustment bracket bolt (2). See Figure 10.
If the belt is to be replaced, remove the old belt

now and install the new belt.
2. Move the A/C compressor to obtain correct

tension. Tighten mounting and adjustment
bracket bolts to secure the compressor.
3. Reinstall the A/C compressor belt guard.
4. Recheck belt tension after 30 minutes of

operation. New belts will stretch with use.

Check Battery
Do not smoke while checking battery electrolyte Figure 11: Battery Location (Typical)
The battery is located behind the perforated
explode swing-out engine guard. See Figure 11.

Figure 12: Checking Battery Electrolyte Acid Level
eye, face and hand protection when working with
(Typical)
batteries.
1. Remove all 6 cell caps from the battery.
See Figure 12.
2. Use a flashlight to check the battery electrolyte

(acid) level in each of the 6 cells. Maintain
electrolyte level to the bottom of the fill opening
(approx. 1-1/2” (38mm)) with distilled water.
If distilled water is not available, clean drinking
water can be used.
3. Check the rubber gasket seal on each cap

before installing. Replace if cracked or
damaged.
Battery electrolyte (acid) is highly corrosive.


1. Allow the engine to cool down before changing
oil.

the machine.

Change Engine Oil & Filter

Figure 1: Remove Engine Oil Sump Access Cover
2. Remove the engine oil sump access cover.

See Figure 1.
3. Remove the oil pan plug and allow oil to

completely drain into a suitable container. See
Appendix A for engine oil capacities.
4. Dispose of waste oil properly.
5. Install oil pan plug.

Position the machine on a level surface. Shut

down engine and wait at least 5 minutes to
allow the oil to drain back into the crankcase.
It is best to change the engine oil while it is still

warm, not hot, from operation. Contamination
or sediment will be suspended in warm oil when
it is drained. As the oil cools, contamination or
sediment may settle to the bottom and not drain Figure 2: Slotted Engine Pivot Guard
with the oil.
6. Remove the upper bolt securing the slotted
Never operate the machine with the engine oil engine pivot guard. Loosen the lower bolt to
level below or above the “FULL” range on the pivot the guard and gain access to the engine
dipstick. Damage to the engine could result. oil filter. See Figure 2.

Figure 3: Engine Oil Filter Location (Typical) Figure 5: Engine Oil Fill Location (Typical)
7. Remove the used engine oil filter and dis- 11. Remove the oil fill cap on the engine. See
pose of properly. The oil filter is located just Figure 5. Fill the engine with new oil. See
behind the alternator. See Figure 3. Appendix A for engine oil type and capacity.
Clean and install engine oil fill cap.
8. Clean the filter mount housing base to remove
any remaining gasket material from the used 12. Start and run the engine at low idle for
filter. 2 minutes. Watch for leaks.
9. Apply a thin coating of oil to the gasket of the 13. Shut down the engine and wait at least
new filter. Install new filter by hand until the 5 minutes to allow the oil to drain back into
filter gasket contacts the housing. Tighten to the crankcase.
filter manufacturers recommendations. Do not
over-tighten. 14. Check engine oil level. Oil level should be
within the “FULL” range on the dipstick.
Add oil if required.
15. Reinstall the engine oil sump access cover

and secure the slotted engine pivot guard and
perforated swing-out engine guard.
Figure 4: Perforated Swing-Out Engine Guard
10. Open the perforated swing-out engine guard to

gain access to the engine oil fill. See Figure 4.

Change Fuel Filters 2. Clean the filter mount housing bases to
remove any remaining gasket material from the
Allow the engine to cool down before changing fuel old filters.
filters. Fuel filters are located behind the perforated
swing-out engine guard. 3. Fill each filter with clean fuel.
Changing Filters NOTE: Failure to fill each fuel filter with clean
fuel before installation will require manual
bleeding of the fuel system during start-up.
4. Apply a thin coating of clean fuel or light oil to

the gasket of the new filter.
5. Install each new filter by hand until the

filter gasket contacts the housing. Tighten to
filter manufacturers recommendations. Do not
over-tighten.
Bleeding Fuel System

See the engine manufacturer’s manual sup-
plied with this machine for fuel system bleeding
Figure 6: Fuel Filters (Typical) procedures.
1. Clean the area around all fuel filter heads.

Remove the old fuel filters by turning COUN-
TER-CLOCKWISE. See Figure 6.

Torque Specific Bolts Swing Motor Mounting
Swing Bearing Mounting Bolts
Torque the 1” swing bearing mounting bolts (qty 22)
Maintain correct torque on all bolts. Failure to 1000 ft.lbs. (1350 Nm). See Figure 10.
to do so may result in severe structural
damage to the machine.
Bolts
Torque the 5/8” swing motor mounting bolts (qty 16)
to 200 ft.lbs. (270 Nm). See Figure 9.
Figure 10: Torque Swing Bearing Mounting Bolts
Figure 9: Torque Swing Motor Mounting Bolts

Hydraulic Tank Mounting Bolts Track Frame Mounting Bolts
Figure 13: Torque Track Frame Mounting Bolts

Figure 11: Torque 1/2” Hydraulic Tank Mounting Bolts
Torque the 1/2” hydraulic tank mounting bolts (qty 7) Torque all 30mm track frame mounting bolts (qty 24)
to 100 ft.lbs. (135 Nm). See Figure 11. to 1,200 ft.lbs. (1,600 Nm). See Figure 13.
Track Shoe Mounting Bolts
Figure 12: Torque 5/8” Upper Hydraulic Tank

Mounting Bracket Bolts
Figure 14: Torque Track Shoe Mounting Bolts (Typical)
Torque the 5/8” upper hydraulic tank mounting 425 - Torque all 20mm track shoe mounting bolts
bracket bolts (qty 2) to 200 ft.lbs. (270 Nm). See (qty 360) to 300 +/- 50 ft.lbs. (400 +/- 70 Nm) plus
Figure 12. 1/3 turn. See Figure 14.
445 - Torque all 22mm track shoe mounting bolts

(qty 360) to 370 +/- 50 ft.lbs. (500 +/-70 Nm) plus
1/3 turn. See Figure 14.

Track Rock Guard Mounting Check Air Conditioner
Bolts Refrigerant
Mounting
Bolt During seasons when the heater will not be
used, close the shut-off valves in the hot water
supply and return lines to the control unit. The
shut-off valves are located on the engine.
Spacer
Bolt
Figure 15: Torque Track Rock Guard Mounting Bolts
425 - Torque all 20mm track rock guard mounting

bolts(16) and spacer bolts(8) to 420 +/- 60 ft.lbs.
(560 +/- 80 Nm). See Figure 15.
445 - Torque all 24mm track rock guard mounting

bolts(16) and spacer bolts(6) to 740 +/- 90 ft.lbs.
(985 +/- 120 Nm). See Figure 15.
It is important to maintain the refrigerant level

in the air conditioner system. Failure to do so
may damage the compressor.
1. Start the engine and set the throttle at half

speed.
2. Activate the air conditioner system.

See Figure 16:
Be sure the knob for the heat selector is turned

all the way to the minimum heat position.
(Minimum = CCW / Maximum = CW)
Select “A/C” at the function select switch.
Select fan speed “HIGH” at the fan speed

select switch.
Adjust temperature of air flow at the thermostat

knob to coldest setting.

Heat / A/C
Air Vents Fan Switch Selector Switch
Temperature Adjustment Temperature Adjustment

Knob, Heat Knob, A/C
Figure 16: Cab Air Conditioner Controls (Typical)
3. Remove the inspection cover over the air

conditioner drier assembly on top of the cab.
See Figure 17.
4. Observe the sight glass on the air conditioner

drier. Note of the condition of the refrigerant
moving past the sight glass.
If the refrigerant is running clear, or there are a

few air bubbles that disappear as engine RPM
varies, the system is operating normally. See
Figure 18.
Figure 18: Clear Refrigerant With Few Air Bubbles
Figure 17: Air Conditioner Drier Inspection Cover

Figure 19: Clear Refrigerant With Many Air Bubbles Figure 20: Air Conditioner Condenser Access
If there are many air bubbles in the sight glass, Clean Air Conditioner
there is a lack of refrigerant in the system. Condenser
Contact an authorized air conditioner repair
service to have the system recharged. The air conditioner condenser is located at the rear
See Figure 19. of the cab. See Figure 20. Remove the star knobs
and swing the perforated access panel upward.
Clean away any debris that has accumulated
If the refrigerant is a milky white color, there
around the condenser.
is compressor oil mixed with the refrigerant.
This is acceptable as long as it is free of air
bubbles.



and basic safety rules, found in Chapter 1 of
this manual, before performing any operation
or maintenance procedures.

the machine.

Check Engine Coolant Figure 1: Radiator Fill Spout Access Cover (Typical)
Antifreeze Concentration 1. Allow the engine and cooling system to cool

down before adding coolant.
2. The radiator fill spout is located under an

access cover on the engine compartment
ROPS panel. See Figure 1. Remove radia-
tor cap slowly to allow any trapped pressure to
escape.
3. Check the engine coolant’s antifreeze

concentration at the fill spout. Low
temperature capability should protect to
o o
-34 F (-37 C) year round.
At operating temperature, the radiator and If required, Adjust coolant antifreeze

hydraulic tank are HOT and under pressure. concentration by adding an appropriate mixture
Allow these components to cool to the touch of low silicone ethylene glycol base antifreeze
before servicing. and distilled water.
Example: If low temperature capability must
boost release valve before opening fill spout. be increased, mix more antifreeze to less
distilled water. If distilled water is not available,
use clean tap water.
4. Fill radiator until coolant level is above the

radiator core and about 2 - 3” (5 - 8 cm) below
the fill spout. Do not over fill.
Do not overfill the radiator. The coolant volume
will expand as the engine reaches operating
temperature. 5. Replace the radiator cap.
Using a mixture of antifreeze and water as engine

coolant increases the operating range of the engine.
Antifreeze lowers the coolant’s freezing point and
raises the boiling point.
Page 8.7.1 Chapter 8 - Service & Maintenance

Check Radiator Hoses
At operating temperature, the engine, exhaust Figure 2: Engine Pivot Guard

Unscrew the bolts securing the slotted engine pivot

guard. Open guard to gain access to radiator and
heater hoses. See Figure 2.
Check the following radiator and heater hoses

for cracks, hose clamps or leaks. See Figure 3.
Replace any damaged hoses immediately:
o
- 90 rubber elbow at base of radiator
- 1” (25mm) radiator bypass hose
- Radiator flex hose at top of engine
- 1/2” (12mm) heater hose
Figure 3: Check Radiator Hoses

Change Air Cleaner Filters
Figure 6: Removing Air Cleaner Secondary Filter
6. The secondary filter can generally be used lon-

ger before replacement than the primary
Figure 4: Removing Air Cleaner Canister Cover filter. Inspect secondary filter and replace
it if required.
1. Shut down the engine.
7. Uncover the engine air intake opening.
2. Loosen the wing nut securing air cleaner
8. Re-install the secondary filter, primary filter and
air cleaner housing cover. Secure wing nuts
finger tight. Do not use a tool to tighten the
wing nuts or damage to the threads could
result.
Reset Button
(press to reset)
Figure 5: Removing Air Cleaner Primary Filter Colored

Piston
canister cover. Remove cover. See Figure 4.
3. Remove the wing nut securing the primary

filter. Remove filter from the air cleaner
housing. See Figure 5. Figure 7: Reset Air Filter Restriction Indicator
4. Remove the wing nut securing the secondary 9. Reset the air filter restriction indicator by
filter. Remove filter from the air cleaner pushing in the reset button. See Figure 7.
housing. See Figure 6.
10. Start the engine and run at high idle. If the
5. Cover the engine air intake opening and wipe filter restriction indicator’s colored piston pops
dust from inside the air cleaner housing and out and is visible again, or exhaust smoke is
cover. still black, shut down the engine and replace
the secondary filter.

Change Hydraulic Oil Filters

At operating temperature, the engine, exhaust any maintenance or repairs.
Return Filters
Hydraulic oil tank under pressure. Escaping

oil can cause serious injury. Vent tank
before removing cap or servicing hydraulic
system.
Preventing the return filters from going into

At operating temperature, the radiator and bypass is extremely important. Return filter
hydraulic tank are HOT and under pressure. bypass allows unfiltered oil into the main tank
before servicing.
where it can contaminate the rest of the hydrau-
lic system. Prevent return filter bypass.
Release pressure from hydraulic tank at the turbo Return filter bypass will result if dirty filters are
boost release valve before opening fill spout. not changed. Change filters in according to
preventive maintenance guidelines, or sooner
if required.
Following this simple rule will help prevent

costly downtime due to hydraulic system
contamination and greatly increase the life of
your equipment.

The return filters should be changed after the first
100 hours of operation and, thereafter, every 500
hours of operation. When changing return filters, care must be
taken to insure that contaminates from around
1. Place booms on the ground and shut down the the top of the tank, the filter head, and no con-
engine. taminated oil is allowed to drain or fall into the
main tank.
Figure 10: Removing Return Filter Element

2. Release boost pressure from the tank by
opening the turbo boost pressure release
valve. See Figure 8. This must be done
before adding oil or working on the hydraulic
system.
Figure 11: Return Filter Element
5. Visually inspect the condition of the element

Figure 9: Return Filter Guard (Typical)
before removing it. See Figure 11. If there are
3. Remove the bolts securing the guard over the no bronze or brass specks visible, remove the
return filters on top of the hydraulic tank. See filter element and install a new one. Dispose
Figure 9. of used filter element properly. Skip to step
#10. If there has been a known pump failure,
4. Remove the filter head cover to expose the or there are bronze or brass specks visible,
filter element. See Figure 10. the whole filter head/canister assembly must
be removed so that contaminated oil cannot
drain into the main tank when the element is
removed. Continue with Step #6.

Case Drains
Filter Head Cover Return Filter
Filter Head Oil Cooler

Return Filter
Disc Saw Circuit

Return Filter
Filter Canister
Hydraulic Oil
Tank
Filter Element
Gasket
Implement Pump
Suction Strainer
Track Drive Charge

Pump Suction
Strainer
Disc Saw Pump

Suction Strainer
Figure 12: Exploded View - Hydraulic Tank Filters & Strainers

11. Repeat for remaining return filters.
Filter Head
12. Close the turbo boost T-valve if no other work
is to be done on the hydraulic system.
Filter Canister
Suction Strainers (Cleanable)

The system pump, system pilot pump and disc
saw pump(optional) suction screen filters can
be accessed from the bottom of the tank. See
Figure 12.
These strainers need cleaning or changing when

changing hydraulic oil or after each 2000 hours of
operation.
Figure 13: Removing Return Filter Assembly
Track Drive Charge Pressure
6. Disconnect the hydraulic lines at the filter
head.
Filter
The track drive charge pressure filter should be
7. Remove the bolts securing the filter head/ changed after the first 100 hours of operation and,
canister assembly in the tank. Lift the thereafter, every 500 hours of operation.
assembly from the tank. See Figure 13.
This forces all oil to drain through the filter
as the assembly is removed.
8. Remove the filter element, thoroughly clean

and degrease the housing, and install a new
filter. Dispose of used filter element properly.
1. Place booms on the ground and shut down

the engine.
2. Release boost pressure from the tank by

Figure 14: Return Filter Rubber Gasket opening the turbo boost pressure release
valve. See Figure 15. This must always
9. Thoroughly clean and de-grease the gas- be done before adding oil or working on the
ket and mounting area on the tank before re- hydraulic system.
installing the assembly into the tank. Be sure
the rubber gasket at the base of the return filter 3. Open the swing-out pump compartment guard
head is in place. See Figure 14. Tighten the to gain access to the track drive charge
retention bolts. Re-connect any hydraulic lines pressure filter assembly. See Figure 16.
that were removed.
10. Re-install filter head.

8. Close the turbo boost T-valve if no other work
is to be done on the hydraulic system.
9. Close and secure the swing-out pump

compartment guard.
Check Slack Adjusters
Figure 16: Swing-Out Pump Access Guard (Typical)
Figure 18: Slack Adjuster

(Right Side Shown)
Located in the main front-to-rear and side-to-

side pivot points are diamond shaped slack
adjusters (shims) equipped with setscrews and
jam nuts. See Figure 18.
The purpose of the slack adjusters is to pre-

vent side movement of the leveling compo-
Figure 17: Track Drive Charge nents across the pivot pins during machine
Pressure Filter Assembly operation. As these pivot points wear, the
resulting increase in tolerance between the
4. Place a container under the wheel drive leveling components must be removed. This is
charge pressure filter assembly to catch oil done by repositioning the slack adjusters.
spillage when removing the filter canister.
Remove filter canister. See Figure 17.
1. Position the machine on a level surface.
5. Remove the filter element and install a new
2. Level the upper turntable.
one. Dispose of used filter element properly.
3. Tighten the setscrews on the front and right
6. Inspect o-ring on the filter canister, replace if
side slack adjusters to take the excess
damaged.
tolerance out of the leveling components.
7. Install filter canister. Do not over tighten the
4. After excess slack has been removed, back all
canister.
setscrews off 1/2 turn and tighten the jam nut.
NOTE: Be very careful not to cross-thread
NOTE: DO NOT leave the setscrews tight
the filter canister into the manifold body. Both
against the slack adjuster. Some tolerance is
components are constructed of aluminum and
required for proper operation of the leveling
will seize together if forced to thread.
system. The setscrew may shear off if left
tight against the slack adjuster.




the machine.

Secure & Clean Battery Battery electrolyte (acid) is highly corrosive.

Do not smoke while checking battery electrolyte

explode Figure 1: Battery Location (Typical)
1. Open the perforated swing-out engine guard

to gain access to the battery and battery box.
See Figure 1.
2. Tighten all battery box hardware to keep

battery securely in place.
3. Disconnect the battery cables.
4. Clean the battery surface with a clean rag.

The rag will get battery acid on it, wear
protective clothing and dispose of the rag
properly.
5. Coat the battery posts with petroleum jelly and
eye, face and hand protection when working with
batteries. re-install the battery cables.
6. Close and secure the perforated swing-out

engine guard.

Change Pump 2. Remove the lower pump access cover to
access the pump drive transmission drain plug.
Drive Transmission Oil See Figure 2.

components and hydraulic system components Figure 3: Swing-Out Pump Access Guard
3. Open the swing-out pump compartment
guard to access to the pump drive transmission
dipstick and oil fill port. See Figure 3.
Position the machine on a level surface. Shut

down engine and wait at least 5 minutes to
allow the oil to drain to the bottom of the pump
drive transmission housing.
It is best to change the pump drive transmission

oil while it is still warm, not hot, from operation.
Contamination or sediment will be suspended
in warm oil when it is drained. As the oil cools,
contamination or sediment may settle to the
bottom and not drain with the oil.
1. Allow the pump drive transmission and hydrau-

lics to cool down before changing oil.
Figure 4: Pump Drive Transmission Housing
Oil Drain Plug
4. Remove the pump drive transmission hous-

ing oil drain plug and allow the oil to completely
drain into a suitable container with at least a
3 gallon (11,35 liters) capacity. See Figure 4.
6. Install oil drain plug.
Figure 2: Remove Lower Pump Access Cover

Change Swing
Gearbox(es) Oil(s)
Figure 5: Pump Drive Transmission Oil Dipstick & Fill

Plug
7. Locate the pump drive transmission oil system components, cooling system
level dipstick and oil fill port where the left rear components and hydraulic system components
engine mount attaches to the pump drive are HOT. Any contact can cause severe burns.
transmission housing. See Figure 5.
8. Add oil specified in appendix A at the oil fill port

until the oil level is within the FULL range on
the dipstick. It is best to change the swing gearbox oil
while it is still warm, not hot, from operation.
Contamination or sediment will be suspended
9. Install oil fill plug.
in warm oil when it is drained. As the oil cools,
10. Close and secure the swing-out pump bottom and not drain with the oil.
compartment guard and lower pump access
cover.
Figure 6: Swing Gearbox Oil Drain Port
The drain port for the swing gearbox(es) is (are)

located in the lower rear section of the housing
near the mounting bolts. (Some models have 2
swing gearboxes.) See Figure 6. To minimize oil
spillage, use the following procedure to drain the
gearbox(es).

Figure 7: Positioning The Machine To Drain Figure 9: Suction Gun (Typical)
The Swing Gearbox Oil
4. Use a suction gun to siphon as much oil
1. Tilt the turntable all the way forward for bet- as possible out the dipstick port. See
ter access to the gearbox drain port. Figure 9. Transfer the waste oil to a container
See Figure 7. with at least a 3 gallon (11,35 liters) capacity.
2. Allow the pump drive transmission and hydrau- 5. Remove the drain port plug and remove as
lics to cool down before changing oil. much oil as possible, then re-install the plug.
7. Start the engine and return the upper turntable

to a level position. Shut-down engine.
8. Add oil as specified in Appendix A at the dip-

stick port until the oil level is within the FULL
range on the dipstick.
9. Install the dipstick.
Figure 8: Swing Gearbox Oil Level Dipstick
3. Remove the swing gearbox oil level dipstick.

See Figure 8.



You must read and understand the warnings It is best to flush the track final drive oil
and basic safety rules, found in Chapter 1 of while it is still warm, not hot, from operation.
this manual, before performing any operation Contamination or sediment will be suspended
or maintenance procedures. in warm oil when it is drained. As the oil cools,
For additional engine maintenance guidelines, bottom and not drain with the oil.
the machine. Overfilling the track final drive will cause the
track motor seals to allow hydraulic oil or water
Perform the following maintenance items after every to enter and contaminate the drive.
Relatively high metal contamination levels are com-
Flush Track Final Drive Oil mon in many track final drive gearboxes during
the break-in period (referred to as break-in wear).
Because most gearboxes do develop contamina-
tion during the first year of operation, the following
flushing procedure should be performed after the
first 100 hours, first 1000 hours and, thereafter,
every 2000 hours.
LEVEL

are HOT. Any contact can cause severe burns. DRAIN
Figure 1: Positioning Final Drive DRAIN Port
1. Position machine so that the DRAIN port in the

final drive cover is at the bottom.
See Figure 1.
2. Place a suitable container with a minimum

capacity of 12 quarts (11.35 liters) under the
drain port. Remove the LEVEL port plug and
Pressure can be maintained in system circuits DRAIN port plug. Allow the oil to drain
long after the engine and pumps have been shut completely. Dispose of waste oil properly.
3. Clean both plugs. Inspect the o-ring seals and
any maintenance or repair procedures.
replace if damaged.
4. Install DRAIN port plug.

5. Flush the final drive by adding 10W hydraulic
oil through the LEVEL port until the oil reaches
Flush Engine Cooling
the bottom of the LEVEL port opening. Install System
LEVEL port plug.
6. With the engine at idle, swing the booms

to the side and lift the track in the air on the
side of the final drive being flushed. Rotate the
track at a slow speed for one minute.
7. Position the final drive with the DRAIN port

plug at the bottom of the final drive cover and
lower the track to the ground.
8. Position the waste oil container used in

step #2 under the DRAIN port plug. Remove
the LEVEL port plug and DRAIN port plug.
Allow the oil to drain completely. Dispose of At operating temperature, the radiator and
waste oil properly. Install DRAIN port plug. Allow these components to cool to the touch
before servicing.
LEVEL Release pressure from hydraulic tank at the turbo

Draining The Cooling System
DRAIN
Avoid skin contact with used antifreeze.

Skin contact with used antifreeze can cause
skin disorders or other personal injury.
Figure 2: Positioning Final Drive LEVEL Port
Wait until engine coolant temperature drops
o o
9. Start machine and reposition the final drive to 120 F (50 C) before removing the radiator
LEVEL port to the 3:00 position. See Figure 2. cap. Hot coolant released under pressure
can cause serious personal injury.
10. Add oil as specified in Appendix A until the oil
reaches the bottom of the LEVEL port opening.
Install plug.
Dispose of waste antifreeze properly. Waste
11. Repeat procedure for the remaining track antifreeze disposal can be subject to local,
final drive. state and federal regulations. Contact your
local authorities or the EPA regarding proper
disposal of waste antifreeze.

Figure 4: Radiator Drain Plug Figure 6: Radiator Fill Spout Access Cover (Typical)
1. The radiator drain plug is located behind the 4. Remove radiator cap slowly to allow any
louvered swing-out radiator guard at the front trapped pressure to escape.
of the machine. See Figure 4.
5. Place a suitable container, with a minimum
capacity of 10 gal. (37,9 liters), below the
radiator drain plug. Remove the drain plug
and allow the radiator to drain completely.
6. Replace the radiator drain plug and dispose of

the waste antifreeze properly.
Figure 5: Engine Pivot Guard (Typical)
2. Remove the bolts securing the slotted engine

pivot guard. Open the guard to gain access to
radiator hoses.
3. The radiator fill spout is located under an

access cover on the engine compartment
Figure 7: Check Radiator Hoses
ROPS plate. See Figure 6. Loosen both star
knobs so that the access cover can rotate to
7. From the right side of the engine, check the
the right and out of the way, exposing the
following radiator hoses for cracking, loose
radiator cap.
hose clamps and leaks. See Figure 7.
Replace any damaged hoses immediately:
o
- 90 rubber elbow at base of radiator
- 1” (25mm) radiator bypass hose
- Radiator flex hose at top of engine

Flushing The Cooling System
Use only flushing solution that will not freeze in

the ambient temperature.
Before filling with coolant, flush the cooling system

per engine manufacturer instructions. Fill per the
following instructions except use the flushing solu-
tion instead of coolant. Drain same as previous
section, and refill with coolant.
Filling The Cooling System Figure 8: Radiator Overflow Tank Sight Glass Location
1. Check the radiator coolant level. The cool-

ant level should be in the middle of the over-
Do not over fill the radiator. Fill radiator until flow tank sight gauge when viewed from the
coolant level is in the middle of the overflow cab, See Figure 8. Do not overfill radiator.
tank sight gauge when viewed from the cab.
The coolant volume will expand as the engine
reaches operating temperature.
All engine options require a coolant mixture of 50%

low silicon ethylene glycol base antifreeze and 50% On some models, the sight gage is not visible
distilled water. If distilled water is not available, from the cab and the sight gage must be viewed
clean tap water will work. See Appendix A for cool- from the ground or from another position on the
ing system capacities. machine outside of the cab.
With most engines, the procedure for filling a 2. Close and secure the engine pivot guard, lou-
completely drained cooling system requires special vered swing-out radiator guard, and the access
steps to prevent air pockets from forming in the cover over the radiator fill spout.
system. Reference the engine manufacturer’s
manuals supplied with your machine for specific
cooling system filling procedures.
After completing the engine manufacturer’s

instructions for filling the cooling system, follow the
steps below to complete the engine cooling system
flushing procedure.

Clean Hydraulic Tank
& Change Hydraulic Oil
Hydraulic Tank Draining


any maintenance or repair procedures.
1. Position the machine on level terrain where

the hydraulic tank can be accessed by a crane
or other lifting device. Lower the boom to the
hydraulic tank are HOT and under pressure. ground and shut down the engine.
before servicing. 2. Release boost pressure from the tank by
Loosen radiator cap slowly to release pressure. opening the turbo boost pressure release
valve. See Figure 9. This must be done
Release pressure from hydraulic tank at the turbo before adding oil or working on the hydraulic
system.
3. The hydraulic tanks of most models have a

capacity of up to 100 gal. (379 liters). A suit-
ably sized container or means of properly dis-
posing of the waste oil must be available.
4. Attach a large funnel to a length of hose or

tubing and place the other end in the waste oil
container.

Figure 10: Pilot Pressure Return Line (Typical)
5. Remove the pilot pressure valve return line

where it enters the tank. See Figure 10.
Use the hose and funnel to catch and route
the oil to the waste container. Drain the tank
completely.
6. Cap the pilot pressure valve return line fitting

and plug the line to keep contaminates from
entering the hydraulic system.
7. Dispose of the waste oil properly.

Hydraulic Tank Re-Filling
Hydraulic oil straight from the drum may

contaminate the hydraulic system resulting in
possible pump failure. Use pre-filtered hydrau-
lic oil only.
Added hydraulic oil must pass through the

return filters. If not filtered, hydraulic system
contamination and possible pump failure may
result. Never add oil through the hydraulic tank
access cover.
Figure 37: Adding Hydraulic Oil With A Hand Pump
Re-fill the hydraulic tank with the same type of
oil already being used in the hydraulic system. See
Appendix A for capacities.
Hand Pump - Hydraulic oil can be added with

a hand pump at a quick-coupling provided on
the return oil manifold located on the left side of
the engine. See Figure 37. The mating female
quick-coupling is shipped with the machine in the
Up-Time Kit located under the operator’s seat. Add
oil until level in the tank is within green zone of sight
gauge at operating temperature or within the yellow
zone when cold.
Electric Fill Pump - An electric fill pump is now

standard equipment on all new machines.
Figure 38: Adding Hydraulic Oil With The
Hydraulic Oil Fill Pump
To add hydraulic oil:
1. Place the fill pump’s suction hose into a con-

tainer filled with pre-filtered oil.
2. Press and hold the fill pump actuation button

located near the return oil manifold on the left side
of the engine. See Figure 38.
3. Add oil until level in the tank is within green

zone of sight gauge at operating temperature or
within the yellow zone when cold.

Hydraulic System Start-Up
Diesel exhaust fumes contain elements that are Figure 39: Hydraulic Oil Sight Gauge
vent exhaust to the outside. 3. Shut down the engine and allow the
machine to sit for 10 - 15 minutes.
NOTE: Air bubbles are created in the oil when

Be sure ALL suction line shut-off valves are the return oil first enters into the tank. These
open. Starting the machine with a suction line air bubbles will damage pumps. Leaving the
shut-off valve closed will destroy the pump in machine sit for a few minutes allows the air
seconds. bubbles to rise to the surface and dissipate.
1. Start engine and operate at idle for a few 4. Check the hydraulic oil level in the tank. See
minutes to cycle the pumps. Listen for any Figure 39. Add oil if required.
unusual sounds coming from the pump area
that could indicate a problem. If you think a 5. Close and secure the swing-out pump guard.
possible problem exists, shut down the engine
immediately, investigate and correct the
problem before continuing.
Check Engine Valve Lash
2. Operate a few implement functions SLOWLY
for about one minute to get the oil cooler return
oil flowing into the tank. If equipped, activate
the disc saw circuit for a few moments to get Check engine valve lash as per the engine manu-
the disc saw circuit return oil flowing into the
facturer’s instructions.
tank.



Chapter 9 - Troubleshooting
Troubleshooting
Section 1
General Troubleshooting Information Page 9.1.2
Section 2
Troubleshooting Track Drives Page 9.2.1
Section 3
Troubleshooting Engine Starting Page 9.3.1
Section 4
Troubleshooting Electrical Page 9.4.1
Section 5
Troubleshooting Air Conditioning / Heater Page 9.5.1
Section 6
Troubleshooting Disc Saw Attachment Page 9.6.1
Section 7
Troubleshooting Implement Circuit Page 9.7.1
Troubleshooting Safety
You must read and understand the warnings and basic safety
rules, found in Chapter 1 of this manual, before performing
any troubleshooting procedures.
For additional troubleshooting guidelines for auxiliary

equipment and attachments, see the manufacturer’s manual
provided with the machine. Before performing maintenance or repairs on the machine,
consult this manual and follow the recommended procedures.
Use recommended protective clothing and safety devices

such as gloves, safety boots, safety hat, reflective vests, and Diesel exhaust fumes contain elements that are hazardous to
eye, ear, and respiratory protection as required by job condi- your health. Always run engine in a well ventilated area.
tions and or applicable regulatory codes. If in an enclosed space, vent exhaust to the outside.
Comply with the instructions in this manual and your

company’s regulations for the operation of this machine.
At operating temperature, the engine, exhaust system com-
YOU MUST BE FULLY TRAINED to operate this ponents, cooling system components, and hydraulic system
machine and its felling attachment. components are HOT. Any contact can cause severe burns.
Chapter 9.1 - Troubleshooting Page 9.1.2

Keep your head, hands, and feet clear of all moving parts. Pressure can be maintained in system circuits long after the
engine and pumps have been shut down. Release trapped
Never wear loose clothing or things such as scarfs that can pressure in hydraulic, fuel, and cooling system lines before
become entangled in moving parts. performing any maintenance or repair procedures.
Keep yourself, all objects and tools away from moving fan Hydraulic oil under pressure can penetrate body tissue
blades. Fan blades will cut or throw and object dropped or causing serious injury and possible death.
pushed into them.
When troubleshooting a hydraulic system for leaks, always
use cardboard or other material as a deflector. DO NOT USE
YOUR HANDS.
If you are injected with hydraulic oil or any other fluids, seek
treatment by a physician immediately.
The radiator and hydraulic tank are HOT and under pressure
at operating temperature.
Loosen radiator cap slowly to release pressure. Release

pressure from the hydraulic system at the turbo boost release
valve.
Page 9.1.3 Chapter 9.1 - Troubleshooting

The only time parts should be replaced is after the seventh step.
Simplified Troubleshooting
Let us now examine the seven steps and how each is used.
There are two ways to tackle and find the cause of problems.
The first is by guessing and replacing parts until the problem 1) Know The System
is corrected (expensive and time consuming). The second is
by troubleshooting (cheap and consistent). With the increasing To be able to troubleshoot, one must be familiar with and
cost of parts and machine downtime, replacing parts until the understand the systems on the machine by doing their
problem is corrected is prohibitive and extremely inefficient. homework. What we mean is getting to know about the machine
This has made troubleshooting a very valuable skill. through the product manuals, bulletins, technical schools and
courses available on the machine, and from other knowledgeable
Troubleshooting is done by stepping back, examining the personal. This may seem overwhelming, but it is not. Much of
facts and symptoms, isolating the cause of the problem, and it can be learned over a period of time and the rest is generally
then verifying the cause of the problem by testing. Parts are available if needed immediately. With this knowledge a person
only ordered after confirming the problem. This reduces costs is prepared to tackle step #2.
by only replacing parts that require replacing and reducing
downtime by getting machines up and running quickly. 2) Ask The Operator
Troubleshooting may sound slow and complicated, but it isn’t.
This is an important step that many people skip. Operators are a
Once a person has learned the basic steps of troubleshooting and
valuable part of troubleshooting. Only they can tell you how the
has used them a few times, it is a quick and easy way to solve
machine acted when the problem first started to occur and if any
problems.
other usual things happened also. They can also tell you if any
adjustments were tried, plumbing moved around, or various other
With this in mind you decide which way you want to solve little bits of valuable information. Once you have thoroughly
problems you encounter. If you want to do it by being a parts interviewed the operator, you are ready to move on to step #3.
replacer... read no further and accept the higher costs of repair
problems. If you want to troubleshoot and repair problems
3) Operate The Machine
economically... read on.
It is important that you operate the machine yourself and
The 7 Step Troubleshooting Method experience the problem. You know what a proper machine feels
and operates like. Find out what feels different now. This will
There are several methods of troubleshooting that can be used also allow you to verify the operator’s story about the machine
to solve problems. The method we are going to explain is and its problem.
the called the Seven Step Method. This method is simple to
learn and easy to use. As with all methodical troubleshooting When you operate the machine you should see if it feels
methods, if used correctly, it will produce accurate and different. Is it sluggish, do the controls feel stiff, unresponsive,
consistent results. The seven steps of troubleshooting are; overly aggressive, spongy, etc.
1) Know the System How do the gauges read, are they normal? How is the
2) Ask the Operator performance? Is it slow, erratic, or does not respond at all?
3) Operate the Machine
4) Inspect the Machine Are there any unusual smells or do you see anything abnormal
like smoke?
5) List the Possible Causes
6) Reach a Conclusion
Are there any strange or unusual noises? If so, where does it
7) Test Your Conclusion seem to come from? What does it sound like? What functions
cause the noises?
You should experience and investigate the problem with all the
senses you possesses (Look, Listen, Feel, Smell, and Taste).

Your senses are very sensitive, can accumulate and analyze 7) Test Your Conclusions
a huge amount of information, and are a integral part of
This is another step that many people skip and go to replacing
troubleshooting. Don’t ignore them, use them, then move on to
parts, hoping that it corrects the problem. You need to test your
step #4.
conclusions to verify what has actually caused the problem.
Only after testing your conclusions should parts be ordered and
4) Inspect The Machine replaced.
Now that you know what the machine is acting like, it is time to
visually inspect the machine using all five senses again (Look, Many of the conclusions can be verified without further testing
Listen, Feel, Smell, and Taste). by logically analyzing the information you already have.
Are there any oil leaks? How is the oil in the reservoir, is it Were all functions bad? If so, then the components that are
milky, foaming, low level, too thin, too thick, dirty, etc.? only common to all parts of the system could cause the problem.
These may include pumps, filters, coolers, tank, etc.
How are the filters, are they plugged?
Was only one circuit or function bad? If so, then you can
Feel the reservoir and other components. Are they overly hot? eliminate any component that is common to all functions. Doing
Is the oil cooler plugged with debris? Any collapsed lines? this will narrow your list of conclusions down to just a few
items.
These are just examples. When you inspect the machine,
specifically the affected system, it will give you many excellent The remaining conclusions can now be tested by using the test
clues to the root of the problem. Now move on to step #5. & adjustment procedures found in this manual to confirm which
item or component caused the problem. Once testing has been
5) List The Possible Causes completed, you will know what caused the problem and be able
to only replace the part(s) required. This simplifies the repair
You are now ready to list the possible causes of the problem and reduces the total cost by eliminating additional unneeded
based on what the operator has told you and the information you parts.
have gained from operating and inspecting the machine. All
your information will provide clues that will point to a problem Congratulations on entering the world of troubleshooting!
or a series of problems. Analyze these clues and combine them
with your knowledge of the machine. Write down each possible
cause of the problem, even if it seems very remote or unlikely.
After making your list move on to step #6.
6) Reach Your Conclusion
Look over your list of possible causes and mark down which
is the most likely and easiest to confirm. The troubleshooting
guides in this section can help you with this. Reach a
conclusion on the most reasonable causes of the problem and
plan to check or confirm these possibilities first. Now move on
to step #7.

Other Helpful Troubleshooting Hints The following sections in this chapter give you some examples of
problems that could occur along with possible causes and action
When troubleshooting problems arise, always try to isolate the to take to correct the problem. We make no guarantee that every
problem by starting with a simple procedure first. problem is covered or that every possible cause and action are
covered.
Depending on the problem, it will usually involve a pressure
check for either system pilot pressure or various pump pressures The distributor that you bought your machine from is capable of
troubleshooting and correcting problems and should be called
such as charge pressure, standby pressure, or POR pressure.
upon for all repairs except for those of a minor nature.
There are quick-couple gauge port adapters provided for each of
these pressure checks.
In case of an implement or travel problem, it is a good idea to

check the return filters first. Bronze or brass flakes in the filters
would indicate a pump failure. DO NOT allow unfiltered oil to
flow into the main tank.
Cross pilot lines or electrical harness leads to see if the problem

is in the control circuit. If the problem moves with the pilot lines
or electrical harness leads, the problem is likely in the control
circuit.
Cross hoses at the A & B work ports of the problem function

valve section to see if the problem appears in the opposite
direction. If the problem continues, the problem is likely in the
valve section.
Change problem function hoses to a different valve section. If

the problem continues, the problem is likely in the cylinder or
motor.

PROBLEM # 1: Track Drives Do Not Work, Implements are O.K.
PROBABLE CAUSES:
A.) Dirty Hydrostatic Charge Filter
B.) Oil Too Cold To Flow Properly Through The Hydrostatic Charge Oil Filter
C.) Wrong Hydraulic Oil Viscosity
ACTION TO BE TAKEN:
A.) Change the hydrostatic charge filter element.
B.) Follow procedures for hydraulic system warm up. (See figure 1)
C.) Change the hydraulic oil to match the ambient conditions. Refer to the decal on the swing-out
pump access guard.
Figure 1: Hydrostatic Charge Filter

PROBLEM # 2: TRACK DRIVES DO NOT WORK AND NO CHARGE PRESSURE
PROBABLE CAUSES:
A.) Dirty Hydrostatic Charge Oil Filter
B.) Charge Pressure Relief Out of Adjustment
C.) Charge Pump Thru Drive Coupling Failure
D.) Charge Pump Failure
E.) RH Track Drive Pump Input Shaft Failure
ACTION TO BE TAKEN:
A.) Change hydrostatic charge filter element (See figure 1)
B.) Perform “Track Drive Charge Pressure” test. If the correct pressure setting cannot be made,
remove the relief cartridge and inspect the seals. Replace the seals or the relief cartridge if required.
C.) Pull the charge pump back from the thru drive adapter and check for a damaged thru drive coupling.
(See figure 2)
D.) Replace the charge pump and change all hydraulic filters.
E.) Pull the RH track drive pump back from the pump transmission and check for a broken input shaft.
Figure 2: Charge Pump Thru Drive Coupling

PROBLEM # 3: BOTH TRACK DRIVES SLOW OR SLUGGISH IN BOTH
DIRECTIONS.
PROBABLE CAUSES:
A.) Dirty Hydrostatic Charge Oil Filter
B.) Charge Pressure Set Too Low
C.) All Track Drive Pump Towing Reliefs Engaged
D.) Leakage In Rotary Manifold Between Track Drive Galleries (Only with continuous rotation)
ACTION TO BE TAKEN:
A.) Change hydrostatic charge filter element (See figure 1)
If the correct pressure setting cannot be made,

B.) Perform “Track Drive Charge Pressure” test.
remove the relief cartridge and inspect the seals. Replace the seals or the relief cartridge if required
(See figure 3)
C.) Disengage all towing reliefs on the track drive pumps.
D.) Replace seals as required
Figure 3: Charge Pressure Relief Location

PROBLEM #4: ONE TRACK DRIVE SLOW OR SLUGGISH IN BOTH DIRECTIONS
PROBABLE CAUSES:
A.) POR Relief Out of Adjustment
B.) POR Relief Sticking
C.) Track Drive Pump Towing Reliefs Engaged
D.) Track Drive Pump or Motor Worn Out or Failed
E.) Pump Stroke Controller Malfunction
ACTION TO BE TAKEN:
A.) Perform “Track Drive Pump POR Pressure” test (See figure 4)
B.) Remove the POR relief cartridge and check for a sticking spool
C.) Disengage towing reliefs on the track drive pump
D.) Check case drain lines and filter for metal flakes then perform case drain flow tests, beginning
with the motor. If debris or a high case flow is found, replace the component.
If case flows are O.K. cap the high pressure drive lines at the track drive motor and re-test
POR pressure.
If POR pressure in now O.K., replace the track drive motor.
Note: If the machine is equipped with continuous rotation and POR pressure remains low, re-test
with the lines capped above the swivel to determine any leakage in the swivel galleries.
E.) Perform the “X1 and X2 Control Pressure” test to determine if the stroke controller has failed.
If X1 and X2 pressures are O.K. the problem is likely the stroke piston, replace the pump. If the
X1 and X2 pressures are low, replace the stroke controller. (See figure 5)

Figure 4: Track Drive Pump POR Relief
Figure 5: Pump Stroke Controller

PROBLEM #5: ONE TRACK DRIVE SLOW OR SLUGGISH IN ONE DIRECTION
PROBABLE CAUSES:
A.) Debris blocking Movement of the Foot Pedal
B.) Directional Relief Out of Adjustment
C.) Directional Relief Sticking
D.) One Track Drive Pump Towing Relief Engaged
E.) Pump Null Out of Adjustment
F.) Pump Stroke Controller Malfunction
ACTION TO BE TAKEN:
A.) Clear debris from under and around the foot pedals
B.) Perform “Track Drive Pump Directional Relief Pressure” test. If correct pressure setting cannot be
made, remove the relief cartridge and inspect the seals. (See figure 6)
C.) Swap directional reliefs on the pump. If the problem moves with the switch, remove the problem
directional relief and check for a sticking spool and/or replace the relief.
D.) Disengage towing relief on the track drive pump.
E.) Perform “Track Drive Pump Null” adjustment procedure.
F.) Perform the “X1 and X2 Control Pressure” test to determine if the stroke controller is sticking or
failed in one direction. (See figure 5)
Figure 5: Track Drive Pump Directional Reliefs

PROBLEM #6: TRACK DRIVES LOSE PRESSURE WHEN RUNNING HOT
PROBABLE CAUSES:
A.) Incorrect Track Drive Pump Pressure Settings
B.) Missing or Incorrect Track Drive Pump Case Flushing Orifice
C.) Wrong Hydraulic Oil Viscosity
D.) Leakage in Rotary Manifold Between Track Drive Galleries (Continuous Rotation Models)
ACTION TO BE TAKEN:
A.) Perform all track drive pump pressure tests. If a correct pressure setting cannot be made, remove
the relief cartridge and inspect the seals. Replace the seals of cartridge if required.
B.) Remove the case flushing orifice cartridge. Remove and clean the 1.2 mm setscrew-style orifice.
Replace the orifice if it is damaged or the wrong size. (See figure 6)
C.) Change the hydraulic oil to match the ambient conditions according to the decal on the swing-out
pump access guard.
D.) Replace the seals as required. Contact your dealer.
Figure 6: Track Drive Pump Case Flushing Orifice Cartridge

PROBLEM #7: MACHINE CREEPS IN NEUTRAL
PROBABLE CAUSES:
A.) Sticking Foot Pedal
B.) Pump Null Out of Adjustment
C.) Leakage In Rotary Manifold Between Track Drive Galleries (Continuous Rotation Models)
ACTION TO BE TAKEN:
A.) Clean debris from under and around the foot pedals and check that the foot pedal centers to the
neutral position.
B.) Perform “Track Drive Pump Null” procedure.
C.) Replace seals aa required. Contact your dealer.

PROBLEM #8: NOT TRACKING STRAIGHT IN BOTH DIRECTIONS
PROBABLE CAUSES:
A.) Incorrect Track Tension
B.) One Track Binds or is Jammed With Debris
C.) One Track Drive Operating Slower Than The Other
ACTION TO BE TAKEN:
A.) Track tension may be tighter on one side than the other. Check and adjust track tension on both
racks.
B.) Visually inspect undercarriage components and track as it travels around the frame. Look for
binding rollers, idler, etc. or debris. Clean, repair, or replace components as required.
C.) Check displacement adjustments on both track drive motors. Adjust if required.
Note: A good indicator of a track drive motor displacement out of adjustment is that the machine
will track straight in only one speed. After shifting, the machine will not track straight even
with the pedals in full deflection forward or reverse.
Note: It is also quite common, especially after a pump or motor replacement, to simply have a
component with a higher efficiency than the rest of the system. Usually a 10% difference in
individual track speed is acceptable. If not, an adjustment to the faster track’s motor dis-
placements will have to be made to slow that track down.

PROBLEM #9: NOT TRACKING STRAIGHT IN ONE DIRECTION
PROBABLE CAUSES:
A.) Debris Blocking Movement of Foot Pedal
B.) One Track Drive Operating Slower In One Direction
C.) Debris Blocking Control Orifice
ACTION TO BE TAKEN:
A.) Clear debris from around and under foot pedals. Be sure foot pedals can make a full stroke in
each direction.
B.) See problem #5.

PROBLEM #9: TRACK BRAKES WILL NOT RELEASE
PROBABLE CAUSES:
A.) No Power At Track Brake Release Solenoid Coil
B.) Track Brake Release Solenoid Valve Malfunction
C.) Automatic Track Brake Pressure Sensor Switch Malfunction
D.) Failed Brake Piston Seals (See figure 7)
E.) Warped or Seized Brake Disc and Plates
F.) No Output Signal From IQAN
ACTION TO BE TAKEN:
A.) Check output signal from IQAN.
B.) Check continuity of coil with ohm meter. Replace coil if required.
C.) Check switch with external air regulator and replace if required.
D.) Remove the track drive motor and brake module from the track final drive and check for damaged
seals. Replace seals if required.
E.) Repair or replace brake module.
F.) Check fuses and replace if required. If fuses are good, contact dealer.
Figure 7: Track Brake Piston Seals

PROBLEM #10: TRACK BRAKES SLIPPING OR WILL NOT HOLD
PROBABLE CAUSES:
A.) Track Brake Release Solenoid Malfunction
B.) Worn or Damaged Brake Discs and Plates
ACTION TO BE TAKEN:
A.) Check continuity of coil with ohm meter. Replace the coil if required. If coil is O.K., remove the
solenoid cartridge and check for contamination or damaged seals. Repair or replace as required.
B.) Repair or replace brake module.
PROBLEM #11: TRACK BRAKES SLOW TO APPLY
PROBABLE CAUSES:
A.) Track Brake Release Solenoid Valve Malfunction
B.) Pinched or Kinked Track Brake Release Signal Hose
C.) Track Brake Control Orifice Out Of Adjustment or Plugged
ACTION TO BE TAKEN:
A.) Check continuity of coil and / or check valve for damaged seals. Repair or replace as required.
B.) Inspect track brake release signal hose between the pilot pressure manifold and the track final
drives for pinching, kinks, or twists. Repair or replace as required.
C.) Adjust the activation of the track brake control orifice valve OUT counter-clockwise. Adjust to suit
the operator’s preference.
If adjustment can not be made, remove the track brake control orifice check valve and inspect for
debris plugging the orifice. Clean or replace the orifice check valve as required.

PROBLEM #12: LOW SPEED LOCK WILL NOT WORK
PROBABLE CAUSES:
A.) No Power At Low Speed Lock Solenoid
B.) Low Speed Lock Solenoid Valve Malfunction
C.) Stuck or Damaged Shift Spool
D.) Internal Damage to Track Drive Motor
ACTION TO BE TAKEN:
A.) Check low speed lock switch on the dash panel and replace if required.
B.) Check continuity of coil with ohm meter. Replace coil if required. If coil is O.K., remove the
cartridge and check for contamination or damaged seals. Repair or replace as needed.
C.) Remove plug and shift spool. Check for damage to the spool housing and spool. Be sure spool
moves freely in the housing. Replace the spool or spool housing if required. (See figure 8)
D.) Contact you dealer.
Figure 8: Track Drive Motor Shift Spool & Spool Housing (Typical)

PROBLEM #13: LOW SPEED LOCK SLOW OR SLUGGISH
PROBABLE CAUSES:
A.) Sticking Shift Spool or Plugged Spool Housing Orifice
B.) Pinched or Kinked Low Speed Lock Signal Hose
ACTION TO BE TAKEN:
A.) Remove plug and shift spool. Check for damage to the spool housing and spool. Be sure spool
moves freely in the housing. Replace the spool or spool housing if required. (See figure 8)
B.) Inspect low speed lock signal hose between the pilot pressure manifold and track final drives for
pinching, kinking, or twists. Correct or replace the hose if required.

PROBLEM #14: ENGINE STALLS AT START UP OR TURNS OVER HARD
PROBABLE CAUSES:
A.) Improper Oil Used In Gearbox, Hydraulics, or Engine For Ambient Conditions
B.) Incorrect Throttle Position For Engine Start
C.) Fuel Lift Pump Malfunction
D.) Air Trapped In Fuel System
E.) Contamination In Fuel Suction Line
F.) No Power at Fuel Pump
ACTION TO BE TAKEN:
A.) Use proper oils for the ambient conditions and follow cold weather starting procedures.
B.) Set throttle to 1/3 range for engine start.
C.) Be sure the electric fuel lift pump has a good electrical ground and check fuel pump calibration.
See the engine manufacturer’s manuals shipped with the machine. Replace lift pump if required.
D.) Check for loose fuel suction lines around hose connections. Bleed the fuel system according to
the engine manufacturer’s manual shipped with the machine.
E.) Flush the fuel suction lines and change fuel filters and bleed the fuel system of air.
F.) Check fuses: mini fuse bank “B” position L (10 amp), position V (2 amp), and position Y (10 amp).
Check fuel lift pump relay, fuel pump relay, and fuel pump latching relay in the Main Electrical
Center. Replace fuses or relays as required.

PROBLEM #15: ENGINE STALLS EASILY DURING NORMAL OPERATION
PROBABLE CAUSES:
A.) Dirty Air Cleaner Elements
B.) Collapsed Or Plugged Muffler
C.) Dirty Fuel Filters or Air Trapped in Fuel Lines
D.) Fuel Line Restriction
E.) Fuel Pump Timing Out Of Adjustment
F.) Fuel Lift Pump Malfunction
G.) Hydraulic Pressure Setting(s) Out of Adjustment
H.) Intake and/or Exhaust Valves Out Of Adjustment or Leaking Gaskets
I.) Engine Malfunction
ACTION TO BE TAKEN:
A.) Clean or change air filter elements.
Note: The inner safety element must never be cleaned, it is replaceable only.
B.) Inspect muffler and replace if required.
C.) Change fuel filters and check that there are no loose connections. Purge air from the fuel lines.
D.) Check for kinked fuel lines or a plugged fuel tank vent. Clean or repair as required.
E.) Contact dealer.
F.) Check fuses, relays, and ground connection. Replace or repair as needed. Replace electric fuel
lift pump is required.
G.) Follow procedures for setting track drive pressures and/or implement pump and control valve
pressures.
H.) Adjust valves as per the engine manufacturer’s manual and replace gaskets if required, or,
contact your dealer.
I.) Contact dealer.

PROBLEM #16: ENGINE LOSES POWER AFTER RUNNING FOR A SHORT TIME
PROBABLE CAUSES:
A.) Dirty Fuel Filters
B.) Fuel Tank Vent Restriction
C.) Wet or Dirty Air Filter Elements
ACTION TO BE TAKEN:
A.) Change fuel filters.
B.) Check for a kinked fuel tank vent line or debris plugging the line where it exits the upper turntable
base plate.
Note: Other indications of a plugged fuel tank vent line are suction on the fuel tank when the fill
cap is removed or the fuel filters are partially filled when removed.
C.) Replace the air filter elements.
PROBLEM #17: ENGINE LABORS EXCESSIVELY WHILE USING TRACK DRIVES
PROBABLE CAUSES:
A.) Track Brakes Not Fully Released
B.) Dirty Air Cleaner Elements
C.) Dirty Fuel Filters
D.) Fuel Injection Pump Malfunction
ACTION TO BE TAKEN:
A.) See “Problem #9”
B.) Clean or replace the air cleaner elements.
C.) Change fuel filters.
D.) Contact you dealer.

PROBLEM #18: ENGINE SURGES OR “HUNTS” EVEN WHEN NOT OPERATING
A FUNCTION
PROBABLE CAUSES:
A.) Air Trapped In Fuel System
B.) Contamination In Fuel Suction Line
C.) Engine Malfunction
D.) Engine Idle or Surge Screws Out Of Adjustment
ACTION TO BE TAKEN:
A.) Check for loose connections on fuel lines. Purge air from the fuel system as per the engine
manufacturer’s manual shipped with the machine.
B.) Flush fuel suction line and change fuel filters.
C.) Contact your dealer.
D.) Contact your dealer.

PROBLEM #19: ENGINE WILL NOT START AND NO ELECTRICAL WILL WORK
PROBABLE CAUSES:
A.) Master Electric Disconnect Switch Turned Off
B.) Main Electrical System Fuse Blown
C.) Battery Cables Loose or Corroded
D.) Battery Electrolyte Level Is Low
E.) Battery Is Dead or Frozen
ACTION TO BE TAKEN:
A.) Turn on the master electric disconnect switch.
B.) Remove and check the main 100 amp electrical system fuse located in the engine compartment and
replace if required.
Warning: Be sure the master disconnect switch is in the off position before removing the main
electrical system fuse to avoid and electric shock.
C.) Clean battery cables and posts and tighten all connections. Coat with dielectric grease to keep from
corroding.
D.) Check and restore battery electrolyte levels.
E.) Replace the battery.

Warning: Never try to charge or jump a frozen battery.

PROBLEM #20: ENGINE WILL NOT START, OTHER ELECTRICAL O.K.
PROBABLE CAUSES:
A.) Low Battery Voltage
B.) Battery Cables Loose or Corroded
C.) Low Battery Electrolyte Level
D.) Starter Relay Malfunction or Blown Fuse
E.) Ignition Switch Malfunction
F.) Starter Malfunction
ACTION TO BE TAKEN:
A.) Have battery tested. Replace or charge if required.
B.) Clean battery cables and posts and tighten all connections. Coat with dielectric grease to prevent
corrosion.
C.) Check and restore battery electrolyte level.
D.) Check 50 amp Start Signal Relay fuse and replace if required. Check the connections on the start
signal relay. Replace if required. (See figure 9)
E.) Check power at the “S” terminal of the ignition switch. Replace ignition switch if required.
F.) Repair or replace starter.
Start Signal Relay 50 amp Start Signal Relay Fuse
Figure 9: Main Electrical Center (Typical)

PROBLEM #21: STARTER TURNS, BUT ENGINE DOES NOT
PROBABLE CAUSES:
A.) Failed Starter Bendix Drive
B.) Damaged Starter Pinion Gear
C.) Engine Flywheel Gear Teeth Broken
ACTION TO BE TAKEN:
A.) Remove starter and repair bendix drive or replace starter. (See figure 10)
B.) Remove starter and repair pinion gear or replace starter. (See figure 10)
C.) Remove starter and check engine flywheel gear teeth. If damaged, replace engine flywheel gear.
(See figure 11)
Bendix Drive
Pinion Gear
Figure 10: Starter (Typical) Figure 11: Flywheel Teeth (Typical)

PROBLEM #22: STARTER MOTOR CONTINUES TO RUN AFTER ENGINE STARTS
PROBABLE CAUSES:
A.) Starter Relay Sticks Closed
B.) Starter Pinion Gear Not Disengaging From Flywheel Gear
C.) Ignition Switch Sticking
ACTION TO BE TAKEN:
A.) Tap on the starter relay. If the starter releases, replace the starter relay. (See figure 9)
B.) Tap on the starter. If the pinion gear releases, repair or replace the starter.
C.) Perform a continuity check on the ignition switch. If sticking, replace the switch.
PROBLEM #23: NOISY ALTERNATOR
PROBABLE CAUSES:
A.) Worn Alternator Belt
B.) Pulley Misalignment
C.) Worn Alternator Bearings
D.) Alternator Malfunction
ACTION TO BE TAKEN:
A.) Replace alternator belt and blow out alternator with compressed air.
B.) Align pulleys.
C.) Remove the belt and spin the alternator pulley by hand. If the pulley spins hard, has excessive play,
or does not spin freely, repair or replace the alternator.
D.) Repair or Replace the alternator.

PROBLEM #24: LIGHTS DO NOT WORK, ALL OTHER ELECTRICAL O.K.
PROBABLE CAUSES:
A.) Blown Fuse
B.) Circuit Relay Malfunction
C.) Faulty Rocker Switch
ACTION TO BE TAKEN:
A.) Check for blown fuses in the light circuit. Mini fuse panel “A” positions A, D, I, and Q / Maxi
Fuse Bank “A” positions 2,3, and 8 / Maxi Fuse Bank “B” position 3. Replace if required.
(See figure 12)
B.) Check to be sure the relays are seated firmly in their mounting bases. Replace relay if required.
(See figure 12)
C.) Perform continuity test on rocker switch. Replace if required.
Mini Fuse Panel “A” Light Circuit Relays
Maxi Fuse Bank “A”
Maxi Fuse Bank “B”
Figure 12: Main Electrical Center (Typical)

PROBLEM #25: ELECTRIC OIL FILL PUMP WILL NOT WORK
PROBABLE CAUSES:
A.) Blown Fuse or Relay Malfunction
B.) Faulty Switch
C.) Fill Pump Motor Malfunction
ACTION TO BE TAKEN:
A.) Check for blown fuse at main electrical center. Maxi Fuse Bank “B” position 2 (30 amp), Maxi
Fuse Bank “A” position 1 (50 amp). Check to be sure the relay is seated in position. Replace
as required. (See figure 13)
B.) Remove wires from switch and perform a continuity test. Replace if required.
C.) Repair or replace the fill pump motor.
Hydraulic Fill Pump Relay

Hydraulic Fill Pump Circuit Fuses
Figure 13: Hydraulic Fill Pump Circuit Relay and Fuses

PROBLEM #26: BOTH AIR CONDITIONER AND HEATER WILL NOT WORK
PROBABLE CAUSES:
A.) Air Conditioner / Heater Fuse Blown
B.) Faulty A/C / Heat Select Switch or Blower Motor Switch
C.) Blower Motor Malfunction
ACTION TO BE TAKEN:
A.) Check fuse 1F in the Main Electrical Center, replace if required.
B.) Remove wires from switch(s) and use an ohm meter to verify switch operation, replace if required.
C.) Check ground wire for blower motor and check for power. Replace motor if required.
PROBLEM #27: AIR CONDITIONER WORKS, BUT NO COLD AIR COMES OUT
PROBABLE CAUSES:
A.) Condenser Plugged With Debris
B.) Hot Water Shut-off Valves At Engine Are Open
C.) Binary Switch Failure
D.) Freon Leak
E.) Blown Relay or Fuse For Condenser Fan
F.) Expansion Valve Malfunction
G.) Thermostat Switch Malfunction
H.) Air Conditioner Compressor Drive Belt Loose or Broken
I.) No Power At A/C Compressor
J.) Condenser Fan Malfunction
ACTION TO BE TAKEN:
A.) Open condenser guard and blow the condenser cooling fins clear of debris and dust. Blow out the
condenser fins on a regular schedule. (See figure 14)
B.) Close the hot water shut-off valves on the engine. Remember, they must be opened again for the
heater to function properly.

C.) Replace binary switch. By keeping the condenser clean, the binary switch will last much longer.
D.) Call you dealer.
E.) Check Mini Fuse 1Z (20 amp), 40 amp Maxi Fuse in Maxi Fuse Bank A in 4th position, and relay
number 2 for condenser fans. Replace if required.
F.) Call your dealer.
G.) Replace thermostat switch.
H.) Check A/C compressor drive belt and tighten if needed.
I.) Check for power at A/C compressor. If no power, locate where wire is broken and repair.
J.) Check for damaged fan blades and repair or replace if required. Check that power supply is O.K. and
that the ground connections are good. Replace motor if required.
Figure 14: A/C Condenser (Guard Open)

PROBLEM #28: HEATER WORKS BUT NO WARM AIR
PROBABLE CAUSES:
A.) Hot Water Shut-off Valves on Engine Are Closed
B.) Water Shut Off Valve On A/C Unit Malfunction
ACTION TO BE TAKEN:
A.) Open both hot water shut-off valves on engine. Remember, they need to be closed for the A/C to
function properly.
B.) Check that the water valve shifts with the heat select switch. Replace valve if required.

PROBLEM #29: DISC SAW WILL NOT START
PROBABLE CAUSES:
A.) Disc Saw Pump Load Sense Orifice Plugged
B.) No Power at Disc Saw Stop Valve Solenoid
C.) Disc Saw Stop Valve Solenoid Malfunction
D.) Pressure and Return Lines Switched
E.) Over Running Check Valve at Saw Motor Failed or Stuck Open
ACTION TO BE TAKEN:
A.) Locate the disc saw pump load sense orifice at the pump pressure output flange block. Remove the
straight fitting containing the orifice and check for contamination. Clean or replace the orifice as
required. (See figure 15)
B.) Check for power at the disc saw stop valve solenoid coil. If no power, replace the disc saw rocker
switch in the dash panel.
C.) Check continuity of the coil with an ohm meter. Replace coil if required. Also check for contamin-
ation or damaged seals by taking out the cartridge. Repair or replace as required. (See figure 16)
D.) Switch lines and re-start.
E.) Remove and inspect check valve. See the head manufacturer’s manual.
Figure 15: Disc Saw Pump Load Sense Line Figure 16: Disc Saw Stop Valve Solenoid

PROBLEM #30: NO STAND-BY PRESSURE, NO FLOW
PROBABLE CAUSES:
A.) Implement Pump Thru Drive Coupling Failure
B.) Worn Disc Saw Pump
C.) Disc Saw Pump with Incorrect Rotation Installed
ACTION TO BE TAKEN:
A.) Remove disc saw pump and check for damage to the thru drive coupling or disc saw pump input
shaft splines. Replace thru drive coupling or pump if required. (See figure 17)
B.) Check case drain line and return filters for metal flakes/particles. If metal flakes are found in the
case drain filter or case drain flow is excessive, the disc saw pump is worn or failed. Replace
the disc saw pump.
Note: If an internal pump/motor failure is suspected, always check the component’s case drain
line and the case drain return filter for metal particle contamination first.
C.) Check the S/N# tag on the disc saw pump. Rotation should be “CCW”.
Figure 17: Thru Drive Coupling (Typical)

PROBLEM #31: DISC SAW CIRCUIT WILL NOT PRODUCE FULL PRESSURE
PROBABLE CAUSES:
A.) Disc Saw Pump Compensator Control Spool Sticking
B.) Air Trapped In Disc Saw Pump Load Sense Line
C.) Worn Disc Saw Pump
ACTION TO BE TAKEN:
A.) Remove disc saw pump compensator spool. Check for free movement in its bore. Free the spool,
replace spool, or replace the entire compensator valve as required. (See figure 18)
B.) Bleed air from disc saw pump load sense line. (See figure 19)
C.) Check case drain filter for metal flakes and perform disc saw pump case drain flow test.
Replace pump if required.
Figure 18: Disc Saw Pump Compensator Figure 19: Disc Saw Pump Load Sense Line
Spool (POR shown)

PROBLEM #32: DISC SAW CIRCUIT LOSES PRESSURE WHEN RUNNING HOT
PROBABLE CAUSES:
A.) Saw Stop Valve Cartridge Leakage
B.) Disc Saw Pump Load Sense Orifice Plugged
C.) Disc Saw Attachment Motor or Valving Malfunction
ACTION TO BE TAKEN:
A.) Remove saw stop cartridge and check o-ring for damage or being rolled over in its groove.
Replace o-ring as required. (See figure 20)
B.) Locate the disc saw pump load sense orifice at the pump pressure output flange block. Remove
the straight fitting containing the orifice and check for contamination. Clean or replace the orifice
as required. (See figure 21)
C.) See manufacturer’s manuals supplied with the attachment.
Figure 20: Disc Saw Stop Valve Cartridge Figure 21: Disc Saw Pump Load Sense
Orifice Location

PROBLEM #33: POOR OR ERRATIC PERFORMANCE OF DISC SAW
PROBABLE CAUSES:
A.) Saw Disc Plugged With Debris
B.) Saw Stop Valve Cartridge Leakage
C.) Disc Saw Pump Stand-by Or POR Pressure Out Of Adjustment
D.) Disc Saw Attachment Motor or Valving Malfunction
ACTION TO BE TAKEN:
A.) Clean debris from saw disc according to the attachment manufacturer’s manual.
B.) Remove the saw stop cartridge and check the o-ring for damage or being rolled over in its groove.
Replace the o-ring if needed. (See figure 20)
C.) Adjust the saw pump pressures.
D.) See the manufacturer’s manuals supplied with the attachment.
PROBLEM #34: DISC SAW BLADE ROTATES WHEN SHUT OFF
PROBABLE CAUSES:
A.) Disc Saw Pump Stand-by Pressure Set Too High
B.) Saw Stop Valve Cartridge Leakage
C.) Disc Saw Attachment Motor Leakage
ACTION TO BE TAKEN:
A.) Adjust the saw pump pressures.
B.) Remove the saw stop cartridge and check the o-ring for damage or being rolled over in its groove.
Replace the o-ring if needed. (See figure 20)
C.) See the manufacturer’s manuals supplied with the attachment.

PROBLEM #35: NO IMPLEMENT FUNCTIONS WORK, TRACK DRIVES O.K.
PROBABLE CAUSES:
A.) Low Implement POR Pressure
B.) No Implement POR Pressure
C.) Worn Pump Or Internal Pump Failure
D.) No Pump Load Sense Pressure
ACTION TO BE TAKEN:
A.) Check and adjust pump pressures. If the implement pump pressure cannot be adjusted, remove the
compensator POR spool and check for contamination. Replace the spool or compensator as
required.
B.) Remove the POR compensator spool and check for damage. Replace the spool or compensator
as required.
C.) Check the case drain filter for metal flakes. If it is suspected that the pump is failing or worn,
perform a case drain flow test. If metal flakes are found in the case drain filter or the case drain
flow is excessive, the implement pump should be replaced.
D.) Check the 0.028 orifice at the in-section of the main control valve assembly. If the orifice becomes
plugged, the loadsense pressure can not get to the pump to allow it to come on pressure.

PROBLEM #36: IMPLEMENT FUNCTION SLOW AND NO POWER,
TRACK DRIVES ARE O.K.
PROBABLE CAUSES:
A.) Sticking Spools In Implement Pump Compensator Control
B.) Air Trapped In Load Sense Line Between Control Valve and Pump
C.) Function(s) Not Properly Adjusted In IQAN
D.) Worn Pump or Internal Pump Failure
E.) Low Implement Stand-by Pressure
ACTION TO BE TAKEN:
A.) Remove the stand-by and POR spools from the compensator control. Inspect them for damage,
clean, and re-install. Replace compensator control if required.
B.) Bleed air from load sense line when it enters the implement pump compensator control.
C.) Adjust function speed with MDM display.
D.) Refer to same problem in #35.
E.) Adjust implement pump stand-by pressure.

PROBLEM #37: IMPLEMENT FUNCTIONS NOT SMOOTH, “JERKY”
PROBABLE CAUSES:
A.) Air Trapped In Load Sense Line Between Control Valve and Implement Pump
B.) High System Pilot Pressure
C.) Functions Not Properly Adjusted In IQAN
D.) Fine Particle Contamination In The Hydraulic System
E.) Improper Oil Or Additives Being Used
F.) Hydraulic Oil Tank Temperature Too High
ACTION TO BE TAKEN:
A.) Bleed air from load sense line where it enters the implement pump compensator control.
B.) Check system pilot pressure, if pressure is too high or too low, check the pilot control valve for
a broken spring or contamination. Replace if required.
C.) Set functions using the MDM display.
D.) Inspect valve components for fine scratches. Take an oil sample for analysis. Replace damaged
valve components and flush the hydraulic system.
E.) Drain and replace hydraulic oil with an oil that meets specifications for quality and ambient
conditions.
F.) Clean debris from coolers, check belt tensions, and check that the fan blades are not damaged.

PROBLEM #38: SINGLE FUNCTION SLOW OR SLUGGISH IN BOTH DIRECTIONS
PROBABLE CAUSES:
A.) Internal Cylinder or Motor Leakage or Damage
B.) Sticking Spool In Function Valve Section
C.) No Load Sense Control Signal
D.) Pressure Compensator Spool Malfunction In Function Valve Section
ACTION TO BE TAKEN:
A.) Remove and inspect seals of suspect cylinder or motor. Replace seals if required.
B.) Remove valve section pilot end cap. Manually check if spool binds in its bore. Replace the valve
section if the spool binds. (See figure 23)
C.) Operate the problem function while operating another function that is known to be good. If the
problem function improves, the trouble is most likely the load sense shuttle in the problem function
valve section. Replace the shuttle or valve section as required. (See figure 22)
D.) Remove pilot end cap and remove the pressure compensator spool and check for missing seals,
that the spool moves freely in the bore, and that the spring is not broken. Replace spring or seals
if required. If the spool sticks in the bore, replace the valve section. (See figure 23)
Shuttle Valve
Note the offset positioning if replacing.
Figure 22: VOAC L90LS Shuttle Valve Location (Typical)

Figure 23: VOAC L90LS Valve Section (Typical)

PROBLEM #39: ELECTRIC OPERATED FUNCTION WILL NOT WORK
PROBABLE CAUSES:
A.) System Not Armed
B.) No Power At Function Solenoid Valve Coil
C.) Pressure Compensator Spool Malfunction In Function Valve Section
ACTION TO BE TAKEN:
A.) Press arming switch. Check fusees in electrical center, replace if blown.
B.) Check fuses and check operation of problem switch. Replace as required.
C.) Remove pilot end cap and remove the pressure compensator spool and check for missing seals,
that the spool moves freely in the bore, and that the spring is not broken. Replace spring or seals
if required. If the spool sticks in the bore, replace the valve section. (See figure 23)

PROBLEM #40: ELECTRIC OPERATED FUNCTION SLOW OR SLUGGISH IN
ONE DIRECTION
PROBABLE CAUSES:
A.) Internal Cylinder or Motor Leakage
B.) Damaged Wire To Solenoid Coil
C.) Main Control Valve Port Relief or Pressure Limiter Out of Adjustment
D.) Function Not Adjusted Properly in IQAN
E.) Sticking Spool in Function Valve Section
F.) Stroke Limiter Out Of Adjustment
G.) Damaged Seals on Solenoid Valve
ACTION TO BE TAKEN:
A.) Remove and inspect seals of suspect cylinder or motor. Replace seals as required.
B.) Check continuity of cable from solenoid coil to the IQAN control box. Repair or replace the wire
as required.
C.) Adjust port relief as required. If the port relief can not be adjusted, remove the relief cartridge and
check for contamination or damaged seals. Replace seals or cartridge if required.
D.) Adjust the function speed using the IQAN MDM unit.
E.) Remove the pilot end cap and try moving the spool manually in the bore. If the spool sticks or
can not be moved, replace the valve section.
F.) Check and adjust stroke limiter as required to obtain a suitable speed.
G.) Remove the solenoid valve and inspect for damaged or missing seals. Replace the seals or solenoid
valve as required.

PROBLEM #41: CAB LEVEL CYLINDER RETRACTS WITHOUT CONTROL INPUT
PROBABLE CAUSES:
A.) Cab Level Cylinder Counter-Balance Valve Cartridge Malfunction
B.) Worn Cylinder Seals
ACTION TO BE TAKEN:
A.) Remove cab level cylinder counter-balance valve cartridges. Check for contamination or damaged
seals. Replace seals or cartridge if required. Replace counter-balance valve is required.
B.) Replace cylinder seals as required.

APPENDIX - A
Machine Specifications
Engine Identification & Specifications ................... Page A.2
Engine Oil & Coolant Information ........................ Page A.6
Hydraulic Oil Information ..................................... Page A.8
Track Final Drive Oil Information ........................ Page A.11
Machine Dimensional Specifications ..................... Page A.12
Boom Sweep Information ....................................... Page A.18
Implement Circuit Information ............................... Page A.22
Undercarriage Information .................................... Page A.27
Upper Structure Information .................................. Page A.30
Cylinder Information .............................................. Page A.31
Operator’s Environment Information ..................... Page A.32
Engine
Your machine comes equipped with a choice between the Cummins Engine or the Sisu Diesel Engine. You can
identify your engine by looking at the tag located on the engine. As well as 2 different engine models, each
model has 2 different sizes depending upon the size of machine purchased.
You will need the engine serial number when ordering spare or replacement parts for you engine or for service
work.
Sisu Diesel serial number identification tag location:
Cummins serial number identification tag location:
Appendix A Page A.2

Sisu Diesel Engine Option
There are two sizes of the Sisu Diesel 84 ETA engine used, 260 Horsepower or 300 Horsepower.
The following specifications apply to both engines unless otherwise noted.
For full details and specifications see the engine manuals shipped with the machine. If any discrepancy should
arise between this manual and the engine manufacturer’s manual, the engine manufacturer’s manual should be
followed.
Sisu Diesel Engine Specifications:

Engine Type 84 ETA
Principal Dimensions and Data

Number of Cylinders 6
Displacement 8.4 Liter
Cylinder Bore 111 mm
Stroke 145 mm
Combustion Direct Injection
Valve Clearance, Intake and 0.35 mm (Cold or Hot)
Exhaust
Injection Timing Marked on the Crankshaft Pulley/Damper
(Installation Mark)
Direction of Rotation from Clockwise
the Engine Front
Fuel System
Injection Pump Bosch VP 44 Or Bosch VP 7100
Fuel Fuel Must be According to Norm EN 590
(See fuel quality chart, figure 1)
Injection Order 1-5-3-6-2-4
Feed Pressure at Idle Speed 1.0 – 1.2 bar (14.5 – 17.4 psi)
Injector 5 Hole Nozzle
Nozzle Opening Pressure 270 bar (3916 psi)
Nozzle Adjusting Pressure 278 bar (4032 psi)
Fuel Pre-Filter Stanadyne 30 µ
Fuel Final Filter Stanadyne 5 µ
Lubrication System
Oil Pressure in Hot Engine 2.5 – 5.0 bar (36.2 – 72.5 psi)
at Running Speed
Oil Pressure at Idle Speed, 1.0 bar (14.5 psi)
(Minimum)
Oil Capacity See Oil Capacity Chart (figure 2),
Dependant Upon Oil Pan Size and Shape
Oil Quality Requirements See Oil Quality Chart (figure 3)
Cooling System
Number of Thermostats 2
Operating Temperature 79°C (174°F) / 83°C (181°F)
Coolant Quality See Chart (figure 4)
Requirements
Page A.3 Appendix A

Cummins Engine Option
There are two sizes of the Cummins QSC 8.3 engine used, 260 Horsepower or 300 Horsepower.
The following specifications apply to both engines unless otherwise noted.
For full details and specifications see the engine manuals shipped with the machine. If any discrepancy should
arise between this manual and the engine manufacturer’s manual, the engine manufacturer’s manual should be
followed.
Cummins Engine Specifications:

Engine Type Cummins QSC 8.3
Principal Dimensions and Data

Number of Cylinders 6
Displacement 8.9 Liter
Cylinder Bore 114 mm (4.49”)
Stroke 144.5 mm (5.69”)
Compression Ratio 16.6:1
Firing Order 1-5-3-6-2-4
Injection Timing (Installation Mark) Marked on the Crankshaft Pulley/Damper
Valve Clearance Intake: 0.3048 mm (0.012”)
Exhaust: 0.5588 mm (0.022”)
Fuel System
Engine Idle Speed 600 – 1200 rpm
Lift Pump Restriction, Max 102 mm Hg (4” Hg)
Fuel Filter Restriction, Max Outlet: 254 mm Hg (10” Hg)
Inlet: 508 mm Hg (20” Hg)
Fuel Drain Line Pressure Maximum: 254 mm Hg (10” Hg)
Fuel Inlet Temperature Maximum: 61°C (140°F)
Engine Cranking Speed Maximum: 150 rpm
Lubrication System
Oil Pressure At Low Idle (minimum allowable):
10 psi (0.7 bar)
At Rated Speed (minimum allowable):
30 psi (2.07 bar)
Oil Capacity Approximately 5 gallons (19 liters),
Note: See engine manual
Oil Quality Requirements See Oil Quality Chart (figure 3)
Cooling System
Number of Thermostats 1
Operating Temperature 84 - 91°C (184 - 195°F)
Coolant Quality Requirements See Chart (figure 4)
Appendix A Page A.4

Fuel Quality Requirements:
Figure 1: Fuel Quality Requirements
Engine Oil Capacity, Sisu Diesel Engine
Oil capacity is dependant upon

the size and shape of the oil pan.
Look at the oil pan on the en-

gine on your machine to deter-
mine the capacity.
Figure 2: Engine Oil Capacity
Page A.5 Appendix A

Oil Quality Requirements: Engine Oil Performance
Information
The use of quality engine lubricating oils combined
with appropriate oil drain and filter intervals are
critical factors in maintaining engine performance and
durability.
The engine manufacturer recommends the use of
Figure 3: Oil Quality Requirements
high quality SAE 15W-40 heavy duty engine oils
Engine Oil Selection: which meet the American Petroleum Institute (API)
performance classification CG-4 (preferred) or CF-4
Select the viscosity grade from the table (figure 5) cor- (allowed).
responging to the outside (ambient) temperature.
A sulfate ash limit of 0.5 mass percent or less is
suggested for optimum valve and piston deposit and
oil consumption control.
All machines have the following decal (below) on

them as a reminder of which engine oil to use for
ambient.
Engine Oil Viscosity Selection

The use of multi-viscosity lubricating oils has been
found to improve oil consumption control and
improve engine cranking in cold temperatures while
maintaining lubrication at high temperatures.
Figure 5: Oil Viscosity Chart
While SAE 15W-40 oil is recommended for most
climates, refer to the Engine Oil Selection Guide
below for oil viscosity recommendations for extreme
conditions.
New Engine “Break-In” Oils

Do not use special “break-in” lubricating oils for new
or rebuilt engines. Use the same type of oil during
the “break-in” as that which is used during normal
operation.
Appendix A Page A.6

Coolant Qualtiy Requirements:
The coolant used must meet the demands of standard

ASTM D 3306 or BS 6580:1992.
• The cooling mixture must consist 40...60 % of

ethylene/propylene-glycol based antifreeze and
water. The best proportion is 50 % of antifreeze
liquid and 50 % of water.
Note: For arctic conditions, use 60/40 ratio.
• The water used must be mechanically clean and
not too acid (e.g. swamp water) or too hard calciferous
well water).
• Check periodically the proportion (the frostproof) Figure 4: Coolant Requirements
of the coolant. Change the coolant every two
years.
A good rule of thumb is if you would not drink the

water, don’t put it in the engine.
Note! Never use only water as coolant!
Page A.7 Appendix A

Hydraulic Oil Information 2.) ISO 46 - A medium weight oil for mid-
range conditions with ambient temper-
Choosing the correct hydraulic oil to use in your atures from +25º to +70ºF (-4º to +21ºC).
hydraulic system is extremely important. Consider 3.) ISO 68 - A heavier oil for warm weather
these two things when selecting hydraulic oil: conditions with ambient temperatures
from +40º to +90ºF (+4º to +32ºC).
1.) Select a hydraulic oil with the properties
that meet the equipment manufacturer’s Although it is not supplied from the factory, the fol-
performance specifications. lowing ISO viscosity is commonly used in extreme
2.) Use the correct ISO viscosity oil for your cold weather.
ambient temperature.
ISO 22 - A light weight oil for arctic cold
Using a hydraulic oil that meets the above require- weather conditions with ambient temper-
ments will help eliminate costly machine downtime atures from -40º to +40ºF (-40º to +4ºC).
and reduce the overall operating cost of your machine.
Failure to use the correct hydraulic oil will only create The viscosity of the hydraulic oil used at the factory is
problems and cost you time and money. determined by the time of year the machine is manu-
factured and where the machine will be shipped.
Hydraulic Oil Type For example: A machine built in December for opera-
tion in Wisconsin would be factory filled with ISO
Modern hydraulic systems use components that 32 hydraulic oil. That same machine if built in June,
require hydraulic oil with specific properties and would be filled with ISO 46 hydraulic oil.
containing additives that reduce wear, foaming,
oxidation, etc. This is called the oil’s “Performance Using the correct hydraulic oil viscosity for your am-
Specifications”. bient conditions is extremely important. If the oil vis-
cosity is too light for ambient, the hydraulic oil system
All machines leaving the factory are filled with high will overheat easily and damage to components can
quality US Oil or Mobile DTE 10M Series hydraulic occur. If the oil viscosity is too heavy for ambient,
oil that meets published performance specification the oil will be too thick to flow easily and damage to
requirements. If you want to use a different brand, components can occur from cavitation. Also, it may
it must meet the recommended hydraulic oil perfor- be harder to start the machine.
mance specifications found in this manual. You can
provide your oil supplier a copy of these specifications Extreme weather conditions may require seasonal oil
so that he can keep you supplied with the proper fluid. viscosity changes.
Hydraulic Oil Viscosity Important: Check with your supplier before mixing
hydraulic oils of different type, brand, or viscosity.
The viscosity of an oil is identified by its “ISO Viscos- Many oils are not compatible and damage to your
ity Rating”. The ISO viscosity rating can be found on hydraulic system could result. When changing oil
the oil container’s label. viscosity, flush and clean the hydraulic system before
adding new oil.
The factory uses three ISO viscosity oils when filling
machines during production.
1.) ISO 32 - A light weight oil for cold wea-
ther conditions with ambient temperatures
from -20 to +50ºF (-29 to +10ºC).
Appendix A Page A.8

Hydraulic Oil Viscosity Selection Here is an example to use for reference:
A “Hydraulic Oil Viscosity Selection Guide” decal ISO Code 14/10 - Cleanliness required by most hy-
(below) is placed on each machine. draulic servo-type systems.
ISO Code 17/14 - Cleanliness required in the Timbco /

Valmet hydraulic systems.
ISO Code 21/19 - Generally, the cleanliness of “new”

hydraulic oil shipped in a drum.
On the ISO Code rating scale, a 14/10 rating is 10X

cleaner than a 17/14 rating, and a 21/19 rating is 10X
dirtier than a 17/14 rating. This is why it is so im-
portant to only add pre-filtered oil to your hydraulic
system and to clean and flush hoses and fittings before
installing.
ISO Code Rating

Cleanliness of hydraulic oil is rated on an ISO Code
scale. An ISO Code rating is made up of two numbers
that reference the approximate number of particles
or contaminates, by size, that can be found in a fixed
volume (1 ml) of hydraulic oil.
For example: ISO Code 17/14 - This is the cleanliness

required by the manufacturer of the pumps and motors
used in you track feller buncher’s hydraulic system.
The lower the ISO Code numbers, the cleaner the oil
is. Generally, the only time you will see an ISO Code
rating is on an oil performance specification sheet or
an oil sample test results sheet. Because an ISO Code
rating is based on particles you cannot see with the
naked eye, it is difficult to use the ISO Code rating un-
less it references test results.
Page A.9 Appendix A

General Hydraulic Oil Minimum Technical Hydraulic Oil
Specification Requirements
For optimum efficiency and hydraulics component Any hydraulic oil utilized in TIMBCO produced
life, Timbco recommends that a high quality, wide equipment should meet the following minimum
temperature range, shear stable hydraulic oil be technical requirements:
utilized which incorporates the following additive
agents and viscosity limits. Specification Minimum Requirement
IMPORTANT: The hydraulic oil is the life blood
of the hydraulic system and should never be FZG Rating, Din 51534 . . . . . . . . . . . . 10+
compromised.
1) Operating hydraulic oil viscosity (at normal Vickers 35VQ Vane Pump Test . . . <90 mg
operating temperature) be selected in the Vickers M-2950-S
range of 81 to 167 SUS (17 to 35 cSt).
Foam Test, ASTM D892 . . . . . . . . . . . 20/0
2) Anti-wear Agents - Zinc dithiophosphate at a I, II, III/ml
minimum level of 800 ppm to provide
lubricity (or equivalent). Emulsion Test, ASTM 1401. . . . . . . 10 max
(minutes to 37ml. Water @ 130°F)
3) Defoamers or Release Agents - Prevents the
Cincinnati Milacron Thermal . . . . . . . . Pass
formation of air bubbles within the hydraulic oil.
Stability (275°F, 168 hours)
4) Anti-Oxidant Agents - Prevents the formation of Rust Test, ASTM D-665. . . . . . . . . . . . Pass
corrosive acids and sludge. Procedures A & B
5) Rust & Corrosion Inhibitors - Protects metallic Sonic Shear Stability, . . . . . . . . . . . . . 5 max
components from water and acids. ASTM D5621 (100C / 40 minutes)
(% viscosity loss)
6) Detergents & Dispersants - Keeps system
components free of deposits. Water In Suspension . . . . . . . . . . . . . . < .1%
( % by Volume)
Reference the oil manufacturer’s specification
data sheet for the above hydraulic oil technical Oil Cleanliness ISO Standard . . . 17/14 min
(16/12 prefer)
requirements.
Viscosity Index, Min:
ISO 32 Rating . . . . . . . . . . . . . . . . . . 169
ISO 46 Rating . . . . . . . . . . . . . . . . . . 145
ISO 68 Rating . . . . . . . . . . . . . . . . . . 135
Pour Point, Max:

ISO 32 Rating . . . . . . . . . . . . . . . . -45°F
ISO 46 Rating . . . . . . . . . . . . . . . . -35°F
ISO 68 Rating . . . . . . . . . . . . . . . . -30°F
Appendix A Page A.10

Track Final Drive Oil IMPORTANT NOTE:
Do not use gear oil in the Lohmann track final
Information drives.
Caterpillar Transmission / Drive Train Oil (TD/TO)
(TO-4) is balanced to give maximum frictional If the Caterpillar Transmission / Drive Train Oil (TD/
material life in power shift transmissions and TO)(TO-4) is not used, then commercial oils meeting
eliminate brake chatter in “wet” brake applications. the TO-4 specification should be used.
This oil has passed the requirements for the new If the TO-4 specification oils are not available, then
Caterpillar TO-4 oil specification which not only the old API CD/CAT TO-2 specification or
includes the frictional requirements, but also has gear MIL-L-2104D or E oils could be used. But, as noted
wear requirements. previously, shortened component life may result.
Page A.11 Appendix A

Technical Specifications
Komatsu Forest reserves the right to change
specifications without notice or obligation.
6’ 9”
(2.06 m)
12'
(3.66 m)
Ground
5’ 3” Clearance: 32” (81 cm)
(1.60 m)
4’ 10” 21’ 5”
(1.47 m) 15’ 7” (6.53 m)
(4.75 m)
Engine Track System Machine Control System
Sisu 84 ETA 260 HP (194 kW) Caterpillar 325 D6 with 600 mm SG track shoes, • Engine management
Torque 885 ft.- lbs. (1200 Nm) @ 1200 RPM greased chain assembly, Lohmann GFT60 Final - Electronic interface between machine
Fuel Capacity 180 gal. (681 litre) drive, Rexroth A6VE107 auto-shift track motors. function & engine
- anti- engine stall independent for track and
Machine Width Tractive Effort 64,360 lb. (29 194 kg) implement systems
STD 600 mm SG 9’8” (2,95 m) Drawbar Pull 60,770 lb. (27 565 kg) • Operator push button interface
OPT 700 mm SG 10’0” (3,05 m) DB Ratio 1.14 - Function speed
OPT 900 mm TG 10'8” (3,25 m) Speed (0-3.5) mph (0-5,6 km/h) - Function smoothness
- 4 operator mode settings
Machine Weight Hydraulics - Multiple Languages
Base Machine 53,270 lb. (24 165 kg) Implement circuits feature IQAN digital control • System Self-Diagnostis
system with Rexroth 145 cc 86 gpm (325 litre) • Troubleshooting Features
Approximate “woods ready” operating weight pump and Parker K220/L90 9-section main - On board multi-meter with graphics error
without attachment, fully serviced including 1/2 control valve. Dual track drives feature closed logging events
tank fuel [90 gal. (341 litres @ 738 lb. (335 kg) loop hydrostatic circuits with seperate Rexroth • Machine Protection
and 175 lb. (80 kg) operator. AA4VG90 55gpm (208 litre) pumps. Independent - Over temperature and under temperature
horsepower control for track drive and implement conditions results in reduced machine
Ground Pressure systems. output
STD 600 mm SG 6.99 psi - System records all over time events
OPT 700 mm DG 6.10 psi Swing
OPT 900 mm TG 4.90 psi Single Swing Motor Optional Equipment
Swing Torque 47,100 ft-lbs - Track shoes widths (Contact Dealer)
Cutting Area (To attachment pin) - Boom configurations (Contact Dealer)
Maximum 21’5” (6,53 m) Booms - SisuDiesel 300 HP (221 kW)
Minimum 7’6” (2,29 m) Box construction with 3" (76 mm) minimum - Cummins 300HP (224 kW)
Swath 13’11” (4,24 m) diameter pins and Timbco's PATENTED boom - Swing Option 2 58,400 ft-lbs
geometry. Main to stick knuckle joint 3 1/2" pin. - Fire suppression system
Lift Capacity (Without attachment) - 1-1/4" front window
@ 10' (3,05 m) 24,250 lb. (11 000 kg) Operator's Cab - Xenon high intensity lighting
@ 15' (4,57 m) 18,200 lb. (8 255 kg) ROPS/FOPS/OPS certified, low noise excellent
@20' (6,10 m) 11,500 lb. (5 216 kg) visibility, and 3 emergency escape routes. Other
features include a Red Dot A/C and heater, AM/FM
radio with cassette, and halogen lighting.

6’ 9”
(2.06 m)
12’ 4”
(3.76 m)
Ground
Clearance: 27.5” (70 cm)
5’ 7”
(1.70 m)
4’ 10” 21’ 5”
(1.47 m) (6.53 m)
14’ 7”
(4.44 m)
Engine Lift Capacity (Without attachment) Operator's Cab

Sisu 84 ETA 260 HP (194 kW) @ 10' (3,05 m) 24,250 lb. (11 000 kg) ROPS/FOPS/OPS certified, low noise excellent
Torque 885 ft.- lbs. (1200 Nm) @ 1200 RPM @ 15' (4,57 m) 18,200 lb. (8 255 kg) visibility, and 3 emergency escape routes. Other
Fuel Capacity 180 gal. (681 litre) @20' (6,10 m) 11,500 lb. (5 216 kg) features include a Red Dot A/C and heater, AM/FM
radio with cassette, and halogen lighting.
Machine Width Track System
STD 600 mm SG 9’8” (2,95 m) Caterpillar 325 D6 with 600 mm SG track shoes, Machine Control System
OPT 700 mm SG 10’0” (3,05 m) greased chain assembly, Lohmann GFT60 Final • Engine management
OPT 900 mm TG 10'8” (3,25 m) drive, Rexroth A6VE107 auto-shift track motors. - Electronic interface between machine
function & engine
Machine Weight Tractive Effort 64,360 lb. (29 194 kg) - anti- engine stall independent for track and
Base Machine 54,000 lb. (24 493 kg) Drawbar Pull 60,770 lb. (27 565 kg) implement systems
DB Ratio 1.15:1 • Operator push button interface
Approximate “woods ready” operating weight Speed (0-3.5) mph (0-5,6 km/h) - Function speed
without attachment, fully serviced including 1/2 - Function smoothness
tank fuel [90 gal. (341 litres @ 738 lb. (335 kg) Hydraulics - 4 operator mode settings
and 175 lb. (80 kg) operator. Implement circuits feature IQAN digital control - Multiple Languages
system with Rexroth 145 cc 86 gpm (325 litre) • System Self-Diagnostis
Ground Pressure pump and Parker K220/L90 9-section main control • Troubleshooting Features
STD 600 mm SG 6.99 psi valve. Dual track drives feature closed loop - On board multi-meter with graphics error
OPT 700 mm DG 6.10 psi hydrostatic circuits with seperate Rexroth AA4VG90 logging events
OPT 900 mm TG 4.90 psi 55gpm (208 litre) pumps. Independent horsepower • Machine Protection
control for track drive and implement systems. - Over temperature and under temperature
Cab Leveling conditions results in reduced machine
Front 27° Swing output
Rear 7° Single Swing Motor - System records all over time events
Side 20° Swing Torque 47,100 ft-lbs
Optional Equipment
Cutting Area (To attachment pin) Booms - Track shoes widths (Contact Dealer)
Maximum 21’5” (6,53 m) Box construction with 3" (76 mm) minimum - Boom configurations (Contact Dealer)
Minimum 7’6” (2,29 m) diameter pins and Timbco's PATENTED boom - SisuDiesel 300 HP (221 kW)
Swath 13’11” (4,24 m) geometry. Main to stick knuckle joint 3 1/2" pin. -Cummins 300HP (224 kW)
-Swing Option 2 58,400 ft-lbs
- Fire suppression system
- 1-1/4" front window
- Xenon high intensity lighting

6’ 9”’
(2.06 m)
12’
(3.66 m)
5’ 3”’
Ground
(1.60 m)
Cle aranc e : 34.5” (88 c m)
4’ 10”’ 21’ 5”’

(1.47 m) (6.53 m)
15’ 4”’
(4.67 m)

Fuel Capacity 180 gal. (681 litre) drive, Rexroth A6VE107 auto-shift track motors. function & engine
- anti- engine stall independent for track
Machine Width Tractive Effort 78,145 lb. (35 446 kg) and implement systems
STD 600 mm SG 10’4” (3,15 m) Drawbar Pull 74,745 lb. (33 904 kg) • Operator push button interface
OPT 900 mm TG 11'4” (3,45 m) Speed (0-3.3) mph (0-5,3 km/h) - Function smoothness
Base Machine 60,000 lb. (27 215kg) Implement circuits feature IQAN digital control • System Self-Diagnostis
system with Rexroth 145 cc 86 gpm (325 litre) • Troubleshooting Features
Approximate “woods ready” operating weight pump and Parker K220/L90 9-section main - On board multi-meter with graphics
without attachment, fully serviced including 1/2 control valve. Dual track drives feature closed error logging events
tank fuel [90 gal. (341 litres @ 738 lb. (335 kg) loop hydrostatic circuits with seperate Rexroth • Machine Protection
and 175 lb. (80 kg) operator. AA4VG90 55gpm (208 litre) pumps. Independent - Over temperature and under temperature
horsepower control for track drive and implement conditions results in reduced machine
Ground Pressure systems. output.
STD 600 mm SG 7.41 psi - System records all over time events
OPT 700 mm DG 6.47 psi Swing
OPT 900 mm TG 5.20 psi Single Swing Motor Optional Equipment
Swing Torque 47,100 ft-lbs - Track shoes widths (Contact Dealer)
Cutting Area (To attachment pin) - Boom configurations (Contact Dealer)
Maximum 21’5” (6,53 m) Booms - SisuDiesel 300 HP (221 KW)
Minimum 7’6” (2,29 m) Box construction with 3" (76 mm) minimum - Cummins 300HP (224 kW)
Swath 13’11” (4,24 m) diameter pins and Timbco's PATENTED boom -Swing Option 2 58,400 ft-lbs
geometry. Main to stick knuckle joint 3 1/2" pin. - Fire suppression system
Lift Capacity (Without attachment) - 1-1/4" front window
@ 10' (3,05 m) 24,250 lb. (11 000 kg) Operator's Cab - Xenon high intensity lighting
@ 15' (4,57 m) 18,200 lb. (8 255 kg) ROPS/FOPS/OPS certified, low noise excellent
@20' (6,10 m) 11,500 lb. (5 216 kg) visibility, and 3 emergency escape routes.
Other features include a Red Dot A/C and heater,
AM/FM radio with cassette, and halogen lighting.

6’ 9”
(2.06 m)
12’ 6”
(3.81 m)
Ground
5’ 9” Clearance: 30” (76 cm)
(1.75 m)
4’ 10” 21’ 5””

(1.47 m) 15’ 4” (6.53 m)
(4.67 m)

Sisu 84 ETA 260 HP (194 kW) @ 10' (3,05 m) 24,250 lb. (11 000 kg) ROPS/FOPS/OPS certified, low noise excellent
Torque 885 ft.- lbs. (1200 Nm) @ 1200 RPM @ 15' (4,57 m 18,200 lb. (8 255 kg) visibility, and 3 emergency escape routes. Other
Fuel Capacity 180 gal. (681 litre) @20' (6,10 m) 11,500 lb. (5 216 kg) features include a Red Dot A/C and heater,
AM/FM radio with cassette, and halogen lighting.
Machine Width Track System
STD 600 mm SG 10’4” (3,15 m) Caterpillar 330 D7 with 600 mm SG track shoes, Machine Control System
OPT 700 mm SG 10’8” (3,25 m) greased chain assembly, Lohmann GFT80 Final • Engine management
OPT 700 mm DG 10'8" (3,25 m) drive, Rexroth A6VE107 auto-shift track motors. - Electronic interface between machine
OPT 900 mm TG 11'4” (3,45 m) function & engine
Tractive Effort 78,145 lb. (35 446 kg) - anti- engine stall independent for track and
Machine Weight Drawbar Pull 74,745 lb. (33 904 kg) implement systems
Base Machine 56,675lb. (25 708 kg) DB Ratio 1:32 • Operator push button interface
Speed (0-3.3 mph (0-5.3 km/h) - Function speed
Approximate “woods ready” operating weight - Function smoothness
without attachment, fully serviced including 1/2 Hydraulics - 4 operator mode settings
tank fuel [90 gal. (341 litres @ 738 lb. (335 kg) Implement circuits feature IQAN digital control - Multiple Languages
and 175 lb. (80 kg) operator. system with Rexroth 145 cc 86 gpm (325 litre) • System Self-Diagnostis
pump and Parker K220/L90 9-section main • Troubleshooting Features
Ground Pressure control valve. Dual track drives feature closed loop - On board multi-meter with graphics
STD 600 mm SG 7.41 psi hydrostatic circuits with seperate Rexroth error logging events
OPT 700 mm DG 6.47 psi AA4VG90 55gpm (208 litre) pumps. Independent • Machine Protection
OPT 900 mm TG 5.20 psi horsepower control for track drive and implement - Over temperature and under temperature
systems. conditions results in reduced machine
Cab Leveling output
Front 27° Swing - System records all over time events
Rear 7° Single Swing Motor
Side 20° Swing Torque 47,100 ft-lbs Optional Equipment
- Track shoes widths (Contact Dealer)
Cutting Area (To attachment pin) Booms - Boom configurations (Contact Dealer)
Maximum 21’5” (6,53 m) Box construction with 3" (76 mm) minimum - SisuDiesel 300 HP (221 kW)
Minimum 7’6” (2,29 m) diameter pins and Timbco's PATENTED boom -Cummins 300HP (224 kW)
Swath 13’11” (4,24 m) geometry. Main to stick knuckle joint 3 1/2" pin. -Swing option 2 58,400 ft-lbs

Komatsu Forest the right to change
6’ 9”
(2.06 m)
12’
(3.66 m)
Ground
5’ 3” Clearance: 34.5" (88 cm)
(1.60 m)
9' 5" 26' 4"

(2.87 m) (8.03 m)
15' 4"
(4.67 m)

Fuel Capacity 400 gal. (1 514litres) drive, Rexroth A6VE107 auto-shift track motors. function & engine
- anti- engine stall independent for track and
Machine Width Tractive Effort 78,145lb. (35 446 kg) implement systems
STD 600 mm SG 10’4” (3,15 m) Drawbar Pull 74, 745 lb. (33,904 kg) • Operator push button interface
OPT 900 mm TG 11'4” (3,45 m) Speed (0-3.3 mph (0-5,6 km/h) - Function smoothness
Base Machine 65,140 lb. (29 547 kg) Implement circuits feature IQAN digital control • System Self-Diagnostis
system with Rexroth 145 cc 86 gpm (325 litre) •Troubleshooting Features
Approximate “woods ready” operating weight pump and Parker K220/L90 9-section main control - On board multi-meter with graphics
without attachment, fully serviced including 1/2 valve. Dual track drives feature closed loop error logging events
tank fuel [200 gal. (757 litres @ 1648 lb. (744 kg) hydrostatic circuits with seperate Rexroth AA4VG90 • Machine Protection
and 175 lb. (80 kg) operator. 55gpm (208 litre) pumps. Independent horsepower - Over temperature and under temperature
control for track drive and implement systems. conditions results in reduced machine
Ground Pressure output
STD 600 mm SG 9.35 psi Swing - System records all over time events
OPT 700 mm DG 8.09 psi Dual Swing Motors
OPT 900 mm TG 6.51 psi Swing Torque 67,000 ft-lbs Optional Equipment
OPT 700 mm SG 8.05 psi - Track shoes widths (Contact Dealer)
Booms - Boom configurations (Contact Dealer)
Cutting Area (To attachment pin) Box construction with 3" (76 mm) minimum - SisuDiesel 300 HP (221 KW)
Maximum 26'4" (8.03m) diameter pins and Timbco's PATENTED boom -Cummins 300 HP (224kW)
Minimum 7'8" (2.34 m) geometry. Main to stick knuckle joint 3 1/2" pin. - Swing option 2 80,500 ft-lbs
Swath 18'8" (5.69 m) - Fire suppression system
Operator's Cab - 1-1/4" front window
Lift Capacity (Without attachment) ROPS/FOPS/OPS certified, low noise excellent - Xenon high intensity lighting
@ 26'4" (8,03m) 12,000 ib. (5 443 kg) visibility, and 3 emergency escape routes. Other
features include a Red Dot A/C and heater, AM/FM
radio with cassette, and halogen lighting

6’ 9”
(2.06 m)
12’ 6”
(3.81 m)
Ground
Clearance: 30" (76 cm)
5” 9”
(1.75 m)
9’ 5”” 26’ 4””

(2.87 m) 15’ 4”” (8.03 m)
(4.67 m)

Sisu 84 ETA 260 HP (194 kW) @ 26' 4" (8,03 m) 12,000 lb. (5 443 kg) ROPS/FOPS/OPS certified, low noise excellent
Torque 885 ft.- lbs. (1200 Nm) @ 1200 RPM visibility, and 3 emergency escape routes. Other
Fuel Capacity 400 gal. (1514 litres) Track System features include a Red Dot A/C and heater, AM/FM
Caterpillar 330 D7 with 600 mm SG track shoes, radio with cassette, and halogen lighting.
Machine Width greased chain assembly, Lohmann GFT80 Final
STD 600 mm SG 10’4” (3,15 m) drive, Rexroth A6VE107 auto-shift track motors. Machine Control System
OPT 700 mm SG 10’8” (3,25 m) • Engine management
OPT 900 mm TG 11'4” (3,45 m) Tractive Effort 78,145 lb. (35 446 kg) - Electronic interface between machine
Drawbar Pull 74,745 lb. (33 904 kg) function & engine
Machine Weight DB Ratio 1.08 - anti- engine stall independent for track and
Base Machine 69,100 lb. (31,343 kg) Speed (0-3.3 mph (0-5,6 km/h) • implement systems
- Operator push button interface-
Approximate “woods ready” operating weight Hydraulics - Function speed
without attachment, fully serviced including 1/2 Implement circuits feature IQAN digital control - Function smoothness
tank fuel [200 gal. (757 litres )@ 1,648 lb. (744 kg) system with Rexroth 145 cc 86 gpm (325 litre) - 4 operator mode settings
and 175 lb. (80 kg) operator. pump and Parker K220/L90 9-section main - Multiple Languages
control valve. Dual track drives feature closed • System Self-Diagnostis
Ground Pressure loop hydrostatic circuits with seperate Rexroth • Troubleshooting Features
STD 600 mm SG 9.35 psi AA4VG90 55gpm (208 litre) pumps. Independent - On board multi-meter with graphics
OPT 700 mm DG 8.09 psi horsepower control for track drive and implement error logging events
OPT 900 mm TG 5.20 psi systems. •Machine Protection
OPT 700 mm SG 8.04 psi - Over temperature and under temperature
Swing conditions results in reduced machine
Cab Leveling Dual Swing Motors output
Front 27° Swing Torque 67,000 ft-lbs - System records all over time events
Rear 7°
Side 20° Booms Optional Equipment
Box construction with 3" (76 mm) minimum - Track shoes widths (Contact Dealer)
Cutting Area (To attachment pin) diameter pins and Timbco's PATENTED boom - Boom configurations (Contact Dealer)
Maximum 26’4” (8.03 m) geometry. Main to stick knuckle joint 3 1/2" pin. - Sisu 300 HP (221 kW)
Minimum 7’8” (2.34 m) -Cummins 300 HP (224 kW)
Swath 18’8” (5.69 m) - Swing option 2 80,500 ft-lbs

Boom Sweep - 425 & 445 EXL
Equipped with Standard Main Boom & Standard Stick Boom
35’ (10.67 m)
Lift Capacities (w/o - Attachment)

30’ (9.15 m)
10’ (3.05 m).....24,500 lb. (11,000 kg)
15’ (4.57 m).....18,200 lb. (8,255 kg)
20’ (6.10 m).....11,500 lb. (5,216 kg)
25’ (7.62 m)
20’ (6.10 m)
15’ (4.57 m)
10’ (3.05 m)
5’ (1.52 m)
0’ (0 m)
23’5” (7.14 m) to attachment mounting pivot at -5’ (-1.52 m)

ground level with maximum reach.
For true cutting swath, add distance from mount-

ing pivot to the throat of the selected attachment.
-10’ (-3.05 m)
0’ 5’ 10’ 15’ 20’ 25’ 30’
(0 m) (1.53 m) (3.05) (4.57 m) (6.10 m) (7.62 m) (9.15 m)

Equipped with Longer Main Boom & Standard Stick Boom
35’ (10.67 m)
30’ (9.15 m)
25’ (7.62 m)
20’ (6.10 m)
15’ (4.57 m)
10’ (3.05 m)
5’ (1.52 m)
0’ (0 m)
-5’ (-1.52 m)
21’5” (6.53 m) to attachment mounting pivot at

-10’ (-3.05 m)
0’ 5’ 10’ 15’ 20’ 25’ 30’
(0 m) (1.53 m) (3.05) (4.57 m) (6.10 m) (7.62 m) (9.15 m)

Equipped with Standard Main Boom & 8’ (2.44 m) Telescopic Stick Boom
40’ (12.19 m)
35’ (10.67 m)
30’ (9.15 m)
25’ (7.62 m)
20’ (6.10 m)
15’ (4.57 m)
10’ (3.05 m)
5’ (1.52 m)
0’ (0 m)
-5’ (-1.52 m)

-10’ (-3.05 m)
-15’ (-4.57 m)
0’ 5’ 10’ 15’ 20’ 25’ 30’ 35’
(0 m) (1.53 m) (3.05) (4.57 m) (6.10 m) (7.62 m) (9.15 m) (10.67 m)

Equipped with 24” (61 cm) Longer Main Boom & 8’ (2.44 m) Telescpoic Stick Boom
40’ (12.19 m)
35’ (10.67 m)
30’ (9.15 m)
25’ (7.62 m)
20’ (6.10 m)
15’ (4.57 m)
10’ (3.05 m)
5’ (1.52 m)
0’ (0 m)
-5’ (-1.52 m)

-10’ (-3.05 m)
-15’ (-4.57 m)
0’ 5’ 10’ 15’ 20’ 25’ 30’ 35’
(0 m) (1.53 m) (3.05) (4.57 m) (6.10 m) (7.62 m) (9.15 m) (10.67 m)

HYDRAULIC SYSTEM:
GENERAL:
TYPE:........................................ Closed center, variable displacement, pressure

compensated.
PUMP TRANSMISSION:
TYPE:........................................ Triple pad type pump drive

MANUFACTURER: ............... Funk Manufacturing
MODEL:.................................... YZ15961
IMPLEMENT PUMP:
REXROTH 145cc:
TYPE: .................................. Variable displacement piston, load sense pressure

compensated.
MANUFACTURER: .......... REXROTH
MODEL: .............................. AA11V0145DRS
DISPLACEMENT: ............. 75 GPM (281 LPM)
PRESSURE CAPABILITY: 6,000 psig (41,38 Mpa)
STANDBY PRESSURE:..... 425 psig (2,93 Mpa)
POR PRESSURE:................ 3,800 psig (26,20 Mpa)
MAX CASE PRESSURE: ... No greater than 10 psig (69 kPa) above the suction
inlet pressure.
TRACK DRIVE PUMP (2):
TYPE:........................................ Variable displacement piston, load sense pressure

compensated hydrostatic.
MANUFACTURER: ................ REXROTH
MODEL:.................................... AA4VG903.2
DISPLACEMENT: .................. 55 GPM (281 LPM)
PRESSURE CAPABILITY: ..... 6,000 psig (41,38 Mpa)
POR PRESSURE: ..................... 5,250 psig (36,20 Mpa)
HIGH PRESSURE RELIEF: .... 5,800 - 6,000 psig (40,00 - 41,38 Mpa)
MAX CASE PRESSURE:......... No greater than 10 psig (69 kPa) above the suction
inlet pressure.
TRACK DRIVE CHARGE PUMP:
TYPE:........................................ Fixed displacement gear

MODEL:.................................... MJ80871
DISPLACEMENT: .................. 30 GPM (114 LPM)
CHARGE PRESSURE:............. 475 psig (3,28 Mpa)

HYDRAULIC SYSTEM (Cont’d):
RETURN OIL FILTRATION:
TYPE:........................................ (ISO Rating 16/12) (Qty. 3) In tank 150 GPM

(569 LPM) rating with diffused bypass
MANUFACTURER:................. SCHROEDER
MODEL:.................................... LRT18S7
FILTRATION: .......................... Varies by ambient conditions
HYDRAULIC TANK:
TYPE:........................................ Steel construction, pressurized and baffled design

equipped with individual suction ports for all pumps
with shut-off valves.
CAPACITY:.............................. 110 US gal. (416 litres)
PRESSURIZATION: ................ 7 psig (48 kPa) from engine turbo boost circuit
LEVEL INDICATOR: .............. Sight glass visible form operator’s seat and low oil
level warning in cab to protect against major oil
loss.
FILL: ......................................... Electric fill pump and 2 addition fill points provided,
all oil is filtered before it enters the main tank.
IMPLEMENT CONTROL VALVE:
TYPE:........................................ 9 or 10-Section pressure compensated load sense

control
MANUFACTURER:................. VOAC
MODEL:.................................... K220 / L90LS
SYSTEM PILOT PRESSURE: 500 - 600 psig (3,45 - 4,14 Mpa)
VALVE PORT RELIEFS: ........ 4,200 psig (28,96 - 29,65 Mpa)

Typical Hydraulic Valve Set Up
Saw Clamp Tool Stick Main Swing / Accm. / Level / Level

Tilt Boom Boom Left Right
Saw / Processor Section: Swing Section:

Port Relief A & B: 4,350 psi (300 bar) Port Relief A & B: 4,350 psi (300 bar)
Pressure Limiter A & B: 3,625 psi (250 bar) A & B ports: 0-32 gpm (0-121 l/m)
A & B ports: 55 gpm (208 l/m)
Accumulator Section:
Clamp Section: Port Relief A & B: 4,350 psi (300 bar)
Port Relief A & B: 4,350 psi (300 bar) Pressure Limiter A & B: 3,625 psi (250 bar)
Pressure Limiter A & B: 3,625 psi (250 bar) A & B ports: 35 gpm (132 l/m)
Level Left Section:
Tool Tilt Section: Port Relief A & B: 3,770 psi (260 bar)
Port Relief A & B: 4,350 psi (300 bar) A & B ports: 7 gpm (25 l/m)
Pressure Limiter A & B: 3,625 psi (250 bar)
A port: 10 gpm (38 l/m) Level Right Section:
B port: 48 gpm (182 l/m) Port Relief A & B: 3,770 psi (260 bar)
Stick Boom Section:
Port Relief A & B: 4,350 psi (300 bar) Lateral Tilt Section (Optional):
A port: 19 gpm (72 l/m) Port Relief A & B: 4,350 psi (300 bar)
B port: 48 gpm (182 l/m) Pressure Limiter A & B: 3,625 psi (250 bar)
Main Boom Section:
Port Relief A & B: 4,350 psi (300 bar)
A port: 19 gpm (72 l/m)
B port: 52 gpm (197 l/m)

VOAC K220 Valve (Typical)
Pressure Limiters Stroke Limiters

Port Reliefs
Port Reliefs
Electro-Hydraulic
Spool Actuators

VOAC L90LS Valve (Typical)
Stroke Limiters
Pressure Limiter
Port Reliefs
Electro-Hydraulic
Spool Actuators

425 EX & EXL UNDERCARRIAGE:
MANUFACTURER:..................... CATERPILLAR, Inc.
TYPE:............................................. 325(D6)
OVERALL TRACK LENGTH:. 14’4” (4,37 m)
OVERALL TRACK HEIGHT: .. 46” (117 cm)
TRACK GAUGE: ........................ 7’8” (2,34 m)
TRACK PITCH: ........................... 8.0” (203 mm)
ROLLERS: .................................... 9 bottom (+2 optional carrier per side)
# OF TRACK SHOES:................. 45 per side
ROCK GUARDS: ......................... Bolt-on
AVAILABLE TRACK SHOES: . STD 24” / 600mm single grouser (SG)

OPT 28” / 700mm single grouser (SG)
OPT 28” / 700mm double grouser (DG)
OPT 32” / 800mm triple grouser (TG)
TRACK MOTORS (2):

MODEL:.................................... A6VE107
TYPE:........................................
Variable displacement, piston
DISPLACEMENT: ................... MIN - 2.56 cu.in. (42 cc)
MAX - 4.88 cu.in. (80 cc)
PRESSURE CAPABILITY: ..... 5500 psi (37,93 Mpa)
BRAKE: .................................... Integral parking brake
PLANETARY FINAL DRIVE GEARBOX (2):
MANUFACTURER: ............... LOHMANN

MODEL:.................................... GFT-60
RATIO:...................................... 105.5 : 1
SPEED:...................................... 0-3.5 mph (0-5,6 km/h)
TRACTIVE EFFORT: .............. 64,360 lb. (29,194 kg)

(After efficiency reductions of 93% for the motors
and 96% for the final drives)
DRAWBAR PULL: .................. 60,770 lb. (27,565 kg)

(Calculation of tractive effort less a rolling
resistance reduction of GVW x .06)
DRAWBAR / WEIGHT RATIO: 1.15:1 with STD 24” / 600mm SG tracks

TYPE:............................................. 330(D7)
OVERALL TRACK HEIGHT:.. 50” (127 cm)
TRACK GAUGE: ........................ 8’4” (2,54 m)
TRACK PITCH: ........................... 8.5” (216 mm)

TRACK MOTORS (2):

MODEL:.................................... A6VE107
TYPE:........................................
MAX - 6.53 cu.in. (107 cc)

MODEL:.................................... GFT-80
RATIO:...................................... 126.9 : 1
SPEED:...................................... 0-3.3 mph (0-5,3 km/h)
TRACTIVE EFFORT: .............. 78,145 lb. (35 446 kg)

DRAWBAR PULL: .................. 74,745 lb. (33 904 kg)

DRAWBAR / WEIGHT RATIO: 1.32 : 1 with STD 24” / 600mm SG tracks

TYPE:............................................. 330(D7)
OVERALL TRACK HEIGHT:.. 50” (127 cm)
TRACK GAUGE: ........................ 8’4” (2,54 m)
TRACK PITCH: ........................... 8.5” (216 mm)

TRACK MOTORS (2):

MODEL:.................................... A6VE107
TYPE:........................................
MAX - 6.53 cu.in. (107 cc)

MODEL:.................................... GFT-80
RATIO:...................................... 126.9 : 1
SPEED:...................................... 0-3.3 mph (0-5,3 km/h)
TRACTIVE EFFORT: .............. 78,145 lb. (35 446 kg)

DRAWBAR PULL: .................. 74,745 lb. (33 904 kg)

DRAWBAR / WEIGHT RATIO: 1.08:1 with STD 24” / 600mm SG tracks

UPPER STRUCTURE:
ROTATING TURNTABLE:
CONSTRUCTION: ................... High quality, high strength alloy steel throughout
SWING SYSTEM:
DEGREES OF ROTATION: .... 270o each direction with automatic swing stop,
540° total swing.
BEARING TYPE: ..................... Large diameter ball bearing with induction hardened
races. Gear teeth located on inner race for protection
from elements and debris.
BEARING DIAMETER: .......... 51” (130 cm)
CAPACITY:.............................. 1,200,000 lb. (8 273 712 kg)
SWING SPEED:........................ Adjustable to 8.5 RPM
LOHMANN SWING MOTOR/GEARBOX

(425 & 445 EX & EXL):
SWING TORQUE:.................... 47,100 lbf (21,364 kg)
TYPE:........................................ Fixed displacement radial piston motor mounted
on reduction gearbox
GEARBOX MANUFACTURER: LOHMANN
MODEL:.................................... GFB-72
GEAR RATIO:.......................... 45.66 : 1
MOTOR MANUFACTURER: . REXROTH
MODEL:.................................... A2FE45/61
DISPLACEMENT: ................... 45 cc
SWING BRAKE: ...................... Integral static swing brake
(475 EX & EXL)
SWING TORQUE: ................... 67,000 lbf (30,390 kg)
TYPE: ........................................ Dual fixed displacement radial piston motors
mounted
on reduction gearboxes.
GEARBOX MANUFACTURER: REXROTH
MODEL: ................................... GFB-17
GEAR RATIO: ......................... 45.70:1
MOTOR MANUFACTURER: REXROTH
MODEL: .................................. A2FE45/61
DISPLACEMENT: .................. 45 cc
SWING BRAKE: .................... Integral static swing brake
BOOMS:
CONSTRUCTION: ................... High quality, high strength alloy steel box section
design with 4-bat power link
PINS: ......................................... Induction hardened and chrome plated for maximum
wear resistance
MAIN / UPPER PIVOT:........... 3.0” (76 mm) straight pin with PATENTED tapered
hub retainers
MAIN / STICK PIVOT: ........... 3.5” (89 mm) teardrop pin retained with 2” UNF
locknut
STICK / ATTACHMENT PIVOT: 2.5” (64 mm) straight pin
BUSHINGS:.............................. Steel w/grease grooves used throughout

CYLINDERS:
MAIN BOOM (HOIST):
TYPE:........................................ Bolt-on bearing retainer design tested to

5,000 psi (34,48 Mpa)
CYLINDER ROD: .................... Induction Hardened Chrome
ROD DIAMETER:.................... 4.00” (102 mm)
BARREL O.D. DIAMETER:.... 7.75” (197 mm)
BORE: ....................................... 6.50” (165 mm)
PISTON RETAINING NUT:.... 2.75-12” UNF
RETRACTED LENGTH: ......... 60.00” (152 cm)
STROKE: .................................. 42.00” (107 cm)
PIN SIZES:................................ 3.00” (65 mm) rod & base
STICK BOOM (JIB):

5,000 psi (34,48 Mpa)
ROD DIAMETER:.................... 3.50” (89 mm)
BORE: ....................................... 5.50” (140 mm)
STROKE: .................................. 34.25” (87 cm)
TOOL TILT:

5,000 psi (34,48 Mpa)
ROD DIAMETER:.................... 3.00” (76 mm)
BORE: ....................................... 5.00” (127 mm)
STROKE: .................................. 42.00” (107 cm)
CAB LEVEL:

5,000 psi (34,48 Mpa)
ROD DIAMETER:.................... 3.50” (89 mm)
BORE: ....................................... 6.50” (165 mm)
PISTON RETAINING BOLT: . 2.00-12” UNF
STROKE: .................................. 14.00” (36 cm)

OPERATOR’S ENVIRONMENT:
CONSTRUCTION:
TYPE:........................................ High quality, high strength allow steel rectangular tube

construction
ROPS/FOPS/OPS:..................... Certified through destructive testing and meets
AE J231, J1040 & J1084 requirements rated to
73,500 lb. (33 340 kg)
WCB:......................................... Certified through destructive testing and meets
WCB G602, G603, G604 & G608 requirements
rated to 73,500 lb. (33 340 kg)
MOUNTING: ............................ Rubber isolators.
WINDOWS: .............................. 1/2” (13 mm) laminated lexan with 3/8” (10 mm) steel
back-up bars
SOUND LEVEL: ...................... Below 82 decibels
AIR CONDITIONER / HEATER:
TYPE: Integral in cab roof

MANUFACTURER: RED DOT, Inc.
OPERATOR’S SEAT:
TYPE:........................................ Fully adjustable knee bend design

MANUFACTURER:................. SEATS, INC.
ADJUSTMENTS: ..................... Seat height
Ride
Seat fore & aft
Joystick fore & aft
Armrest up & down
Lumbar
Backrest angle
EMERGENCY ESCAPES:
NUMBER:................................. 3
LOCATION: ............................. Rear sliding window assembly
Front kick-out window assembly
Cab door

OPERATOR’S ENVIRONMENT (Cont’d):
CONTROLS:
UPPER HAND CONTROL (JOYSTICK):
QUANTITY:........................ 2
TYPE: .................................. Ergonomically designed cast aluminum
MANUFACTURER: ........... CYBERTECH, INC.
MODEL: .............................. 8900
SWITCHES: ........................ (2) 2-way rocker switches for main electrical function
control
(2) auxiliary positions for push-button or toggle
switches
LOWER HAND CONTROL:
QUANTITY:........................ 2
TYPE: .................................. Pilot hydraulic valve assembly
MANUFACTURER: ........... VICKERS, INC.
MODEL: .............................. HRC4
FOOT CONTROL (PEDAL):
QUANTITY:........................ 2 (extra foot control available)

TYPE: .................................. Pilot hydraulic valve assembly
MANUFACTURER: ........... VICKERS, INC.
MODEL: .............................. HRC2

OPERATOR’S ENVIRONMENT (Cont’d)
INSTRUMENTATION:
GAUGES:
MANUFACTURER: ............. F.W. MURPHY

TYPE:..................................... Individually backlit “light-pipe”
MONITORING:..................... Return filter by-pass
Engine oil pressure
Engine coolant temperature
Hydraulic oil temperature
Voltmeter
Hourmeter
WARNING LIGHTS:
MANUFACTURER: ............. F.W. MURPHY

TYPE:..................................... Individually backlit “light-pipe”
MONITORING:..................... Hydraulic oil level alarm/light (Hydraulic oil level sight
gauge also provided)
Coolant temperature alarm/light
Return filter by-pass alarm/light
Engine low pressure alarm/light
Hydraulic oil temperature alarm/light
ENGINE INTERFACE:
MANUFACTURER: . . . . . F.W. MURPHY

TYPE: . . . . . . . . . . . . . . . POWER VIEW
MONITORING:. . . . . . . . . Engine coolant temperature (alarm/light)
Engine oil pressure (alarm/light)
Engine speed
Voltmeter, hourmeter
HYDRAULIC CONTROL INTERFACE:
MANUFACTURER: . . . . . PARKER
TYPE: . . . . . . . . . . . . . . . . IQAN - MASTER DISPLAY MODULE (MDM)
MONITORING:. . . . . . . . . Implement circuits, joystick circuits, hydrostatic circuits
Hydraulic oil temperature, machine hours, operator
parameters, troubleshooting

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Table Of Contents ...

Section 1.1 - General Safety Information

T.1 Table Of Contents

Section 2.1 - Starting the Machine

Section 2.2 - Pro-Heat Instructions

Auxiliary Heater System (PROHEAT)(Optional). . . . . . . . . . . . . . . . . . . 2.2.1

Section 2.3 - Jump Starting

Starting with Jumper Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1

Section 2.4 - Operating Track Drives

Controlling the Track Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1

Section 2.5 - Attachment Operation

Controlling the Implements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.1

Section 2.6 - General Operating Instruction

Parking the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2

Table Of Contents T.2

Group 4 - Cab Environment

Section 4.1 - General Information

Section 4.2 - Dash Panel

T.3 Table Of Contents

Auxiliary Oil Cooler (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.6

Section 4.2 - PowerView Display

Section 4.3 - IQAN Master Display Module (MDM)

Section 5.1 - Hydraulic System Description

Types of Hydraulic Systems:

Table Of Contents T.4

Hydraulic System Cleanliness

Section 5.1.6 - Hydraulic Tank and Filters

Hydraulic Oil Filtration System

Section 5.3 - Valve Bank Pressure Adjustments

Differential Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3.2

Section 5.4 - Disc Saw Pressure Adjustments

Disc Saw Pump Stand-by Pressure Adjustment . . . . . . . . . . . . . . . . . . 5.4.1

T.5 Table Of Contents

Section 5.5 - Implement Pump Pressure Adjustments

Implement Pump Stand-By Pressure Adjustment Procedure . . . . . . . . 5.5.1

Section 5.6 - Hydrostatic Pressure Adjustments

Charge Pressure Relief Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6.1

Section 5.7 - Emergency Towing Procedure

Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7.1

Group 7 - Fire Extinguisher

Fire Extinguisher Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1.2

Table Of Contents T.6

Section 8.1 - General

Section 8.2 - Daily Maintenance

Section 8.3 - Service as Required

Change Air Conditioner/Heater Unit Blower Filter . . . . . . . . . . . . . . . . . 8.3.1

Section 8.4 - 50 Hour Checks

Test Door Safety Interrupt System Operation . . . . . . . . . . . . . . . . . . . . 8.4.1

Table Of Contents T.7 Table Of Contents

Section 8.5 - 100 Hour Checks

Check Engine Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.1

Section 8.6 - 250 Hour Checks

Change Engine Oil & Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.1

Section 8.7 - 500 Hour Checks

Check Engine Coolant Atifreeze Concentration . . . . . . . . . . . . . . . . . . . 8.7.1

Section 8.8 - 1000 Hour Checks

Secure & Clean Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8.1

Table Of Contents T.8 Table Of Contents