Scaler Op and Maint Manual With Training

OPERATION AND MAINTENANCE MANUAL
PUBLICATION NUMBER 1676 REVISION 7 © 2017 All rights reserved.
STANDARD FEATURES
 MECHANICAL FIXED BOOM SCALER

 FOPS/ROPS ENCLOSED CAB
 HYDRAULIC WET DISC BRAKES
 AUTO SECONDARY BRAKES

 SEALED POINT TO POINT WIRING
 CATALYTIC PURIFIER AND SILENCER

 HEAVY DUTY TIMKEN BEARINGS
 TELESCOPIC BOOM MINE SCALING VEHICLE

 BOOM MOUNTED ROCK DEFLECTOR SV-11, SV-18, SV-22, SV-26
 AUDIO BACKUP ALARM
 OSCILLATION LOCKOUT
MACHINE OPTIONS
PICK TOOL OR HAMMER
11, 18, 22, OR 26 FT REACH
AUTO TIMER CENTRAL GREASE
FIRE SUPPRESSION SYSTEM
FOAM FILLED SLICK TIRES
AIR RIDE OPERATORS SEAT
SWIVEL OPERATOR SEAT
WATER SPRAY SYSTEM
REAR VIEW CAMERA
DRIVETRAIN
CUMMINS, MTU, OR CAT TIER 3 DIESEL ENGINE
CLARK 32000 TRANSMISSION
JOHN DEERE OR KESSLER HEAVY DUTY DRIVE AXLES
2141 Woodward Avenue Kingsford, MI 49802 (906) 774-1500 Fax: (906) 774-1505
TABLE OF CONTENTS
TABLE OF CONTENTS
Section Page
1. SAFETY
Machine Misuse ................................................................................................................................. 1-2
Safety Signal Words .......................................................................................................................... 1-2
General Safety Precautions ............................................................................................................... 1-3
Operation Safety Precautions ............................................................................................................ 1-5
Maintenance Safety Precautions ....................................................................................................... 1-6
Hazardous Atmospheres ................................................................................................................... 1-7
2. INTRODUCTION
Vehicle Systems ............................................................................................................................. 2-2
General Information ........................................................................................................................ 2-3
Machine Components ..................................................................................................................... 2-5
Permissible Environmental Conditions ........................................................................................... 2-6
Machine Data Plates ....................................................................................................................... 2-6
Glossary of Terms........................................................................................................................... 2-7
3. OPERATION
Controls and Indicators
Fuel System .................................................................................................................................... 3-2
Hydraulic Oil System....................................................................................................................... 3-4
Engine & Transmission ................................................................................................................... 3-8
Brakes ............................................................................................................................................. 3-11
Cab .............................................................................................................................................. 3-16
Dump Bypass Switch ...................................................................................................................... 3-34
Battery Main Disconnect ................................................................................................................. 3-35
Fire Suppression ............................................................................................................................. 3-37
Vehicle and Equipment Operation

Pre-Operation Checklist.................................................................................................................. 3-41
Vehicle Start-Up .............................................................................................................................. 3-42
Driving the Vehicle .......................................................................................................................... 3-43
Brake Test....................................................................................................................................... 3-46
Scale Brake Mode .......................................................................................................................... 3-47
Vehicle Stopping and Shutdown ..................................................................................................... 3-47
Boom Operation .............................................................................................................................. 3-48
Tool Operation ................................................................................................................................ 3-49
Emergency Operation ..................................................................................................................... 3-49
i
TABLE OF CONTENTS
TABLE OF CONTENTS (CONTINUED)
Section Page
4. MAINTENANCE
Scheduled Maintenance
Pre-Shift (8hr) ........................................................................................................................ 4-2
First 40 Hours ........................................................................................................................ 4-17
Every 40 Hours ..................................................................................................................... 4-19
First 100 Hours ...................................................................................................................... 4-21
Every 250 Hours ................................................................................................................... 4-22
Every 500 Hours ................................................................................................................... 4-29
Every 1000 Hours ................................................................................................................. 4-35
2000 and 5000 Hours............................................................................................................ 4-38
Adjustments and Alignments

Check System Hydraulic Pressure ....................................................................................... 4-39
Adjust System Hydraulic Pressure ........................................................................................ 4-39
Check Accumulator Pre-Charge ........................................................................................... 4-43
Charge Accumulator ............................................................................................................. 4-44
Adjust Boom Rollers.............................................................................................................. 4-47
Adjust Park Brake ................................................................................................................. 4-50
Lube Charts ........................................................................................................................... 4-51

Maintenance Checklists ........................................................................................................ 4-66
Recommended Fluids ........................................................................................................... 4-70
Machine Filters ...................................................................................................................... 4-71
Cleaning the Machine ........................................................................................................... 4-72
Long Term Storage ............................................................................................................... 4-73
Torque Tables ....................................................................................................................... 4-74
5. TROUBLESHOOTING
General Troubleshooting....................................................................................................... 5-2
Troubleshooting Guide .......................................................................................................... 5-3
6. FUNCTIONAL DESCRIPTION
Scalers with SAHR Axle Brakes (Kessler) and SAHR Transmission Brakes ...................... 6-2
SV-11 Scalers and Models Equipped with Kessler Axles (SAHR Brakes)
and HASR Transmission Brakes ......................................................................................... 6-10
Scalers with HASR Axle Brakes and SAHR Transmission Brakes ...................................... 6-16
7. MACHINE REPORTS
Machine Reports and Forms ................................................................................................. 7-1
ii
SAFETY
1. SAFETY
This Operation and Maintenance Manual contains the information necessary to safely operate, maintain, and
troubleshoot your machine. Safe and efficient operation requires that the operator be familiar with the vehicle,
understand its capabilities and follow the recommended operating procedures in this manual.
New Operators must be thoroughly trained by qualified personnel and must never operate the machine
unsupervised. Information in this manual must be reviewed and understood before using this machine. Failure
to comply could result in serious injury or death.
In addition to all safety measures outlined in this manual, personnel shall adhere to all applicable workplace
practices and regulations. To maintain optimum performance from this equipment, any questions concerning
this publication should be directed to the manufacturer.
1-1
SAFETY
MACHINE MISUSE
DO NOT USE THIS MACHINE TO…
LIFT, LOWER, OR TRANSPORT PERSONNEL OR OBJECTS
OPERATE IN EXPLOSION HAZARDOUS ATMOSPHERES
DRIVE ON PUBLIC ROADWAYS
TOW OTHER MACHINES OR MACHINERY
THIS MACHINE IS INTENDED FOR SCALING APPLICATIONS ONLY AND MACHINE COMMISSIONING SHALL BE
PERFORMED BY QUALIFIED OEM PERSONNEL!
USE OF THE MACHINE PRIOR TO COMMISSIONING OR FOR ANY OTHER PURPOSE IS CONSIDERED MISUSE
AND WILL VOID WARRANTY COVERAGE!
Safety Signal Words
This is the safety-alert symbol. When you see this symbol on your machine, you must be alert to the
potential for personal injury. Follow recommended precautions and safe operating practices.
The signal words DANGER, WARNING, or CAUTION are used with the safety-alert symbol. Each covers a
different level of probability or severity.
A Danger identifies the most serious hazards that will result in serious injury or death.
A Warning identifies critical hazards that could result in serious injury or death.
A Caution identifies potential hazards that could result in minor injury.
A Notice identifies the potential for major damage to the machine or other equipment.
1-2
SAFETY
General Safety Precautions
The machine shall not be used during inclement weather which may affect the safe operation of the
equipment. The machine shall not be used anytime lightning is present.
It is important to keep the equipment clean for safe operation. Dirt and mud can build up on the
equipment causing an unsafe condition. It is also important to keep the equipment clean for proper
operation of the moving components and for serviceability of the equipment.
Do not operate this equipment to lift, lower or transport personnel or objects. Do not operate this
equipment in an explosive hazardous atmosphere. Do not operate this equipment on or near public
roadways.
Carefully read all safety messages in this manual and on your equipment. Keep safety signs or
decals in good condition. Replace any missing or damaged signs. Follow all maintenance
recommendations to keep the equipment in proper working condition.
Learn how to operate the machine and how to use controls properly. Do not let anyone operate
without instruction. Keep your machine in proper working condition. Unauthorized modifications to
the machine may impair the function and safety, and affect machine service life.
Wear tight fitting clothing and safety equipment appropriate for the job. This may include, but not be
limited to, the following items: eyewear, gloves, hardhat, steel-toe boots, and hearing protection.
Operating requires full attention. Do not wear music headphones while operating the equipment.
Prolonged exposure to loud noise can damage your hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against loud noise.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music
headphones while operating machine.
Prepare for emergencies. Be prepared if a fire starts and keep a first aid kit and fire extinguisher
handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near
a telephone.

Handle fluids safely and avoid fires. Prevent fires by keeping the equipment clean and free of
accumulated grease or debris. Always stop the engine before refueling the machine. Fill fuel tank in
a well ventilated area. Always clean up spilled fluids and oils. Do not leave oily rags on the
equipment as they can ignite and burn spontaneously. Alert mine personnel of any fire hazards.
Handle fuel with care: it is highly flammable. Do not refuel a machine while smoking or near open
flame or sparks. Store flammable fluids away from fire hazards. Do not incinerate or puncture
pressurized containers. Keep all fire suppression actuators in operational condition.
1-3
SAFETY
Avoid high pressure fluids. Escaping high pressure fluid can penetrate skin, causing serious injury.
Relieve pressure before disconnecting hydraulic or other pressure lines. Tighten all connections
before restoring system pressures. Do not use hands or feel for leaks. If an accident occurs, see a
doctor immediately. ANY fluid injected into the skin must be surgically removed as soon as possible
or gangrene may result.
ALWAYS chock wheels before performing any maintenance. Whether parked on an incline or flat
surface, always take the necessary precautions to prevent the vehicle from rolling. Do not rely
exclusively on the park brake to hold the vehicle in place. Also place the articulation lock in the
locked position prior to performing any maintenance.
Stay clear of rotating drivelines. Be alert when working around rotating drivelines. Entanglement in
rotating driveline can cause serious injury or death.
Tie long hair behind your head. Do not wear a neck tie, scarf, necklace, or loose fitting clothing
when working around operating machine. These items can get caught and pull you into moving
parts, resulting in severe injury or death. Stop engine and be sure driveline is stopped before
performing maintenance.
Practice safe maintenance. Understand service procedure before doing work. Read appropriate
technical manual first. Keep work area clean and dry.
Never lubricate or service machine while it is operating or moving. Keep hands, feet, hair, and
clothing clear of rotating parts. Disengage all power and operate controls to relieve pressures.
Lower equipment to the ground. Stop the engine and allow machine to cool.
Securely support any machine components that must be raised for service.
Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or
broken parts. Remove any buildup of grease, oil, dirt, or debris.
Disconnect negative battery cable before performing any maintenance on electrical system.
Work in a well ventilated area. Engine exhaust fumes can cause sickness or death. If operating the
engine for extended period of time in enclosed area, remove exhaust gases with an exhaust
extension.
Use proper lifting equipment. Lifting heavy components incorrectly can cause severe injury or
machine damage. Never work under suspended loads without safety devices in place.
Dispose of waste properly. Improperly disposal of waste can damage the environment and ecology.
Potentially harmful waste can include such items as oil, fuel, coolant, brake fluid, hydraulic fluid,
filters, and batteries.
Use leak-proof containers when draining fluids. Do not use beverage containers that may mislead
someone into drinking from them.
Do not pour waste onto the ground, down the drain, or into any water source.
1-4
SAFETY
Air conditioning refrigerants escaping into the air can damage the Earth's atmosphere. Recover and
recycle refrigerants when servicing the air conditioning system.
Handle chemicals safely. Direct exposure to hazardous chemicals can cause serious injury.
Potentially hazardous chemicals used with Cannon equipment include such items as hydraulic fluid,
lubricants, coolants, and paints.
A Material Safety Data Sheet (MSDS) provides specific details on chemicals: physical and health
hazards, safety procedures, and emergency response techniques.
Check the MSDS before starting any job using a chemical, to know exactly what the risks are and
how to do the job safely.
Prevent machine movement. ALWAYS chock wheels before performing any maintenance.
Whether parked on an incline or flat surface, always take the necessary precautions to prevent the
vehicle from rolling. Do not rely exclusively on the park brake to hold the vehicle in place.
Also place the articulation lock in the locked position prior to performing any maintenance.
Do not operate the vehicle on grades greater than 18° (31%).
Operation Safety Precautions

 Ensure area around the vehicle is clear and parking brakes are applied.
 NEVER start a machine that has been tagged OUT OF SERVICE.
 Make sure windows are up and cab is ventilated properly if hearing protection is not worn.
 Ensure the transmission directional control switch is in the NEUTRAL position.
 ALWAYS sound the horn before starting the engine, to alert anyone who might be close to the vehicle.
 Ensure all scheduled maintenance has been performed.
 DO NOT operate the vehicle unless all dash gauges display operation in the normal indication range.
 Ensure all accessories are properly stowed.
 DO NOT allow riders except in equipped seats.
 Do not leave the vehicle unattended with the engine running.
 Remove wheel chocks only when parking brake is applied.
 Keep the haulage or roadways clear of loose rock and debris.
 Know the area of operation (loose or hanging rock, low voltage electrical cables, harmful mined gases, etc.)
 ALWAYS scale with the vehicle under previously scaled or supported roof conditions working toward the un-
scaled area. Scale from the highest point to the lowest.
 ALWAYS drive with the operator seat either facing full forward or facing full rearward.
1-5
SAFETY
Maintenance Safety Precautions
 NEVER perform service in hinged area without articulation lock in place.
 Unless otherwise specifically directed all checks listed shall be performing while the Vehicle Engine is off.
 Do not run vehicle if the hydraulic fluid is low, failure to comply will result in vehicle damage.
 Ensure the fuel tank is full. Excessive condensation may occur inside fuel tank if vehicle is low on fuel. This
can damage the engine
 Do not run vehicle with a dirty filter. The filter is bypassed when the dirt alarm indicates a dirty condition. The
hydraulic system can become contaminated, causing serious damage to hydraulic components.
 Do not operate the vehicle with a dirty Hydraulic Tank Filter. Contamination can cause serious damage to
hydraulic system components.
 Do not run the vehicle with a dirty Fuel Filter. Engine damage may occur. Do not run vehicle with a dirty air
element. Dirty Air can cause engine damage.
 ALWAYS chock wheels, install boom cylinder locks, and articulation lock bar during maintenance.
 ALWAYS provide proper ventilation when performing any maintenance with the engine running.
 NEVER work under boom without adequate support. If available, cylinder lock collars are designed to support
elevated booms and should be used.
 NEVER work on inner or outer boom assembly without locking inner boom from moving in or out. Chaining
and blocking boom is MANDATORY.
 Never inflate tire and wheel assemblies without proper safeguards.
 ALWAYS use proper lifting equipment to remove and install tires and wheels.
 NEVER work on hydraulic system without removing pressure from system.
 ONLY remove radiator cap when system is cool.
 Cyberstick pilot controls may allow steering movement, tool rotation, and boom functions after engine has
been shut down. This is due to stored energy in the accumulator circuit. Always block machine from
movement and drain accumulator pressure before performing maintenance.
 Do not run the vehicle with a dirty Transmission Filter. Serious damage to the transmission can occur.
1-6
SAFETY
Hazardous Atmospheres
Evaluating Hazardous Atmospheres:
A hazardous atmosphere means an atmosphere that may expose employees to the risk of death, incapacitation,
impairment of ability to self-rescue (escape unaided from a permit space), injury, or acute illness from one or
more of the following causes:
 Oxygen concentration below 19.5% or above 23.5%

 Flammable gas, vapor, or mist in excess of 10% of its Lower Explosive Limit (LEL)
 Combustible dust at a concentration that meets or exceeds its LEL
 Atmospheric concentration in excess of any substance’s published dose or Permissible Exposure Limit
(PEL) which is capable of causing death, incapacitation, impairment of ability to self-rescue, injury, or acute
illness due to its health effects
 Any other atmospheric condition that is immediately dangerous to life or health
You must do air monitoring to determine if a hazardous atmosphere exists!
Atmospheric conditions in a confined space can change very quickly!
Oxygen Levels:
Is the oxygen level too high or too low? Below are oxygen levels and what is considered too high or low.
 23.5% and above is too HIGH

 20.8% - 21% is NORMAL
 19.5% and below is DEFICIENT
What are some causes or indications of possibly having a deficient oxygen atmosphere inside a space?
Inerting or purging, which means the displacement of the atmosphere in a space by a noncombustible gas
(such as nitrogen) to such an extent that the resulting atmosphere is non-combustible. The following is a list of
dangers of low oxygen levels.
 16-12% oxygen in air generally causes deep breathing, fast heartbeat, poor attention, poor
thinking, and poor coordination
 14-10% oxygen in air generally causes faulty judgment, intermittent breathing, rapid fatigue
(possibly causing heart damage), very poor coordination, and lips turning blue
 10% or less oxygen in air generally causes nausea (vomiting), loss of movement, and loss of
consciousness followed by death.
 Less than 6% oxygen in air generally causes spasmodic breathing, convulsive movement, and
death in approximately eight minutes. 4-6% oxygen in air can lead to a coma in 40 seconds.
1-7
SAFETY
Flammable/Explosive Gases, Vapors, or Mists:
At atmosphere is hazardous if it exceeds 10% of its Lower Explosive Limit (LEL). The Lower Explosive Limit
(LEL) is the lowest concentration where a material is flammable in the air. Upper Explosive Limit (UEL) is the
highest concentration where a material is flammable in the air. LEL and UEL can also be referred to as a
Lower Flammable Limit (LFL) and Upper Flammable Limit (UFL). Check your Material Safety Data Sheets
(MSDS) or other resources for the chemical’s LEL and UEL.
The following diagram shows the flammable or explosive range from minimum (LEL) to maximum (UEL)
limits. It also shows where 10% LEL is.
Ignition
Too Rich
UEL
Concentration in Air
Flammable
LEL Oxygen Fuel
Region
10% LEL
Too Lean
Don’t forget airborne
combustible dust.
Flash Point Combustible solids,
when finely dispersed
Temperature and raised, can explode
when its concentration is
between LEL and UEL.
Toxic Substances:
The atmosphere is hazardous if it exceeds the dose or Permissible Exposure Limit (PEL) and capable of
causing death, incapacitation, impairment of ability to self-rescue, injury, or acute illness due to its health
effects. Most chemicals have permissible exposure limits.
Even non-toxic or low-toxic chemicals can replace oxygen if levels are high enough.
The most common toxic chemicals in confined space fatalities are Hydrogen Sulfide and Carbon Monoxide.
Hydrogen Sulfide (H2S) gas is commonly found in sewers and can be instantly fatal at higher levels in
confined spaces. Disturbing sewage sludge can release hydrogen sulfide gas. Carbon Monoxide (CO)
comes from operating internal combustion and propane-powered engines in or near confined spaces. Fatal
levels of CO are quickly reached in confined spaces.
Other toxic chemicals can include welding fumes, vapors from liquid residues in storage tanks, or chemical
products used in confined spaces. Chemicals can quickly reach toxic levels in the air of a confined space,
especially gases, solvent vapors, or sprayed products.
1-8
INTRODUCTION
2. INTRODUCTION
Read and understand

manual and safety
information before
operating!
This Operation and Maintenance Manual contains the information necessary to safely operate and maintain your
machine. Safe and efficient operation requires that the operator be familiar with the vehicle, understand its
capabilities and follow the recommended operating procedures in this manual.
New Operators must be thoroughly trained by qualified personnel and must never operate the machine
unsupervised. Information in this manual must be reviewed and understood before using this machine. Failure to
comply could result in serious injury or death.
In addition to all safety measures outlined in this manual, personnel shall adhere to all applicable workplace
practices and regulations. To maintain optimum performance from this equipment, any questions concerning this
publication should be directed to the manufacturer.
In this section of your Operation and Maintenance Manual is a general description of the machine, including all
standard equipment and machine options, as well as machine dimensions and specifications. A description of all
the major machine components is provided and includes component dimensions and specifications. All machine
generated levels and machine limitations are listed and the location of the machine data plate is indicated.
The electronic copy of this manual has been prepared using the software Adobe® Acrobat® (pdf format). The
user is encouraged to become familiar with the features of Adobe Acrobat or Reader to facilitate navigating the
manual electronically. The electronic manual has incorporated such features as bookmarks, hypertext links, text
search capabilities, etc. to enable the user to quickly locate the desired information. Hypertext links allow the
reader to click on the text and go to the desired location. Navigating the document is made easier by opening the
bookmarks and thumbnails option. Using text search allows the user to quickly locate instances in the manual for
a word or phrase.
2-1
INTRODUCTION
Mine Scaling Vehicle Systems
OPTIONS
 PUSH BLADE
 AUTOMATIC ANSUL FIRE SUPPRESSION SYSTEM
 DIESEL PARTICULATE FILTER
 MANUAL GREASING PORTS WITH LUBE DISTRUBUTION DIVIDER BLOCKS
 AUTO GREASING SYSTEM
 AMBER STROBE LIGHT
 WIGGINS FAST FUEL FILL SYSTEM
 WIGGINS HYDRAULIC FAST FILL SYSTEM
 WATER SPRAY SYSTEM
 HYDRAULIC HAMMER
 SOOT FILTER AND MONITOR
 SPARE TIRE
 VIDEO CAMERA SYSTEM
 20 LB FIRE EXTINGUISHER
BOOM
HYDRAULIC
ELECTRICAL
CAB
ENGINE END FRAME DRIVE TRAIN BOOM END FRAME
2-2
INTRODUCTION
GENERAL INFORMATION
The Scaler is a single-boom machine designed to scale in large rooms or low narrow entries. On the front frame
of the machine is the heavy duty boom with a FOPS rock deflector. The boom may be equipped with a pick tool
or a hydraulic hammer, or both. Hydraulic hammers include the Atlas Copco SB452E, the Okada 0KB305, the
NPK GH2TS and the Atlas Copco SB302. An optional push blade is available. On the rear frame of the machine
is the ROPS/FOPS certified open operators cab. Available diesel engines include the 4.5 Cummins QSB Tier III,
the MTU 904 Tier III, and the Caterpillar C6.6, Tier III (except SV-11 Models).
The frame is made from high strength steel and includes ball bearing oscillation and tapered roller bearing
articulation. Nylon dividers in the front and rear frames protect the cables and hoses throughout the articulation
joint.
The boom is mounted low for better visibility. No adjustments are required for the boom with access to
components without removing the inner boom. All grease points are external, while some vehicles are equipped
with an auto-lube system. Extend and retract boom stops extend the life of the extension cylinder. All roller
assemblies are interchangeable and accessed from outside the boom. The boom rotator has 180-degree rotation
with Rotek bearing designed specifically for scaling.
The open operators cab includes a 1” Lexguard bulletproof windshield and inside the cab are the operator
controls with fluid two handed joystick controls that provide fluid back scaling motion, proportional control, and
synchronous movement. A full-rotation operators seat (to view out rear window) is an available option on some
models.
The hydraulic system includes a high pressure filter on the brake circuit, spin-on filters, load-sensing pumps, and
main control valves that have port relief and pressure settings built in. All hydraulics include bolt-on end caps for
reduced load and improved geometry.
The electrical system includes point-to-point wiring with Nema 4 stainless steel boxes and hinged dash panels for
easy access. The DIN connectors are waterproof with locking setscrews and LED indicator lights.
The drive train includes a diesel engine, 4-speed power-shift transmission with a wet-disc SAHR or HASR brake,
and Kessler (SAHR brakes) or John Deere (HASR brakes) drive axles. Some models include a SAHR driveline
brake. Also included on some models is a heavy-duty external cooling package with easy access for cleaning.
Extendible Boom &

Rock Deflector Diesel Engine
ROPS/
FOPS
Cab
2-3
INTRODUCTION
Rotary
Actuator
180 degree ROPS/FOPS
rotation Certified Open Cab
Rotation with 1” Lexguard
Bearing Windshield
Dana 32000
Kessler or John Powershift Frame Oscillation at
Frame Oscillation with
Deere Axles Transmission with Rear Axle (SV-11)
Tapered Sealed Roller
Bearings (Except SV-11) Wet Disc Brake
2-4
INTRODUCTION
MACHINE COMPONENTS
Standard:
 Tier 3 Cummins QSB4.5 160HP diesel engine,
 or MTU 904 Tier III 174 HP diesel engine.
 Caterpillar C6.6 Tier 3, 174 HP diesel engine (Except SV-
11 Model)
 24V, 100A Alternator, sealed point-to-point wiring.
 Full reversing 32000 series, 4-speed powershift
transmission.
 Heavy duty Kessler Drive Axles,
 or John Deere 1200 Teammate II Drive Axles.
 Four wheel drive with hydraulic axle service braking and
driveline SAHR (Kessler axles) or HASR (John Deere
axles) disc brake.
 Transmission mounted SAHR park brake.
 Heavy-duty articulation with Timken tapered roller
bearings.
 Cyber Stick steering with 30 degrees articulation each side.
 10 micron “spin-on” or 3 micron in tank filtration.
 Pressure compensated pumps with load sensing.
 ROPS/FOPS open cab with bulletproof Lexguard
windshield.
 Boom with rock deflector and rotation for the hammer or pick.
 4 front and 2 rear tramming lights.
 4 cab and 4 boom working lights.
 Boom swing capability on SV-11 Vehicles.
Optional:
 Tier 4i Cummins QSB4.5 160HP diesel engine (Except
SV-11)
 Cummins QSB 5.9, 155 HP diesel engine (Except SV-11)
2-5
INTRODUCTION
PERMISSIBLE ENVIRONMENTAL CONDITIONS

The machine is designed to be used underground but may also be used on the surface. If the machine is to be
used on the surface it shall not be used during inclement weather that may affect the safe operation of the
machine. The machine shall not be used anytime lightning is present. Refer to Machine Limitations below for
ambient temperature and humidity limitations.
It is important to keep the machine clean for safe operation. Dirt and mud can build up on the steps and work
platform causing an unsafe condition. It is also important to keep the machine clean for proper operation of the
moving components and for serviceability of the machine.
MACHINE DATA PLATES
The machine serial number plate is located on the engine end frame right hand side just below the cab (as
shown). This plate indicates key machine information such as manufacturer, model number and serial number.
At the left hand dash, immediately in front of the operator is the certification label. The label contains
manufacturer information, machine make, model and weight, and ROPS, FOPS and canopy certification
information.
Machine Serial
Number Plate
●Manufacturer
●Model Number
●Serial Number
Certification Label
2-6
INTRODUCTION
GLOSSARY OF TERMS
ACCUMULATOR:
A container in which fluid is stored under pressure, most commonly with a gaseous space above the fluid.
AIR REGULATOR:
A device used to set an air pressure that is lower than the system air pressure.
BOOM:
The arm that positions the pick tool or hydraulic hammer.
BOOM EXTENSION:
The section of the boom that can be extended and retracted with a hydraulic cylinder.
CHARGE PUMP PRESSURE:

The Pressure used to keep a closed loop system filled with fluid.
CHECK VALVE:
A valve that allows fluid flow in only one direction.
DIN CONNECTOR WITH LED:

A type of waterproof electrical connection with an indicator light built into the connector.
HYDRAULIC RESERVOIR:
The tank where hydraulic oil is stored, and where the return filter is located.
JOY STICK:
The control stick used for various machine functions.
MANIFOLD:
A junction point, where two or more hoses are connected.
PARKING BRAKE:
A spring applied, hydraulic released (SAHR) brake intended to prevent the equipment from moving when applied.
PRESSURE FILTER:
A filter that cleans the high pressure oil before it enters to the drifter.
RETURN FILTER:
A filter that cleans hydraulic oil before it returns to the reservoir.
SAHR: Spring-Applied, Hydraulically-Released Brake
HASR: Hydraulically- Applied, Spring-Released Brake
2-7
INTRODUCTION
THIS PAGE INTENTIONALLY BLANK
2-8
OPERATION
3. OPERATION
This section of your Operation and Maintenance Manual provides a description of all Controls and Indicators, and
a description of Vehicle and Equipment Operation procedures.
Only authorized personnel (trained and certified) shall operate this machine. Always review the Safety section of
this manual prior to operating this machine.
Read and understand

manual and safety
information before
operating!
3-1
OPERATION
CONTROLS AND INDICATORS

Fuel System
The fill cap is located on top of the fuel tank next to the fuel/water separator filter. The cap includes a strainer to
ensure a cleaner fuel supply into the tank when filling. If equipped with the Wiggins Remote Fill Option, the fuel is
added using a ground-level remote fill connector and the tank includes a Wiggins air vent.
A Fuel Supply Shut-Off Valve is mounted at the fuel inlet. Shown in the “open” position, rotate handle 90° to the
“close” position to shut off flow of fuel.
Fuel / Water Fill Cap &

Separator Filter Strainer Fuel Tank
Note: This Illustration is

Applicable to SV-18, SV-22, and
SV-26 Machines Only. See
Next Page for SV-11 Machine.
Wiggins Remote Fill Option

includes Wiggins air vent and
ground-level Wiggins fuel fill
connector
3-2
OPERATION
Fill Cap &

Breather
Strainer
Fuel Tank
Fuel/Water
Separator
Filter
Note: This Illustration is Applicable
to SV-11 Machine Only. See
Previous Page for SV-18, SV-22,
and SV-26 Machines.
Fuel Filter
3-3
OPERATION
Hydraulic Tank
The Hydraulic Oil Level and Temperature Gauge is located on the side of the hydraulic tank. Oil level should be
approximately in the middle of the gauge. The gauge is also equipped with a thermometer (oil temperature
gauge) that indicates the temperature of the hydraulic oil. If equipped with the Wiggins Remote Fill Option, the
hydraulic oil is added using a Wiggins remote fill connector with dust cap.


includes Wiggins remote fill
connector with dust cap
Hydraulic Oil Level and

Temperature Gauge
Hydraulic Oil Fill Cap
3-4
OPERATION

Temperature Gauge
Note: This Illustration is Applicable to

SV-11 Machine Only. See Previous
Page for SV-18, SV-22, and SV-26
Machines.
3-5
OPERATION
Hydraulic High Pressure Filter – SV-11 Model

Some UV-11 models are equipped with two 10 micron high pressure hydraulic filters. Other models are equipped
with a single 3 micron high pressure hydraulic filter. The filters are located on or beneath the engine end frame
assembly just behind the left rear wheel well. Each filter is typically equipped with a visual dirt indicator that
provides an indication of when it is time to change the filter element (in place of the visual dirt indicator, some
models use an electric pressure switch which illumines a hydraulic oil filter clogged warning light in the dash).
When the filter element clogs and is bypassed, a highly visible orange disk springs or “pops up”. Once activated,
the orange signal continues to indicate a bypass or clogged condition even after equipment shut down. The
signal will not change until it is manually reset.
High Pressure Hydraulic

Filter Dirt Indicator
Engine End Frame Assembly
Dual 10 Micron High Pressure Filters
Single 3 Micron High Pressure Filter
High Pressure Hydraulic

3-6
OPERATION
Hydraulic High Pressure Filter – SV-18, 22 and 26 Models
Some models are equipped with two 3 micron high pressure hydraulic filters. Other models are equipped with two
10 micron high pressure hydraulic filters. The filters are located at the front of the engine end frame assembly,
just behind the articulation joint. Each filter is equipped with a visual dirt indicator that provides an indication of
when it is time to change the filter element (in place of the visual dirt indicator, some models use an electric
pressure switch which illumines a hydraulic oil filter clogged warning light in the dash). When the filter element
clogs and is bypassed, a highly visible orange disk springs or “pops up”. Once activated, the orange signal
continues to indicate a bypass or clogged condition even after equipment shut down. The signal will not change
until it is manually reset.
Dual 3 Micron High Pressure Filters
Engine End
Frame Assembly
Dual 10 Micron High Pressure Filters Hydraulic High Pressure Filter Dirt
Indicator (Same on Each Filter)
Hydraulic High Pressure

Filter Dirt Indicator (At
top of each Filter)
Engine End
Frame Assembly
3-7
OPERATION
Engine Oil Dipstick

Refer to the Engine Operation and Maintenance Manual for specific Oil Level Dipstick location and information.
Coolant Fill
The Coolant Sight Check is located on the radiator. The face of the Coolant Sight Check has a glass observation
window where engine coolant can be observed. If engine coolant is not visible in the Coolant Sight Check,
coolant should be added at this coolant fill point.
Coolant Fill Coolant Sight Check
3-8
OPERATION
Transmission Filter
The Transmission Filter is equipped with a Mechanical Dirt Indicator that shows a red visual indicating signal.
The mechanical indicator has a Manual Reset Button. Once activated the red signal continues to indicate a
bypass or clogged condition even after equipment shut down.
Mechanical Dirt Indicator
Transmission Filter
Some machines are

equipped with
ground-level access
to the transmission
filter. Locations may
vary depending on
the option selected.
Transmission Fluid Level Dipstick

3-9
OPERATION
Transmission Fluid
The Transmission Fluid Level Dipstick is used to check the transmission fluid level.
Transmission
Filter
Transmission Fill Point

Mechanical Dirt
Indicator Transmission Fluid Level Dipstick
Note: This Illustration applies to

the SV-11 Machine.
Transmission Filter
3-10
OPERATION
Manual Accumulator Relief Dump Valves

For vehicles equipped with John Deere hydraulic applied, spring release (HASR) service brakes, the Manual
Accumulator Relief Dump Valves relieve the hydraulic pressure in the two brake accumulators. The Accumulator
Dump Relief Valves are located below the access panel on the engine end frame. The control cap above
designated port “A1” releases the accumulator pressure for the front brakes and the control cap above the
designated “A2” port releases the accumulator pressure for the rear brakes. Pull up on the control cap to open
the valve and release pressure in the accumulator. Push down on the control cap to retain pressure in the
accumulator.
Control Cap
Manual Accumulator
Dump Relief Valves
A1 A2
3-11
OPERATION
Manual Brake Release
For Vehicles with John Deere Axles:
On these vehicles, only the transmission park brake and the driveline brake (on vehicles so equipped) have the
capability of being manually released [the axle brakes on these vehicles are hydraulically-applied (set) and spring-
released (HASR), and are therefore naturally in the released position when the vehicle is not operating.]. The
transmission mounted park brake and the driveline brake (on vehicles so equipped) are spring-applied and
hydraulically-released (SAHR). It takes a minimum 1100 psi of hydraulic pressure in the brake release circuit to
overcome the spring to release the park brake (260 psi of hydraulic pressure is required to fully release the
driveline brake). If hydraulic pressure in the brake system drops below 1100 psi, the spring assembly will
automatically apply (set) the transmission brake (if brake system hydraulic pressure drops below 260 psi, the
driveline brake will automatically apply). The spring will keep the brake applied (set) until sufficient hydraulic
pressure is available to release. During normal operation hydraulic system pressure is directed to release the
park brake. If system and accumulator pressure is not available, it is possible to manually pressurize the park
brake (transmission and driveline, if so equipped) release circuit using the manual brake release hand pump
located on the floor of the cab next to the seat. To do this, the Park Brake Manual Override Solenoid Valve SV17
must first be manually actuated to direct pressure to the transmission and driveline (if so equipped) park brakes.
This valve is mounted on the right side rear or the engine end frame. While having SV17 held manually actuated,
close the release valve on the hand pump by turning it clockwise and pump the handle to build pressure until the
brake releases. To apply the brakes, turn the release valve on the hand pump counterclockwise to release
pressure, and release the solenoid valve manual actuator.
For Vehicles with Kessler Axles:
On some models, both the transmission park brake and the axle brakes are spring-applied and hydraulically
released (SAHR). Both the park brake and the axle brakes have the capability of being manually released when
the vehicle is not running. It takes a minimum 1100 psi of hydraulic pressure in the brake release circuit to
release the park brake, and a minimum of 1900 psi to release the axle brakes. During normal operation hydraulic
system pressure is directed to release the park brake and axle brakes. If system and accumulator pressure is not
available, it is possible to manually pressurize the park brake release circuit using the manual brake release hand
pump located on the floor of the cab next to the seat. To prevent Solenoid Valve SV21 from dumping brake
circuit flow to tank, preventing pressurization of the brake circuit, manually actuate Solenoid Valve SV21 at the
Brake Manifold on the engine end frame. To release the park brake, the Transmission Park Brake Solenoid Valve
SV3 must first be manually actuated to direct pressure to the park brake. [Note: This step is not necessary on
vehicles with Kessler Axles and transmission brakes that are hydraulically-applied spring-released (HASR).
These brakes do not need manual release as they automatically release if there is no hydraulic pressure.] This
valve is mounted on the Brake Manifold on the engine end frame. While having SV3 held manually actuated,
close the release valve on the hand pump by turning it clockwise and pump the handle to build pressure until the
brake releases. To apply the transmission brakes, turn the release valve on the hand pump counterclockwise to
release pressure, and release the solenoid valve manual actuator. Similarly, to release the axle brakes, the
Transmission Axle Brake Solenoid Valve SV17 must first be manually actuated to direct pressure to the axle
brakes. This valve is also mounted on the Brake Manifold on the engine end frame. While having SV17 held
manually actuated, close the release valve on the hand pump by turning it clockwise and pump the handle to build
pressure until the brakes release. To apply the brakes, turn the release valve on the hand pump
counterclockwise to release pressure, and release the Transmission Axle Brake Solenoid Valve SV17 manual
actuator. When finished with manual brake release procedures, release the Solenoid Valve SV21 manual
actuator.
3-12
OPERATION
Manual Brake Release Hand Pump
Release Valve
3-13
OPERATION
Brake Pressure
The brake pressure indicators are either gauges or digital displays. Vehicles equipped with John Deere axles
have two brake pressure gauges (0 - 5000 psi) or two digital displays: one shows the hydraulic pressure in the
front axle brake circuit; the other shows hydraulic pressure in the rear axle brake circuit. Vehicles equipped with
Kessler axles have one brake pressure gauge (0 - 5000 psi) or one digital display which shows system brake
pressure for both the front and rear axles. The brake pressure gauge/digital display should maintain 2295-2500
psi on vehicles with John Deere axles, 2295-2800 psi on vehicles with Kessler axles (except SV-11 vehicles), and
2295-2900 psi on SV-11 vehicles with Kessler axles, at all times during operation. Readings may fluctuate during
operation.
Transmission Pressure
The transmission pressure indicator is either a pressure gauge or a digital display. The transmission pressure
gauge (0-400 psi)/digital display registers hydraulic pressure available to shift the transmission. The
gauge/display should read 240 – 280 psi during operation.
Transmission Transmission
Pressure Gauge Pressure Gauge
Brake Pressure Gauges

(John Deere Axles)
Inside the Cab
Brake
Pressure Gauge (Kessler Axles)
Location of controls and indicators may vary depending

on options selected. Standard machines are shown.
For example, machines with a full-rotation swivel seat will

have a different configuration or control panel than
standard machines. However, all machines control
functions remain the same.
3-14
OPERATION
Transmission Brake Pressure Digital Display (Kessler Axles)
Pressure Digital Display
Dash 712457
Location of controls and indicators may vary depending on options selected. Standard machines are
shown.
For example, machines with a full-rotation swivel seat will have a different configuration or control panel
than standard machines. However, all machines control functions remain the same.
Transmission
Pressure Digital Display Brake Pressure Digital Displays (John Deere Axles)
Dash 712811 or 713077
3-15
OPERATION
CONTROLS AND INDICATORS – DASH PANEL
Power View Display
Various engine operating parameters are displayed on either dash gauges (see below) or on an engine display.
The Power View and Cantrak engine displays include a graphical backlit LCD screen which displays various
engine operating parameters and service codes, such as:
Engine Oil Pressure (and Low Pressure Warning)

Engine (Coolant) Temperature (and High Temperature Warning)
Engine RPM
System Voltage
Hour Meter
Engine Ready (to start) Indication
These displays include a graphical backlit LCD screen, which can be controlled by an external dimmer
potentiometer or via the menu. The display can show either a single parameter or a quadrant display showing
four different parameters simultaneously. Four or five buttons allow display navigation. The Display is equipped
with ultra-bright alarm and shutdown LED’s (amber and red). An audible alarm is provided for warning and
shutdown. See Vendor Manuals more information about Power View and Cantrak engine displays.
Engine Oil Pressure

The engine oil pressure gauge (0 - 100 psi) registers active engine oil pressure. Oil pressure is normally between
80 and 100 psi.
Converter Temperature
The converter temperature gauge (140-300F) registers the active converter operating temperature. Operating
temperature is normally between 180 and 240F.
Engine Temperature
The engine temperature gauge (100-250F) registers the active engine operating temperature. Operating
temperature is normally between 160 and 200F.
Tachometer
Registers engine Revolutions Per Minute (RPM). Tachometer range is 0-3000 RPM.
System Voltmeter
Registers engine operating voltage. Voltage range is 18-32 Volts.
Hour Meter
Registers hours of operation.
Fuel level gauge

Indicated fuel level in fuel tank (E - ½ - F).
Engine Ready (to start) Indicator:

Comes on when the engine is ready to be started.
Scale Brake On Indicator Light:

Red warning lamp, which comes on when the scale brake function is activated. The Park Brake/Reset
indicator light will come “on” with “Scale Brake On” indication.
3-16
OPERATION
Park Brake/Reset Switch:

The Park Brake Reset Switch is located in the dash panel except for models equipped with the swivel seat, where
it is located on the auxiliary control panel.
Park brake will SET automatically and Park Brake/Reset light will come “on” with Brake Fail
indication. With Brake Fail light extinguished park brake will have to be RESET before normal operation can
resume.
The Park Brake/Reset Switch is a three-position, push-pull (red illuminated) selector switch. The switch has
two maintained positions for normal operation and a third “momentary” position for RESET operation. Push
“IN” to normally set the parking brake. Red cap light will come on. Pull “OUT” to normally release the parking
brake. Red cap light will turn off. With switch in the brake released position (out/maintained), pull “OUT” to
RESET. Switch will spring-return to brake released (out/maintained) position when released.
NOTE: Red cap light will also come “on” whenever the scale brake or park brake is activated.
Brake Fail Indicator Light:

Red warning lamp, which comes “on” when hydraulic pressure in either brake accumulator (front or rear)
drops below 1100 psi on vehicles with John Deere axles, 1900 psi on vehicles with Kessler axles, or the
transmission charge pressure drops below 60 psi. Alarm buzzer activated with warning light.
Air Filter Blocked Indicator Light:

Red warning lamp, which comes “on” when airflow through the engine air intake filter is restricted to the
maximum recommended limit. The indicator automatically resets itself after the filter is serviced. Alarm
buzzer activated with warning light.
Hydraulic Oil Filter Blocked Indicator Light:

Red warning lamp, which comes “on” when oil flow though either the high pressure (hydraulic) oil filter or
the dual element, return line (hydraulic) filter is restricted to the point where changing the filter element is
required.
Axle Filter Blocked Indicator Light (Kessler Axles Only):

Red warning lamp, which comes “on” when oil flow though the Kessler axle brake circuit oil filter is
restricted to the point where changing the filter element is required.
Hydraulic Oil High Temperature Indicator Light:

Red warning lamp, which comes “on” when temperature of the oil in the hydraulic tank reaches 180°F.
Alarm buzzer activated with warning light. Automatic engine shut down after 5 minutes.
Hydraulic Oil Low Level Indicator Light:
Continued operation with Hydraulic Oil Low Level indication could result in catastrophic
damage to the hydraulic system.
Red warning lamp, which comes “on” when oil level in the hydraulic tank is below the minimum level
required to properly sustain normal operation. Alarm buzzer activated with warning light. Automatic
engine shut down after 90 seconds. The Hydraulic Oil Low Level warning light comes “on” when
hydraulic oil level is reduced by approximately 40%. The engine will shut down automatically when
hydraulic oil level is reduced by approximately 55 %.
3-17
OPERATION
Engine Switch:
Refer to Vehicle and Equipment Operation, for further instructions on starting the engine.
Improper operation of the starting circuit can lead to serious engine damage.
The OFF/ON/START Engine Switch and an engine heater indicator work together in the starting circuit. The
OFF/ON/START switch is a three position rotary switch with manual selection between OFF and ON
positions. Momentary, manual hold to START position with spring return to ON.
ON: Turn selector to “ON” position to complete starting circuit and enable engine starting operation. The
Engine Ready Indicator indicates that the glow plug preheat timer is energized. The Engine Ready Indicator
light goes “off” when glow plug preheat sequence is complete. Engine is ready for cold weather start.
DO NOT hold on START for more than 20 seconds at one time. If engine does not fire, wait
one minute then try again. If engine does not start after two attempts refer to the Engine Operation and
Maintenance Manual.
START: Turn and hold momentarily to energize the engine starter (turn over the engine). Release as soon
as engine fires. Selector spring returns to ON when manually released.
Letting the engine idle for at least 20 seconds prior shut off will prolong the life of the engine.
OFF: Turn selector to OFF to open the engine starting circuit and shut off engine and/or disable the engine
starting circuit.
Brake Test Pushbutton:
Application of the park brake test button will release the service brakes. This may cause the
vehicle to roll freely and can cause serious injury or death. Prepare for vehicle movement prior to using the
brake test button. DO NOT initiate the brake test with anyone near the vehicle.
Momentary pushbutton (normally open) switch. To test, press and hold the pushbutton. Release to terminate
test mode.
Horn:
On SV-11 Vehicles only, the Pushbutton used to sound the horn is located on the dash panel. On all
other models, the horn pushbutton is located on the L.H. Control Handle.
Boom Swing Enabled Indicator Light:

On SV-11 Vehicles only, the Yellow lamp illuminates when the Boom Swing mode is selected at the LH
Control Handle.
3-18
OPERATION
Tram Mode Indicator Light:

On SV-11 Vehicles only, the Green lamp illuminates when the boom is within 10 degrees either side of facing
straight forward. If the boom is swung more than 10 degrees either side of straight ahead, the Tram Mode
indicator light will go off and tramming will not be allowed.
Front Windshield Wiper Control:

On models with swivel seat only, the front Windshield Wiper Control is located in the Dash Panel.
Otherwise, it is located in the Auxiliary Control Panel. Rotary switch. Controls the windshield wiper. Turn
clockwise to energize and increase the speed of the wiper motor. Turn counter-clockwise to decrease
speed and de-energize the wiper motor. Press rotary switch to energize washer spray. Release to de-
energize washer spray.
Water Spray Switch:

Some models equipped with a hammer have a water spray option with a Water Spray Switch in the Dash Panel.
For most models, this switch is found in the Auxiliary Control Panel. 2-Position, toggle switch. Toggle selector to
“ON” to energize the water spray system. Toggle selector to “OFF” to de-energize the water spray system.
Water Spray Indicator Light:

Some models equipped with a hammer have a water spray option with a Water Spray Indicator Light in the Dash
Panel. For most models, this indicator light is found in the Auxiliary Control Panel. Yellow lamp, which comes
“on” when the water spray system is energized and ready for use.
3-19
OPERATION
On All Vehicles except SV-11:

Dash model shown with engine gauges and with brake and transmission pressure gauges (located to the left of
the dash panel).
Indicating Lights:
-Brake Fail
Park Brake/Reset
-Engine Oil Low Pressure
-Engine High Temp Axle Filter Engine Oil Pressure
-Air Filter Blocked Blocked
-Hydraulic Oil Filter Blocked (Kessler Axles)
-Hydraulic Oil High Temp Tachometer
-Hydraulic Oil Low Level
Converter Temp
Brake Test
Dash 709061
Scale Engine Fuel Engine Engine Hour Meter Voltmeter

Brake On Temperature Gauge Switch Ready
Indicator
Location of controls and indicators may vary slightly

depending on options selected. Dash panels for
standard machines are shown.
3-20
OPERATION
On All Vehicles except SV-11:
Dash shown with electronic engine display and electronic brake pressure and electronic transmission pressure
digital displays.
Indicating Lights:
-Brake Fail Electronic Transmission
-Engine Oil Low Pressure Pressure Digital Display
-Engine High Temp
-Air Filter Blocked
Park Brake/Reset
-Hydraulic Oil Filter Blocked
-Hydraulic Oil High Temp Power View (or Cantrak)
-Hydraulic Oil Low Level Engine Display
Electronic Brake Pressure
Brake Test Digital Displays
Dash 712811
Fuel
Engine Gauge
Scale Engine
Ready
Brake On Switch Converter Temp
Indicator
Location of controls and indicators may vary slightly depending on options selected. Dash Panels
for standard machines are shown.
For example, the dash panel shown is for machines with John Deere axles. If Kessler axles were
present, the Axle Filter Blocked indicator light would appear on the dash panel and only one
electronic brake pressure digital display would be present. If the swivel seat was present, the Park
Brake/Reset Switch would be located to the left of the Dash Panel, at the Auxiliary Control Panel,
and the Front Wiper Switch would be located in the Dash Panel. Some models equipped with a
hammer have a water spray option with a Water Spray Switch and a Water Spray Indicator Light in
the Dash Panel.
3-21
OPERATION
On SV-11 Vehicles:
Dash shown for swivel seat, with electronic engine display, and electronic brake pressure and electronic
transmission pressure digital displays.
Electronic Transmission Indicating Lights: Indicating Lights:

Pressure Digital Display -Brake Fail -Boom Swing Enabled
-Engine Oil Low Pressure -Pick Rotation Enabled
-Engine High Temp -Tram Mode
Front Wiper
-Air Filter Blocked -Scale Brake On
Switch
-Hydraulic Oil Filter Blocked -Axle Filter Blocked
-Hydraulic Oil High Temp
Power View (or Cantrak) -Hydraulic Oil Low Level
Engine Display
Brake Test Axle Filter

Blocked
Dash 712457
Engine
Switch Fuel
Engine
Horn Gauge
Ready
Indicator
Converter Temp
Location of controls and indicators may vary depending on options

selected. Dash panels for standard machines are shown.
Electronic Brake Pressure
Digital Display For example, the dash shown is used with the swivel seat, where the Park
Brake/Reset Switch is located to the left of the Dash Panel, at the Auxiliary
Control Panel, and the Front Wiper Switch is located in the Dash Panel.
Some models equipped with a hammer have a water spray option with a
Water Spray Switch and a Water Spray Indicator Light in the Dash Panel.
3-22
OPERATION
CONTROLS AND INDICATORS – AUXILIARY CONTROL PANEL
Manual Transmission Selector Switch:

5-Position rotary selector switch. Controls the transmission shifting selection. Select (1), (2), (3) or (4) to set and
maintain operation in an operator selected gear. Operation works the same in forward (FWD) and reverse (REV)
directions of travel.
Scale Lights:
2-Position, toggle switch. Toggle selector to “ON” to illuminate scaling boom and cab mounted spotlights. Toggle
selector to “OFF” to extinguish scaling boom and cab mounted spotlights.
Front Lights:
2-Position, toggle switch. Toggle selector to “ON” to illuminate front facing (clear) spotlights and rear facing (red)
running light. Toggle selector to “OFF” to extinguish front facing spotlights and rear facing running light.
Rear Lights:
2-Position, toggle switch. Toggle to “ON” to illuminate rear facing (clear) spotlights and front facing (red) running
light. Toggle to “OFF” to extinguish rear facing spotlights and front facing running light.
Strobe Light:
2-Position, toggle switch. Toggle to “ON” to illuminate strobe light. Toggle to “OFF” to extinguish strobe light.
Front Windshield Wiper Control:

On models with swivel seat only, the front Windshield Wiper Control is located in the Dash Panel. Otherwise, it is
located in the Auxiliary Control Panel. Rotary switch. Controls the front windshield wiper. Turn clockwise to
energize and increase the speed of the wiper motor. Turn counter-clockwise to decrease speed and de-energize
the wiper motor. Press rotary switch to energize washer spray. Release to de-energize washer spray.
Rear Windshield Wiper Control:

On models with swivel seat only. Rotary switch. Controls the rear windshield wiper. Turn clockwise to energize
and increase the speed of the wiper motor. Turn counter-clockwise to decrease speed and de-energize the wiper
motor. Press rotary switch to energize washer spray. Release to de-energize washer spray.
Audible Alarm:
The audible alarm will sound automatically as an alarm signal when the following conditions exist:
 Hydraulic oil temperature exceeds 180°F.
 Oil level in hydraulic tank below minimum level.
 Engine oil pressure below is below 15 psi.
 Engine coolant temperature exceeds 235°F.
 Engine coolant level below minimum level.
Pick Rotate Enabled Indicator Light:

For models with standard seat, indicator light is at the Auxiliary Control Panel. For models with the swivel seat,
the indicator light is located at the Dash Panel. Orange lamp, which comes “on” when Pick Rotate trigger or
pushbutton is engaged at either the LH or RH Control Handle. This is referred to as the Pick Rotate Mode.
3-23
OPERATION
Water Spray Switch:
For models with standard seat, switch is located in the Auxiliary Control Panel. For models with swivel seat,
switch is in the dash panel. 2-Position, toggle switch. Toggle selector to “ON” to energize the water spray
system. Toggle selector to “OFF” to de-energize the water spray system.
Water Spray Indicator Light:

For models with standard seat, indicator light is located in the Auxiliary Control Panel. For models with swivel
seat, indicator light is in the dash panel. Yellow lamp, which comes “on” when the water spray system is
energized and ready for use.
Circuit Breaker 1:
10 amp circuit breaker. Press to reset. Travel Control Circuit: Transmission Solenoid 1, Transmission Solenoid
2, Transmission Solenoid 3, Park Brake Test Button and Solenoid, Horn, Pick Rotate/Steering, Reverse Solenoid,
Backup Horn, Neutral Relay, Forward Solenoid.
Circuit Breaker 3:
20 amp circuit breaker. Press to reset. Starter motor solenoid circuit: Starter Motor, Dump Solenoid.
Circuit Breaker 2:
10 amp circuit breaker. Press to reset. HVAC circuit: HVAC Controller, HVAC Unit, Binary Switch and AC
Compressor.
Circuit Breaker 4:
10 amp circuit breaker. Press to reset. Micrologic Power Source, R.H. Control Handle: Park Brake, Scale Brake,
Pick Rotate/Steering
Circuit Breaker 5:
10 amp circuit breaker. Press to reset. Hydraulic Oil Level Audible Alarm, Hydraulic Oil Low Level Lamp, Dirty
Air Filter Lamp/Switch, Engine Shutdown, Hydraulic Oil Clogged Filter Pressure Switch, Hydraulic Oil Clogged
Filter Switch (Return Line), Hydraulic Oil Mid-Level Switch, Hydraulic Oil Low-Level Switch.
Circuit Breaker 6:
20 amp circuit breaker. Press to reset. Brake Fail Lamp, Park Brake Relay (Set), Controller, Park Brake Lamp
(Set), Park Brake Relay (Reset), Park Brake (Release), Transmission Converter Temperature Meter,
Transmission Converter Temperature Sender, Fuel Meter, Fuel Level Sensor, Scale Brake, Axle Brake On Lamp,
Pick Rotate (Left), Pick Rotate (Right), Pick Rotate Enabled Indicator, Hydraulic Oil Filter Blocked Lamp, Lamp
Test, Air Filter Blocked Lamp, Hydraulic Oil High Temperature Lamp, Hydraulic Oil Temperature Switch.
Circuit Breaker 7:
20 amp circuit breaker. Press to reset. Starting Circuit: Ignition ON/OFF/START Switch, Park Brake, Neutral,
Ignition ON Relay, Throttle Position Signal, Throttle Return, Intermediate Speed Input.
Circuit Breaker 8:
20 amp circuit breaker. Press to reset. Accessory Circuit: Windshield Wiper Control Switch, Windshield Wiper
Motor, Windshield Washer Motor, Regeneration Pressure Switch and Solenoid.
Circuit Breaker 9:
20 amp circuit breaker. Press to reset. Front lighting circuit: Front Light Switch, Front Lights, Rear Running
Lights, Dome Light, Boom Light Relay.
Circuit Breaker 10:

20 amp circuit breaker. Press to reset. Boom, bar, rear lighting circuit: Rear Light Switch, Rear Lights, Cab Bar
Lights (LH)
3-24
OPERATION
Circuit Breaker 13:

60 amp circuit breaker. Press to reset. Circuit Breaker CB1, Circuit Breaker CB2, Circuit Breaker CB4, Circuit
Breaker CB5, Circuit Breaker CB6, Circuit Breaker CB8.
Circuit Breaker 14:

80 amp circuit breaker. Press to reset. Dump Solenoid.
Circuit Breaker 15:

20 amp circuit breaker. Press to reset. Boom Lights Switch, Boom Lights, Cab Bar Lights (RH).
3-25
OPERATION
Auxiliary Control Panel (Standard Seat)

Strobe Light HVAC Controller
Scale Lights Audible Alarm
Manual Transmission Rear Front Front Windshield Pick Rotate Enabled

Selector Switch Lights Lights Wiper Control Indicator Light
CB1 CB3 CB5 CB7 CB9 CB15 CB13
CB2 CB4 CB6 CB8 CB10
Water Spray Pump Location of controls and indicators

Indicator Light may vary slightly depending on
options selected. Standard machines
are shown.
Water Spray
Pump Switch
3-26
OPERATION
Auxiliary Control Panel (Swivel Seat)
CB13
Scale Lights
Strobe Light Hammer Hour Meter
Front
Lights
Audible Alarm
Rear
Lights
Park Brake/Reset
Aux Control Panel 712457 Manual Transmission

Selector Switch
CB9 CB10
CB8
CB2 CB6 CB11
CB1 CB7
Rear Windshield CB3 CB15 CB16
Wiper Control
Location of controls and indicators

may vary slightly depending on
CB5 options selected. Standard machines
are shown.
CB4
3-27
OPERATION
CONTROLS AND INDICATORS – LH AND RH CONTROL HANDLES
Left Hand (LH) and Right Hand (RH) Control Handles are mounted on the arm rests of the operator seat. They
are used to control:
 Directional selection and Steering
 Park brake and scale brake activation
 Boom positioning
 Tool or hammer rotation and actuation
 Push blade positioning
 Horn (All Vehicles except SV-11)
There is no need for the operator to switch from one set of controls to another when positioning the Scaler
between scaling operations. Each control consists of a lever actuated hydraulic pilot unit with electric control
switches mounted in the handle. The following paragraphs describe the various controls associated with each
control handle.
Left Hand (LH) Control Handle

The Left Hand Control Handle is a multi-function, 2-axis hydraulic pilot valve with multiple electric function
selection on the handle. Actuation of the hydraulic pilot valve controls the BOOM UP, BOOM DOWN, BOOM
EXTEND and BOOM RETRACT functions. PICK ROTATE (engage/disengage), HAMMER (if equipped), MOVE
FWD / NEUTRAL / MOVE REV, and HORN functions are controlled by the electrical switches.
BOOM UP - Pull the LH control handle back to raise the boom.

BOOM DOWN - Push the LH control handle forward to lower the boom.
On SV-11 Vehicles, Boom Extend is enabled unless Boom Swing mode is engaged.
BOOM EXTEND - Move the LH control handle left to extend the boom.
BOOM RETRACT - Move the LH control handle right to retract the boom.
SWING LEFT (SV-11 Vehicles Only) - Move the LH control handle left to swing the boom to the left.
SWING RIGHT (SV-11 Vehicles Only) - Move the LH control handle right to swing the boom to the right.
With engine running and the travel direction selector switch is set in NEUTRAL, the brakes are
released and the vehicle is free to roll unless the PARK BRAKE is set, the SCALE BRAKE is engaged or the
BRAKE PEDAL is manually actuated.
Shift Travel Direction Switch only when the vehicle is at a complete stop. On SV-11 Vehicles only,
the Tram Mode Indicator light on the dash panel will illuminate when the boom is within 10 degrees either side of
facing straight forward and tramming is allowed. If the boom is swung more than 10 degrees either side of
straight ahead, the Tram Mode indicator light will go off and tramming will not be permitted.
TRAVEL DIRECTION SWITCH (MOVE FWD / NEUTRAL / MOVE REV): 3-Position rocker-type toggle switch.
Used to select neutral or the direction of machine travel. Select MOVE FWD to tram in the forward direction.
Select NEUTRAL to shift the transmission into neutral. Select MOVE REV to tram in the reverse direction.
3-28
OPERATION
PICK ROTATE: Pushbutton. Press to enable pick rotate mode. Press again to disable pick rotate mode. When
enabled, the PICK ROTATE ENABLED indicator light on the auxiliary control panel is illuminated. In this mode
(pick rotate enabled), the RIGHT HAND (RH) CONTROL HANDLE is used for tool or hammer rotation. When
pick rotate is not enabled, the vehicle is in “Steering Mode” and can be articulated left or right using the RIGHT
HAND (RH) CONTROL HANDLE.
The Tram Mode Indicator light on the dash panel will illuminate when the boom is within 10 degrees
either side of facing straight forward and tramming is allowed. If the boom is swung more than 10 degrees either
side of straight ahead, the Tram Mode indicator light will go off and tramming will not be permitted.
BOOM SWING (SV-11 Vehicles Only): Pushbutton. Press to enable boom swing mode. Press again to disable
boom swing mode. When enabled, the BOOM SWING ENABLED indicator light on the dash panel is illuminated.
In this mode (boom swing enabled), the LEFT HAND (LH) CONTROL HANDLE is used to swing the boom. When
boom swing is not enabled, the vehicle is in “Boom Extend Mode” and the boom can be extended or retracted
using the LEFT HAND (LH) CONTROL HANDLE.
HAMMER AND WATER SPRAY: Trigger switch. Squeeze the trigger on the LH control handle to actuate the
hammer. Trigger is spring return to STOP. Water spray is actuated whenever the hammer is actuated.
HORN (All Vehicles except SV-11): Momentary pushbutton. Press to activate horn. Horn will sound as long as
pushbutton is pressed. Release pushbutton to deactivate horn.
3-29
OPERATION
A
D E
B
A) MOVE FWD
C B) NEUTRAL
C) MOVE REV
F D) PICK ROTATE
E) HORN (All Vehicles Except SV-11)
BOOM SWING (SV-11 Vehicles)
F) HAMMER (OPTIONAL)
BOOM DOWN
BOOM BOOM
EXTEND RETRACT
SV-11 ONLY SWING LEFT SWING RIGHT
BOOM UP
LH CONTROL HANDLE
3-30
OPERATION
Right Hand (RH) Control Handle

The Right Hand Control Handle is a multi-function, 2-axis hydraulic pilot valve with multiple electric function
selection on the handle. Actuation of the hydraulic pilot valve controls the PICK FWD, PICK REV, STEER
LEFT/TOOL ROTATE LEFT (CCW) and STEER RIGHT/TOOL ROTATE RIGHT (CW) functions. SCALE BRAKE
(engage/disengage), PARK BRAKE (engage/disengage), and PICK ROTATE (engage/disengage) functions are
controlled by the electrical switches.
PICK FWD - Push the RH control handle forward to actuate the pick forward.
PICK REV - Pull the RH control handle back to actuate the pick in reverse.
The steering is enabled unless Pick Rotate mode is engaged.
STEER LEFT - Move the RH control handle left to articulate left.

ROTATE CCW - Move the RH control handle left to rotate tool counter-clockwise (CCW).
STEER RIGHT - Move the RH control handle right to articulate right.
ROTATE CW - Move the RH control handle right to rotate tool clockwise (CW).
With engine running and the travel direction selector switch is set in NEUTRAL, the brakes are
released and the vehicle is free to roll unless the PARK BRAKE is set, the SCALE BRAKE is engaged or the
BRAKE PEDAL is manually actuated.
SCALE BRAKE: Pushbutton toggle switch. Press and release to engage the scale brake mode (scale brake
mode will remain engaged). Scale Brake On lamp will come “on”. Press and release again to disengage the
scale brake mode. Scale Brake On lamp will go “off”. Scale brake mode Engaged will automatically set the park
brake, engage the wheel brakes, lock the oscillation cylinders, shifts transmission to “neutral” and set engine
speed at 2400 RPM. Park brake indicator light will come “on”. Scale brake indicator will come “on”. If while in
Scale Brake Mode, “Steering Mode” is selected (as opposed to PICK ROTATE Mode; see LH Control Handle),
and the RH Control Handle is used to articulate or steer the machine, the wheel brakes and the oscillation
cylinder lock will temporarily release, permitting machine movement/articulation in order to position the pick or
hammer. As soon as the RH Control Handle is returned to the center position, the wheel brakes and oscillation
cylinders will lock. The transmission park brake stays engaged at all times.
PARK BRAKE: Pushbutton toggle switch. Press and release to SET the park brake (park brake will remain set).
Park Brake/Reset cap light on the main gage/relay panel will come “on”. Press and release again to release the
park brake. Park Brake/Reset cap light will go “off”. The PARK BRAKE pushbutton duplicates the operation of
the Park Brake/Reset (push/pull) selector switch located on the main gauge/relay panel with the exception that if
the push/pull selector is pushed “in” (maintained park brake SET position) the brake cannot be released or reset
using the momentary pushbutton on the control handle. Park brake indicator light will stay “on”. When resetting
the brake, the vehicle will be free to roll as soon as the brake is reset. Always maintain pressure on the wheel
brake pedal when releasing and/or resetting the park Brake.
PICK ROTATE: Trigger switch. Squeeze the trigger on the RH control handle to enable pick rotate mode.
Release to disable pick rotate mode. When enabled, the PICK ROTATE ENABLED indicator light on the auxiliary
control panel is illuminated. In this mode (pick rotate enabled), the RIGHT HAND (RH) CONTROL HANDLE is
used for tool rotation. When pick rotate is not enabled, the vehicle is in “Steering Mode” and can be articulated
left or right using the RIGHT HAND (RH) CONTROL HANDLE.
3-31
OPERATION
A
C D
A) BLADE UP
B) BLADE DOWN
C) SCALE BRAKE PICK FWD
D) PARK BRAKE
E) PICK ROTATE
STEER LEFT STEER RIGHT
ROTATE CCW ROTATE CW
PICK REV
RH CONTROL HANDLE
3-32
OPERATION
Accelerator Pedal:
The accelerator pedal is the right pedal on the floor of the operator cab. Pressing down on the accelerator pedal
will accelerate the engine and letting off of the accelerator pedal will decelerate the engine. The pedal is spring
return to zero throttle.
Brake Pedal
(Service Brake)
Accelerator Pedal
Location of pedals shown are

for standard seat.
3-33
OPERATION
Brake Pedal (Service Brake):

The brake pedal (or service brake) is the left pedal on the floor of the operator cab. When pressed, it controls a
valve that causes oil to flow to the disc brake assemblies inside of the front and rear drive axles. Press the foot
pedal to apply hydraulic pressure to the brakes causing them to engage or set. Let off of the foot pedal to relieve
pressure and release the brakes. Braking is proportional to the force applied to the brake pedal.
Accelerator Pedal
(Brake Pedal at Left)
Location of pedals shown are

for swivel seat.
Dump Bypass Switch:

2-Position toggle switch, located in the J-Box-1 Assembly in the engine compartment. In cold weather, toggle
switch to the “ON” position to destroke the RH hydraulic pump. This lightens the load on the engine during warm-
up, allowing the engine and hydraulic fluid to gradually warm. When in the ON position, various machine
hydraulic functions are inoperative. Turn to OFF position after engine warm-up, before further machine operation.
It should be noted that for vehicles with John Deere axles, which are hydraulically applied, when the
Dump Bypass Switch is in the ON position, the axle brakes will not function. With the John Deere axle brakes
non-functional, there are three different machine braking configurations that supply spring-applied braking in the
absence of hydraulic power. Spring-applied braking may be supplied by the spring-applied transmission brake.
Some machines, in addition to the spring-applied transmission brake, have an additional spring-applied driveline
brake. A third braking configuration includes a hydraulically applied transmission brake (not operable in the
absence of hydraulic power), coupled with the spring-applied driveline brake. When using this switch, block
vehicle tires as needed to prevent unintended vehicle movement.
3-34
OPERATION
Dump Bypass Switch
J-Box-1 Assembly in the

Engine Compartment
Main Disconnect
2–Position, toggle selector switch. Located inside of the battery box, on engine end frame. Used to disconnect
the batteries from the rest of the vehicle electrical system. Turn selector to ON to connect the batteries to the
system. Turn selector to OFF to disconnect the batteries from the system.
Circuit Breaker
20 amp circuit breaker. Press to reset.
Fuse
Inline 150 AMP cartridge fuse (F1) located inside the battery box.
3-35
OPERATION
Disconnect Switch Circuit Breaker Fuse (F1)
All Models Except SV-11

Below right rear cab entry.
Disconnect Switch SV-11 Models Circuit Breaker
3-36
OPERATION
Fire Suppression System:

The fire suppression system may be fully manual, requiring manual activation, or provide for a combination of
manual and automatic activation modes. All systems provide for manual activation from either of two locations.
One actuator is dash mounted inside the cab, to the right side of the main dash panel. A second remote actuator
is located on the left side of the engine end frame chassis. Some suppression systems are equipped with a
Checkfire® automatic activation system, which through the use of detection wires, automatically activates the
suppression system if a fire is detected. Refer to the Vendor Manuals and Warranty document for additional
operating instruction found in ANSUL Vendor Manuals.
Activation of the fire suppression system will automatically shut off engine and set the parking
brake. Exit vehicle immediately.
To activate the fire suppression system from either manual actuator location:
a. Shut OFF vehicle power.
b. Pull the ring pin.
c. Strike the actuator button.
If activated, the system must be serviced and recharged before it can be used again.
Actuator Button Ring Pin
Located to the Right of

the Dash Panel
Manual Activation in Cab
3-37
OPERATION
Manual Actuator Button Ring Pin

the Dash Panel
Checkfire SC-N Automatic

Detection and Control System.
(For additional information, refer to
ANSUL Vendor Manuals in.the
Vendor Manuals and Warranty
document.)
Manual Activation in Cab with

Accompanying Checkfire SC-N
Automatic Detection and Control
System.
3-38
OPERATION

the Dash Panel
Checkfire 210 Automatic Detection

and Control System Manual Actuator
and Display Module. (For additional
information, refer to ANSUL Vendor
Manuals in.the Vendor Manuals and
Warranty document.)
3-39
OPERATION
Actuator Button Ring Pin
Remote Actuator Located on the Left Side of the

Engine End Frame Chassis
3-40
OPERATION
VEHICLE AND EQUIPMENT OPERATION
The following paragraphs describe how to operate the vehicle, test the brakes, operate in scale brake mode,
operate the boom, tool, and hammer, and emergency operation. Refer to controls and indicators section for
descriptions and illustrations of each control and indicator.
PRE-OPERATION CHECKLIST
OPERATOR: ______________ DATE: ______________________ HOUR METER: ____________________
BEFORE ENGINE START (Park Brake is set, Main Disconnect is OFF)
O.K. NOT EQUIPMENT PROBLEM
Perform walk-around vehicle inspection ...........................................

Inspect tires and lug nuts; check tire pressure ...................................
Inspect hydraulic hoses and connections for leaks ............................
Verify all grease points are full .........................................................
Check fuel level. Inspect fuel strainer & fuel filter ..........................
Check hydraulic oil level...................................................................
Check coolant level ...........................................................................
Check engine oil and air cleaner .......................................................
Check transmission fluid level ..........................................................
Check Kessler axle brake cooling oil level .......................................
Check hydraulic pumps for leaks ......................................................
Check hydraulic high pressure filter indicator ..................................
Check washer fluid level ...................................................................
Inspect electrical enclosures ..............................................................
Inspect pick insert and lock ...............................................................
Inspect water level and spray system ................................................
AFTER ENGINE START (see Vehicle Startup to start engine, let idle for 3-5 minutes)
O.K. NOT
Check hydraulic high pressure filter dirt indicator ............................

Check transmission filter ...................................................................
Check hydraulic system return line filter at gauge panel ..................
Check engine conditions (Dash Assembly) .......................................
Check converter temperature.............................................................
Perform park/service brake test (see Brake Test).............................
Verify operation of warning indicator lights (“on” 3 sec) .................
Verify operation of lights (front, rear, scale) .....................................
Verify operation of accessories (horn, wipers) ..................................
Check Kessler axle filter at gauge panel ...........................................
3-41
OPERATION
VEHICLE START-UP
Always sound the horn and make sure that the area around the vehicle, especially around
the articulation joint, is clear before starting the engine. Never start the engine without first knowing how
to shut it off.
a. Make sure of the following:
 BATTERY DISCONNECT SWITCH is in the “On” position.

 FUEL SUPPLY SHUT-OFF VALVE is in the “Open” position.
 CONTROL HANDLES or ACCELERATOR PEDAL is not actuated.
 PARK BRAKE/RESET SWITCH on gauge/relay panel is pushed “In” (Set position).
 TRAVEL DIRECTION SWITCH on left hand control handle is in the “Neutral” position.
b. Turn the ENGINE SWITCH to the “On” position. Wait for ENGINE READY INDICATOR to indicate that
the engine can be started.
c. In cold weather, the Dump Bypass Switch, located in the J-Box-1 Assembly in the engine compartment,
may be used to destroke the RH hydraulic pump, thereby lightening the load on the engine and hydraulic
system during warm up. Refer to the Controls and Indicators section for additional information.
d. When the ENGINE READY INDICATOR illuminates, turn ENGINE SWITCH to the momentary “Start”
position to crank the engine. If the engine fails to start within 20 seconds, release the switch and it will
spring return to the “On” position.
Do not actuate the starter for more than 20 seconds. If engine fails to start, wait two
minutes then try again.
e. When engine starts, immediately verify the following:
 All warning lights come “on” and go “off”.

 There is engine oil pressure. (at Powerview or Cantrak Engine Display on select vehicles.)
 The tachometer reads 750 RPM. (at Powerview or Cantrak Engine Display on select vehicles.)
 The Park Brake/Reset Switch is in “set” (full in) position.
 Brake accumulator pressure gauges (digital pressure displays on some models) read 2295-2500 psi
on vehicles with John Deere axles, 2295-2800 psi on vehicles with Kessler axles (except SV-11
vehicles), and 2295-2900 psi on SV-11 vehicles with Kessler axles.
 The Voltmeter reads + 24 to + 28 volts. (at Powerview or Cantrak Engine Display on select vehicles.)
 All remaining gauges read in the normal ranges.
 No “red light” indications on gauge panels.
f. If the Dump Bypass Switch was used, turn it to the OFF position before attempting to drive or operate the
Scaler. See Controls and Indicators Section for additional information.
3-42
OPERATION
DRIVING THE VEHICLE
The vehicle will travel in either forward or reverse. The same gear ratios are used in forward and reverse and the
transmission will provide equal speeds in each range selection; in either direction of travel. Direction of travel is
manually controlled by the TRAVEL DIRECTION SWITCH on the left hand control handle. Gear selection is
manually controlled by the MANUAL TRANSMISSION SELECTOR SWITCH on the auxiliary control panel.
Engine RPM is operator controlled in travel mode with an automotive-type ACCELERATOR PEDAL (RPM is
computer controlled automatically in scale brake mode). Dynamic (axle) braking is operator applied with an
automotive-type BRAKE PEDAL. Articulated steering, in travel mode, is hydraulically actuated and manually
controlled by the operator using the CONTROL HANDLES (steering control becomes boom swing control in scale
mode).
When operating the vehicle always remember the following:
 The engine must be at idle speed and the vehicle stopped before shifting the travel direction selector
switch.
 Always start out in first gear and shift into higher ranges as the vehicle accelerates and as conditions
permit.
 Never operate the vehicle on grades greater than 18° (31%).
 NEVER coast in “Neutral”.
 Use the transmission to decelerate the vehicle whenever possible.
 BEFORE proceeding onto a downhill grade, ALWAYS stop and manually select the lowest gear ratio (1).
 DO NOT down shift the transmission unless the vehicle is traveling at a speed suitable for the slower
range.
 NEVER shift the directional control switch to neutral or select the opposite direction of travel unless the
vehicle is completely stopped.
 DO NOT touch hand pump release valve or handle while operating.
 If the boom is swung (SV-11 Models Only) more than 10 degrees either side of straight ahead, the Tram
Mode indicator light will go off and tramming will not be permitted. To return to Tram Mode, swing the
boom to within 10 degrees of pointing straight ahead. The Tram Mode Indicator light on the dash panel
will illuminate and tramming will be allowed.
Never operate the vehicle in a direction perpendicular to (side slope) grades greater than 18°
(31%). Operating the vehicle on a side slope greater than 18° risks rolling over, which may cause serious
personal injury or death and serious machine damage.
3-43
OPERATION
DRIVING THE VEHICLE (CONTINUED)
1. Releasing the park brake (with engine running).
When activating the park brake (from gauge panel and/or control handle), the vehicle will stop
suddenly upon activation. ALWAYS wear your seat belt to avoid injury.
a. While applying the service brakes (pressing down on the BRAKE PEDAL), release the park brake by
doing one of the following:
Release from the PARK BRAKE/RESET SWITCH on the main gauge/relay panel; pull “out” on
mushroom cap to normally release parking brake. The red cap light will go “off”.
Or
Release from the control handle; press and release the PARK BRAKE pushbutton to release the park
brake. Park brake indicator light (park brake/reset switch) will go “off”.
b. (If Necessary) Reset the park brake by doing one of the following:
With the engine running, the transmission in neutral and while depressing the BRAKE PEDAL, reset the
PARK BRAKE/RESET SWITCH by pulling to “release position”, then pull again for “reset position” and
let go.
Or
With the engine running, the transmission in neutral and while depressing the BRAKE PEDAL, press the
PARK BRAKE pushbutton on the control handle to reset the park brake in the “released” mode.
c. Keep pressure on the BRAKE PEDAL until desired direction and gear are selected.
2. Using the TRAVEL DIRECTION SWITCH (FWD / NEUTRAL / REV).
With the engine running and the TRAVEL DIRECTION SWITCH in “Neutral”, the brakes are
released and the vehicle is free to roll unless the PARK BRAKE/RESET SWITCH is in the “set” position (light
“on”) or the brake pedal is manually depressed.
If the transmission should overheat (converter temperature exceeds 240°F), stop the vehicle, put
the transmission in “Neutral”, and run the engine at half-speed until the temperature drops to within normal
operating temperature range. If the temperature does not drop rapidly, trouble is indicated and the problem
should be corrected before resuming operation. Generally, operating in a gear not suitable for conditions causes
overheating.
a. Use the TRAVEL DIRECTION SWITCH to select the direction of machine travel. Select forward (MOVE
FWD), Neutral (NEUTRAL) or reverse (MOVE REV).
MOVE FWD – Engages the transmission to drive the vehicle in the forward direction.
NEUTRAL – Disengages the transmission.
3-44
OPERATION
MOVE REV – Engages the transmission to drive the vehicle in the reverse direction.
NEVER attempt to change the TRAVEL DIRECTION SWITCH while the vehicle is in motion. ONLY
select direction after the vehicle is at a complete stop.
3. Using the MANUAL TRANSMISSION SELECTOR SWITCH.
ALWAYS begin travel (from stop) in 1st gear; this applies to forward and reverse.
a. Use the MANUAL TRANSMISSION SELECTOR SWITCH to manually control the transmission gearshift
selection. Select (1), (2), (3) or (4) to engage and maintain operation in a selected gear. The same gear
ratios are used in forward and reverse providing equal speeds in each range selection.
1 – Lowest gear ratio; used for heavy loads and steep grades at low speed.
2 & 3 – Intermediate gear selections for varying loads and grades and also deceleration.
3 – Moderate loads and grades. Also selection used for brake test.
4 – Highest gear ratio for light loads and top speed on level surfaces.
4. Steering the Vehicle.
- NEVER allow anyone to stand in the pivot area near the articulation joint.
- Watch the complete length of the vehicle on both sides, particularly when operating in confined
areas.
- Depending upon direction of travel, extend the leading end, before making a sharp turn,
otherwise, the side of the vehicle may contact the wall or other obstruction.
- Steering is disabled when in pick rotate mode.
- Steering is active in scale brake mode with pick rotate disabled. Watch boom swing.
In scale mode steering is disabled and steering control becomes pick/hammer rotate control.
The vehicle has an articulated steering arrangement (pivots at the center between the front and rear
frames). It is recommended that the operator experiment and practice with this type of steering arrangement by
driving the vehicle in an open area prior to operating in a confined space.
a. Move the RH CONTROL HANDLE to the right to turn the machine to the right. The control handle will
spring return to the center if released. The angle of articulation will remain unchanged after the control
handle is centered.
3-45
OPERATION
b. Move the RH CONTROL HANDLE to the left to turn the machine to the left. The control handle will spring
return to the center if released. The angle of articulation will remain unchanged after the control handle is
centered.
5. Moving the Vehicle.
When the TRAVEL DIRECTION SWITCH is set in “Neutral” and the brakes are released, the
vehicle is free to roll even if the accelerator pedal is not pressed down.
The ACCELERATOR PEDAL electronically controls the fuel governor throttle shaft on the engine. Pressing down
on the accelerator pedal will accelerate the engine and move the vehicle in the desired direction of travel that was
selected. Releasing the accelerator pedal will allow the engine to return to idle and the vehicle will slow down.
DO NOT press down on the ACCELERATOR PEDAL while holding down the BRAKE PEDAL.
6. Swinging the Boom While Moving (SV-11 Vehicles Only).
If the boom is swung more than 10 degrees either side of straight ahead, the Tram Mode
indicator light will go off and tramming will not be permitted. To return to Tram Mode, swing the boom to
within 10 degrees of pointing straight ahead. The Tram Mode Indicator light on the dash panel will
illuminate and tramming will be allowed.
If it is necessary to swing the boom while moving the machine, enter Boom Swing mode at the Left Hand Joystick
and move the joystick left or right as required.
BRAKE TEST
Application of the park brake test button will release the service brakes. This may cause the
vehicle to roll freely and can cause serious injury or death. Prepare for vehicle movement prior to using the brake
test button. DO NOT initiate the brake test while bystanders are near.
DO NOT use the park brake test button while standing outside the operator’s compartment.
Never operate the vehicle if the service or park brakes do not operate properly.
The brake test electrically disables the mechanism that automatically applies the service brakes isolating the park
brake to test for operational integrity. The park brake should be tested prior to operation and again prior to shut
down. Test the park and service brakes for safe operation as follows:
1. Test the Park Brake.
a. “Set” the PARK BRAKE.
b. DO NOT actuate the service BRAKE PEDAL.
c. Manually shift the MANUAL TRANSMISSION SELECTOR SWITCH into 3rd gear.
d. Press and hold the BRAKE TEST pushbutton.
3-46
OPERATION
BRAKE TEST (CONTINUED)
e. Toggle TRAVEL DIRECTION SWITCH to FWD.
f. Slowly depress accelerator to full throttle. Vehicle must not move at full throttle.
g. Repeat operation with TRAVEL DIRECTION SWITCH in REV.
h. Refer to the MAINTENANCE section of this manual and inspect the park brake. Make sure that it is
physically actuating and that the park brake is working properly.
2. Test the Service Brakes.
a. Drive the vehicle forward slowly and apply the service BRAKE PEDAL.
b. Verify the vehicle comes to a full and immediate stop.
c. Repeat test in the opposite direction.
SCALE BRAKE MODE
Engaging the scale brake mode will set the park brake, engage the wheel brakes, lock the oscillation cylinders,
disable travel and automatically set engine speed. The PARK BRAKE/RESET SWITCH will illuminate “red”. The
SCALE BRAKE ON INDICATOR LIGHT will illuminate.
1. Place the TRAVEL DIRECTION SWITCH in “Neutral”.
2. Press and release the SCALE BRAKE pushbutton on the RH CONTROL HANDLE to engage the scale brake
mode (scale brake mode will remain engaged). The SCALE BRAKE ON INDICATOR LIGHT on the main
gauge/relay panel will come “on”.
3. Actuate the RH CONTROL HANDLE to automatically release the wheel brakes and oscillation cylinder lock.
The park brake will remain set and the PARK BRAKE/RESET SWITCH will remain illuminated. The machine
will now articulate in either direction. The vehicle will not be able to move forward or backward with the park
brake set, however the left and right wheels (front and back) will rotate in opposite directions to allow the
machine to articulate left or right to re-position the vehicle. Wheel brakes and oscillation cylinder lock will re-
engage automatically when control handle is returned to the center position.
4. Press and release the SCALE BRAKE pushbutton on the RH CONTROL HANDLE again to disengage the
scale brake mode. The SCALE BRAKE ON INDICATOR LIGHT on the main gauge/relay panel will go “off”.
VEHICLE STOPPING AND SHUTDOWN
1. Stop the vehicle.
a. Stop the vehicle by pressing and holding down the BRAKE PEDAL until the vehicle comes to a complete
stop. Continue holding down the BRAKE PEDAL.
b. Place the TRAVEL DIRECTION SWITCH in “Neutral”.
c. Push in the PARK BRAKE/RESET SWITCH or press and release the PARK BRAKE pushbutton to set
the park brake. Park brake indicator light (park brake/reset switch) will go “on”, indicating the park brake
is set.
d. Let up on the BRAKE PEDAL.
3-47
OPERATION
VEHICLE STOPPING AND SHUTDOWN (CONTINUED)
2. Run engine at low idle for approximately 3 minutes prior to shutting down. This allows internal temperatures
to reduce gradually.
3. Turn the ENGINE SWITCH to “Off”.
4. Turn the BATTERY DISCONNECT SWITCH to “Off”.
BOOM OPERATION
Scale brake mode must be engaged prior to boom operation. Moving the control handles to
operate the boom, without being in scale brake mode, may lead to injury or vehicle damage.
The steering is enabled unless Pick Rotate mode is engaged.
1. Boom up/down operation.
a. Refer to Scale Brake Mode paragraph and engage scale brake mode. This enables the control of boom
raising and lowering with the LH CONTROL HANDLE.
b. Pull the LH CONTROL HANDLE back to raise the boom.
c. Push the LH CONTROL HANDLE forward to lower the boom.
2. Boom extend/retract operation.
a. Refer to Scale Brake Mode paragraph and engage scale brake mode. This enables the control of boom
extending and retracting with the LH CONTROL HANDLE.
b. Move the LH CONTROL HANDLE left to extend the boom.
c. Move the LH CONTROL HANDLE right to retract the boom.
Boom Swing functionality is enabled only if Boom Swing mode is engaged.
3. Boom swing operation (SV-11 Vehicles Only).
a. Refer to Scale Brake Mode paragraph and engage scale brake mode. The boom is swung with the LH
CONTROL HANDLE.
b. Move the LH CONTROL HANDLE left to swing the boom to the left.
c. Move the LH CONTROL HANDLE right to swing the boom to the right.
3-48
OPERATION
TOOL OPERATION
Hammer operation is an option available on this vehicle and when used, it replaces the normal
pick operation. Tool rotate operation will rotate either the pick or the hammer. The water spray system, once
energized, will operate with the use of the hammer trigger switch.
1. Pick or Hammer rotate operation.
a. Press PICK ROTATE pushbutton on the LH CONTROL HANDLE or squeeze PICK ROTATE trigger on
the RH CONTROL HANDLE to enable Pick Rotate mode. Verify the PICK ROTATE ENABLED indicator
light on the auxiliary control panel is illuminated.
b. Move the RH CONTROL HANDLE left to rotate the tool or hammer counter-clockwise (CCW) or right to
rotate the tool or hammer clockwise (CW).
c. Press PICK ROTATE pushbutton on the LH CONTROL HANDLE again or release the PICK ROTATE
trigger on the RH CONTROL HANDLE to disable Pick Rotate mode. Verify the PICK ROTATE ENABLED
indicator light on the auxiliary control panel is no longer illuminated.
2. Pick forward and reverse operation.
a. Push the RH CONTROL HANDLE forward to actuate the pick forward. Release the control handle and it
will spring return to the neutral position.
b. Pull the RH CONTROL HANDLE back to actuate the pick in reverse. Release the control handle and it
will spring return to the neutral position.
3. Hammer operation.
a. Squeeze the HAMMER trigger on the LH CONTROL HANDLE to actuate the hammer and water spray.
b. Release the HAMMER trigger on the LH CONTROL HANDLE to stop the hammer and stop water spray.
EMERGENCY OPERATION
1. Towing the vehicle.

ANY AND ALL TOWING OF MOBILE EQUIPMENT SHOULD BE CONDUCTED IN ACCORDANCE WITH MSHA
30CFR56/57.14209.

Lake Shore Systems, Inc. does not recommend towing the Mine Scaler. However, if it becomes necessary to do
so, the following suggestions are offered to aid in conducting a safe towing operation. The following guidelines
are intended to be used only for towing a disabled vehicle.
FAILURE TO FOLLOW THESE SAFETY GUIDELINES
MAY RESULT IN INJURY OR DEATH TO PERSONNEL.

These guidelines apply ONLY to towing a disabled vehicle:
3-49
OPERATION
Most Scaler models have both hydraulically applied / spring released brakes (brake
automatically releases when hydraulic pressure is absent) and spring applied /
hydraulically released brakes (hydraulic pressure is required to release the brake).
When the brakes release automatically absent hydraulic pressure, or are released
manually through the application of hydraulic pressure, the vehicle is free to roll.
DO NOT release the parking brakes without first taking the following safety
precautions:
 Always use tow vehicles and tow bars, chains, or cables of sufficient load capacity to safely
move the Scaler.
 If the customer elects to tow using chains or cables, as opposed to a rigid bar, a second tow
vehicle is strongly encouraged to be utilized on the other end of the Scaler to stabilize it
during movement.
 If a rigid tow bar is used, the customer should securely install a towing lug or hitch to either
the front or the back end of the Scaler (depending on the desired direction of movement). The
lug or hitch should have a safety device to secure the tow bar to the lug / hitch and prevent
the tow bar from inadvertently being disconnected during the towing operation.
 Always block all four wheels of the vehicle with wheel chocks before releasing brakes.
 On the towing vehicle, block all four wheels, set the parking brake and shut off engine.
- Preparation:
If tow chains are used, attach chains from each tow vehicle to the main frame at the front and rear ends and
apply a slight tension to the chains. If a rigid tow bar is used, attach the tow bar from the tow vehicle to the
disabled vehicle and secure the hitch/lug to the tow bar with a safety device. Set the tow vehicles’ parking
brakes to prevent undesired movement. Ensure the boom is positioned within a safe zone as viewed from the
cab. If the disabled vehicle is articulated to any degree, straighten the vehicle and install the articulation lock (if
equipped).
- Understanding the brake system:
All scaler models have at least one (some have two) brake (e.g., axle, transmission, driveline) that is spring
applied / hydraulically released, which serves as a parking brake. This brake automatically applies should
hydraulic pressure be lost. Most models also have a hydraulically applied / spring released brake that
automatically releases if hydraulic pressure is lost.
For vehicles with John Deere axles, the axle brakes are hydraulically applied / spring released (does not require
manual release). Most models with John Deere axles have a transmission park brake that is spring applied /
hydraulically released (does require manual release). Some of these models also have a spring applied /
hydraulically released driveline brake (does require manual release). Some models with John Deere axles
have a transmission park brake that is hydraulically applied / spring released (does not require manual release),
coupled with a spring applied / hydraulically released driveline brake (does require manual release). For the
spring applied / hydraulically released park brake and the spring applied / hydraulically released driveline brake,
if hydraulic pressure in the system drops, spring assemblies will automatically set the brakes and the springs
will keep the brakes set until sufficient hydraulic pressure is available.
For vehicles with Kessler axles, the axle brakes are spring applied / hydraulically released (requires manual
release). Vehicles with Kessler axles may have a hydraulically applied / spring released (does not require
manual release) parking brake or a spring applied / hydraulically released (does require manual release)
parking brake. For the spring applied / hydraulically released axle and the spring applied / hydraulically
3-50
OPERATION
released park brake, if hydraulic pressure in the system drops, spring assemblies will automatically set the
brakes and the springs will keep the brakes set until sufficient hydraulic pressure is available.
- If the hydraulic system is fully operational:

Refer to the “Driving the Vehicle” section to verify the transmission is in neutral and release the park brake.
Tow at low (crawl) speed, not to exceed 5 mph. If possible, start the engine and run at idle while towing to
lubricate the transmission clutches. Once the disabled vehicle is in place, set the tow vehicle(s) parking brakes
and apply wheel chocks. Set the park brake and verify the transmission is in neutral.
- If hydraulic power is not available:
Verify the transmission is in neutral and release the park brake using the MANUAL BRAKE RELEASE HAND
PUMP. Refer to the following to release the park brake using the hand pump:
a. Make sure the PARK BRAKE/RESET SWITCH is in the “release position”.
b. Remove pump handle from storage mount and install on pump.
c. Perform manual overrides as follows (push and turn override knob counter-clockwise to actuate):
1. On vehicles with John Deere axles, the Park Brake Manual Override Solenoid Valve (SV17) must first
be manually actuated to direct pressure to the park brake (depending on machine model, the park
brake may be the transmission brake, the driveline brake, or both). This valve is mounted on the right
side rear or the engine end frame.
2. On vehicles with Kessler axles, the dump solenoid SV21 on the Brake Manifold on the engine end
frame needs to be manually actuated, to prevent dumping hand pump generated flow to tank.
On vehicles with Kessler axles and the spring applied / hydraulically released transmission park
brake, the Transmission Park Brake Solenoid Valve (SV3) must first be manually actuated to direct
pressure to the park brake, then the Axle Brake Solenoid Valve (SV17) must be manually actuated to
direct pressure to the axle brakes. These valves are mounted on the Brake Manifold on the engine
end frame.
On vehicles with Kessler axles and the hydraulically applied / spring released transmission park
brake, the Axle Brake Solenoid Valve (SV17) must be manually actuated to direct pressure to the
axle brakes. This valve is mounted on the Brake Manifold on the engine end frame.
d. Turn the RELEASE VALVE clockwise and pump the handle to build pressure until brake releases.
Tow at low (crawl) speed, not to exceed 5 mph. If possible, start the engine and run at idle while towing to
lubricate the transmission clutches. Once the disabled vehicle is in place, set the tow vehicle(s) parking brakes
and apply wheel chocks. Turn the RELEASE VALVE counter-clockwise to release pressure and set the brakes.
- If hydraulic system cannot be pressurized (severe leak):

For vehicles with John Deere axles, the drivelines can be disconnected allowing the vehicle to move freely. For
vehicles with Kessler axles, the axle brakes are also spring applied / hydraulically released and disconnecting
the driveline will not allow the vehicle to move freely. If there is a hydraulic system failure that will not allow use
of the hydraulic hand pump to build hydraulic pressure, troubleshooting is required to locate the failure and
correct it.
3-51
OPERATION
2. Operating the FIRE SUPPRESSION SYSTEM (from either actuator location).
Activation of the fire suppression system will automatically shut off engine and set the parking
brake. Exit vehicle immediately.
If activated, the fire suppression system must be serviced and recharged before it can be used
again.
a. Shut “Off” vehicle power.
b. Pull the RING PIN.
c. Strike the ACTUATOR button
3-52
MAINTENANCE
4. MAINTENANCE
This section of your Operation and Maintenance Manual provides basic service information for the Scaler. A
lubrication chart identifies machine lubrication points. Scheduled maintenance tasks are listed along with
accompanying instructions. The Adjustments and Alignments portion of this section contain tasks necessary for
effective operation of your Scaler.
Only authorized personnel (trained and certified) shall operate this machine. Always review the Safety section of
this manual prior to operating this machine.
Read and understand

manual and safety
information before
operating!
4-1
MAINTENANCE
SCHEDULED MAINTENANCE
The following table furnishes a complete listing of regularly scheduled maintenance to be performed on the
Scaler. Not all tasks apply to all machines. For example, tasks that discuss the pick tool would not apply to
Scalers equipped with the hydraulic hammer only. Some features discussed are optional. The first column of the
chart denotes the task performance interval. This listing is arranged by Periodicity and includes Pre-Shift/8 Hour
Intervals, First 40 Hour Service, 40 Hour Intervals, first 100 Hour Service, 250 Hour Intervals, 500 Hour Intervals,
1000 Hour Intervals, and 2000 and 5000 Hour Intervals. The second column contains a brief description of the
Task to be performed. The Criteria column contains detailed descriptive information, notes, and safety data to
perform the applicable task.
As noted below, the vehicle Diesel Engine, Transmission, and Drive Axles have specific manufacturer supplied
maintenance schedules. These manufacturers recommended maintenance schedules should be utilized to
ensure warranty validity.
Unless otherwise specifically directed all checks listed shall be performing while the Vehicle Engine is Off.
Maintenance Schedule
Periodicity Task Criteria
Pre-Shift/8 Visually inspect condition of Walk around entire vehicle; inspect top, side, underneath, front
Hours overall vehicle, correct and rear. This is to check for fluid leaks, broken lights, structure
situation or call for for stability, loose items needing to be removed, prior stowage of
maintenance assist as all equipment/components and any visually notable problems.
necessary
Pre-Shift/8 Inspect for Leaks at Hoses Walk around entire vehicle; inspect top, side, underneath, front
Hours and Fittings and rear. Specifically check hydraulic hoses and fittings for fluid
leaks, cracks, broken fittings or hoses, or any other signs of
appreciable wear to any hydraulic component.
Pre-Shift/8 Inspect Electrical Inspect enclosures for moisture and signs of corrosion. Inspect
Hours Enclosures terminals and connections for corrosion, discoloration, or signs of
(Junction Boxes, Control overheating. Clean accessible areas of electrical enclosures and
Consoles, etc.) replace any part that does not operate properly.
Pre-Shift/8 Inspect Pick Insert and Visually inspect for damage or wear. Replace as necessary.
Hours Lock
Pick
Lock
4-2
MAINTENANCE
Pre-Shift/8 Inspect parking brakes, On SV-18, SV-22, and SV-26 machines, inspect parking brake
Hours service if required. actuator and linkage for damage or wear. Inspect pivot points
(SV-18, SV-22, and SV-26 and make sure they are free to move.
Machines Only) On all Machines, inspect all electrical and hydraulic connections
related to the Park Brake and make sure all valves are operating
properly. If necessary, perform park brake adjustment.
Actuator
Linkage Cable
Pivot Points

SV-18, SV-22, and SV-26 Machines Only.
4-3
MAINTENANCE
Pre-Shift/8 Check Tire Pressure, Perform the following:
Hours Wheel Nuts
Do not over torque Wheel Nuts.
Check Wheel Nut torques for both front and rear wheels. Refer to
Scaler Parts Manual for fastener hardware size, thread pitch and
material grade. Refer to Scaler Parts Manual, Torque Tables in
the Introduction, and axle vendor service (John Deere or Kessler)
manual for torque and Loctite recommendations.
Do not inflate tires over 120 PSI.
Check Air Pressure in all tires. Fill Tires with Air as required.
Torque Wheel Nuts
Check Tire Pressure at valve stem
4-4
MAINTENANCE
Pre-Shift/8 Check water spray system Check water tank water level.
Hours (Optional) water tank fluid
level, service as required Add water as required.
Pre-Shift/8 Check windshield washer Check windshield washer fluid level.
Hours fluid level, service as
required Add Washer Fluid as required.
Water Tank Fill Cap
Water Level Sight Gauge
Windshield
Windshield Washer
Fluid Reservoir
4-5
MAINTENANCE
Pre-Shift/8 Check hydraulic oil level Check hydraulic tank fluid level.
Hours
Do not run vehicle if the hydraulic fluid is low, Failure to
comply will result in vehicle damage.
If Hydraulic Tank Fluid level is low, refer to suggested lubricants

for recommended fluid and fill tank.

includes Wiggins remote fill
connector with dust cap

Temperature Gauge

SV-18, SV-22, and SV-26 Machines Only.
See Next Page for SV-11 Machine.
4-6
MAINTENANCE

Temperature Gauge
Note: This Illustration is Applicable to SV-

11 Machine Only. See Previous Page for
SV-18, SV-22, and SV-26 Machines.
4-7
MAINTENANCE
Pre-Shift/8 Check fuel level, service as Check fuel level
Hours Required (see fuel gauge on gauge/relay panel inside cab)
Ensure the fuel tank is full. Excessive condensation may

occur inside fuel tank if vehicle is low on fuel. This can damage
the engine.
If Fuel Tank Fluid level is low, use recommended fuel and fill the
tank.
Fuel / Water Fill Cap &


18, SV-22, and SV-26 Machines Only.
Wiggins Remote Fill Option includes

Wiggins air vent and ground-level
Wiggins fuel fill connector
4-8
MAINTENANCE
Fill Cap &

Strainer
Fuel Tank

SV-11 Machine Only. See Previous
Page for SV-18, SV-22, and SV-26
Machines.
4-9
MAINTENANCE
Pre-Shift/8 Check hydraulic pumps for Check hydraulic pumps for leaks.
Hours leaks, service as required
If leaks are found, replace faulty seals.
Refill pump case with one of the suggested lubricants.
Hydraulic Pumps
Engine End Frame
4-10
MAINTENANCE
Pre-Shift/8 Check engine air cleaner;
Hours replace air cleaner filters as Do not run vehicle with a dirty air element. Dirty air can
required. The “Air Filter cause engine damage.
Blocked” indicator light at
the gauge panel will Check air cleaner filters.
illuminate when airflow
through the engine air If dirty, replace air cleaner filters
intake filter is restricted to (Primary – UV401162, Safety – UV401163).
the maximum
recommended limit.
Air Cleaner Filters Inside
4-11
MAINTENANCE
Pre-Shift/8 Check engine coolant fluid Check engine coolant fluid level.
Hours level, service as required
NOTE – Using the coolant sight check, ensure coolant level is
visible through the glass. Coolant is added to the vehicle radiator
at the coolant fill point.
Wait for the engine to completely cool before removing the

radiator fill cap at the coolant fill point. Pressurized steam will
escape if the cap is removed while the engine is hot. Burns can
result. Avoid prolonged contact with anti-freeze. Prolonged
contact can cause irritation to skin.
Fill radiator with suggested Coolant.
Coolant Fill Coolant Sight Check
4-12
MAINTENANCE
Pre-Shift/8 Check transmission fluid Use dipstick to check transmission fluid level.
Hours level, service as required
To add transmission fluid, refer to the transmission service
information provided in the manufacturers manual for fill location,
and add transmission fluid.
Pre-Shift/8 Inspect Transmission Filter Check mechanical dirt indicator. If necessary, replace
Hours Dirt Indicator transmission filter.
Transmission Fluid Level Dipstick
Mechanical Dirt Indicator
Transmission Filter
4-13
MAINTENANCE
Pre-Shift/8 Check hydraulic high Check the hydraulic high pressure filter dirt indicator.
Hours pressure filter dirt indicator,
replace filter element as
required. Do not run vehicle with a dirty filter. The Filter is bypassed
when the dirt alarm indicates a dirty condition. The Hydraulic
system can become contaminated, causing serious damage to
hydraulic components.
Replace Filter Element as required (UV402011). Note: At the

gauge panel, the red Hydraulic Oil Filter Blocked indicator lamp
comes “on” when oil flow though the high pressure (hydraulic) oil
filters or the dual element, return line (hydraulic) filter is restricted
to the point where changing the filter element is required.

4-14
MAINTENANCE
Pre-Shift/8 For vehicles equipped with
Hours Kessler axles, check the Do not run vehicle with a dirty filter element. Dirty oil can
“Axle Filter Blocked” cause hydraulic system damage.
indicator light at the gauge
panel. It will illuminate The filter head snout/post must be lubricated before
when flow through the axle spinning on a new filter to prevent thread damage.
brake circuit oil filter is
restricted to the point where If required, replace filter element, part number 706319.
changing the filter element
is required.
Electrical Service Indicator Sends

Signal to Gauge Panel when Filter
Service Required.
Kessler Axle Brake

Circuit Oil Filter.
Axle Filter Blocked Indicator

Light at the Gauge Panel
Filter Element
4-15
MAINTENANCE
Pre-Shift/8 For vehicles equipped with Check to ensure the oil level at the reservoir is between the MIN
Hours Kessler axles, check the oil and MAX fill indicator lines. If required, add oil in as specified in
level in the wet disk cooling the Recommended Fluids table.
housing lubricating oil
reservoir.
MIN and MAX Fill Indicator Lines Kessler Axle Wet Disk Cooling
Housing Lubricating Oil Reservoir.
4-16
MAINTENANCE
First 40 Hours Replace hydraulic high Replace the hydraulic high pressure filter element
pressure filter element (UV402011)
Do not run vehicle with a dirty filter. The Filter is

bypassed when the dirt alarm indicates a dirty condition. The
Hydraulic system can become contaminated, causing serious
damage to hydraulic components.
First 40 Hours Replace hydraulic system Replace the hydraulic system return line filter element
return line filter element (UV401172)
Do not run vehicle with a dirty filter. The Hydraulic

Dual Spin-On
High Pressure Return Line
Filters (2) Filters
4-17
MAINTENANCE
First 40 Hours Replace transmission filter Change the transmission filter element
element (709742)
Do not run the vehicle with a dirty Transmission Filter.

Serious damage to the transmission can occur.
Transmission Filter
4-18
MAINTENANCE
Lube Inner and Outer Boom Lubricate the inner and outer boom roller bearings.
Rollers
Inspect Inner and Outer With boom fully retracted, remove side wipers at front of boom
Boom Roller Wear And/Or and lower front roller cover. Inspect for boom roller damage or
Inner Boom Tube Wear excessive wear and/or inner boom tube wear indicating a need to
adjust the boom rollers. If necessary, perform roller adjustment.
Notes: During the first 40 hours of operation, some “run-in” wear
on the inner boom tube wear strips is considered normal. During
boom break-in period (first 500 hours), boom roller adjustments
are typically required every 40 hours.
Inspect and Lube Steering
Cylinder Pivot Joints
Inspect and Lube
Articulation Pivot
Inspect and Lube
Oscillation Lock Cylinder
Pivot Joints
Inspect and Lube Boom Lift
Cylinder Pins
Inspect and Lube Boom
Pivot Pin
Inspect and Lube Front
First 40 Hours Driveline Carrier Bearing
Inspect and Lube Boom
- AND - Extend Cylinder Pins
Inspect and Lube Rotary
40 Hr Interval Actuator
Inspect and Lube Tool Refer to lube chart for illustration of all lubrication points and
Extend Cylinder Base End grease fittings.
Pin
Inspect and Lube Tool Refer to fluid list for recommended grease or lubricant.
Extend Cylinder Rod End
Pin
Inspect and Lube Tool Pivot
Pin
Inspect and Lube Tool
Rotation Bearing
Inspect and Lube
Oscillation Bearing
Inspect and Lube Mid Drive
Shaft Slip Joint
Inspect and Lube Rear
Drive Shaft Slip Joint
Inspect and Lube Front
Drive Shaft U-Joint
Inspect and Lube Mid Drive
Shaft U-Joints
Inspect and Lube Rear
Drive Shaft U-Joints
4-19
MAINTENANCE
First 40 Hours Check tightness of boom The boom stop bolts should be torqued to 600 Ft lbs.
- AND - stop bolts.
40 Hr Interval
Boom Stop Boom Stop Bolts
Boom Stop Boom Stop Bolts
4-20
MAINTENANCE
First 100 For vehicles equipped with
Hours a hydraulic hammer, Do not operate the hammer with a dirty filter element. Dirty
change the hammer filter oil can cause hydraulic system damage.
assembly filter element.
The hammer element part number is 712198.
Hammer Filter
Assembly
Filter Element
4-21
MAINTENANCE
250 Hours Inspect Electrical Inspect enclosures for moisture and signs of corrosion. Inspect
Enclosures terminals and connections for corrosion, discoloration, or signs of
(Junction Boxes, Control overheating. Clean accessible areas of electrical enclosures and
Consoles, etc.) replace any part that does not operate properly.
250 Hours Inspect all pins and Refer to 40 Hour Service Interval for list and location of pins and
bushings bushings.
250 Hours Clean engine fuel strainer Clean engine fuel strainer.
(if equipped)
Clean Fuel Tank Fill Remove cap and strainer from fuel tank and clean. Coat Strainer
Strainer with clean Fuel and reinstall in tank.
Replace Fuel / Water

Separator Filter Element
Wiggins Remote Fill

Fuel / Water Fill Cap & Option includes
Wiggins air vent and
ground-level Wiggins
fuel fill connector

SV-18, SV-22, and SV-26 Machines
Only. See Next Page for SV-11
Machine.
4-22
MAINTENANCE
Fill Cap &

Strainer
Fuel Tank

4-23
MAINTENANCE
250 Hours Pressure Wash Radiator Pressure Wash the Radiator.
Be careful not to damage the radiator. Pressure wash from

a safe distance and wear appropriate eye protection.
Radiator
4-24
MAINTENANCE
250 Hours Inspect engine mounts Inspect engine mounts, retighten if necessary.
Engine Mounts
Engine Mounts
Caterpillar Engine
Engine Mounts
Cummins and MTU

Engines
Engine Mounts
4-25
MAINTENANCE
250 Hours Inspect Air Intake Tract Clean and Inspect air intake tract rubber boots for any cracks or
excessive wear. Replace any rubber boot that is cracked or
worn.
250 Hours Replace engine air cleaner

filters. Do not run vehicle with a dirty air element. Dirty air can
cause engine damage.
Replace air cleaner filters
Primary – UV401162 Safety – UV401163
Refer to Pre-Shift/8 Hours Service Interval for illustration.
250 Hours Clean Water Spray System Remove the water filter housing by loosening the hex bolt on
(Option) water filter top. Remove the stainless steel filter element and flush clean.
element. When reinstalling the element, ensure the rubber head gasket is
properly seated.
Hex Bolt
Water Filter Housing
4-26
MAINTENANCE
250 Hours Inspect and clean batteries Inspect and clean batteries.
Ensure the Battery Disconnect Switch is in the OFF

position prior to performing the following procedures!
Place Battery Disconnect Switch in the OFF position.
Inspect battery terminals for corrosion and wipe clean. If

necessary, tighten battery connections.
Place the Battery Disconnect Switch in the ON position.
Batteries Battery Disconnect Switch
Engine End Frame
Note: Illustration is Typical only. Some machines may vary slightly.
4-27
MAINTENANCE
250 Hours For vehicles equipped with
a hydraulic hammer, Do not operate the hammer with a dirty filter element. Dirty
change the hammer filter oil can cause hydraulic system damage.
assembly filter element.
The hammer element part number is 712198.
Hammer Filter
Assembly
Filter Element
4-28
MAINTENANCE
500 Hours Replace hydraulic high Replace the hydraulic high pressure filter element
pressure filter element (UV402011)
Do not run vehicle with a dirty filter. The Filter is bypassed

when the dirt alarm indicates a dirty condition. The Hydraulic

4-29
MAINTENANCE
500 Hours Replace hydraulic system Replace the hydraulic system return line filter element
return line filter element (UV401172)
Do not run vehicle with a dirty filter. The Hydraulic system

can become contaminated, causing serious damage to hydraulic
components.
Dual Spin-On
High Pressure Return Line
Filters (2) Filters
4-30
MAINTENANCE
500 Hours Inspect hydraulic oil tank Inspect the hydraulic oil tank breather cap/filter. If necessary,
breather cap/filter, replace if replace filter (UV402797).
necessary.
Do not run vehicle with a dirty filter. The Hydraulic system
can become contaminated, causing serious damage to hydraulic
components.
Wiggins Remote Fill

Option includes Wiggins
remote fill connector with
dust cap

Temperature Gauge
Hydraulic Oil Fill

Breather Cap/Filter

18, SV-22, and SV-26 Machines Only.
4-31
MAINTENANCE

Hydraulic Oil Breather
Temperature Gauge
Cap/Filter

4-32
MAINTENANCE
500 Hours Inspect engine mounts Inspect engine mounts, retighten if necessary.
Engine Mounts
Engine Mounts
Caterpillar Engine
Engine Mounts
Cummins and MTU

Engines
Engine Mounts
4-33
MAINTENANCE
500 Hours Replace transmission filter Change the transmission filter element
element (709742)
Do not run the vehicle with a dirty Transmission Filter.

Serious damage to the transmission can occur.
Transmission Filter
4-34
MAINTENANCE
1000 Hours Drain/Clean/Refill Hydraulic Drain/Clean/Refill Hydraulic Tank
Tank
Drain oil from hydraulic tank.
Clean the tank and inspect for any signs of corrosion that could
contaminate the hydraulic oil.
Refill with appropriate fluid.
1000 Hours Inspect water spray system Inspect water spray system.
(Option)
Inspect all hoses/tubing for cracks.
Inspect all connections.
Check nozzles for proper spray direction.
Ensure water tank is free of any cracks or corrosion.
4-35
MAINTENANCE
1000 Hours Inspect fire suppression Inspect fire suppression system.
system
Inspect all hoses/tubing for cracks.
Inspect all connections.
Check nozzles for proper spray direction.
Ensure all Tanks, Cartridges and Extinguishers are fully charged
30 LB TANK NOZZLE #3
NOZZLE #5
NOZZLE #6
NOZZLE #4
NOZZLE #2
NOZZLE #1
4-36
MAINTENANCE
NOZZLE #6
NOZZLE #5
NOZZLE #4
NOZZLE #2
DISTRIBUTION
TEE
NOZZLE #3
OUTSIDE
MANUAL
ACTUATOR
NOZZLE #1
CAB CHECKFIRE
30 LB TANK MANUAL
CHECK VALVE W/CARTRIDGE SYSTEM
ACTUATOR MONITOR
arrow points
toward actuator
4-37
MAINTENANCE
2000 and Clean and Flush Radiator Refer to Engine OEM Documents.
5000 Hours
Pressure Wash the Radiator.
Be careful not to damage the radiator. Pressure wash from

a safe distance and wear appropriate eye protection.
2000 and Adjust Parking Brake See Adjust Park Brake (Applies to machines with John Deere
5000 Hours axles, and SV-18 and SV-22 machines with Kessler axles. This
Task is not applicable to SV-11 machines.
Radiator
4-38
MAINTENANCE
ADJUSTMENTS AND ALIGNMENTS
CHECK SYSTEM HYDRAULIC PRESSURE
Two people are required to check the system hydraulic pressure. Station one person in the cab to control the
machine operation. Station the other at the test port bulkhead to observe the pressure gauge and to make
pressure adjustments. A test port hose assembly (401846) is supplied with the machine for this procedure. A
5000 PSI pressure gauge, not supplied, is also required. To check/set the system hydraulic pressure, refer to the
following:
The test port hose assembly with 5000 PSI gauge attached may be safely installed or removed
from the test port fitting with the hydraulic system fully pressurized. However, the 5000 PSI
gauge should only be installed or removed from the test port hose with the hydraulic system
depressurized (engine off).
1. Attach the 5000 PSI pressure gauge to the test port hose assembly (401846).
2. Locate the test port bulkhead on the engine end of the machine frame. Unscrew the dust cap for the Pump A
test port, allowing it to hang by its chain.
3. Thread the test port hose assembly with attached gauge by hand onto the test fitting. No tools are required.
4. Start the vehicle in accordance with Operation procedures. Ensure the park and service brakes are engaged.
5. Turn on scale brake mode using the pushbutton on the right hand control handle. This will raise engine
speed to 2000 RPM and disable steering.
6. Retract the boom fully and use the control handle to hold the boom in a retracted position for the duration of
the pressure check.
7. Read the pressure gauge measurement. The correct system pressure is 2500 PSI (John Deere Axles) or
2900 PSI (Kessler Axles). If the pressure gauge reading is correct, proceed to step 8. If the pressure gauge
reading is not correct, proceed to step 8, then adjust the system pressure per the following procedure.
8. Turn off scale brake mode and shut down machine. Remove the test port hose assembly and gauge from the
test port fitting and install the dust cap.
ADJUST SYSTEM HYDRAULIC PRESSURE
Two people are required to adjust the system hydraulic pressure. Station one person in the cab to control the
machine operation. Station the other at the test port bulkhead to observe the pressure gauge and to make
pressure adjustments. A test port hose assembly (401846) is supplied with the machine for this procedure. To
adjust the system hydraulic pressure, refer to the following:
The test port hose assembly with 5000 PSI gauge attached may be safely installed or removed
from the test port fitting with the hydraulic system fully pressurized. However, the 5000 PSI
gauge should only be installed or removed from the test port hose with the hydraulic system
depressurized (engine off).
1. Attach the 5000 PSI pressure gauge to the test port hose assembly (401846).
4-39
MAINTENANCE
2. Locate the test port bulkhead on the engine end of the machine frame. Unscrew the dust cap for Pump A,
allowing it to hang by its chain.
3. Thread the test port hose assembly with attached gauge by hand onto the test fitting. No tools are required.
Use caution to avoid losing the sealing washer between the cap and the lock nut on the pump
control adjustments.
6. At the low pressure standby control (farthest from pump body) on Pump A, remove the cap. Loosen the lock
nut. Retain sealing washer between cap and locknut.
7. Turn the low pressure standby adjustment screw fully clockwise to force Pump A into high pressure stand-by
mode.
8. Read the pressure gauge measurement. The correct system pressure is 2500 PSI (John Deere Axles) or
2900 PSI (Kessler Axles). If the pressure gauge reads the correct pressure, proceed to step 9 to isolate and
adjust Pump B. If the pressure gauge reading is not correct, proceed to step 17 to adjust the system
pressure.
9. Turn the low pressure standby adjustment screw on Pump A counterclockwise until the gauge reads 350 PSI.
10. To ensure the 350 PSI gauge reading is accurate ensure that the load sense pressure is zero. To do so,
remove the hose assembly with attached gauge from the test fitting at the Pump A test port. Unscrew the
dust cap from the Load Sense A test port and thread the hose assembly with gauge onto the Load Sense A
test port. The gauge should read zero. If the load sense pressure is not zero, some machine function is
attempting to stroke the pump. Troubleshoot why a machine function is being activated without engagement
of the associated control.
11. Being careful not to move the adjustment point, tighten the lock nut at the pump pressure compensator
control, install the sealing washer, and reattach the cap.
12. Turn off the machine. Remove test hose assembly and gauge from Pump A test port to Pump B test port.
Use caution to avoid losing the sealing washer between the cap and the lock nut.
15. At the low pressure standby control (farthest from pump body) on Pump B, remove the cap. Loosen the lock
nut. Retain sealing washer between cap and locknut.
16. Turn the low pressure standby adjustment screw fully clockwise to force Pump B into high pressure stand-by
mode.
4-40
MAINTENANCE
Use caution to avoid losing the sealing washer between the cap and the lock nut.
17. At the pump pressure compensator control (closest to pump body) on Pump A or B as applicable, remove the
cap. Loosen the lock nut. Retain sealing washer between cap and locknut.
18. At the pump pressure compensator control adjustment point, use a metric allen key to increase or decrease
pump pressure. To increase pump pressure, turn the key clockwise. To decrease pump pressure turn the
key counterclockwise. Make adjustment as required until the pressure gauge reads 2500 PSI John Deere
Axles) or 2900 PSI (Kessler Axles).
19. Being careful not to move the adjustment point, tighten the lock nut at the pump pressure compensator
control, install the sealing washer, and reattach the cap.
20. Observe the pressure gauge one last time to confirm that the system pressure is correct.
21. Turn the low pressure standby adjustment screw counterclockwise until the gauge reads 350 PSI for Pump A
or 400 PSI for Pump B, as applicable.
22. Being careful not to move the adjustment point, tighten the lock nut at the pump control, install the sealing
washer, and reattach the cap.
23. Turn off scale brake mode and shut off machine.
24. Remove pressure gauge from test port hose assembly.
BRAKE B1 BRAKE B2 BRAKE B1
BRAKE MANIFOLD CYBERSTICK BRAKE MANIFOLD CYBERSTICK
PUMP -A- PUMP -B- PUMP -A- PUMP -B-
LOAD SENSE -A- LOAD SENSE -B- LOAD SENSE -A-
PRIORITY PRIORITY
LOAD SENSE PARK BRAKE LOAD SENSE PARK BRAKE
TEST PORT BULKHEAD TEST PORT BULKHEAD

(JOHN DEERE AXLES) (KESSLER AXLES)
4-41
MAINTENANCE
LOW PRESSURE STAND-BY

PORT X CONTROL
PUMP PRESSURE
COMPENSATOR CONTROL
CAP
LOCKNUT
PUMP A
Note: Rexroth Pumps Shown. Eaton Pumps Similar. For Eaton

Pumps, Locations Of Low Pressure Standby Control And Pump
Pressure Compensator Control Are Switched.
PORT X LOW PRESSURE STAND-BY

CONTROL
PUMP PRESSURE
COMPENSATOR CONTROL
CAP
LOCKNUT
PUMP B
4-42
MAINTENANCE
CHECK ACCUMULATOR PRE-CHARGE
A charge kit (UV404798), not provided with the machine, is required to test the accumulator pre-charge. The
charge kit is packed in a plastic carrying case and includes a charging and gauging unit and an 8-foot flexible
charging hose that connects to a commercially available nitrogen bottle. Two accumulators (400301) are installed
on machines with John Deere axles. One accumulator (708884) is installed on machines with Kessler axles. To
check the accumulator pre-charge, refer to the following.
1. In accordance with Operation procedures, set the brakes with the park brake/reset switch.
2. Shut vehicle off and tag OUT OF SERVICE.
Always drain the hydraulic fluid completely from the accumulator before performing any work.
3. On machines with John Deere axles, at the brake manifold located at the driver side engine end frame, pull
up on both Manual Accumulator Pressure Relief Valve pressure release knobs. This discharges all hydraulic
oil from the accumulator, allowing the accumulator piston to bottom against the hydraulic end cap. When
released, the Manual Accumulator Pressure Release will spring-return to the closed position.
On machines with Kessler axles, at the brake manifold located on the left side engine end frame, turn the
manual override on Accumulator Dump Valve SV21. This discharges all hydraulic oil from the accumulator.
The Accumulator Dump Valve S21 also automatically dumps accumulator pressure with the key off, so
manually releasing it is for safety just in case the valve sticks.
4. At the accumulator, remove the valve protection cap. Slightly loosen the socket head cap screw one-half turn
with a 6mm Allen wrench.
5. Close the release valve.
Use caution to avoid looping or twisting the hose.
6. Attach the charging and gauging unit connector to the accumulator gas valve by hand. Turn the unit into a
position that the gauge can be easily read.
7. Open the accumulator gas valve by turning the T-handle counterclockwise. When the needle of the gauge
begins to move, turn the T-handle one more complete turn counterclockwise. The gauge now shows the
charging pressure in the accumulator. The pressure should be 725 PSI (John Deere Axles) or 1958 PSI
(Kessler Axles). If the pressure is less than the correct pressure, see the following paragraph to charge the
accumulator.
8. To remove the charging assembly, turn the T-handle all the way clockwise then open the release valve to
relieve residual gas charge in the charging assembly.
9. Hold the gas valve from turning and loosen the connector. Remove the charging and gauging unit.
10. Tighten the socket head cap screw one-half turn with the Allen wrench and replace valve protection cap.
4-43
MAINTENANCE
CHARGE ACCUMULATOR
A charge kit (UV404798), not provided with the machine, is required to charge the accumulator. The charge kit is
packed in a plastic carrying case and includes a charging and gauging unit and an 8-foot flexible charging hose
that connects to a commercially available nitrogen bottle. Two accumulators (400301) are installed on machines
with John Deere axles. One accumulator (708884) is installed on machines with Kessler axles. To charge an
accumulator, refer to the following.
1. In accordance with Operation procedures, set the brakes with the park brake/reset switch.
2. Shut vehicle off and tag OUT OF SERVICE.
Always drain the hydraulic fluid completely from the accumulator before performing any work.
3. On machines with John Deere axles, at the brake manifold located at the driver side engine end frame, pull
up on both Manual Accumulator Pressure Relief Valve pressure release knobs. This discharges all hydraulic
oil from the accumulator, allowing the accumulator piston to bottom against the hydraulic end cap. When
released, the Manual Accumulator Pressure Release will spring-return to the closed position.
On machines with Kessler axles, at the brake manifold located on the left side engine end frame, turn the
manual override on Accumulator Dump Valve SV21. This discharges all hydraulic oil from the accumulator.
The Accumulator Dump Valve S21 also automatically dumps accumulator pressure with the key off, so
manually releasing it is for safety just in case the valve sticks.
4. Make sure the nitrogen supply is shut off at nitrogen bottle.
5. Connect the charging and gauging unit to the nitrogen bottle with the flexible hose at the nitrogen tank fitting.
6. At the accumulator, remove the valve protection cap. Slightly loosen the socket head cap screw one-half turn
with a 6mm Allen wrench.
7. Close the release valve on the charging and gauging unit.
Use caution to avoid looping or twisting the hose.
8. Attach the charging and gauging unit connector to the accumulator gas valve by hand. Turn the unit into a
position that the gauge can be easily read.
9. Turn the t-handle counterclockwise until the gauge starts showing the pressure in the accumulator (if any).
10. Open the nitrogen bottle shut-off valve slightly and SLOWLY fill the accumulator with gas. The first 20 to 25
PSI should take 2 to 3 minutes to fill. Shut off nitrogen flow when gauge indicates pre-charge pressure of 725
PSI (John Deere Axles) or 1958 PSI (Kessler Axles).
11. Let the pre-charge set for 10 to 15 minutes. This will allow the gas temperature to stabilize. Close the
nitrogen bottle valve. If the desired pre-charge is exceeded, then slowly open the release valve until the
pressure equals 725 PSI (John Deere Axles) or 1958 PSI (Kessler Axles).
12. To remove the charging assembly, turn the t-handle all the way clockwise then open the release valve to
relieve residual gas charge in the charging assembly.
13. Hold the gas valve from turning and loosen the connector. Remove the charging and gauging unit. Remove
the nitrogen bottle from charging and gauging assembly.
14. Tighten the socket head cap screw one-half turn with the Allen wrench and replace valve protection cap.
4-44
MAINTENANCE
PRESSURE
RELEASE
KNOBS
JOHN DEERE AXLES
KESSLER AXLES Brake Manifold
Accumulator Dump Valve SV21
4-45
MAINTENANCE
T-HANDLE
RELEASE VALVE
CHECK VALVE
CONNECTOR
PRESSURE GAUGE
CHARGING AND GAUGING UNIT
VALVE PROTECTION CAP

(WHERE APPLICABLE)
O-RING (WHERE APPLICABLE)
ALLEN WRENCH 6MM
SOCKET HEAD
CAP SCREW (M8)
SEAL RING
ACCUMULATOR GAS VALVE
4-46
MAINTENANCE
ADJUST BOOM ROLLERS
To adjust the boom rollers, refer to the following:
1. In accordance with Operation procedures, fully retract the boom and set the park brake.
2. Turn off the machine and tag OUT OF SERVICE.
3. Inspect and lubricate the roller assemblies as described in Service.
4. Visually inspect inner boom to bottom guide (inside of outer boom weldment) clearance. Clearance distance
should be 0.250”.
5. Loosen center hex head capscrew and remove the end two hex head capscrews attaching shims to bottom
roller, Roller #2 (400669). Retain washers. Re-shim Roller #2 (400669), as required to acquire the clearance
distance of 0.250”. Reinstall capscrews and washers and tighten to hold shims in place.
6. When Roller #2 is adjusted, remove shims in the same way from Roller #3 (402092) and Roller #4 (400669).
7. Measure distances between roller plates and the outer boom. Add 0.063” to measured dimension for total
shim thickness.
8. Install shims for Rollers #3 and #4. Check for 0.063” clearance between rollers and top of inner boom.
9. Remove shims from Roller #5 (402092) and Roller #7 (400669). Tighten two 1.00” mounting bolts in center of
roller mounting plate to 100 ft-lbs.
10. Measure distance between roller plates and the outer boom. Add 0.063” to measured dimension for total
shim thickness.
11. Install shims for Rollers #5 and #7. Check for 0.063” clearance between rollers and top of inner boom.
Check for 0.125” clearance between each roller and side of the inner boom.
12. Maintain equal shim stacks for Rollers #5 and #6 and Rollers #7 and #8 from one side to the other (i.e. plus or
minus 0.250”) to center inner to outer boom.
4-47
MAINTENANCE
ROLLER #8 ROLLER #6
SECTION A-A SECTION B-B
ROLLER #7 ROLLER #5
ROLLER #4 ROLLER #3
ROLLER #1
ROLLER #2
4-48
MAINTENANCE
ROLLER #4 SHIMS
ROLLER
PLATE
ROLLER #8
OUTER
BOOM
CENTER
CAPSCREW
INNER
BOOM
END
CAPSCREW
ROLLER #7
ROLLER #2
SECTION A-A
ROLLER #3
INNER
ROLLER #6
ROLLER #5 BOOM
OUTER
BOOM
ROLLER #1
SECTION B-B
4-49
MAINTENANCE
ADJUST PARK BRAKE.
NOTE: this procedure only applies to machines with John Deere axles, and SV-18 and SV-22 machines with
Kessler axles. The procedure is not applicable to SV-11 machines.
To adjust the park brake, refer to the following:
1. In accordance with Operation procedures, chock the wheels and start the machine (engine running).
2. At the lever end, between the clevis and the threaded end of the cable, remove the clevis pin and
hairpin.
3. Loosen the jam nut and turn the clevis to adjust the length.
4. Adjust the length until the cable it tight and there is no free play. Loosen several turns so there is a
little slack (so that the brakes do not drag in this position).
5. If necessary, adjustment can also be made between the threaded cable end and the brake canister
by loosening the locknut and turning the cable to adjust length.
6. When adjustment is complete, perform a Brake Test.
Clevis
Jam Nut
Lever End
Threaded Cable End

Brake Canister
Pins
4-50
MAINTENANCE
LUBE CHARTS
Boom Extend Cylinder Pins

2 Grease Fittings
Rotary Actuator Tool Extend Cylinder Base End Pin

1 Grease Fitting 1 Grease Fitting
4-51
MAINTENANCE
Tool Pivot Pin

1 Grease Fitting
Tool Rotation
Bearing
12 Grease Fittings
Tool Extend Cylinder Rod End Pin

1 Grease Fitting
Boom Lift Cylinder Pins

QuickLub®
Boom Pivot Pin

QuickLub®
4-52
MAINTENANCE

1 Grease Fitting Each End
Boom Pivot Pin

1 Grease Fitting
4-53
MAINTENANCE
Oscillation Bearing
1 Grease Fitting
4-54
MAINTENANCE
Front Driveline Carrier Bearing Front Drive Shaft U-Joint

1 Grease Fitting 1 Grease Fitting
4-55
MAINTENANCE
Mid Drive Shaft Slip Joint

1 Grease Fitting
Mid Drive Shaft U-Joints

2 Grease Fittings (1 each)
4-56
MAINTENANCE
Rear Drive Shaft Slip Joint

1 Grease Fitting
Rear Drive Shaft U-Joints

2 Grease Fittings (1 each)
4-57
MAINTENANCE
QuickLub® - Block E
Boom Pivot Pin
Front Driveline Carrier
Boom End Frame
QuickLub® - Block J
Push Blade Cylinders
(mounted just below Block C)
QuickLub® - Block C
Oscillation Lock Cylinder
Boom Lift Cylinder
QuickLub® - Block B
Steering Cylinder Articulation Pivot QuickLub® Block F QuickLub® Block A
NOTE: THIS PAGE IS APPLICABLE TO ALL MACHINES EXCEPT SV-11
4-58
MAINTENANCE
Boom End Frame
QuickLub® - Block D
Inner & Outer Boom Rollers
4-59
MAINTENANCE
Boom End Frame
Grease Reservoir
Grease Pump Grease Fitting (Fill Point)
4-60
MAINTENANCE
Lube Steering Cylinder Pivot Joints
NOTE: THIS PAGE IS APPLICABLE TO SV-11 MACHINES ONLY
4-61
MAINTENANCE
Articulation Pivot
4-62
MAINTENANCE
Oscillation lock Cylinder Pivot Joints
4-63
MAINTENANCE
Boom Pivot Pin
4-64
MAINTENANCE
Swing Cylinder Grease Fittings
One Fitting
at Rod End
Two Fittings
at Base End
4-65
MAINTENANCE
MAINTENANCE CHECKLISTS
TASK REMARKS
PRE-SHIFT / 8 HOUR INTERVAL
General Vehicle Inspection
Inspect Parking Brakes and Adjust if necessary
Service Engine, Transmission, and Drive Axles (see OEM)
Check for leaks at hoses and fittings
Inspect Electrical Enclosures
Check Tire Pressure, Wheel Lug Bolts
Inspect Pick Insert and Lock
Check Washer Fluid Level
Check Hydraulic Oil Level
Check Water Spray System Water Tank Level
Check Hydraulic Pumps for leaks
Check Fuel Level
Check Engine Air Cleaner
Check Engine Coolant Level
Check Transmission Fluid Level
Check Hydraulic High Pressure Filter Indicator
Check Transmission Filter Dirt Indicator
Verify all grease points are full (see Lube Charts)
Check Kessler Axle Filter at Gauge Panel
TASK REMARKS
FIRST 40 HOUR SERVICE
Replace Hydraulic High Pressure Filter Element
Replace Hydraulic System Return Line Filter
Replace Transmission Filter Element
Lubricate Steering Cylinder pivot joints
Lubricate Articulation pivot
Lubricate Oscillation Lock Cylinder Pivot Joints
Lubricate Boom Lift Cylinder Pins
Lubricate Inner/Outer Boom Roller Bearings
Lubricate Boom Pivot Pin
Lubricate Front Driveline Carrier Bearing
Inspect For Boom Roller Damage And/Or Excessive Boom Wear
4-66
MAINTENANCE
TASK REMARKS
FIRST 40 HOUR SERVICE - CONTINUED
Lubricate Tool Pivot Pin
Lubricate Tool Rotation Bearing
Lubricate Rotary Actuator
Lubricate Oscillation Bearing
Lubricate Mid Drive Shaft Slip Joint
Lubricate Rear Drive Shaft Slip Joint
Lubricate Front Drive Shaft U-Joint
Lubricate Mid Drive Shaft U-Joints
Lubricate Rear Drive Shaft U-Joints
Lubricate Boom Extend Cylinder Pins
Lubricate Tool Extend Cylinder Base End Pin
Lubricate Tool Extend Cylinder Rod End Pin
TASK REMARKS
40 HOUR INTERVAL
Lubricate Steering Cylinder pivot joints
Lubricate Articulation pivot
Lubricate Oscillation Lock Cylinder Pivot Joints
Lubricate Boom Lift Cylinder Pins
Lubricate Inner/Outer Boom Roller Bearings
Lubricate Boom Pivot Pin
Lubricate Front Driveline Carrier Bearing
Lubricate Boom Extend Cylinder Pins
Lubricate Tool Extend Cylinder Base End Pin
Lubricate Tool Extend Cylinder Rod End Pin
Lubricate Tool Pivot Pin
Lubricate Tool Rotation Bearing
Lubricate Rotary Actuator
Lubricate Oscillation Bearing
Lubricate Mid Drive Shaft Slip Joint
Lubricate Rear Drive Shaft Slip Joint
Lubricate Front Drive Shaft U-Joint
Lubricate Mid Drive Shaft U-Joints
Lubricate Rear Drive Shaft U-Joints
Inspect For Boom Roller Damage And/Or Excessive Boom Wear
4-67
MAINTENANCE
TASK REMARKS
FIRST 100 HOUR SERVICE
Change Hammer Filter Assembly Filter Element
TASK REMARKS
250 HOUR INTERVAL
Inspect Electrical Enclosures
Replace Fuel/Water Separator Filter Element
Clean Engine Fuel Strainer
Clean Fuel Tank Fill Strainer
Inspect Air Intake Tract
Inspect Engine Mounts
Replace Engine Air Filters
Inspect and Clean Batteries
Change Hammer (If Equipped) Filter Assembly Filter Element
Clean Water Spray System (Option) Water Filter Element
Pressure Wash Radiator
Inspect all pins and bushings (see 40 Hr Lube)
TASK REMARKS
500 HOUR INTERVAL
Replace Hydraulic High Pressure Filter Element
Replace Hydraulic System Return Line Filter
Inspect/Replace Hydraulic Oil Tank Breather Cap/Filter
Inspect Engine Mounts
Replace Transmission Filter Element
TASK REMARKS
1000 HOUR INTERVAL
Inspect Water Spray System (Option)
Inspect Fire Suppression System
Drain, Clean and Refill Hydraulic Tank
4-68
MAINTENANCE
TASK REMARKS
2000 & 5000 HOUR INTERVALS
Clean and Flush Radiator
Adjust Parking Brakes (All Machines Except SV-11)
4-69
MAINTENANCE
RECOMMENDED FLUIDS
The following table lists recommended fluids and capacities. For vendor supplied items, refer to the vendor
literature provided with this manual. When there is conflicting information, ALWAYS follow the vendor
instructions. Fluid capacities are listed for multiple engine and axle manufacturers. Use the values shown for
the engine and axle supplied with your machine. Material Safety Data Sheets (MSDS) for each fluid are
provided with your manual.
Part
Component Capacity Description
Number
Drive Axles, John Deere 20 Gallons UV400906 Donax TD "SHELL"
303 Fluid "AMOCO"
Tractor Fluid "ARCO"
Tractor Hyd Fluid "CITGO"
Power Transmission 11 "CONOCO"
Universal Tractor "GULF"
Mobilfluid 423 "MOBIL"
Altran J20A "SUN"
303 TDH Oil "TEXACO"
Torque Fluid 56 "EXXON"
Drive Axles, Kessler Center and Planetary See The drive axles have three different sections with
Ends: 60 lbs Description oil. 80W90 (API-GL5 or Mobil HD90) can be
used in the center and planetary ends, which are
Two Sections Containing connected internally. The wet disc brake piston
Brake: 20 Gallons UV400907 section is supplied with the machine hydraulic oil
UV400907. The wet disc cooling housing is
lubricated with API-GL4 or Mobil 424 and will
enter the cooling inlet and exit the cooling outlet
ports. This oil will be cycled through the axle
ends by the cooling pump. Refer to documents
WN85601 and WN85602 (provided with this
manual) for permissible oil recommendations.
Hydraulic Tank 85 Gallons UV400907 Tellus 68 "SHELL"
Amovis AW 68 "AMOCO"
Duro AW 315 "ARCO"
AW 68 "CITGO"
CPS 37 "CONOCO"
Harmony 68AW "GULF"
DTE 26 "MOBIL"
Sunfleet 300 "SUN"
RO 68 "TEXACO"
Nuto H68 "EXXON"
Engine (Coolant) Cummins 4.5 QSB Tier UV400910 Dex-Cool, Pre-Mix, 50/50 Blend “HAVOLINE”
III 160 HP: 8.5 Gallons The drive axle has various sections which use two
different oils. 80W90 should be used in the
Caterpillar C6.6, Tier III center and planetary ends, which are connected
156 HP: 8.5 Gallons internally and require 60 lbs of oil. The two
sections containing the brake use twenty gallons
MTU 904 Tier III 173 of Mobil 424. Refer to documents WN85601 and
HP: 8.5 Gallons WN85602 (provided with this manual) for
additional permissible oil recommendations.
Fuel Tank 75 Gallons 33272 ASTM Number 2D Diesel Fuel
4-70
MAINTENANCE
RECOMMENDED FLUIDS-Continued
Component Capacity Part Description

Number
Engine (Oil) Cummins 4.5 QSB Tier UV400903 SAE 15W-40 HD Oil (Valvoline® Premium
III 160 HP: 27 Quarts (26 Blue®)
Liters) Rotella "SHELL"
300 "AMOCO"
Caterpillar C6.6, Tier III Arcofleet Plus S-3 "ARCO"
156 HP: 4.75 gallons. C-500 "CITGO"
Diesel Oil S-3 Fleet "CONOCO"
MTU 904 Tier III 173 Super Duty "GULF"
HP: (16.9 Quarts) 16 Delvac 1300 "MOBIL"
Liters. Sunfleet S-3 "SUN"
Ursa Oil Super 3 "TEXACO"
XD-3 "EXXON"
Grease 8 Liter QuickLub® UV400908 Super Duty Lithium MDS "SHELL"

reservoir capacity (SV-18, Molylith "AMOCO"
SV-22, and SV-26 EP Moly "ARCO"
Machines) Extra Range "CITGO"
+ Super Lube M "CONOCO"
Grease fittings Gulfex Moly "GULF"
(as required) Mobilgrease Special "MOBIL"
Prestige Moly "SUN"
Marfok Multi-grease "TEXACO"
Beacon Q-2 "EXXON"
Transmission (Oil) 5 Gallons UV400904 Donax T-5 "SHELL"

C-3 "AMOCO"
C-3 "ARCO"
Torque Converter 250 "CITGO"
Hyd Transmission C-3 "CONOCO"
HT C-3 "GULF"
MULT-PURPOSE ATF "MOBIL"
C-3 Transmission "SUN"
Torque Fluid 47 "TEXACO"
Multi-Purpose C4 "MOBIL"
Windshield Washer 1 Gallon UV400911 General Purpose Washer Fluid
Air Conditioner 2.75 lbs 42642 R-134A-30
MACHINE FILTERS
To identify the proper replacement filters and elements for your machine, refer to the serial-number specific
parts manual. Located near the end of the parts manual is a complete list of machine replacement filters. Refer
to the parts manual table of contents, which identifies the part number of the serial-number specific filter list
(e.g., the filter list for machine with serial number 490065 would have part number “490065 Filter List”). The
filter list identifies the part numbers for all machine filters.
4-71
MAINTENANCE
CLEANING THE MACHINE

ALWAYS wear protective clothing, gloves, and eyewear when applying any de‐icing fluid.

ALWAYS wear protective clothing, gloves, and eyewear when pressure washing the machine.
DE-ICING AND ICE REMOVAL

Use a propylene glycol type de-icing fluid (SAE AMS 1428 and AMS 1424) to remove any ice accumulation or
build-up. If not already diluted, dilute with water using a 70% deicing fluid and 30% water mixture. If using a Type
I or Type III fluid, spray on hot (54° - 82° C or 130° - 180° F) at high pressure to remove ice or frost.
PRESSURE WASHING THE MACHINE

In order to use a pressure washer effectively it is important to choose the right attachments for each type of job.
Most pressure washers will come with a series of interchangeable nozzles and tips, each one designed for a
specific application. These interchangeable tips serve a dual purpose. On the one hand they help to lower the
pressure in the washer and draw the detergents and cleaners through the system. On the other hand, the
interchangeable nozzles help to provide a high pressure rinse at various angles. Be sure to locate the pressure
washer instruction manual and read it thoroughly before use.
Before actually pressure washing the machine, test the pressure washer first. Even if you have used a pressure
washer before, each device will have its own unique characteristics. You may not be used to the power of a large
pressure washer, and as a result the washer could get out of control if you are not ready. Start by making a few
test sprays in the general direction of the items you want to clean, while not actually touching those items.
Experiment with the nozzles until you have the spray you want. Only after you have completed this test should
you actually begin pressure washing the machine.
During the testing phase it is important to get a feel for the trigger on the pressure washer. While some pressure
washers are more sensitive than others, holding the trigger down on a pressure washer generally takes more
strength than pulling the trigger on a hose nozzle.
4-72
MAINTENANCE
LONG TERM STORAGE

When de‐commissioning the machine, disposal of machine fluids may be necessary. Always
follow applicable mine procedures and dispose of hazardous waste properly. Failure to comply
could result in serious injury or death to personnel.
1. Take a hydraulic oil sample to check the condition of the oil. Based on the sample taken, take
appropriate corrective action to ensure the system is clean and free of damaging oil properties.
2. Refer to the Maintenance section of this manual and pressure wash the entire machine, taking special
care to clean air to oil coolers and radiators.
3. Refer to the Maintenance section of this manual and grease all lubrication points with high quality, multi-
purpose grease.
4. Spray all exposed hydraulic cylinder rods liberally with a rust preventative.
5. Check with local oil supplier regarding recommended storage additives for hydraulic oil, engine coolant,
and diesel fuel.
6. Once machine is parked, cover all air filters, hydraulic tank breathers, and the exhaust pipe to prevent
foreign material from entering the systems.
7. Disconnect the batteries.
4-73
MAINTENANCE
TORQUE TABLES
Standard Steel Bolt Torque Specifications

(Standard Dry Torque in Foot-Pounds)
Bolt Size Coarse Threads/inch SAE SAE SAE SAE SAE SAE
Inches Gr 0,1,2 Gr 3 Gr 5 Gr 6 Gr 7 Gr 8
1/4 20 6 9 10 12.5 13 14
5/16 18 12 17 19 24 25 29
3/8 16 20 30 33 43 44 47
7/16 14 32 47 54 69 71 78
1/2 13 47 69 78 106 110 119
9/16 12 69 103 114 150 154 169
5/8 11 96 145 154 209 215 230
3/4 10 155 234 257 350 360 380
7/8 9 206 372 382 550 570 600
1 8 310 551 587 825 840 700
1-1/8 7 480 872 794 1304 1325 1430
1-1/4 7 375 1211 1105 1815 1825 1975
1-3/8 6 900 1624 1500 2434 2500 2650
1-1/2 6 1100 1943 1775 2913 3000 3200
1-5/8 5.5 1470 2660 2425 3985 4000 4400
1-3/4 5 1900 3463 3150 5189 5300 5650
1-7/8 5 2360 4695 4200 6980 7000 7600
2 4.5 2750 5427 4550 7491 7500 8200
Copyright  2004-2006 – EngineersHandbook.com
Metric Steel Bolt Torque Specifications

(Standard Dry Torque in Foot-Pounds)
Bolt Size Coarse Threads Pitch Standard Standard Standard Standard
Millimeters 5D 8G 10K 12K
6 mm 1.00 5 6 8 10
8 mm 1.00 10 16 22 27
10 mm 1.25 31 40 45 49
12 mm 1.25 34 54 70 86
14 mm 1.25 55 89 117 137
16 mm 2.00 83 132 175 208
18 mm 2.00 111 182 236 283
22 mm 2.50 182 284 394 464
24 mm 3.00 261 419 570 689
Copyright  2004-2006 – EngineersHandbook.com
4-74
TROUBLESHOOTING
5. TROUBLESHOOTING
Only authorized personnel (trained and certified) shall troubleshoot this machine. Always review the Safety
section of this manual prior to troubleshooting this machine.
Read and understand

manual and safety
information before
troubleshooting!
5-1
TROUBLESHOOTING
GENERAL TROUBLESHOOTING
The purpose of this section is to aid personnel in the location, isolation, and correction of problems that occur
during operation of the Scaler. The troubleshooting guide defines specific problems and solutions. Checking
common types of causes may eliminate the need for more specific troubleshooting. The following preliminary
checks should be made to expedite troubleshooting by eliminating common malfunctions.
a. Eliminate operator error as a cause. The Scaler has been designed with certain safety features
to protect personnel and equipment. If the equipment appears to be operating as designed, refer
to the Operation section of this manual.
b. Refer to the Maintenance section of this manual to ensure the equipment has been maintained
properly and all adjustments and alignments have been correctly performed.
c. Verify that mounting hardware, electrical connections, and hydraulic connections are not loose
due to mechanical vibration.
d. Visually inspect the machine to make sure there are no fluid leaks. Repair all leaks.
f. Refer to the Electrical Schematic and verify that all electrical wiring and connections are correct
and intact. Ensure that there are no bare or broken electrical wires.
g. An indicator or lamp that fails to illuminate may be a failed bulb.
h. Check the circuit breakers and fuses before conducting an extensive disassembly procedure.
i. Refer to the Hydraulic Schematic and verify that all hydraulic hoses and connections are correct
and intact. Ensure that there are no cracked, loose, or burst hydraulic hoses or fittings.
TROUBLESHOOTING GUIDE
The following table is provided as a guide for troubleshooting. Symptoms/malfunctions, probable cause, and
corrective actions are listed. For certain malfunctions, multiple probable causes can exist. Eliminate causes that
can be corrected simply before attempting an extensive repair. Personnel should not attempt an action that
exceeds their maintenance capability.
A review of the Functional Description of the Scaler that is provided in Section 6 of this manual, will also be
helpful in troubleshooting failures.
Component nomenclature and reference designators used in the Troubleshooting Guide are typical, and may vary
slightly depending on the vehicle. Refer to the electrical and hydraulic schematics provided with the Scaler.
Unless otherwise specified, before performing any corrective maintenance actions turn the main battery
disconnect switch to OFF and tag the equipment “OUT OF SERVICE.”
Tagging the electrical wires and/or hydraulic hoses prior to disconnecting will facilitate reconnection.
5-2
TROUBLESHOOTING
TROUBLESHOOTING GUIDE
Symptom/Malfunction Probable Cause Corrective Action
Engine will not start. Operator error. The machine is responding

correctly. Personnel shall study
Vehicle and Equipment
Operation procedures and
proceed.
Out of fuel Refer to Engine Service Manual

to re-pressurize fuel system. Add
fuel if necessary.
The engine switch (S2) is in the The engine start switch must be
OFF position or is faulty. in the ON START position to
start the machine. Refer to
Vehicle and Equipment
Operation procedures. Replace
switch if faulty.
The battery disconnect switch The battery disconnect switch

(S1) is in the OFF position or is must be in the ON position to
faulty. have power to the machine.
Refer to Vehicle and Equipment
switch if faulty.
The directional control switch The directional control switch

(S30) is not in NEUTRAL must be in the NEUTRAL
position or is faulty. position to start the machine.
switch if faulty.
The park brake/relay switch (S26) The park brake/relay switch must
on gauge/relay panel is not be pressed in to engage the park
pushed “In” (Set position), or is brake prior to machine start.
faulty. Refer to Vehicle and Equipment
switch if faulty.
Battery Fuse (F1) is blown (fuse Inspect/replace fuse.

located in the battery box).
Start circuit relay (K1) failure. Replace relay.
High hydraulic oil temperature Replace switch if faulty.

condition or temperature switch Hydraulic oil temperature must
(S22) failure. be less than 180° F for the
machine to start. Indicator light
(DS6) will illuminate when
hydraulic oil is 180° or higher.
Wait until oil has cooled
(indicator no longer illuminated)
and restart engine.
5-3
TROUBLESHOOTING
TROUBLESHOOTING GUIDE (CONTINUED)

Engine will not start - Continued. Circuit breaker (CB3 or CB7) is Ensure circuit breakers are On.
Off or failed. Replace if faulty.
Low hydraulic level switch

(S7-L) failure or low hydraulic Replace switch if faulty. Refer to
oil level. Fluids List for fluid specifications
and capacity to fill hydraulic oil.
Faulty starter motor (M1). Replace starter motor.
Plugged fuel filter. Refer to Engine Service Manual

for fuel filter replacement.
Broken alternator belt. Refer to Engine Parts Manual for

part number. Refer to Engine
Service Manual for repair.
Broken engine fan belt. Refer to Engine Parts Manual for

part number. Refer to Engine
Service Manual for repair.
Engine fault. Refer to Power View Manual and

Engine Service Manual for
information regarding engine
fault codes.
Machine will not travel forward. The directional control switch The directional control switch
(S30) is not in FORWARD must be in the FORWARD
position or is faulty. position to travel in that direction.
Refer to Operation procedures.
Replace switch if faulty.
Forward solenoid (SV12) failure. Replace solenoid or valve if

faulty.
Machine will not travel in The directional control switch The directional control switch
reverse. (S30) is not in REVERSE must be in the REVERSE
position or is faulty. position to travel in that direction.
switch if faulty.
Reverse solenoid valve (SV13) Replace solenoid or valve if

failure. faulty.
Machine will not travel forward Accelerator pedal failure (A5). Replace accelerator pedal.
or reverse, or travels slowly.
Machine will not shift gears. Gear selector switch (S11) Replace switch.
failure.
Transmission solenoid (SV14, Replace solenoid or valve if

SV15, or SV16) failure. faulty.
5-4
TROUBLESHOOTING
Machine will not shift gears – Transmission failure. Refer to Transmission Service
Continued. Manual.
Machine will not turn left or Button (S34) failure on left hand Replace button.
right. control handle.
Trigger switch (S31) failure on Replace switch.

right hand control handle.
Right hand control handle valve Replace valve.

failure.
Steering cylinder failure. Repair cylinder.
Machine is sluggish or has Hydraulic pressure settings are Adjust hydraulic system pressure
inefficient performance. out of adjustment. settings.
Service brakes will not set. Brake pedal actuator is faulty. Replace pedal if faulty.
Park brake test push button (S13) The park brake test pushbutton
has been pressed or is faulty. releases the service brakes. Refer
to Vehicle and Equipment
pushbutton if faulty.
Brake test solenoid (SV2) has The park brake test pushbutton
been activated or is faulty. activates the park brake test
(Vehicles with John Deere axles solenoid and releases the service
only.) brakes. Refer to Vehicle and
Equipment Operation procedures.
Replace solenoid if faulty.
Axle brake solenoid valve (SV17) Replace solenoid or valve if

is faulty. (Vehicles with Kessler faulty.
axles only.)
Brake Manifold failure. Inspect and repair brake

manifold.
Park brake will not set. Park brake/reset switch (S26) Replace switch.
failure.
Scale brake mode is active or Deactivate scale brake mode.

pushbutton (S33) on right hand Refer to Vehicle and Equipment
control handle is faulty. Operation procedures Replace
Park brake relay (K5) failure. Replace relay.
5-5
TROUBLESHOOTING
Park brake will not set – Park brake pressure switch (S3) Replace switch.
Continued. failure.
Park brake solenoid valve (SV3) Replace solenoid or valve if

has failed. faulty.
Park brake manual override Replace solenoid or valve if

solenoid valve (SV17) has failed. faulty.
(Vehicles with John Deere axles
only.)
Park brake will not set from right Park brake pushbutton (S35) Replace pushbutton.
hand control handle. failure on right hand control
handle.
Park brake will not release. Park brake/reset switch (S26) Replace switch.
failure.
Park brake release solenoid (SV3) Replace solenoid or valve if

failure. faulty.
Park brake release valve failure. Repair or replace valve.
Boom will not extend or retract. Left hand control handle valve Replace valve.
failure.
Boom extend cylinder failure. Repair cylinder.
Oscillation lock valve failure. Replace valve.
Oscillation lock cylinder failure. Repair cylinder.
Boom will not lift or lower. Left hand control handle valve Replace valve.
failure.
Boom lift cylinder failure. Repair cylinder.
Oscillation lock valve failure. Replace valve.
Oscillation lock cylinder failure. Repair cylinder.
Scale brake mode does not Scale brake mode pushbutton Replace pushbutton.
activate. (S33) on right hand control
handle is faulty.
Scale brake solenoid (SV1 on Replace solenoid.

vehicles with John Deere axles,
SV2 on vehicles with Kessler
axles) failure.
5-6
TROUBLESHOOTING
Scale brake mode does not Scale mode relay (K13) failure. Replace relay.
activate - Continued.
Micrologix unit or memory Replace Micrologix unit or
module failure. memory module.
Tool does not rotate left or right. Pick rotate left solenoid valve Replace solenoid or valve if
(SV4) or pick rotate right faulty.
solenoid valve (SV5) failure.
Tool does not rotate left or right. Button (S34) failure on left hand Replace button.
control handle.
Trigger switch (S31) failure on Replace switch.

right hand control handle.
Scale brake mode is not active or Activate scale brake mode. Refer
pushbutton (S33) on right hand to Vehicle and Equipment
control handle is faulty. Operation procedures. Replace
Right hand control handle valve Replace valve.

failure.
Cushion valve failure. Replace valve.
Rotary actuator failure. Replace actuator.
Tool (optional) does not move Right hand control handle valve Replace valve.
forward and reverse. failure.
Tool cylinder failure. Repair or replace cylinder.
Hammer (optional) does not Hammer trigger switch (S36) Replace switch.
actuate. failure on left hand control
handle.
Hammer solenoid valve (SV8) Replace solenoid or valve if

failure. faulty.
Supply valve failure. Repair or replace valve.
Water Spray (Optional) does not Hammer trigger switch (S36) Replace solenoid.
actuate. failure on left hand control
handle.
Water spray solenoid (SV28) Replace solenoid.

failure.
Supply valve failure. Repair or replace valve.
5-7
TROUBLESHOOTING
5-8
FUNCTIONAL DESCRIPTION
6. FUNCTIONAL DESCRIPTION
This section of your Operation and Maintenance Manual provides a functional description of Vehicle and
Equipment Operation. Component nomenclature and reference designators used in the Functional Descriptions
are typical, and may vary slightly depending on the vehicle. Refer to the electrical and hydraulic schematics
provided with the Scaler.
Read and understand

manual and safety
information before
troubleshooting!
6-1
SCALERS WITH SAHR AXLE BRAKES (KESSLER) AND SAHR TRANSMISSION BRAKES
The following paragraphs provide a functional description of system operation on Scalers that are equipped with
Kessler axles with spring-applied hydraulically-released (SAHR) axle brakes and SAHR transmission brakes. For
SV-11 Scalers and models equipped with Kessler axles (SAHR axle brakes) and hydraulically-applied spring-
released (HASR) transmission brakes, refer to the SV-11 SCALERS AND MODELS EQUIPPED WITH KESSLER
AXLES (SAHR BRAKES) AND HASR TRANSMISSION BRAKES functional description. Refer to the hydraulic
schematic and electrical schematic provided with the Scaler. Reference to the electrical schematic and electrical
controls are made as necessary for electrical interface with the hydraulic system components. This functional
description refers to a typical hydraulic schematic (709084) and electrical schematic (707479) applicable to
Scalers with SAHR axle brakes and SAHR transmission brakes). Slight deviations between the schematics used
in this description and actual machine schematics may exist. These small deviations do not affect the accuracy of
the schematic and the functioning of the system hydraulic components of the machine.
When a part number is listed on a schematic, it should be used only to identify the name of the various hydraulic
components graphically represented. For the correct component part number, always refer to the Parts Manual.
The functional description follows the normal sequence of scaler operation, beginning with Vehicle Start-Up.
VEHICLE START-UP
Prior to Start-Up, with the Ignition Switch S2 in the OFF position, Accumulator Dump Valve solenoid SV21 is
deenergized and connecting the system pressure lines in the brake circuit and accumulator to the tank return line.
Similarly, Park Brake Valve solenoid SV3 is also deenergized, connecting the park brake pressure line to the tank
return line. This ensures that the vehicle axle brakes and the transmission park brake are always relieved of
pressure and are spring-set whenever the ignition is off.
When the vehicle operator turns the Ignition Switch S2 to the START position, the Cold Start Valve solenoid SV9,
mounted on Pump A, is energized and destrokes the pump, thereby lightening the load on the engine and
hydraulic system during starting. After the vehicle engine starts and the operator releases the Ignition Switch S2
to the ON position, SV9 is deenergized.
With the vehicle engine running, Pump A and Pump B are being driven by the vehicle transmission. The
Accumulator Dump Valve solenoid SV21 is now energized and blocking the connection between the system
pressure lines in the brake circuit and accumulator to the tank return line, so that pressure is able to build up in
the accumulator. The Brake Pressure Gauge indicates the pressure in the brake circuit and accumulator, and will
indicate 2800 psi at startup with the vehicle engine running and no hydraulic load demand, and will fluctuate
between 2295 psi and 2800 psi during operation.
PUMP OPERATION AND CIRCUIT PRIORITY
Both Pump A and Pump B are axial piston, variable displacement pumps with flow/pressure compensated control.
Each pump has a pressure and flow control valve that controls the pump flow and pressure. Anytime that a
hydraulic action is initiated, such as application of the axle brakes, operation of steering cylinders etc., the load
induced pressure on the actuator is conveyed through a series of shuttle valves to the load sensing port on the
pump(s). The shuttle valves are arranged so that the highest load induced pressure is provided to the pump(s).
The control valves stroke the pump so that actuator demand is met. The pump control senses the difference
between the load and pump output, and varies the pump displacement. The pump flow control maintains pump
output flow so that the pressure is greater than the load pressure, 350 psi for Pump A so that it will stroke first,
and 400 psi for Pump B. The pressure control valve limits the pumps maximum output pressure to 2900 psi. This
type of load sensing pump control eliminates excessive pump flow and pressure that results in heat and lost
power.
6-2
SCALERS WITH SAHR AXLE BRAKES (KESSLER) AND SAHR TRANSMISSION BRAKES (CONTINUED)
Hydraulic pressure and flow from the two pumps is provided to the system separately, in such a way that the
brake circuit has priority, followed by steering, then the other hydraulic functions. Output from Pump A passes
through the Pressure Filter A to the Flow Regulator valve FR1 in the Manifold Block of the Steering Valve
assembly. The function of FR1 is as a priority valve, to ensure that the brake circuit flow and pressure
requirements are met before flow and pressure are provided to other parts of the hydraulic system. Pump flow at
the FR1 valve inlet from the P port on the brake manifold is delivered first to the port PR that is connected to the
brake circuit, while excess flow is proportionally directed to the outlet port that is connected to the steering circuit
and other circuits. FR1 maintains controlled flow to the brake circuit port regardless of changes in inlet pressure
or load pressure at either outlet port.
Priority flow enters the brake manifold port P1 and delivered to the brake circuit through Check Valve CV1, while
a portion is metered through Flow Control valve FC1 to the Unloading Valve UV1. Note that the Priority Load
Sense line is connected between FC1 and UV1, and provides the load sense pressure to the load sense circuit
arranged at the shuttle valves SV1 and SV2 in the steering valve manifold block. The load sense pressure is then
conveyed to the stroke control valves on Pump A. The function of UV1 is to make the pump go on stroke
whenever the pressure in the brake circuit drops below 2295 psi, and to destroke the pump when pressure
reaches 2700 psi. At 2700 psi, UV1 shifts to connect the load sense line to tank, rather than to the pump stroke
control valve, causing the pump to destroke.
Also connected to the Load Sense port LS1 on the brake manifold, is the inlet port of Relief Valve RV1 in the
manifold block of the Steering Valve. RV1 limits the maximum pressure in the brake circuit to 2800 psi, by porting
the load sense pressure to tank at 2800 psi. This action allows Flow Regulator Valve FR1 to proportionally shift,
once brake circuit demand is met, and allow flow through FR1 to the steering circuit in the Steering Valve, and to
the inlet port of Differential Pressure sensing valve DP1. Similar to the function of RV1, Relief Valve RV2 limits
the maximum pressure in the steering circuit to 1750 psi.
The outlet port of DP1 is connected to the pressure line for the remainder of the hydraulic circuit, which is initially
provided solely by the output of Pump B. When DP1 senses a 250 psi difference between the Pump A supplied
priority circuits, and the Pump B supplied circuits, it opens and cross-connects Pump A and Pump B supply.
Output from Pump B passes through the Pressure Filter B to the supply pressure port(s) P on the Lift/Rotate
Valve Assembly, Extend/Tool Valve Assemblies, and optional valve assemblies for Push Blade and/or Hammer
as applicable. Prior to those valve assemblies, a hard pipe is connected that cross-connects Pump B to Pump A
at the P2 port/DP1 valve on the Steering Valve. A portion of Pump B output flow is also branched off to the
Hydraulic Cooling Circuit.
AXLE BRAKE CIRCUIT
Refer to the electrical schematic in addition to the hydraulic schematic. The SAHR axle brakes are spring set
when the vehicle engine is not running, and are hydraulically released at start-up. As stated in the Start-Up
description, the Accumulator Dump Valve solenoid SV21 is now energized when the vehicle is running, and
blocking the connection between the system pressure lines in the brake circuit and accumulator to the tank return
line, so that pressure is able to build up in the accumulator and brake circuit. With the vehicle brake pedal
released, brake circuit pressure from the P1 port on the Brake Manifold passes through the Brake Pedal Valve to
the Axle Brake Valve SV17. SV17 is energized through the normally closed K5 contact, normally closed K23
contact, and Diode D26, and ports brake circuit pressure to Scale Brake Valve SV2. Refer to the Park Brake
Circuit description for a complete description of the K5 latching relay and the conditions for the K5 contact being
closed. The K23 relay is only energized, and the K23 contact opened, during Scale Brake Mode. Refer to the
Scale Brake Mode description for a complete description. When deenergized, Scale Brake Valve SV2 ports the
brake circuit pressure from SV17 out of the Brake Manifold to each of the four SAHR Brake Cylinders, which acts
against the brake springs, releasing the axle brakes. SV2 is only energized, blocking pressure to the axle brake
6-3
cylinders, when in Scale Brake Mode. With the axle brakes thus released, Axle Brake Pressure switch S5 is
opened, and Scale (Axle) Brake ON Lamp DS26 is extinguished.
Prior to releasing the Park Brake to drive the vehicle, the operator must press on the Brake Pedal to set the axle
brakes. In order to set the axle brakes, pressure to the brake cylinders must be below 1900 psi, at which point
the brakes are just beginning to engage. When the operator presses on the brake pedal, the brake pedal valve
proportionally reduces brake pressure by shifting some of the brake pressure to Tank. The harder the operator
presses the pedal, the more pressure is ported to Tank, and the less pressure is applied to the brake cylinders.
With the pedal fully depressed, all brake pressure is ported to tank, pressure is reduced to 0 psi at the cylinders,
and the brakes are fully set. When the brake pressure is reduced below 1900 psi by the operator pressing the
brake pedal, Axle Brake Pressure switch S5 is closed, and Scale (Axle) Brake ON Lamp DS26 is illuminated.
PARK BRAKE CIRCUIT
The following discusses the operation of the park brake circuit, and the series of events that must occur before
the park brake can be released, and those events that result in its automatic application. Refer to the electrical
schematic in addition to the hydraulic schematic.
In order to understand how the park brake is released, and re-set when the vehicle is running, operation of the K5
Latching Relay must be understood. The K5 relay has two independent coils, K5 LAT and K5 REL. When the K5
LAT coil is energized, the normally closed contact K5 is opened. Contact K5 is latched in the open position, and
closes again only if coil K5 LAT is deenergized and coil K5 REL is energized.
Prior to start-up, the Park Brake Valve solenoid SV3 is deenergized and the park brake is spring set. The Park
Brake/Reset switch should be already in the pushed Set position. Since the vehicle engine and hydraulic pumps
are not running, and the deenergized Accumulator Dump Valve SV21 has released accumulator pressure in the
brake circuit, the Brake Accumulator Pressure switch S4 and Transmission Pressure switch S6 are both closed.
Since there is no pressure in the hydraulic line to the Park Brake Cylinder, Pressure switch S3 is closed, and the
Park Brake Set light is illuminated.
When the vehicle is initially started, K5 LAT is energized through the closed S4 and S6 contacts. Hydraulic
pressure in the brake circuit accumulator and transmission fluid pressure then quickly builds up so that S4 and S6
are opened, and K5 LAT is deenergized. The K5 contact, which is in series with the SV3 solenoid, is now closed,
and the park brake is ready for being released by the operator.
To release the park brake, the Park Brake/Reset switch S26 contact in the SV3 circuit and contacts K5 and K23
must be closed in order to energize the Park Brake Release Valve solenoid SV3. The K5 contact is already
closed due to K5 LAT being deenergized. The operator pulls out the Park Brake/Reset switch to the Release
position, closing the S26 contacts, which are maintained in that position. SV3 energizes and shifts, porting
system Pressure to the park brake cylinder and the brake is released. When pressure in the park brake line
reaches 1000 psi, Pressure switch S3 opens, deenergizing the Park Brake Set light.
To set the Park Brake with the vehicle running, the operator pushes in the Park Brake/Reset switch S26, and the
S26 contact in the SV3 circuit opens, deenergizing SV3, which ports pressure in the park brake line to Tank,
allowing the park brake spring to set the brake.
In order to again release the park brake, the K5 contact must be closed, but it is being held in the latched open
position. In order to Reset the K5 relay and allow the K5 contact to close, the K5 SET coil must first be energized.
The operator pulls out on the Park Brake/Reset switch S26 from the released position to the momentary Reset
position. This energizes the K5 SET coil, and the K5 contact closes. The Park Brake/Reset switch spring-returns
to the released position. Alternately to using the Park Brake/Reset switch to energize the K5 SET coil and reset
6-4
SCALERS WITH SAHR AXLE BRAKES (KESSLER) AND SAHR TRANSMISSION BRAKES CONTINUED)
the K5 contact, the operator can push the Park Brake button the on the RH control handle. This produces an
output from the Micrologix controller that energizes the K5 SET coil.
If during operation of the vehicle, pressure in the brake circuit and accumulator drops below 1900 psi, Brake
Accumulator Pressure switch S4 closes, energizing the K5 LAT coil, which opens the K5 contact, deenergizing
Park Brake Release Valve solenoid SV3 and setting the park brake.
If releasing the park brake using Hand Pump, the hand pump output is connected to the P2 pressure port on the
Brake Manifold, and to the brake circuit pressure line. The Park Brake Release Valve SV3 has a manual override
that must be actuated to port hand pump pressure to the park brake and release it. (Similarly, the Axle Brake
Valve SV17 also has a manual override that can be actuated and the hand pump can be used to release the axle
brakes.)
LH AND RH CONTROL HANDLES

The LH Control Handle and RH Control Handle are an integrated electrical and hydraulic manually operated
joystick controller. Each has a two-axis joystick with electrical controls on the joystick handle. Moving the joystick
operates proportional valves that provide pilot pressure to the Steering, Lift/Rotate, Extend/Tool valve assemblies
for directional control of the hydraulic cylinders or rotary actuator. The pilot pressure originates at the Pressure
Reducing valve PR1 on the brake manifold. PR1 is fed from a branch from the brake pressure circuit, and
reduces the pressure to 400 psi at the CP port of the brake manifold, and is then connected to the pilot pressure
inlets on both the RH and LH Control Handle valves.
Note that the control valves provide proportional control, so that the more the control handle is pushed, the more
pilot pressure is directed to proportionally shift the directional control valve, resulting in increased flow and
actuator speed.
DRIVING THE VEHICLE

The vehicle drive axles are not hydraulically operated. The Axle Brake are maintained released unless the Brake
Pedal is depressed during vehicle travel. Refer to the OPERATION section of this manual and the electrical
schematic for information regarding forward and reverse travel of the vehicle.
STEERING THE VEHICLE

The vehicle is steered left or right by operation of the two Steering Cylinders, and is controlled by the operator
moving the Cyberstick RH Control Handle to the left or right. Operation of the joystick left/right axis operates a
valve that ports pilot pressure to shift the Steering Directional Control Valve on the Steering Valve manifold. This
ports a pilot pressure command to port C1 (Steer Left) or C2 (Steer Right) of the Steering CMX100 Valve
Assembly. The meter-in element proportional directional control shifts accordingly and ports pressure to the
Steering Cylinders. Load pressure is communicated back to the pump through the load sense circuit shuttle
valves. The Steering valve assembly has 2030 psi cylinder port reliefs. The Steering Valve Assembly utilizes a
load-sensing CMX100 sectional valve assembly, that is also used as the valve assemblies for Boom Lift, Pick
Rotate, Boom Extend, and Tool Operation. Refer to the description of the CMX100 Valve Assembly below for
details of operation.
Note that the left-right axis of the RH Control Handle is used for both Steering of the vehicle, and for left-right
rotation of the Pick tool. Steering is electrically enabled unless Pick Rotate mode is engaged by the Trigger
Switch S31 on RH Control handle or the PICK ROTATE pushbutton S34 at the LH Control Handle. Refer to the
PICK/ROTATE description. When steering is enabled, both Steer/Rotate Valve solenoids SV4 and SV5 on the
brake manifold are deenergized, and the pilot pressure lines from the RH Control Handle valve are lined up with
the pilot lines to the Steering Directional Control Valve that is part of the Steering Valve Assembly. When the RH
6-5
Control handle is pushed to left or right, pilot pressure is routed to either SV4 (left) or SV5 (right), and being
deenergized, ports pilot pressure to the pilot operated directional control valve on the steering manifold. The
valve shifts and ports steering circuit pressure to the appropriate steering cylinder, and passes fluid leaving the
opposite cylinder back to Tank.
Note on the schematic the Shuttle Valve SH1 and Steer Pressure switch S40. When Cyberstick pilot pressure
passes through either SV4 or SV5 to the Steering Valve, SH1 ports whichever is present to the S40 switch, which
closes and energizes the K21 relay. This relay has a NO contact in the electrical circuit leg to the Axle Brake
Valve SV17. When K21 is energized, and its contact closes, and ensures that the SV17 remains energized and
the axle brakes released during vehicle steering. This allows the vehicle wheels to rotate as necessary as the
vehicle frame is being articulated.
DESCRIPTION OF TYPICAL CMX100 VALVE ASSEMBLY OPERATION

The CMX100 Valve Assemblies are used for operation and directional control of the hydraulic cylinders used for
Steering, Boom Lift, Boom Extend, and Tool Operation, and the hydraulic rotary actuator used for Pick Rotate. All
of the valve assemblies are similar, the only difference being the pressure settings of valve components. The
CMX100 valve assembly is a pilot-operated load-sensing sectional valve assembly including a directional control
valve, meter-in and meter-out elements, check valves, and relief valves. The valve assemblies are designed to
provide load sensing pressure signals back to the pump controls, so that the pump flow and pressure will match
the load requirement, without producing unnecessary excess flow or pressure, which reduces heat and lost
power. The load sense LS port of the valve is connected to the load sense circuit, which through a series of
shuttle valves and load sense lines to other valve assemblies, is fed back to the pump control. The pump control
senses the difference between the load and the pump outlet pressure, and varies the pump displacement (stroke)
to keep the difference at a constant load sense differential pressure. This differential pressure is applied across
the CMX100 meter-in spool, resulting in pump flow being determined by the degree of spool opening,
independent of load pressure.
Prior to a pilot pressure command from the LH or RH Control Handle valves being sent to the CMX100 valve
assembly, the meter-in spool of the 5-way directional control valve in the CMX100 is in the neutral center position.
Refer to the diagram below of the Meter-In element. Command pressure is applied to either C1 or C2 and directs
flow to the desired actuator port. During this explanation, assume command pressure is applied to C1. When
command pressure reaches a level that overrides meter-in spring force, the meter-in spool moves to the right.
Movement of the spool will close the chamber drain opening through the spool and open pressure to the load
drop check and load sense check valve. The load sense check poppet then shifts to the left, allowing pressure to
the load sensing feedback port LS. Pump outlet pressure (P) will be approximately 290 psi higher than the load
sensing feedback pressure at port LS. By varying pilot command pressure at C1, the meter-in spool will modulate
flow to the cylinder “B” port and precise metering of flow to the load can be obtained. Flow to the cylinder from
the meter-in spool goes through two parallel check valves; the first going to the cylinder for load-holding, and the
second to the load sense line, for preventing backpressure to the meter-in spool from the load sense line.
6-6
Note the orifices shown in the CMX100 schematic, in the pilot pressure command lines for ports C1 and C2. If
command pressure at C1 is reduced, spring force will center the meter-in spool and the load sensing pressure will
decay through the load sense decompression orifice. This allows pump outlet pressure to reduce to standby
pressure.
To port A To port B
A B
end end
LS LS
C1 C2
Typical CMX100 Meter-In Element
Refer to the diagram below of the Meter-Out element. There are two meter-out elements, one for each cylinder
port. Essentially, the CMX meter-out element is a variable orifice between one of the actuating ports and the
reservoir. The meter-out element is used to restrict exhaust flow from an actuator (cylinder or rotary actuator). As
flow is restricted, the speed of the actuator slows down. The meter-out element is positioned by a simple bleed
servo which is controlled by command pilot pressure at C1. Command pilot pressure causes the piston to move
and the stem, being connected to the piston, automatically follows. This opens the left side of the meter-out
poppet to the reservoir. Pressure then lowers in the spring chamber, and actuator port pressure causes the
poppet to shift to the left, allowing more oil into the reservoir. When command pilot pressure decreases at C1, the
piston and stem move under the influence of the spring in the opposite direction. This causes the meter-out
poppet to start restricting flow; consequently, less oil is ported into the reservoir. When the meter-out poppet
bottoms against its seat in the body, exhaust oil flow ceases to the reservoir, and actuator movement stops.
Piston Meter-out
poppet
Head
Stem
Seat
Spring area
Command To tank or
pressure reservoir
Typical CMX100 Meter-Out Element
6-7
FRAME OSCILLATION LOCK CYLINDERS
The SV Scaler vehicle is provided with frame oscillation capability that allows the front and rear frame sections
and axles to skew plus or minus 10 degrees from each other. The frame sections are free to oscillate while the
vehicle is being driven in order to accommodate uneven terrain. When the operator places the Scaler in Scale
Brake Mode when the vehicle is in place for Scaler work, the oscillation cylinders are locked in position (and Park
Brake and Axle Brakes are set; refer to the section below on Scale Brake Mode) to prevent any vehicle
movement. Refer to the electrical schematic in addition to the hydraulic schematic.
When not in Scale Brake Mode, the Articulation Lock Valve solenoid SV1 is deenergized, and blocks pilot
pressure to the two pilot-operated valves in the Oscillation Lock Valve. In this position, the valves are open and
allow fluid to flow freely between the two Cylinders when they move in and out as vehicle travels and the frame
sections oscillate from each other. When the operator presses the Scale Brake Mode, SV1 is energized by an
output from the Micrologix controller. SV1 then opens to provide pilot pressure to the two pilot-operated valves in
the Oscillation Lock Valve, which then close, blocking fluid flow between the two cylinders and locking them in
that position.
SCALE BRAKE MODE
Scale Brake Mode automatically sets the Park Brake and Axle Brakes, and locks the Oscillation Lock Cylinders
(and also shifts the transmission to “neutral” and sets engine speed at 2400 RPM). When the vehicle is placed in
Scale Brake Mode, initiated by the operator pressing the Scale Brake pushbutton S33 on the RH Control Handle,
the Micrologix controller output that provides electric power to the circuit legs of the Park Brake Release Valve
solenoid SV3 and Axle Brake Valve solenoid SV17, is removed, deenergizing the solenoids and causing the park
brake and axle brakes to set. The Park Brake indicator light S26 will be illuminated by the closing of Park Brake
Pressure switch S3 as pressure is removed from the Park Brake Cylinder, and the Scale Brake indicator light
DS26 will be illuminated by the closing of Axle Brake Pressure switch S5 as pressure is removed from the Axle
Brake Cylinders. The Oscillation Lock Cylinders are locked when in Scale Brake Mode, as described in the
section above.
On the electrical schematic, note the normally closed K21 relay contact in the circuit leg to the Articulation Lock
Valve solenoid SV1, and also the normally open K21 relay contact in the circuit leg to the Axle Brake Valve
solenoid SV17. The K21 relay is controlled by the Steer Pressure switch S40, which is closed whenever there is
a pilot pressure steering command from operation of the RH Control Handle. If the operator attempts to steer the
vehicle while it is in Scale Brake Mode, when S40 closes, K21 is energized. This opens the normally closed K21
relay contact in the circuit leg to the Articulation Lock Valve solenoid SV1, and it deenergizes, causing the
Oscillation Lock Cylinders to be unlocked. This closes the normally open K21 relay contact in the circuit leg to the
Axle Brake Valve solenoid SV17, and it energizes, causing the Axle Brakes to be released. The Park Brake
however remains set. The machine will now articulate in either direction. The vehicle will not be able to move
forward or backward with the park brake set, however the left and right wheels (front and back) will rotate in
opposite directions to allow the machine to articulate left or right to re-position the vehicle. Wheel brakes and
oscillation cylinder lock will reengage automatically when control handle is returned to the center position.
BOOM LIFT OPERATION
Boom Lift operation is controlled by the vehicle operator using the forward/back axis of the LH Control Handle
(Boom Up, Boom Down). This ports a pilot pressure command to port C1 (Boom Lift) or C2 (Boom Lower) of the
Lift CMX100 Valve Assembly. The meter-in element proportional directional control shifts accordingly and ports
pressure to the Lift Cylinders. Load pressure is communicated back to the pump through the load sense circuit
shuttle valves. The boom lift valve assembly has 3000 psi and 700 psi cylinder port reliefs.
6-8
PICK ROTATE OPERATION
Pick Rotate operation is initiated by the vehicle operator by pushing the either the Pick Rotate pushbutton switch
S34 at the LH Control Handle, or by pressing and holding the Pick Rotate trigger switch S31 on the RH Control
Handle. This causes Micrologix controller to send an output that energizes the Steer/Rotate Valve solenoids SV4
and SV5. This ports pilot pressure commands from the LH Control Handle Valves to the Rotate CMX100 Valve
Assembly, rather than to the steering circuit. (Note that steering is thus disabled when in Pick Rotate mode.) The
Micrologix controller to send an output that illuminates the Pick Rotate Enabled indicator light DS27. The
Micrologix controller removes the pick/rotate outputs when the operator either presses the Pick Rotate pushbutton
or releases the trigger switch.
Energizing SV4 or S5 in Pick Rotate mode sends a pilot pressure command to port C1 (Rotate CW) or C2 (Rotate
CCW) of the Rotate CMX100 Valve Assembly. The meter-in element proportional directional control shifts
accordingly and ports pressure to the Rotary Actuator. Load pressure is communicated back to the pump through
the load sense circuit shuttle valves. The tool rotate valve assembly has 1450 psi cylinder port reliefs.
Note the Cushion Valve prior to the Rotary Actuator on the hydraulic schematic. These relief valves are set at
1600 psi and open to cushion the extreme ends of actuator travel.
BOOM EXTEND OPERATION
Boom Extend operation is controlled by the vehicle operator using the left/right axis of the LH Control Handle
(Boom Extend, Boom Retract). This ports a pilot pressure command to port C1 (Boom Ret.) or C2 (Boom Ext.) of
the Extend CMX100 Valve Assembly. The meter-in element proportional directional control shifts accordingly and
ports pressure to the Extend Cylinder. Load pressure is communicated back to the pump through the load sense
circuit shuttle valves. The boom extend valve assembly has 3000 psi cylinder port reliefs.
Note that the Extend Valve Assembly is provided with an additional Regen Manifold. Regeneration is used on the
Extend stroke, so that the cap end and rod end of the cylinder are connected, and fluid exiting the rod end is
added to the fluid entering the cap end. This increases the extend speed of the cylinder. When an Extend pilot
pressure command from the LH Control Handle is applied to the C2 port of the valve assembly, it is also applied
to the C2 port of the Regen Manifold. Regen Valve solenoid SV18 is deenergized, so the pressure is applied to
the Sequence Valve in the Regen manifold. Since the Control Handle provides proportional control, the further
that operator pushes the lever, the pilot pressure increases and the more the Extend valve shifts to extend the
cylinder faster. When the applied pilot pressure exceeds 250 psi, the Sequence Valve shifts and applies pressure
to the pilot-operated directional control valve, which shifts and ports the rod end to the cap end for regeneration.
If pressure in the extend end (cap end) of the cylinder drops below 1500 psi, Regen Pressure switch S23 closes,
energizing Regen Valve solenoid SV18. SV18 shifts, connecting the sequence valve pressure to Tank, and the
directional valve shifts. The cylinder rod end fluid is now ported to Tank, rather than regenerating to the cap end.
TOOL OPERATION
Tool operation is controlled by the vehicle operator using the forward/back axis of the RH Control Handle (Pick
Fwd, Pick Rev). This ports a pilot pressure command to port C1 (Pick Rev.) or C2 (Pick Fwd.) of the Tool
CMX100 Valve Assembly. The meter-in element proportional directional control shifts accordingly and ports
pressure to the Tool Cylinder. Load pressure is communicated back to the pump through the load sense circuit
shuttle valves. The boom lift valve assembly has 2320 psi cylinder port reliefs.
6-9
PUSH BLADE (OPTIONAL)
Operation of the optional Push Blade is controlled by the operator by using the Blade Up and Blade Down
pushbutton switch S29 located on the RH Control Handle. This energizes either Push Blade Valve solenoids SV6
(Up) or SV7 (Down) of the Push Blade Valve solenoid-operated directional control valve, which shifts according to
direct pressure and return to the Push Blade Cylinder. Note the cross-connected pilot-operated check valves
PC1 and PC2 that provide load/blade position holding until pressure is applied to the opposite end of the cylinder.
Load pressure is communicated back to the pump through the load sense circuit shuttle valves.
HAMMER OPERATION (OPTIONAL)
Hammer operation is initiated by the vehicle operator by pressing and holding the Hammer trigger switch S36 on
the LH Control Handle. System pressure is always available to the inlet port 1 of the Hammer Valve SV8 pilot-
operated valve. When the solenoid of SV8 is energized by the trigger switch S36, SV8 shifts and relieves pilot
pressure from one side of the pilot-operated valve and it shifts to provide pressure to the hammer circuit. A pilot-
operated valve inside the hammer passes pressure to the hammer which extends against the internal spring
force. At the same time, the applied pressure also shifts the valve which relieves pressure to the hammer and it
cycles back and retracts under spring force. As pressure again immediately builds the valve shift again and the
cycle repeats. Load pressure is communicated back to the pump through the load sense circuit shuttle valves.
A relief valve set at 2180 psi provides overpressure protection from shock loading of the hammer.
SV-11 SCALERS AND MODELS EQUIPPED WITH KESSLER AXLES (SAHR BRAKES) AND HASR
TRANSMISSION BRAKES
The following paragraphs provide a functional description of system operation on SV-11 Scalers and models
equipped with Kessler axles [equipped with spring-applied hydraulically-released (SAHR) axle brakes] and
hydraulically-applied spring released (HASR) transmission brakes. For Scalers equipped with Kessler axles with
spring-applied hydraulically-released (SAHR) axle brakes and SAHR transmission brakes refer to the SCALERS
WITH SAHR AXLE BRAKES (KESSLER) AND SAHR TRANSMISSION BRAKES functional description. Refer to
the hydraulic schematic and electrical schematic provided with the Scaler. Reference to the electrical schematic
and electrical controls are made as necessary for electrical interface with the hydraulic system components. This
functional description refers to a typical hydraulic schematic (710826) and electrical schematic (710058)
applicable to SV-11 Scalers and models equipped with Kessler axles (SAHR axle brakes) and HASR
transmission brakes. Slight deviations between the schematics used in this description and actual machine
schematics may exist. These small deviations do not affect the accuracy of the schematic and the functioning of
the system hydraulic components of the machine.
VEHICLE START-UP
Prior to Start-Up, with the Ignition Switch S2 in the OFF position, Accumulator Dump Valve solenoid SV21 is
deenergized and connecting the system pressure lines in the brake circuit and accumulator to the tank return line.
Similarly, Park Brake Valve solenoid SV3 is also deenergized, connecting the park brake pressure line to the tank
return line. This ensures that the vehicle axle brakes and the transmission park brake are always relieved of
pressure and are spring-set whenever the ignition is off.
6-10
TRANSMISSION BRAKES (CONTINUED)
With the vehicle engine running, Pump A and Pump B are being driven by the vehicle transmission. The
Accumulator Dump Valve solenoid SV21 is now energized and blocking the connection between the system
pressure lines in the brake circuit and accumulator to the tank return line, so that pressure is able to build up in
the accumulator. The Brake Pressure Gauge indicates the pressure in the brake circuit and accumulator, and will
indicate 2900 psi at startup with the vehicle engine running and no hydraulic load demand, and will fluctuate
between 2295 psi and 2900 psi during operation.
PUMP OPERATION
power.
Unlike other vehicles, SV-11 Scalers and models equipped with Kessler axles and HASR transmission brakes do
not have a brake priority circuit. Hydraulic pressure and flow from the two pumps is not provided to the system
separately. Outputs from Pump A and Pump B passes through the Pressure Filters A and B to the Check Valves
CV1 and CV2 in the Main Control Valve Assembly. Pump outputs through CV1 and CV2 are combined in the
control valve assembly, and full system pressure of 2900 psi maximum is provided to the Brake manifold and
hydraulic circuits in the main control valve for other functions.
System pressure enters the brake manifold port P1 and delivered to the brake circuit through Dump Bypass
Solenoid Valve SV27, which is deenergized and opened by Time Delay Relay T3 a short time after the vehicle
ignition is turned on. From SV27, the brake circuit branches through Check Valve CV1, while a portion is metered
through Flow Control valve FC1 to the Unloading Valve PU1. Note that the Priority Load Sense line is connected
between FC1 and PU1, and provides the load sense pressure to the load sense circuit. The load sense pressure
is then conveyed to the stroke control valves on Pumps A and B. The function of PU1 is to make the pumps go
on stroke whenever the pressure in the brake circuit drops below 2295 psi, and to destroke the pump when
pressure reaches 2700 psi. At 2700 psi, PU1 shifts to connect the load sense line to tank, rather than to the
pumps stroke control valves, causing the pumps to destroke.
AXLE BRAKE CIRCUIT

Refer to the electrical schematic in addition to the hydraulic schematic. The SAHR axle brakes are spring set
when the vehicle engine is not running, and are hydraulically released at start-up. As stated in the Start-Up
description, the Accumulator Dump Valve solenoid SV21 is now energized when the vehicle is running, and
blocking the connection between the system pressure lines in the brake circuit and accumulator to the tank return
line, so that pressure is able to build up in the accumulator and brake circuit. With the vehicle brake pedal
released, brake circuit pressure from the P1 port on the Brake Manifold passes through the Brake Pedal Valve to
the Axle Brake Valve SV17. SV17 is energized through the normally closed K5 contact, normally closed K23
6-11
contact, and Diode D26, and ports brake circuit pressure to Scale Brake Valve SV2. Refer to the Park Brake
Circuit description for a complete description of the K5 latching relay and the conditions for the K5 contact being
closed. The K23 relay is only energized, and the K23 contact opened, during Scale Brake Mode. Refer to the
Scale Brake Mode description for a complete description. When deenergized, Scale Brake Valve SV2 ports the
brake circuit pressure from SV17 out of the Brake Manifold to each of the four SAHR Brake Cylinders, which acts
against the brake springs, releasing the axle brakes. SV2 is only energized, blocking pressure to the axle brake
cylinders, when in Scale Brake Mode. With the axle brakes thus released, Axle Brake Pressure switch S5 is
opened, and Scale (Axle) Brake ON Lamp DS26 is extinguished.
brakes. In order to set the axle brakes, pressure to the brake cylinders must be below 1900 psi, at which point
the brakes are just beginning to engage. When the operator presses on the brake pedal, the brake pedal valve
proportionally reduces brake pressure by shifting some of the brake pressure to Tank. The harder the operator
presses the pedal, the more pressure is ported to Tank, and the less pressure is applied to the brake cylinders.
With the pedal fully depressed, all brake pressure is ported to tank, pressure is reduced to 0 psi at the cylinders,
and the brakes are fully set. When the brake pressure is reduced below 1900 psi by the operator pressing the
brake pedal, Axle Brake Pressure switch S5 is closed, and Scale (Axle) Brake ON Lamp DS26 is illuminated.
PARK BRAKE CIRCUIT

schematic in addition to the hydraulic schematic. Unlike other vehicles, SV-11 Scalers and models equipped with
Kessler axles and HASR transmission brakes, the Park Brake is not spring set, and must have pressure applied
to set the brake.
Prior to start-up, the Park Brake Valve solenoid SV3 is deenergized. The Park Brake/Reset switch should be
already in the pushed Set position. Since the vehicle engine and hydraulic pumps are not running, and the
deenergized Accumulator Dump Valve SV21 has released accumulator pressure in the brake circuit, the Brake
Accumulator Pressure switch S4 and Transmission Pressure switch S6 are both closed. Since there is no
pressure in the hydraulic line to the Park Brake Cylinder, Pressure switch S3 is open, and the Park Brake Set light
is extinguished.
When the vehicle is initially started, K5 LAT is energized through the closed S4 and S6 contacts. Hydraulic
pressure in the brake circuit accumulator and transmission fluid pressure then quickly builds up so that S4 and S6
are opened, and K5 LAT is deenergized. The K5 contact, which is in series with the SV3 solenoid, is now closed,
and the park brake is ready for being set by the operator.
S26 contact in the SV3 circuit opens, deenergizing Park Brake Relay K26. The K26 contact closes, energizing
Park Brake Solenoid Valve SV3. SV3 ports system pressure through Pressure Reducing Valve PR2, which
lowers the pressure being provided to the park brake to 1500 psi. When pressure in the park brake line reaches
1000 psi, Pressure switch S3 closes, energizing the Park Brake Set light.
6-12
Accumulator Pressure switch S4 closes, energizing the K5 LAT coil, which opens the K5 contact, which
deenergizes SV17. When SV17 is denergized, the SV17 Brake Valve dumps all brake circuit flow to tank. With
no hydraulic pressure in the brake circuit, the SAHR Kessler axle brakes fully apply and the HASR transmission
brake releases.
Brake Manifold, and to the brake circuit pressure line. The Park Brake Release Valve SV3 has a manual override
that must be actuated to port hand pump pressure to the park brake and release it. (Similarly, the Axle Brake
Valve SV17 also has a manual override that can be actuated and the hand pump can be used to release the axle
brakes.

joystick controller. Each has a two-axis joystick with electrical controls on the joystick handle. Moving the joystick
operates proportional valves that provide pilot pressure to the Steering, Lift/Rotate, Extend/Tool valve assemblies
for directional control of the hydraulic cylinders or rotary actuator. The pilot pressure originates at the Pressure
Reducing valve PR1 on the brake manifold. PR1 is fed from a branch from the brake pressure circuit, and
reduces the pressure to 400 psi at the CP port of the brake manifold, and is then connected to the pilot pressure
inlets on both the RH and LH Control Handle valves.
actuator speed.
DRIVING THE VEHICLE


valve that ports pilot pressure to shift the Steering Directional Control Valve on the Main Control Valve Assembly.
This ports a pilot pressure command to port C1 (Steer Left) or C2 (Steer Right) of the Steering CMX100 Valve
Rotate, Boom Extend, Boom Swing, and Tool Operation. Refer to the description of the CMX100 Valve Assembly
as described in the section for other vehicles with SAHR brakes for details of operation.
6-13
deenergized, ports pilot pressure to the pilot operated directional control valve on the steering manifold. The valve
shifts and ports steering circuit pressure to the appropriate steering cylinder, and passes fluid leaving the opposite
cylinder back to Tank.
Note on the schematic the Shuttle Valve SH1 and Steer Pressure switch S40. When Cyberstick pilot pressure
passes through either SV4 or SV5 to the Steering Valve, SH1 ports whichever is present to the S40 switch, which
closes and energizes the K21 relay. This relay has a NO contact in the electrical circuit leg to the Axle Brake
Valve SV17. When K21 is energized, and its contact closes, and ensures that the SV17 remains energized and
the axle brakes released during vehicle steering. This allows the vehicle wheels to rotate as necessary as the
vehicle frame is being articulated.
Steering, Boom Lift, Boom Extend, Boom Swing, and Tool Operation, and the hydraulic rotary actuator used for
Pick Rotate. These valve assemblies are identical to those used on other vehicles, except for some of the port
relief pressure settings. Also, on SV-11 Scalers and models equipped with Kessler axles and HASR transmission
brakes, all of the various CMX 100 valve assemblies are stack-mounted on the Main Control Valve Assembly,
rather than on separate manifolds. Refer to the description of the CMX100 Valve Assembly as described in the
section for other vehicles with SAHR brakes for details of operation.
When not in Scale Brake Mode, the Articulation Lock Valve solenoid SV1 is deenergized, and blocks pressure to
the two pilot-operated-to-close check valves mounted on the cap end ports of the cylinders. In this position, the
check valves are open and allow fluid to flow freely between the two cylinders when they move in and out as
vehicle travels and the frame sections oscillate from each other. When the operator presses the Scale Brake
Mode, SV1 is energized by an output from the Micrologix controller. SV1 then opens to provide pressure to the
two check valves, which then close, blocking fluid flow between the two cylinders and locking them in that
position.
6-14
SCALE BRAKE MODE
Scale Brake Mode on SV-11 Scalers and models equipped with Kessler axles and HASR transmission brakes
operates similarly to other vehicles with SAHR axle brakes (Kessler) and SAHR transmission brakes, except for
difference in Park Brake operation as described above for SV-11 Scalers and models equipped with Kessler axles
and HASR transmission brakes. Refer to the SAHR axle brakes (Kessler) and SAHR transmission brakes section
for details of scale brake mode operation.
BOOM LIFT OPERATION
shuttle valves. The boom lift valve assembly has 1450-4200 psi and 700 psi cylinder port reliefs.
circuit shuttle valves. The boom extend valve assembly has 1450-4200 psi and 700 psi cylinder port reliefs.
6-15
BOOM SWING OPERATION
Boom Swing operation is controlled by the vehicle operator using the left-right axis of the LH Control Handle
(Swing Left, Swing Right). The left-right axis of the LH Control Handle is enabled for boom swing operation rather
than for boom extend operation by the operator pressing the Boom Swing pushbutton on the control handle.
Operation of the control handle ports a pilot pressure command to port C1 (Swing Right) or C2 (Swing Left) of the
pressure to the Boom Swing Cylinders. The cylinder rod ends and cap ends are cross-connected so that
pressure is applied to the cap end of one cylinder and rod end of the other cylinder. Load pressure is
communicated back to the pump through the load sense circuit shuttle valves. The boom swing valve assembly
has 3045 psi cylinder port reliefs.
TOOL OPERATION
Tool operation is similar to that described for other vehicles with SAHR brakes. Refer to the section for other
vehicles with SAHR brakes for details of tool operation.

Optional Push Blade operation is similar to that described for other vehicles with SAHR brakes. Refer to the
section for other vehicles with SAHR brakes for details of push blade operation.

Optional Hammer operation is similar to that described for other vehicles with SAHR brakes. Refer to the section
for other vehicles with SAHR brakes for details of hammer operation.
SCALERS WITH HASR AXLE BRAKES AND SAHR TRANSMISSION BRAKES
The following paragraphs provide a functional description of system operation on Scalers that are equipped with
John Deere axles with hydraulically-applied spring-released (HASR) axle brakes, and spring-applied hydraulically-
released (SAHR) transmission brakes. Refer to the hydraulic schematic and electrical schematic provided with
the Scaler. Reference to the electrical schematic and electrical controls are made as necessary for electrical
interface with the hydraulic system components. This functional description refers to a typical hydraulic schematic
(709987) and electrical schematic (705706) applicable to Scalers with HASR axle brakes and SAHR transmission
brakes. Slight deviations between the schematics used in this description and actual machine schematics may
exist. These small deviations do not affect the accuracy of the schematic and the functioning of the system
hydraulic components of the machine.
6-16
SCALERS WITH HASR AXLE BRAKES AND SAHR TRANSMISSION BRAKES (CONTINUED)
VEHICLE START-UP
Prior to Start-Up, the vehicle axle brakes are released, since they are hydraulically-applied spring-released
(HASR), and there is no hydraulic pressure prior to start-up. Note that the Park Brake is spring-applied
hydraulically-released (SAHR), so is set prior to vehicle start-up. Park Brake Valve solenoid SV3 is deenergized,
connecting the park brake pressure line to the tank return line. This ensures that the vehicle axle brakes and the
transmission park brake are always relieved of pressure and are spring-set whenever the ignition is off.
With the vehicle engine running, Pump A and Pump B are being driven by the vehicle transmission. The Manual
Accumulator Pressure Relief Valve is un-actuated, blocking the connection between the system pressure lines in
the brake circuit and accumulators to the tank return line, so that pressure is able to build up in the accumulators.
The Brake Pressure Gauge indicates the pressure in the brake circuit and accumulators, and will indicate 2500
psi at startup with the vehicle engine running and no hydraulic load demand, and will fluctuate between 2295 psi
and 2500 psi during operation.
PUMP OPERATION AND CIRCUIT PRIORITY
power.
Hydraulic pressure and flow from the two pumps is provided to the system separately, in such a way that the
brake circuit has priority, followed by steering, then the other hydraulic functions. Output from Pump A passes
through the Pressure Filter A to the Flow Regulator valve in the Manifold Block of the Steering Valve assembly.
The function of the flow regulator is as a priority valve, to ensure that the brake circuit flow and pressure
requirements are met before flow and pressure are provided to other parts of the hydraulic system. Pump flow at
the valve inlet from the P port on the brake manifold is delivered first to the port PR that is connected to the brake
circuit, while excess flow is proportionally directed to the outlet port that is connected to the steering circuit and
other circuits. The Flow Regulator valve maintains controlled flow to the brake circuit port regardless of changes
in inlet pressure or load pressure at either outlet port.
Priority flow enters the brake manifold port P and delivered to the brake circuit through Check Valve CV1, while a
portion is metered through Flow Regulator valve FR1 to the Unloading Valve UP1. Note that the Priority Load
Sense line is connected between FR1 and UP1, and provides the load sense pressure to the load sense circuit
arranged at the shuttle valves SV1 and SV2 in the steering valve manifold block. The load sense pressure is then
conveyed to the stroke control valves on Pump A. The function of UP1 is to make the pump go on stroke
whenever the pressure in the brake circuit drops below 2000 psi, and to destroke the pump when pressure
reaches 2500 psi. At 2500 psi, UP1 shifts to connect the load sense line to tank, rather than to the pump stroke
control valve, causing the pump to destroke.
6-17
Also connected to the Load Sense port LS on the brake manifold, is the inlet port of Relief Valve in the manifold
block of the Steering Valve. This relief valve limits the maximum pressure in the brake circuit to 2500 psi, by
porting the load sense pressure to tank at 2500 psi. This action allows Flow Regulator Valve to proportionally
shift, once brake circuit demand is met, and allow flow through the flow regulator to the steering circuit in the
Steering Valve, and to the inlet port of Differential Pressure sensing valve. The other Relief Valve in the steering
valve limits the maximum pressure in the steering circuit to 1750 psi.
The outlet port of the Differential Pressure sensing valve is connected to the pressure line for the remainder of the
hydraulic circuit, which is initially provided solely by the output of Pump B. When the DP sensing valve senses a
250 psi difference between the Pump A supplied priority circuits, and the Pump B supplied circuits, it opens and
cross-connects Pump A and Pump B supply. Output from Pump B passes through the Pressure Filter B to the
supply pressure port(s) P on the Lift/Rotate Valve Assembly, Extend/Tool Valve Assemblies, and optional valve
assemblies for Push Blade and/or Hammer as applicable. Prior to those valve assemblies, a hard pipe is
connected that cross-connects Pump B to Pump A at the P2 port on the Steering Valve. A portion of Pump B
output flow is also branched off to the Hydraulic Cooling Circuit.
AXLE BRAKE CIRCUIT

Refer to the electrical schematic in addition to the hydraulic schematic. The HASR axle brakes are spring
released when the vehicle engine is not running, and are hydraulically applied only by the operator pressing on
the brake pedal when the vehicle is running. As stated in the Start-Up description, the Manual Accumulator
Pressure Relief Valve is un-actuated, blocking the connection between the system pressure lines in the brake
circuit and accumulators to the tank return line, so that pressure is able to build up in the accumulators and brake
circuit. With the vehicle brake pedal released, brake circuit pressure from the P port on the Brake Manifold
branches into two separate parallel circuits, through Check Valves CV1 and CV2. The CV1 branch is for the front
axle brake and front accumulator, and the CV2 branch is for the rear axle brake and rear accumulator.
brakes. In order to set the axle brakes, pressure to the brake cylinders must be above 1000 psi, at which point
the brakes are just beginning to engage. When the operator presses on the brake pedal, the dual-element brake
pedal valves proportionally provide brake pressure to the front and rear axle brakes. The harder the operator
presses the pedal, the more pressure is provided to the brake cylinders. With the pedal fully depressed, all brake
pressure is ported to the cylinders, and the brakes are fully set.
PARK BRAKE CIRCUIT
schematic in addition to the hydraulic schematic.
Prior to start-up, the Park Brake Valve solenoid SV3 and the Park Brake Manual Override Solenoid Valve SV17
are deenergized and the park brake is spring set. The Park Brake/Reset switch should be already in the pushed
Set position. Since the vehicle engine and hydraulic pumps are not running, and the Manual Accumulator
Pressure Relief Valve is un-actuated, the Brake Accumulator Pressure switches S4 and S5 and Transmission
Pressure switch S6 are all closed. Since there is no pressure in the hydraulic line to the Park Brake Cylinder,
Pressure switch S3 is closed, and the Park Brake Set light is illuminated.
6-18
When the vehicle is initially started, K5 LAT is energized through the closed S4, S5, and S6 contacts. Hydraulic
pressure in the brake circuit accumulator and transmission fluid pressure then quickly builds up so that S4, S5
and S6 are opened, and K5 LAT is deenergized. The K5 contact, which is in series with the SV3 solenoid, is now
closed, and the park brake is ready for being released by the operator.
To release the park brake, the Park Brake/Reset switch S26 contact in the SV3/SV17 circuit and contacts K5 and
K23 must be closed in order to energize the Park Brake Release Valve solenoid SV3. The K5 contact is already
closed due to K5 LAT being deenergized. The operator pulls out the Park Brake/Reset switch to the Release
position, closing the S26 contacts, which are maintained in that position. SV3 and SV17 energize and shift,
porting system Pressure to the park brake cylinder and the brake is released. When pressure in the park brake
line reaches 1000 psi, Pressure switch S3 opens, deenergizing the Park Brake Set light.
S26 contact in the SV3/SV17 circuit opens, deenergizing SV3 and SV17, which ports pressure in the park brake
line to Tank, allowing the park brake spring to set the brake.
Accumulator Pressure switches S4 and S5 close, energizing the K5 LAT coil, which opens the K5 contact,
deenergizing Park Brake Release Valve solenoid SV3 and Park Brake Manual Override Solenoid Valve SV17,
setting the park brake.
Brake Manifold, and to the brake circuit pressure line. The Park Brake Release Valve SV3 and Park Brake
Manual Override Solenoid Valve SV17 have a manual override that must be actuated to port hand pump pressure
to the park brake and release it.

joystick controller. Each has a two-axis joystick with a electrical controls on the joystick handle. Moving the
joystick operates proportional valves that provide pilot pressure to the Steering, Lift/Rotate, Extend/Tool valve
assemblies for directional control of the hydraulic cylinders or rotary actuator. The pilot pressure originates at the
Pressure Reducing valve mounted separately from the brake manifold, and supplied from brake manifold ports S1
and S2 via the Cyberstick Shuttle Valve. This Pressure Reducing valve PR1 reduces the pressure to 650 psi, and
is then connected to the pilot pressure inlets on both the RH and LH Control Handle valves.
actuator speed.
6-19
DRIVING THE VEHICLE

valve that ports pilot pressure to shift the Steering Directional Control Valve on the Steering Valve manifold. This
ports a pilot pressure command to port C1 (Steer Left) or C2 (Steer Right) of the Steering CMX100 Valve
Rotate, Boom Extend, and Tool Operation. Refer to the description of the CMX100 Valve Assembly below for
details of operation.
deenergized, ports pilot pressure to the pilot operated directional control valve on the steering manifold. The
valve shifts and ports steering circuit pressure to the appropriate steering cylinder, and passes fluid leaving the
opposite cylinder back to Tank.

Steering, Boom Lift, Boom Extend, and Tool Operation, and the hydraulic rotary actuator used for Pick Rotate.
These valve assemblies are identical to those used on other vehicles, except for some of the port relief pressure
settings. Refer to the description of the CMX100 Valve Assembly as described in the section for other vehicles
with SAHR brakes for details of operation.

When not in Scale Brake Mode, the Scale Brake Solenoid Valve SV1 is deenergized, and blocks pilot pressure to
the series of pilot-operated valves PD1 through PD4 that are used to initiate application of the axle brakes, park
brake, and oscillation lock cylinders. When not in Scale Brake Mode, the two pilot-operated valves in the
Oscillation Lock Valve are open and allow fluid to flow freely between the two Cylinders when they move in and
out as vehicle travels and the frame sections oscillate from each other. When the operator presses the Scale
Brake Mode, SV1 is energized by an output from the Micrologix controller. SV1 then opens to provide pilot
6-20
pressure to the pilot-operated valves PD1 through PD4, which in turn provide pilot pressure to two pilot-operated
valves in the Oscillation Lock Valve, which then close, blocking fluid flow between the two cylinders and locking
them in that position.
SCALE BRAKE MODE

Scale Brake Mode automatically sets the Park Brake and Axle Brakes, and locks the Oscillation Lock Cylinders
(and also shifts the transmission to “neutral” and sets engine speed at 2400 RPM). When the vehicle is placed in
Scale Brake Mode, initiated by the operator pressing the Scale Brake pushbutton S33 on the RH Control Handle,
the Micrologix controller output energizes the Scale Brake Solenoid Valve SV1. SV1 provides pilot pressure to the
series of pilot-operated valves PD1 through PD4 that are used to initiate application of the axle brakes, park
brake, and oscillation lock cylinders. The Brake Pilot Pressure Reducing Valve then provides pressure to the
Brake Pedal Actuating Valves, so that pressure is applied to the brakes without the pedal being pressed. To set
the Park Brake, the Micrologix controller output in the SV3/SV17 park brake release circuit is removed,
deenergizing those solenoid valves and causing the park brake to set. A Micrologix controller output is also
produced that energizes and illuminates the Scale Brake On indicator light DS26.
BOOM LIFT OPERATION

shuttle valves. The boom lift valve assembly has 2750 psi and 700 psi cylinder port reliefs.


circuit shuttle valves. The boom extend valve assembly has 2750 psi cylinder port reliefs.
6-21
TOOL OPERATION
Tool operation is similar to that described for vehicles with SAHR brakes. Refer to the section for other vehicles
with SAHR brakes for details of tool operation.
Optional Push Blade operation is similar to that described for other vehicles with SAHR brakes. Refer to the
section for vehicles with SAHR brakes for details of push blade operation.
Optional Hammer operation is similar to that described for other vehicles with SAHR brakes. Refer to the section
for other vehicles with SAHR brakes for details of hammer operation.
6-22
MACHINE REPORTS AND FORMS
7. MACHINE REPORTS AND FORMS

This section of your Operation and Maintenance Manual provides the reports and forms that are used by Lake
Shore Systems, Inc. service personnel.
Read and understand

manual and safety
information before
operating!
7-1
MACHINE REPORTS AND FORMS
7-2
SCALER COMMISSIONING REPORT
SCL-CR-010
Dealer Customer
Address Address
City State City
Country Zip Country
Dealer Rep. Cust. Contact
Model Serial Number Hours Date
CHECK THE FOLLOWING FLUID LEVELS

ENGINE OIL FULL Add Fluid Type Used
TRANS. FLUID FULL Add Fluid Type Used
OSCL. AXLE FULL Add Fluid Type Used
RIGID AXLE FULL Add Fluid Type Used
HYDRAULIC OIL FULL Add Fluid Type Used
COOLANT FULL Add Fluid Type Used
BATTERY FULL Add Fluid Type Used
TEST AND RECORD THE FOLLOWING AT NORMAL OPERATING TEMPERATURE

ENGINE TEMP Low Idle High Idle Converter Stall
ENGINE OIL PRESS Low Idle High Idle
ENGINE MODEL#
ENGINE STALL TEST:
With Park Brake on, Select 3rd Gear forward, Increase engine RPM to stall speed. Do not allow torque converter temp to rise above 240 degrees F and do not
stall for more than 30 seconds. Record stall RPM and compare to RPM data for particular engine used. Return Trans to Neutral and allow to cool for 1
minute, repeat test to verify reading.
Engine Stall RPM (1750 or 1900 RPM) 2nd Test
TRANS. CLUTCH PRESS. at 2000 Engine RPM, Vehicle Stopped, Park Brake Applied
1st Gear 2nd Gear 3rd Gear Forward Reverse
STEERING PRESSURE at Engine Idle, Steering Wheel Turned and Held Against the Stops.
ACCUMULATOR NITROGEN PRECHARGE- with Engine Stopped, Keyswitch On, Depress and Release the Park Brake Test Button. Record the Pressure Reading on
the Service Brake Pressure Guages Just Prior to Falling To or Neat Zero PSI.
Front Rear
DUAL CHARGING VALVE- With the Engine Running at Idle Record the Following: Maximum Pressure Reading on the Service Brake Pressure Guages. When the Dual
Charging Valve Switches Off.
Minimum Pressure Reading on the Service Brake Pressure Guages. When the Dual Charging Valve
Switches On.
MAXIMUM BRAKE PRESSURE AT EACH AXLE- Tee a Pressure Gauge in the Brake Line of Each Axle. With the Engine Running, Fully Depress the Brake Pedal and
Record the Pressure of Each.
Front Rear
SCL-CR-010
TEST AND RECORD THE FOLLOWING AT NORMAL OPERATING TEMPERATURE
USING THE FACTORY INSTALLED PRESSURE TEST GUAGES, WITH THE ENGINE SET AT 1800 RPM, TEST AND RECORD THE FOLLOWING:
Bom Up Pressure Boom Down Pressure

Boom Ext. Pressure Boom Ret. Pressure
Tool Up Pressure Tool Down Pressure
Tool Left Pressure Tool Right Pressure
INSTALL A PRESSURE GAUGE IN THE PRESSURE SUPPLY LINE OF THE JOYSTICK CONTROLS. WITH THE ENGINE RUNNING AT 1800 RPM CHECK THE
JOYSTICK PILOT PRESSURE.
RECORD THE FOLLOWING AT NORMAL OPERATING TEMPERATURE
Engine Temperature Air Intake Indicator Reading

Transmission Temperature Exhaust Back Pressure
Hydraulic Oil Temperature (Inches in Water)
PERFORM THE FOLLOWING CHECKS AND RECORD THE CONDITION OF EACH

Adjustment Gauges and Operational Condition Operational Condition
Required Condition Instruments Yes No Good Poor Controls Yes No Good Poor
Belts Yes No Good Poor Hour Meter Start Switch
Fan Belts Engine Temp. Ft Lt Switch
Alternator Engine Oil Press. Rr Lt Switch
Voltmeter Bm Lt Switch
Lights Operational Condition Engine Fault Light Park Brake Button
Yes No Good Poor Power Indicator Park Brake Test
Light Button
Left Front Tachometer Lt Joystick
Trans. Clutch Scale Brake
Right Front
Press. Switch
Left Boom Trans. Oil Temp. Rt Joystick
Park Brake Trans.Direct.
Right Boom
Indicator Light Lever
Front Brake
Left Rear Trans. Gear Lever
Warning Light
Rear Brake
Right Rear Hand Throttle
Warning Light
Front Brake Press.
Rear Red Light Foot Throttle
Gauge
Rear Brake Press. Service Brake
Spot Light
Gauge Pedal
Hydraulic Oil
Lt Swing Pedal
Temp. Gauge
Preheat Indicator Horn Button
L. Hand Hyd. Test
Rt Swing Pedal
Gauge
Center Hyd. Test Battery
Gauge Disconnect
R. Hand Hyd. Test
Gauge
SCL-CR-010
CHECK THE FOLLOWING BOLT TORQUES
Wheel Mounting Bolts 300 LB-FT 2-3/4 Inch Articulation Bolts 300 LB-FT
Axle Mounting Bolts 325-425 LB-FT 10-1/2 Allen Head Articulation Bolts 90-100 LB-FT
PERFORM THE FOLLOWING BRAKE TEST
SERVICE BRAKES - With the Engine Running, Park Brake Released, Transmission in Second Gear, Depress the Service Brake Pedal and Fully Apply the
Throttle. The Unit Should Not Move.
Servicing Required YES NO
PARK BRAKES - With the Engine Running, Park Brake Released, Transmission in Second Gear, Depress the Service Brake Pedal and Fully Apply the
Throttle. The Unit Should Not Move.
Adjustment Required YES NO
WAS THERE ANY DAMAGE DURING SHIPPING? Yes (List Below) No
HAVE ALL DECALS AND WARNING PLATES BEEN INSTALLED? Yes No
LOCATE AND IDENTIFY THE FOLLOWING
Engine Oil Filter Fuel Filter Hydraulic Return Filter Main Electrical Fuse & Spare
Transmission Filter Air Intake Filter Hydraulic Suction Strainer
PERFORM THE FOLLOWING
Grease the Entire Machine Check for Leaks Check for Unusual Noises
Operate the Unit through All Gears Check for Interferences
Check for Loose or Missing Bolts
IS THE OPERATOR'S AND MAINTENANCE MANUAL ON MACHINE? Yes No
DEMONSTRATE THE FOLLOWING
How to Preheat and Start the Motor How to Properly Apply and Test the Parking Brakes
How to Operate all Switches and Controls How to Place the Vehicle in the Service Position
Operator Skills Good Fair Poor Mechanical Skills Good Fair Poor
Previously Trained Yes No Previously Trained Yes No
Retraining Required Yes No Retraining Required Yes No

Time Spent on Training Time Spent on Training
SCL-CR-010
LIST ALL CUSTOMER COMPLAINTS AND INDICATE WHETHER EACH HAS BEEN RESOLVED
Next Visit Schedule For

Will the Customer be Charged for the Next Visit? Yes No
Dealer Rep. Signature Date:
Customer Signature Date:

SERVICE WORK ORDER
SW-040
Machine Model: Customer:

Machine Serial Number: Business Unit:
Serviced By: Address:
Purchase Order: City:
Location: Contact:
Hours:
SERVICE REQUIRED
Warranty Customer Training Invoicing Repair

Contract In-House Training Follow-Up On-Site
Single Face Drill UV-11 UV-6 SV-26
Auto Bolter Manual Bolter Double Face Drill SV-45
SERVICE INFORMATION
Purpose for Call:
Who did you work with?
What did the customer do to correct the problem (prior to call)?
Was this a repeat problem?
WORK PERFORMED
REASON FOR FAILURE

SERVICE WORK ORDER
SW-040
SUGGESTIONS FOR IMPROVEMENT
FOLLOW-UP REQUIREMENTS
CHARGES: PER DAY: TOTAL:

Air Fare / Mileage / Rental
Travel Time
Service Time
Contract Cost
TOTAL:
Work Performed By: Date:
Approved By: Date:

WARRANTY REQUEST FORM
WR-060
Customer: Date:
Machine Serial Number: Name of Mine:
Reported By: Preparer:
WARRANTY REQUEST
Are replacement parts required immediately? If yes, P.O. #:
Are there spares in stock within our system?

(No - parts already replaced from stock. If under warranty issue credit to appropriate field service center)
Returned Part Production Information -
Part #: Part Name: Labor Costs Incurred:
Quantity Returned: Facility Returned To:
Description of the Problem:
Is this the first occurrence? If not, previously reported on:
Reported to: Previous WCR#:
Representative Review:
Date this machine was shipped from the OEM?
Findings of the quality review:
Is the part a purchased part? If yes, supplier is:
Supplier’s Authorization Number: Date Returned:
Supplier’s Findings: Under Warranty? Credit to be Issued: $
Personnel notified regarding this problem?
Findings (Under Warranty?): No, Claimant Notified Yes, Replacement / Credit Issued
Closed On: Closed By:

WARRANTY REQUEST FORM
WR-060
Cannon VERBAL ORDER REQUEST
P.O. Box 1470, River Road, Claremont, NH 03743 - Phone (603) 542-9548
Manufacturers of Mining and Material Handling Machinery
DATE RECEIVED AGENT NO. CUSTOMER ORDER NO. CUSTOMER REQ NO. RELEASE NO.
STAMLER ORDER NO. MACH SER. NO. TO: FROM:
A SHIP VIA FINAL CARRIER

G WRS
E
N
T
M A: S:
A D: H:
I D: I:
L R: P:
I E:
N S: T:
G S: O:
CUSTOMER SURVEY
CUSTOMER SURVEY
Customer Survey of Equipment upon Delivery & Start Up
Customer: _____________________________________ Location: _______________________________________
Machine Description: _____________________________________________________________________________

(Model Number Description and Serial Number)
Date Shipped: ________________ Date Arrived: ________________ Dave In Service: _____________
Shipped From: _____________________________ Prepared By: ____________________________________

(Prepared by Customer’s Representative)
Please rate our performance in the following areas with respect to the equipment purchased. Place an “X” or
check mark in the column that best describes your opinion.
Question Poor Good Excellent

Adherence to Delivery Schedules
Correct / Complete Equipment Received
Condition of Equipment Received
Quality of Manuals / Literature
Start-up Assistance
Equipment Performance
Production Quality
Service Support
Other (Please Specify)
If you experienced any problems, were they resolved to the customer’s satisfaction?
Yes __________ No __________
Please indicate below, your overall level of satisfaction with Lake Shore Systems, Inc. (LSSI) and its divisions as
a supplier of your equipment. Place an “X” or check mark next to the statement that best fits your opinion.
Rating Description
Completely Satisfied. LSSI Exceeded Expectations
Reasonably Satisfied. LSSI Met Expectations
Dissatisfied. LSSI Did Not Meet Expectations
General Comments: _____________________________________________________________________

________________________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
____________________________________________________________
Signature: ______________________________________ Date: _______________
LSSI Field Representative –

Please FAX completed form to Internal Sales Department Representative at (414) 446 6038
SCALER TRAINING
For Scaler Models SV-11, SV-18, SV-22, SV-26
PARTICIPANT TRAINING GUIDE

PUBLICATION NUMBER 1727 REVISION 3 © 2017 All rights reserved.
FAMILIARIZATION TRAINING
• Machine Introduction
• Accessories
• Operation
• Water Spray System
• Fire Suppression System MINE SCALING VEHICLE
• Special Options
SV-11, SV-18, SV-22, SV-26
• Maintenance
• Reports/Warranty
• Spare/Repair Parts
• Contact Information
OPERATORS TRAINING MAINTENANCE TRAINING

• Safety • Safety
• Pre-Op Checks • Maintenance Checklist
• Controls • Fluid and Filter Lists
• Indicators • Visual Inspections
• Start-Up • Fluid Levels
• Driving and Brake Tests • Tire Maintenance
• Scale Brake Mode • Filter Maintenance
• Shutdown • Lubrication Fittings
• Boom and Tool • Adjustments/Alignments
• Emergency • Troubleshooting/Functional
2141 Woodward Avenue Kingsford, MI 49802 (906) 774-1500 Fax: (906) 774-1505
Training - 1
SCALER TRAINING
SCALER TRAINING INCLUDES…

FAMILIARIZATION TRAINING OPERATORS TRAINING MAINTENANCE TRAINING
• Machine Introduction • Safety • Safety
• Accessories • Pre-Op Checks • Maintenance Checklist
• Operation • Controls • Fluid and Filter Lists
• Water Spray System • Indicators • Visual Inspections
• Fire Suppression System • Start-Up • Fluid Levels
• Special Options • Driving and Brake Tests • Tire Maintenance
• Maintenance • Scale Brake Mode • Filter Maintenance
• Reports/Warranty • Shutdown • Lubrication Fittings
• Spare/Repair Parts • Boom and Tool • Adjustments/Alignments
• Contact Information • Emergency • Troubleshooting/Functional
Familiarization Training: Review the model SV-11, SV-18, SV-22, and SV-26 Scalers, components,
and systems. Review of technical documentation.
Operators Training: Full review of machine safety. Review the design, controls, and operation of
the model SV-11, SV-18, SV-22, and SV-26 Scalers.
Maintenance Training: Full review of machine safety. Review of schedule (checklists) and
maintenance instructions for each machine component or system, component related
troubleshooting, and functional descriptions.
Training - 1
SCALER TRAINING
CANNON MINE SCALERS

• Accessories
Blue Text links to applicable • Operation
section of Operation and • Water Spray System
Maintenance Manual • Fire Suppression
• Special Options
• Maintenance
• Reports/Warranty
• Spare/Repair Parts
Specific Training Lessons • Contact Information
Training - 2
SCALER TRAINING
Machine Systems
General Machine Overview
Environmental Conditions
Machine Data Plates
Machine Warranty
Terminology
Training - 3
SCALER TRAINING
• Mine Scaling Accessories
Hydraulic Push
Hammer Blade
(Option) (Option)
Pick Tool
Training - 4
SCALER TRAINING
• Machine Operation
Scale Brake Mode
Using the Pick Tool
Using the Hydraulic Hammer
• Functional Descriptions
Scalers with SAHR Axle Brakes (Kessler) and SAHR
Transmission Brakes
SV-11 Scalers and Models Equipped with Kessler
Axles (SAHR Brakes) and HASR Transmission Brakes
Scalers with HASR Axle Brakes and SAHR
Transmission Brakes
Training - 5
SCALER TRAINING
• Water Spray System

Water Spray Pump Indicator
Hammer & Water Spray Trigger Switch
Water Spray System Actuation
Water Spray System Scheduled Maintenance
Water Spray System Troubleshooting
Training - 6
SCALER TRAINING
• Fire Suppression System

Two Manual Actuators
10 lb Fire Extinguisher
System Activation (Operation)
System Inspection (Maintenance)
Training - 7
SCALER TRAINING
• Special Options
Video Camera System
Wiggins Fuel Fast Fill and
Wiggins Hydraulic Fast Fill Systems
Automatic ANSUL Fire Suppression
• Grease Options
Manual Grease Blocks
Auto Greasing System
Training - 8
SCALER TRAINING
• Scaler Maintenance
Maintenance Checklists
- Every Shift
- Every 40 Hours
- Every 250 Hours
- Every 500 Hours
- Every 1000 Hours
- Every 2000 & 5000 Hours
Recommended Fluids
Recommended Filters
Specific Maintenance Tasks
Training - 9
SCALER TRAINING
• Reports, Forms, and Warranty

Commissioning Report
Service Work Order
Warranty Request
Training - 10
SCALER TRAINING
• Spare / Repair Parts

Spare Parts Lists can be made
available for specific machine build
• Parts Manual
Provides service and repair parts
information to identify and order
spare parts.
Includes component Serial Numbers
Illustrated Parts Breakdowns of

Parts Groups
Training - 11
SCALER TRAINING
• Contact Information
- Back Covers of Manuals
- Direct Service Toll Free Number
- Contact us by Email
- Regional Sales and Service
- International Sales and Service
Training - 12
SCALER TRAINING
OPERATOR TRAINING
CANNON MINE SCALERS

• Safety
• Pre-Op Checks
Blue Text links to applicable • Controls
section of Operation and • Indicators
Maintenance Manual • Start-Up
• Driving and Brake Tests
• Scale Brake Mode
• Shutdown
• Boom and Tool
Specific Training Lessons • Emergency
Training - 13
SCALER TRAINING
OPERATOR TRAINING
• Operator Safety Read and understand

manual and safety
Machine Misuse information before

operating!
Safety Symbols and Words

A Danger identifies the most serious
Protective Equipment hazards that will result in serious injury or death.
General Safety Precautions A Warning identifies critical hazards that

could result in serious injury or death.
Confined Spaces
A Caution identifies potential hazards that
could result in minor injury.
Operation Instructions
A Notice identifies the potential for major
damage to the machine or other equipment.
MSDS Sheets
Training - 14
SCALER TRAINING
OPERATOR TRAINING
• Pre-Operation
Pre-Op Checklist!
- Name, Date, and Hours
- Start Up (Warm Up)
- General Inspections
- Fluid Checks
- Engine Conditions
- Accessory Operation
- Brake and E-Stop Tests
Training - 15
SCALER TRAINING
OPERATOR TRAINING
• Machine Controls
Accumulator Dump
Manual Brake
Operator Console
Control Handles
Brake Pedals
Fire Suppression
- Functional Descriptions
Training - 16
SCALER TRAINING
OPERATOR TRAINING
• Machine Indicators
Engine Display
Operator Console
Circuit Breakers
Filter Indicators Murphy PowerView
Tank Levels Engine Display
- Functional Descriptions
Training - 17
SCALER TRAINING
OPERATOR TRAINING
• Machine Start-Up
Starting the Engine
Dump Bypass Switch
Status of Indicators
Training - 18
SCALER TRAINING
OPERATOR TRAINING
• Brake Tests and Driving

Release/Reset Park Brake
Directon of Travel
Steering
Brake Tests
• Scale Brake
Scale Brake Mode
Training - 19
SCALER TRAINING
OPERATOR TRAINING
• Shutdown
Stopping the Vehicle
Machine Shutdown
Chock the Wheels!
• Boom and Tool Operation

Operating the Boom
Operating the Tool (Pick or Hammer)
Training - 20
SCALER TRAINING
OPERATOR TRAINING
• Emergency Operation
Towing the Machine
In Case of Fire (Fire Suppression)
Training - 21
SCALER TRAINING
MAINTENANCE TRAINING
CANNON MINE SCALERS

 Safety
 Checklists
Blue Text links to applicable  Fluid-Filter Lists
section of Operation and  Inspections
Maintenance Manual  Fluid Levels
 Tire Maintenance
 Filter Maintenance
 Lubrication-Grease
 Adjustments
Specific Training Lessons  Troubleshooting
Training - 22
SCALER TRAINING
• Maintenance Safety Read and understand

manual and safety
Machine Misuse
information before
operating!
Safety Symbols and Words

A Danger identifies the most serious
Protective Equipment hazards that will result in serious injury or death.
General Safety Precautions A Warning identifies critical hazards that

could result in serious injury or death.
Confined Spaces
A Caution identifies potential hazards that
could result in minor injury.
Maintenance Instructions A Notice identifies the potential for major

damage to the machine or other equipment.
MSDS Sheets
Training - 23
SCALER TRAINING
• Maintenance Checklists
Scheduled Maintenance
- Every Shift
- Every 40 Hours
- Every 250 Hours
- Every 500 Hours
- Every 1000 Hours
- Every 2000 & 5000 Hours
Training - 24
SCALER TRAINING
• Scaler Fluids and Filters
Filter List
Fluid List
Training - 25
SCALER TRAINING
• Visual Inspections
- General Vehicle Inspection
- Hose and Pump Leaks
- Electrical Wiring/Boxes
- Park Brake System
- Bearings, Pins, Bushings
- Rotary Actuator
- Pick Tool or Hammer
- Drive Shafts and Engine Mounts
- Engine Mounts and Batteries
- Fire Suppression and Water Spray
- Kessler Axle Oil Filter (option)
Training - 26
SCALER TRAINING
• Check Fluid Levels

- Diesel Fuel
- Hydraulic Oil
- Engine Coolant
- Transmission
- Windshield Washer
- Water Tank (option) Hydraulic Tank
(Wiggins Remote Fill Option Shown)
Fuel Tank -
Wiggins
Remote Fill
Option Shown
Training - 27
SCALER TRAINING
• Check Wheels and Tires

- Wheel Lug Torque
- Tire Pressure and Inspection
Training - 28
SCALER TRAINING
• Check/Change Filters
- Engine Air Cleaner
- Transmisison Filter (Dirt Indicator)
- High Pressure Filter (Dirt Indicator)
- Hydraulic Oil Tank Breather
- Hydraulic Return Line
- Engine Oil and Fuel Filters
- Hammer Filter (option)
- Water Spray Filter (option)
- Kessler Axle Oil Filter (option)
Training - 29
SCALER TRAINING
• Machine Lubrication
- Lube Chart and Fluid List
- Manual Grease
- Auto Grease System
Lube Chart
Auto Grease
Manual Grease
Training - 30
SCALER TRAINING
• Machine Adjustments
- Check Hydraulic Pressure
- Adjust Hydraulic Pressure
- Check Accumulator Precharge
- Charge Accumulators
- Adjust Boom Rollers
- Adjust Park Brake
Training - 31
SCALER TRAINING
• Machine Troubleshooting
- Troubleshooting Guide
Troubleshooting
• Functional Descriptions Guide
-Scalers with SAHR Axle Brakes (Kessler) and

SAHR Transmission Brakes
-SV-11 Scalers and Models Equipped with
Kessler Axles (SAHR Brakes) and HASR
Transmission Brakes
-Scalers with HASR Axle Brakes and SAHR
Transmission Brakes
• Schematics Machine Specific Hydraulic and

Electrical Schematics
- Machine Specific
- Hydraulic and Electrical
Training - 32

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OPERATION AND MAINTENANCE MANUAL

PUBLICATION NUMBER 1676 REVISION 7 © 2017 All rights reserved.

 MECHANICAL FIXED BOOM SCALER

 HYDRAULIC WET DISC BRAKES

 AUTO SECONDARY BRAKES

 CATALYTIC PURIFIER AND SILENCER

 TELESCOPIC BOOM MINE SCALING VEHICLE

Vehicle and Equipment Operation

TABLE OF CONTENTS (CONTINUED)

Adjustments and Alignments

Lube Charts ........................................................................................................................... 4-51

DO NOT USE THIS MACHINE TO…

LIFT, LOWER, OR TRANSPORT PERSONNEL OR OBJECTS

OPERATE IN EXPLOSION HAZARDOUS ATMOSPHERES

DRIVE ON PUBLIC ROADWAYS

TOW OTHER MACHINES OR MACHINERY

Safety Signal Words

A Caution identifies potential hazards that could result in minor injury.

General Safety Precautions

Do not operate the vehicle on grades greater than 18° (31%).

Operation Safety Precautions

 NEVER start a machine that has been tagged OUT OF SERVICE.

 Ensure the transmission directional control switch is in the NEUTRAL position.

 Ensure all scheduled maintenance has been performed.

 Ensure all accessories are properly stowed.

 DO NOT allow riders except in equipped seats.

 Do not leave the vehicle unattended with the engine running.

 Remove wheel chocks only when parking brake is applied.

 Keep the haulage or roadways clear of loose rock and debris.

 NEVER perform service in hinged area without articulation lock in place.

 Never inflate tire and wheel assemblies without proper safeguards.

 NEVER work on hydraulic system without removing pressure from system.

 ONLY remove radiator cap when system is cool.

Evaluating Hazardous Atmospheres:

 Oxygen concentration below 19.5% or above 23.5%

You must do air monitoring to determine if a hazardous atmosphere exists!

Atmospheric conditions in a confined space can change very quickly!

 23.5% and above is too HIGH

Flammable/Explosive Gases, Vapors, or Mists:

Read and understand

Mine Scaling Vehicle Systems

ENGINE END FRAME DRIVE TRAIN BOOM END FRAME

Extendible Boom &

PERMISSIBLE ENVIRONMENTAL CONDITIONS

MACHINE DATA PLATES

CHARGE PUMP PRESSURE:

DIN CONNECTOR WITH LED:

SAHR: Spring-Applied, Hydraulically-Released Brake

HASR: Hydraulically- Applied, Spring-Released Brake

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CONTROLS AND INDICATORS

Fuel / Water Fill Cap &

Note: This Illustration is

Wiggins Remote Fill Option

Fill Cap &

Note: This Illustration is

Wiggins Remote Fill Option