4300B - 4310B Service Manual (Standard) 113050

4300B/4310B Service
Manual
Drum Chipper
Effective on serial number:
4300B: 43B-34-1921 and up
4310B: 46B-20-1855 and up
113050 English
Copyright © 2015 Peterson Pacific Corp. Document History
All rights reserved. Document Number: 113050
Peterson Pacific Corp. reserves the copyright for this Publication Date: January, 2015
manual and the sole right to add, change, summarize,
delete, or otherwise edit and update information con- Reference Documents
tained in this manual, including text, images, tables, The following documents for the 4300B and 4310B
translations, formatting, and all forms of information chippers are provided to purchasers of new machines.
herein. • The Operator Safety and Maintenance Manual
Peterson Pacific Corp. is an Astec Industries Co. describes basic safety and operating information.
The maintenance sections provide step-by-step pro-
Trademarks cedures for many common maintenance activities,
Peterson and the Peterson icon are trademarks of Peter- such as lubrication, replacing bits, grates, and some
son Pacific Corp. Caterpillar, and CAT are registered other common wear parts, operating parts and sub-
trademarks of Caterpillar, Incorporated. All other prod- systems for maintenance access, a maintenance
ucts or services mentioned in this document are identi- schedule and log, and more.
fied by the trademarks or service marks of their
The Operator Safety and Maintenance Manual
respective companies or organizations, and Peterson
should be kept at the equipment at all times for the
Pacific Corp disclaims any responsibility for specifying
use of operators and others who are expected to
their ownership. Any such marks are used in an editorial
work with or on the chipper.
way, to the benefit of the owner, with no intention of
infringement. • The Parts Book makes ordering replacement parts
easier and quicker. It is shipped separately from the
Patents machine. The book is provided by the Peterson dis-
The 4300B and 4310B are remote-controlled machines tributor, which is the primary source for replace-
with critical parts licensed under U.S. Patents. For a list ment parts. The Parts Book is available on CD-
of Peterson patents, active and pending, go to the Pat- ROM, which in some cases, may make it possible to
ents page of the Peterson website. have a copy of it at the work site.
Additional copies and replacement copies of these man-
California Proposition 65 Warning uals may be purchased. Copies of the manuals are also
Diesel engine exhaust and some of its constituents are available to regional dealers.
known to the State of California to cause cancer, birth Peterson welcomes your comments for improving the
defects, and other reproductive harm. content, design, and usefulness of these documents.
Contacts
Contact your Peterson distributor for current operation,
safety, maintenance, and service information.
Peterson Pacific Corp
PO Box 40490
Eugene, Oregon 97404
U.S.A.
Peterson Product Support 888.813.0712
Fax 541.689.0804
www.petersoncorp.com
ABOUT THIS MANUAL
The information about this manual describes all the manuals that support the drum chipper, the safety notices you
need to follow, the definitions of special terms, and the text of the limited warranty.
The Manual Set Important Messages and

Notes
Please do not remove manuals from the machine. Miss-
ing manuals can lead to hazards and delays when the In addition to the hazard alert messages that refer to pos-
manuals are not read or cannot be found by those who sible of injury to people, the manual uses the following
need them. type of alert message:
All Peterson chipper machine tech- Important
nicians should become thoroughly Indicates a situation that, if not noticed or avoided,
familiar with this manual, as well as may result in equipment or property damage. This
the Operator Safety and Mainte- message type is also used to call attention to
nance Manual supplied with the opportunities for improving machine performance
machine to help ensure safe, effi- or efficiency.
cient material processing and long machine life.
NOTE: Provides additional information to enhance
understanding of the topic.
Alert Messages
Throughout this manual and on many decals mounted
Safety Instructions
on the machine, you will see three types of hazard alert
Be sure to thoroughly read the entire Safety chapter
messages that refer to risks of possible injury to people. (“Working Safely” on page 5) to avoid hazardous oper-
These messages are shown with the following safety
ations and to become aware of hazards that may arise
alert symbols:
during maintenance.
1 DANGER
Indicates an immediate hazard that, if not
avoided, will result in death or serious injury.
1 WARNING
Indicates a potential hazard that, if not avoided,
could result in death or serious injury.
1 CAUTION
Indicates a potential hazard that, if not avoided,
may result in minor or moderate injury.
Because alert messages can disrupt the flow of a proce-
dure, shortened alert messages may appear in the step-
by-step task descriptions.
113050 4300B/4310B DRUM CHIPPER SERVICE MANUAL 3

ABOUT THIS MANUAL
Units of Weight and Measure Small Numbers on Figures

In this manual, U.S. customary units of weight and mea- In Peterson product manuals, we insert a number, such
sure are stated first, followed by their SI (metric) values as F05555, in small typeface below each graphic to
in parentheses. For example, 10 lb (4.5 kg). identify its file name. This number is for editorial use
Many SI units have been rounded to avoid an improper only.
appearance of precision.
U.S. customary units are sometimes stated in words or
abbreviations, such as ft for foot or feet, ° F for tempera-
ture degrees Fahrenheit, and in. for inch or inches, lbs
for pounds, and psi for pounds per square inch.
Ft-lb is an abbreviation for “foot-pounds of torque,”
although in some fields the abbreviation lb-ft, for
“pound-feet of torque” is used.
A period (.) after the abbreviation is not included in
most cases, but is retained for the abbreviation of inch
(in.) to avoid confusion with the word “in” of similar
spelling.
N/A means “not applicable.”

ABOUT THIS MANUAL
Limited Warranty
Peterson Chippers and Flails
This warranty is Peterson’s entire and only warranty to the Distributor and Distributor customers on resale
with respect to the Products sold hereunder. This warranty is expressly in lieu of all other warranties,
expressed or implied, and any implied warranties of merchantability or fitness for a particular purpose are
hereby excluded. This is a Limited Warranty, referring only to the product, machine, part(s), or unit iden-
tified on the original sales order and is subject to other limitations established by Peterson’s Warranty Pol-
icy and as hereinafter set forth. Peterson Pacific Corp. is here also referred to by its logo and abbreviation
Peterson. Only Peterson may assume any liability pertaining to its products.
This Peterson product is warranted to be free from defects in workmanship and materials under normal
use and conditions for a period of twelve (12) months, or 2000 operating hours, or 2000 service meter
units, whichever occurs first, from the warranty start date. Products sold as complete machines or operat-
ing units have a warranty start date defined by the operating start date. Products sold as parts have a war-
ranty start date defined by the date of installation of the part. If the machine into which the replacement
part is installed is no longer within the warranty period, no labor or mileage costs are reimbursed.
Should any defect in workmanship or materials be found and reported within the warranty period, Peterson
liability shall be limited to replacement parts and technician service for replacement, and shall be furnished
as stated in the Warranty Policy.
NOTE: Peterson’s products are not designed for processing rocks, metal, or other non-crushables. Process-
ing non-crushables can damage the machine and/or its parts. Peterson shall not be liable for any damage
or personal injury as a result of rocks, metal, or other non-crushables going through the machine.
This warranty shall not apply to any Peterson equipment where the equipment has been subjected to acci-
dent or misuse, or alterations unless Peterson has given prior written consent. Peterson liability under this
warranty is limited to the repair or replacement of defective parts or workmanship and in no event shall
Peterson be liable for incidental, consequential or indirect damages of any kind.
This warranty is null and void if other than genuine Peterson’s parts are used. Peterson makes no warran-
ties with respect to trade accessories or component parts not manufactured by or distributed by Peterson.
Those accessories or components are subject only to such warranties, if any, as may be made by their
respective manufacturers. Peterson and its customers may expect that certain operating parts of the product
or unit require replacement as a result of normal use during the warranty period. These parts include, but
are not limited to: wear liners, chains, bits or knives, bearings, filters, light bulbs, belts, etc. Replacement
of such parts is not included within the warranty.
Before evaluating a warranty claim Peterson reserves the right to require defective parts to be returned for
inspection with all charges prepaid.
(January, 2014)

ABOUT THIS MANUAL

CONTENTS
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . 3 Electrical Energy Hazards. . . . . . . . . . . . . 14
The information about this manual describes all the manuals Moving Parts . . . . . . . . . . . . . . . . . . . . . . . . . 15
that support the drum chipper, the safety notices you need to
follow, the definitions of special terms, and the text of the lim- Crushing and Pinching Hazards . . . . . . . . 15
ited warranty. Feed System Hazards . . . . . . . . . . . . . . . . 15
The Manual Set. . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Rotor Hazards . . . . . . . . . . . . . . . . . . . . . . 16
Alert Messages . . . . . . . . . . . . . . . . . . . . . . . . .3 Chip Spout Hazards. . . . . . . . . . . . . . . . . . 16
Important Messages and Notes . . . . . . . . . . . . .3 Drive Tracks (4310B) . . . . . . . . . . . . . . . . 18
Guards and Shields . . . . . . . . . . . . . . . . . . 18
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . .3
Units of Weight and Measure . . . . . . . . . . . . . .4 Fire Prevention and Suppression . . . . . . . . . . . . . 18
Small Numbers on Figures . . . . . . . . . . . . . . . .4 Daily Fire Prevention . . . . . . . . . . . . . . . . . . . 18
Peterson Chippers and Flails . . . . . . . . . . . . . . .5 Before Operation . . . . . . . . . . . . . . . . . . . . 18
During Operation . . . . . . . . . . . . . . . . . . . 18
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . .5
After Operation . . . . . . . . . . . . . . . . . . . . . 19
1. WORKING SAFELY . . . . . . . . . . . . . . . . . . . . . 5 Sources and Causes of Fires . . . . . . . . . . . . . . 19
Safe working conditions require you to avoid machine and Fire Suppression Equipment . . . . . . . . . . . . . 20
job-site hazards, to practice fire prevention, and to follow safe-
ty instructions. Fire Extinguishers . . . . . . . . . . . . . . . . . . . 20
Water Pump Sprayer (4310B) . . . . . . . . . . 21
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Hazards, Techniques, Features and Devices . . .5 Job Site Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Moving Machinery . . . . . . . . . . . . . . . . . . . . . 22
Safety First! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Flying Objects Hazard . . . . . . . . . . . . . . . . . . 22
Responsibility for Safety . . . . . . . . . . . . . . . . . .6
Noise Hazard . . . . . . . . . . . . . . . . . . . . . . . . . 22
Use Only for the Designed Purpose . . . . . . . . .6
Creating a Safe Workplace. . . . . . . . . . . . . . . 23
Qualified Operators . . . . . . . . . . . . . . . . . . . . . .6
Wear Protective Gear . . . . . . . . . . . . . . . . 23
Operating the Machine Safely . . . . . . . . . . . . . . . .7 Create Safe Conditions . . . . . . . . . . . . . . . 23
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . .7 Practice Safe Behaviors. . . . . . . . . . . . . . . 23
Disconnect Switches . . . . . . . . . . . . . . . . . .7 Operating and Hazard Zones . . . . . . . . . . . . . 24
Disconnect Lockout/Tagout . . . . . . . . . . . . .8
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . 26
Emergency Machine Stop . . . . . . . . . . . . . .9
Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . 27
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Remote Machine Stop . . . . . . . . . . . . . . . . .9
SECTION 1000
Stored Energy . . . . . . . . . . . . . . . . . . . . . . . . . 10 POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . 29
Compression Roll Housing Precautions. . . 10
Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Rotor Precautions . . . . . . . . . . . . . . . . . . . . 11
Remove the Clutch Sheave. . . . . . . . . . . . . . . 29
Jams or Blockage . . . . . . . . . . . . . . . . . . . . 14
Install the Clutch Sheave . . . . . . . . . . . . . . . . 29
Falling Objects . . . . . . . . . . . . . . . . . . . . . . 14
Pressurized Gases and Fluids . . . . . . . . . . . 14 Remove the Clutch . . . . . . . . . . . . . . . . . . . . . 30
Install the Clutch . . . . . . . . . . . . . . . . . . . . . . 32
113050 4300B/4310B SERVICE MANUAL 1

CONTENTS
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Pressure Limiter Settings . . . . . . . . . . . . . . . . 66

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Setting Up the Tracks . . . . . . . . . . . . . . . . . . . 70
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Specifications for Straight Travel . . . . . . . 72
Belt Idler Assembly (4310B) . . . . . . . . . . . . . . . 35 3-Section Valve Pressure Settings . . . . . . . . . 73
Idler Shaft Removal . . . . . . . . . . . . . . . . . . . . 35 Adjusting Pressures (4300B) . . . . . . . . . . . . . . . . 74
Seal and O-Ring Replacement . . . . . . . . . . . . 36 Main System Pressures . . . . . . . . . . . . . . . . . . 74
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Pressure Limiter Settings . . . . . . . . . . . . . . . . 78
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 37 7-Section Valve Pressure Settings . . . . . . . . . 79
Installation . . . . . . . . . . . . . . . . . . . . . . . . 37 System Pressures . . . . . . . . . . . . . . . . . . . . . . . . . 80
Idler Shaft Installation . . . . . . . . . . . . . . . . . . 40 4300B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Torque Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 4310B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Hydraulic Fittings and Torque Tables . . . . . . . . . 81
SECTION 2000
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . 43 Straight Thread O-Ring Boss (ORB) Low
This section covers the service, troubleshooting, and set-up
Pressure with 37o Seat . . . . . . . . . . . . . . . . 82
of pumps, motors, valve assemblies, and cylinders. Straight Thread O-Ring Boss (ORB) High
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Pressure with ORS . . . . . . . . . . . . . . . . . . . 82
ORS (O-Ring Seal) . . . . . . . . . . . . . . . . . . 83
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 45
SAE 37o (JIC) . . . . . . . . . . . . . . . . . . . . . . 83
Troubleshooting Basics . . . . . . . . . . . . . . . . . 45 Metric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Tools for Troubleshooting . . . . . . . . . . . . . . . 45 BSPP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Calling Product Support. . . . . . . . . . . . . . . . . 45
Troubleshooting Tables . . . . . . . . . . . . . . . . . 46 SECTION 3000
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . 85
Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 The machine’s electrical system can be a troubleshooting tool
In Case of Pump Failure. . . . . . . . . . . . . . . . . 48 for technicians. Wiring can be checked for shorts and opens,
and the display can be used to get information from pressure
Troubleshooting a Pump . . . . . . . . . . . . . . . . 48 transducers and every switch on the machine.
Pump Removal. . . . . . . . . . . . . . . . . . . . . . . . 49
Troubleshooting Machine Circuits. . . . . . . . . . . . 85
Pump Installation . . . . . . . . . . . . . . . . . . . . . . 50
Required Tools. . . . . . . . . . . . . . . . . . . . . . 85
Bleeding Air from the Hydraulic System . . . 51
Ground Connections . . . . . . . . . . . . . . . . . . . . 85
Valve Assemblies . . . . . . . . . . . . . . . . . . . . . . . . 52 Alternator 60A Circuit Breaker. . . . . . . . . . . . 86
Directional Control Valves . . . . . . . . . . . . . . 52 ECM Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Monoblock Valve Assembly . . . . . . . . . . 55 Clutch Controller Faults . . . . . . . . . . . . . . . . . 86
Removing a Valve Manifold. . . . . . . . . . . 56 Radio Status Lights . . . . . . . . . . . . . . . . . . . . . 86
Replacing a Valve Spool. . . . . . . . . . . . . . 56
IQAN System Control Modules . . . . . . . . . . . 86
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Control Power . . . . . . . . . . . . . . . . . . . . . . 86
Troubleshooting Cylinders. . . . . . . . . . . . . . . 58 Troubleshooting with the IQAN Display . 87
Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Control System Faults . . . . . . . . . . . . . . . . 88
Troubleshooting a Motor . . . . . . . . . . . . . . . . 60 Tracing an Example Circuit . . . . . . . . . . . . . . . . . 92
Connect and Test a New Feed Motor. . . . . . . 61 Updating the Machine Control Software . . . . . . 100
Adjusting Pressures (4310B). . . . . . . . . . . . . . . . 62 Return Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Main System Pressures . . . . . . . . . . . . . . . . . 62
MCR Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

CONTENTS
SECTION 4000 Replacing Paddles . . . . . . . . . . . . . . . . . . . . 143

FEED SYSTEM . . . . . . . . . . . . . . . . . . . . . . 107
Chip Spout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Tail Drum and Bearings . . . . . . . . . . . . . . . . . . .107 End Load Spout (4300B) . . . . . . . . . . . . . . . 144
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 144
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .107 Installation. . . . . . . . . . . . . . . . . . . . . . . . 144
Feed Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 End Load Spout (4310B) . . . . . . . . . . . . . . . 145
Removal and Installation. . . . . . . . . . . . . . . .109 Removal . . . . . . . . . . . . . . . . . . . . . . . . . 145
Method I—Remove Old Chain First . . . .109 Installation. . . . . . . . . . . . . . . . . . . . . . . . 145
Method II—Use Old Chain to Pull On New Top Load Spout . . . . . . . . . . . . . . . . . . . . . . 146
Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . .110 Removal (4310B) . . . . . . . . . . . . . . . . . . 146
Feed Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Installation. . . . . . . . . . . . . . . . . . . . . . . . 147
Remove the Feed Drive . . . . . . . . . . . . . . . . .111 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Remove the Motor (Only) . . . . . . . . . . . . . . .112
Install the Feed Drive or Motor . . . . . . . . . . .112
Compression Roll . . . . . . . . . . . . . . . . . . . . . . . .116
Remove the Motor and Bearing . . . . . . . . . .116
Install the Motor and Bearing . . . . . . . . . . . .117
Remove the Compression Roll Housing . . . .120
Install the Compression Roll Housing. . . . . .121
SECTION 5000
PROCESSOR SYSTEM . . . . . . . . . . . . . . . . . 125
Rotor Sheave and Bushing . . . . . . . . . . . . . . . . .125
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Removal . . . . . . . . . . . . . . . . . . . . . . . . . .131
Installation . . . . . . . . . . . . . . . . . . . . . . . .131
SECTION 6000
DISCHARGE SYSTEM . . . . . . . . . . . . . . . . . 135
Chip Accelerator. . . . . . . . . . . . . . . . . . . . . . . . .135
Removing the Accelerator. . . . . . . . . . . . . . .135
Bearing Removal . . . . . . . . . . . . . . . . . . . . . .135
Bearing Installation . . . . . . . . . . . . . . . . . . . .136
Non-Drive-Side Bearing . . . . . . . . . . . . .136
Drive Side Bearing . . . . . . . . . . . . . . . . . .139
Installing the Accelerator . . . . . . . . . . . . . . .142

CONTENTS

C HAPTER 1
WORKING SAFELY
Safe working conditions require you to avoid machine and job-site hazards, to practice fire prevention, and to follow
safety instructions.
Introduction Hazards, Techniques,

Features and Devices
This chapter provides information about how to work
safely while operating and maintaining the drum chip- Safe operation requires understanding the hazards that
per. exist, the techniques for avoiding unsafe situations, and
Six topics are covered in this chapter: the features and devices of the machine that support
using it safely.
Safety First: Discusses your responsibility for taking
safety seriously. Hazards: When operating the machine, the main haz-
ards arise from movement of machine parts, the possi-
Operating the Machine Safely: Describes the haz- bility of fire, and flying or falling materials. Limited
ards of operating the machine and identifies safety visibility and difficult communication around the
devices and special precautions for individual assem- machine increases these risks.
blies.
Techniques: Techniques for reducing the risk of
Fire Prevention and Suppression: Describes fire injury involve keeping people a safe distance from the
risks, best practices for fire risk prevention, and fire- machine and keeping the machine clean and well main-
fighting preparations. Covers use of the fire extin- tained.
guisher and the pump sprayer.
Features and Devices: The primary safety devices
Job Site Safety: Discusses the hazards and necessary for machine operation are guards, shields, hazard warn-
precautions for setting up and operating a chipper. ing labels, a remote control system, and an emergency
Safety Labels: Displays danger, warning, and cau- stop system.
tion labels attached to the machine and lists the warning The primary safety devices for machine maintenance
messages for performing maintenance. are electrical power disconnect and lockout switches;
Maintenance Safety: Discusses the importance of support pins; proximity sensor switches; and secure,
maintaining the machine for peak performance and slip resistant access.
safety.

WORKING SAFELY
Safety First! Use Only for the Designed

Purpose
Make safety your first priority. Become familiar with
this entire Operation & Maintenance Manual and with Do not attempt to defeat any factory-installed safety
all controls before starting the machine, or attempting to system. The machine must only be used to do the work
operate it. for which it was designed.
Do not allow anyone to work on the machine who does Unsafe conditions may occur if the machine is operated:
not put safety first. Failure to follow safety warnings,
• With material it was not designed to process, such
messages, and other hazard alert signals could result in
as metals and rocks
serious injury or death.
• With accessories or attachments not furnished or
No one except the operator and those support persons approved by Peterson
who have been trained to safely perform maintenance
on the machine should be near the machine while it is • With modifications that change its operation or
being set up, maintained, or prepared for transport. capacity
• With modifications that void the warranty and
Responsibility for Safety increase risks of safety hazards
See the limited warranty statement at the start of this
Read the safety information carefully to avoid hazard- manual.
ous operating conditions. It is not possible for Peterson
Pacific to foresee all such conditions. It remains the
responsibility of the owner/operator to anticipate and
Qualified Operators
avoid unsafe conditions. Safety must be the full-time Those selected to be operators must possess the follow-
responsibility of the owner, operator, and every person ing qualities:
working around or on the machine.
Must be 18: In the U.S. operators of the machine must
The machine is designed for safe operation. It must be at least 18 years old. See Code of Federal Regula-
always be started, operated, and serviced with strict tions: Labor 29: 570.2,a, I.
attention to safety.
Must be alert and sober: Never operate the
Operators should carefully read all
machine while under the influence of drugs and/or alco-
safety information and avoid hazardous
hol. Use of prescription or over-the-counter drugs
conditions. Failure to adhere to safety
requires medical advice on whether or not you can
warnings, messages, and other hazard
safely operate this machine.
alert signals could result in serious
injury or death. Must not have health restrictions: Do not operate
the machine if you are subject to dizziness, seizures, or
Do not permit anyone to operate, service, repair, or
motion disturbance.
work on or around this machine unless they have read
and understood the safety and operating information. Must be authorized and trained: Operators must
Peterson strongly recommends starting and maintaining be authorized by the owner of the machine, and must be
a complete safety program, including active safety trained in all its functions and capabilities before oper-
training and on-going, on-site safety improvement pro- ating it.
grams.
Peterson strives to maintain hazard alert messages and
other safety communications in conformance with stan-
dards established by American National Standards
Institute (ANSI) and the Occupational Safety and
Health Administration (OSHA).

WORKING SAFELY
Operating the
Machine Safely
This section describes the hazards of operating the
machine and identifies the safety devices for reducing
risk of injury.
Safety Controls 1
2
Safe use of the machine during normal operation, main-

tenance, and emergencies requires full control of the
engine and energized systems. This section describes
how to use the disconnect switches and the emergency F08704
stop buttons. 1. Main Battery Disconnect

2. Control Power Disconnect
Disconnect Switches
Figure 1: Disconnect Switches (Shown in Off Position) and
The disconnect switches are located on the left side next Emergency Stop Switch (1 of 4)
to the air cleaner (Figure 1). These switches connect and
disconnect battery electrical power. The two disconnect
switches are: 1 CAUTION
• Use the control power disconnect switch to discon- Do not use the disconnect switches to attempt
nect electrical power to all systems except the work shutdown. Doing so can cause serious damage
lights and water sprayer. to machine electronics
• Use the battery disconnect switch to disconnect Turning off the disconnect switches while the engine is
electrical power to the control power disconnect running can create electrical loads, spikes, and surges
switch and to the work lights and water sprayer. that cause expensive electrical damage to the alternator,
Use the battery disconnect switch to turn off the electri- micro-processor, Electronic Control Module (ECM), or
cal control system: other sensitive parts.
• When the machine is left unattended Use the ENGINE switch for normal shut down. Only
when the engine has fully stopped should you then turn
• When the machine is being transported off a disconnect switch.
• When you do not need to use the work lights or
water sprayer
• To prevent unexpected starting
• To lock out the machine
NOTE: Prevent accidental startup by turning off and
locking out the battery disconnect switch.
When you want to disconnect power but need to
use the work lights, turn off only the control
power disconnect switch.

WORKING SAFELY
Disconnect Lockout/Tagout Everyone maintaining or servicing the

machine must lock and tag it out.
Lockout/tagout procedures must be
1 WARNING followed as written by federal (OSHA
When the battery disconnect is in the Off posi- in the U.S.), state (such as OR-OSHA
tion, the electrical system is de-energized, but in Oregon, U.S.), provincial, or local
NOT locked out until the switch is closed and authorities.
padlocked.
 To lock out or tag out the machine
The disconnect switches (Figure 2) are a safety lockout
point for the machine. Lockout of the switches prevents 1. If the clutch is engaged, press the CLUTCH button
accidental start-up and other hazards. on the control panel (Figure 3).
2. Turn the ENGINE switch to the stop position.
F08706
Figure 2: Disconnect Switches Lockout/Tagout 3
The battery disconnect switch must be in the Off posi-

tion to remove the key. The key must be removed to
close the lock cover. When the key is removed, a hinged
lockout cover can be placed over the switch opening.
F08708
The control power disconnect switch does not have a 1. Emergency Stop Button with LED
key or cover. Instead, the switch must be in the Off posi- 2. Clutch Button
3. Engine Switch
tion in order to lock.
Keep the battery disconnect switch key and padlock Figure 3: Control Panel
keys in a secure location when the machine is shut
down.
3. Turn off the master battery disconnect, remove the
1 WARNING key, close the cover, lock, and tag out.

OR
After correctly shutting down and locking out
the machine, hazards from stored energy can If you need to use the work lights or water sprayer,
still exist. See “Stored Energy” on page 10. keep the battery disconnect closed (on) and turn off
the control power disconnect switch. Lock the con-
trol power switch and tag out.
4. Observe the following precautions:

WORKING SAFELY
• When more than one person is working on or Remote Machine Stop

around the machine, use multiple lockout
devices so that each person has their own pad- The OFF & STOP button on the remote transmitter
lock and key. (Figure 4) can stop the machine by shutting off the con-
• Do not disregard lockout procedures. Doing so trol system. This causes the engine to shut down.
can be very dangerous. Do not use the OFF & STOP button for normal shutdown
of the machine. Use it only to turn off the transmitter
Emergency Machine after the machine is shut down normally. See the notices
Stop below
The transmitter is effective at a distance of up to 300
An Emergency Stop (E-Stop) button feet (90 m) under conditions where stable radio fre-
(Figure 3) is the primary means for quency signals are possible.
rapidly shutting down the entire
machine in an emergency.
The machine has four emergency stop buttons.. These
1 CAUTION
The OFF & STOP button is not an Emergency
buttons lock when pushed. They must be manually Stop. It depends on a radio signal transmitting
rotated and pulled out before restarting the engine. and batteries and should not be relied upon in an
The E-Stop on the control panel (Figure 3) has an LED emergency.
in the center of the button. If the operator presses the Important
Control Power button and this LED comes on, it alerts If you move the transmitter out of range while the
the operator that one of the E-stops are depressed. machine is running, or if the batteries become too
weak, the effect is the same as pressing the OFF &
 To shut down in an emergency: STOP button.
• Push in any one of the emergency stop buttons on Do not move the transmitter out of range while the
the machine. machine is operating. This will cause loss of con-
trol power and engine shutdown.
Horn
The horn button located on the control panel can be used
to warn others in the area that important safety-related
events are about to occur, such as starting up the engine.
Use the horn as needed to alert others.
F08743
Figure 4: Remote Transmitter OFF & STOP Button

WORKING SAFELY
Stored Energy
Some machine systems retain stored energy after the
engine is shut down and the disconnect switches are
locked out. Accidental release of this energy could
cause serious injury or death.
The following sources of stored energy are discussed in
this section:
• Compression roll housing in a raised position
• Drum rotor and chip discharge accelerator while
coasting to a stop
• Jams or blockage
• Falling objects F06550
• Pressurized gases and fluids Figure 5: Compression Roll in Raised Position

• Electrical energy
Compression Roll Safety
Compression Roll Housing
Locking Pins
Precautions Always use the safety pins any
time the compression roll housing is in the raised posi-
During chipping, the compression roll raises and lowers
tion. Be sure to use both pins, one on each side of the
automatically (Figure 5). The movements can crush or
machine. The pins are identified by a label.
severely injure anyone near the compression roll hous-
ing or lift system. Stay back when the compression roll
system is operating. 1 DANGER
• Do not raise the compression roll housing when the Crushing hazard.
drum is running except to help clear blockages or to The compression roll is extremely heavy. Do not
counteract trouble with feeding, and then only to the depend on the hydraulic system to hold the com-
minimum extent necessary. pression roll in a raised position.
• Do not climb on top of the compression roll housing Always set BOTH safety locking stops any time
unless the engine is shut down and locked out. Stay that:
off this area when the engine is running or when the
• Maintenance, inspection, or repair work is to be
drum is turning. done under a raised compression roll housing.
• Keep hands clear of the moving parts on the com- • The compression roll is to be left in a raised
pression roll housing. position for any reason
The compression roll housing can cause serious and Never attempt to remove the pins from inside or
fatal crushing injuries if it drops onto someone. To pre- while a person is in the feed chamber, under the
vent this from happening, a safety locking pin is pro- weight of the compression roll housing, or near
vided on each side of the machine to support the the point of operation.
compression roll housing in its raised position. After they are installed, pins can come out if the housing
is not resting on them. To prevent this, lower the hous-
ing onto the pins as soon as the pins are installed. Each
time the housing is raised and lowered back onto the
pins, check the pins to be sure that they are secure.

WORKING SAFELY
1 WARNING
Crushing hazard.
Using the wrong safety pins or pins not
approved and supplied by Peterson could result
in serious injury or death.
Rotor Precautions
The chipping area is the zone around the rotor from the
feed plate to the discharge side of the rotor.
Rotor Motion
Do not enter the feed hopper until the rotor has stopped
F06524
completely. The belts must be absolutely motionless.
The rotor can free-spin for some time after the clutch
Figure 6: Compression Roll Safety Pin Installed
disengages it from the engine. The rotor is massive with
considerable inertia while rotating. Do not try to stop it.
Wait until it stops completely. Even slow rotor move-
 To secure the compression roll in the raised
ment is hazardous.
position:
1. Make sure logs have passed completely through the Rotor Lock-Out Pin
feed system and chipper. A safety lock-out pin (Figure 7
2. Disengage the clutch and allow the drum to come to on page 12) must be used any
a complete stop. time anyone is working near or on the rotor or whenever
3. Raise the housing to the highest position. you enter or work inside the feed area.
4. Insert the two safety pins fully
 To secure the rotor:
into the holes in the side of the
machine. They must go all the 1. Disengage the clutch.
way to the point where the 2. Shut down and lock out the machine.
head of the pin makes contact 3. Check to see that the rotor has stopped moving.
with the frame.
4. Rotate the rotor until a hole is exposed where the
5. Lower the compression roll onto the pins. locking pin can be inserted:
 To remove safety pins from the a. First read “Turning the Rotor Manually” on
compression roll: page 12.
b. Pivot the shaft bearing guard away from the
1. Visually inspect the area under and at the sides of
chipper housing.
the housing or roll to be sure no person or tools are
in the hazard zones. c. On the left side of the machine, insert a pry bar
into one of the holes of the shaft collar and turn
2. Start the engine.
the rotor.
3. Raise the housing.
5. Remove the snap pin from the handle.
4. Pull out the pins and place them in the pin holders.
6. Push the handle in completely.
5. Lower the housing. The locking pin is now
Important inserted into the rotor.
Immediately replace pins that are bent, damaged, 7. Insert the snap pin into the
deformed or do not easily slide in and out by hand. lower hole on the handle.
Use only Peterson-approved safety pins.

WORKING SAFELY
1 2
F07846
3 4 1. Shaft Collar
2. Bearing Guard
Figure 8: Shaft Collar Used for Turning the Rotor
1 WARNING
F08991
1. Slot Cover 3. Locking Pin
2. Snap Pin 4. Handle
Pinching, cutting, amputation hazard.
Figure 7: Rotor Locking Pin Assembly Injuries to the fingers, hands and feet can occur
when working around the rotor. The knives are
sharp.
Turning the Rotor Manually Exercise great care when working around the
When turning the rotor, keep hands and fingers away chipper knives.
from the sides and from close clearance points. Use a
• Keep all body parts away from the pinch points and
pry bar inserted into the shaft collar for turning the rotor.
knives when turning the rotor.
1 WARNING Chipper Hood

Crushing, pinching, cutting, amputation hazard! The chipper hood provides access to the top of the rotor
Wear safety shoes with steel toes and keep
for maintenance (Figure 9). The hood is secured shut by
hands, arms, and feet away from the chipper four bolts. Two spring latches secure the door in addi-
housing when manually turning the rotor. tion to the bolts.
Small spaces between the rotor and the housing
can pinch, crush or amputate body parts. 1 WARNING
• Turn the rotor slowly backward (opposite direction Avoid bodily harm. Wait until the rotor has come
to knife edge travel). Do not rotate the drum for- to a complete stop before opening the chipper
hood door.
ward so the knife edges move towards the anvil.

WORKING SAFELY
 To open the chipper hood: 1 WARNING

1. Disengage the clutch. Avoid bodily harm. Wait until the accelerator has
2. Shut down and lock out the machine. come to a complete stop before opening the
accelerator hood access door.
3. Check to see that the rotor has stopped moving.
4. Lock out the rotor. See “To secure the rotor:” on Proximity Sensors
page 11. A proximity sensor is installed at the chip accelerator
5. Pull and twist the spring latches until they are hood (Figure 11) and at the chipper hood (Figure 12 on
locked in place. page 13). The sensors send a signal to the controller
6. Lift the access door by the side handle. indicating whether the hood doors are open or closed.
When either of these access doors are open the engine is
disabled and an alert message appears on the display.
The signal inputs can be monitored at the display.
F07201
Figure 9: Spring Latches, Chipper Hood Access F08284
Figure 11: Proximity Sensor, Accelerator Hood

Accelerator Hood Access Door
A door (Figure 10) on the chip accelerator hood pro-
vides access for inspecting the accelerator and for clean-
ing out debris.
F08774
F08283 Figure 12: Proximity Sensor, Chipper Hood

Figure 10: Accelerator Hood Access Door

WORKING SAFELY
Jams or Blockage Diesel Vapor: Diesel fuel

produces vapors that can be
Never try to remove a jam when the machine is running. explosively ignited when the
Stop the machine completely if material is jammed any- fuel is at or near its flash point
where in the machine. Shut down and lock out the temperature. Any exposure to
machine before removing the jam. flame, spark, or ar can ignite
these vapors. Do not weld or perform any hot work on
Do not attempt to manually force jammed materials into
fuel tanks that contain fuel vapors. See “Diesel Fuel
or out of the machine while it is running.
Vapors:” on page 20.
If the compression roll is blocked from closing or keep-
ing it in a raised position, removal of the blockage could Electrical Energy Hazards
place you at risk of being crushed or pinched if the hous-
ing were to fall suddenly. Accidental release of electrical energy can cause shock,
To remove a jam, see “Removing Jammed Logs” on burns, or fire. The 24-volt system uses industrial-duty
page 16. Also, see “To prevent a jam in the spout:” on batteries with up to 1300 amperes cranking power when
page 17. fully charged.
Falling Objects 1 WARNING

Avoid physical injury and chemical burns.
Any raised device has stored energy and can fall. Do not Explosive hydrogen gas may be present around
place yourself under any object that can fall or move batteries.
due to loss of hydraulic pressure.
Do not allow cigarette smoking, flame or sparks
around the battery.
4300B Front Support (Landing Gear)
It is possible for the machine to suddenly shift or drop Wear safety goggles and skin covering that is
when the front end of the 4300B is being raised up for impervious to battery acid when working around
hitching to a towing vehicle. the batteries.
The 4300B can sink when parked on weak, compress- Battery box lids must be bolted down at all
ible or unstable ground. Hydraulic system leaks or dam- times.
age related to landing gear can allow the 4300B to drop.
1 WARNING
Pressurized Gases and Fluids Avoid electric shock from battery. Improper han-
dling of batteries, wiring and connections must
Accidental release or leak of pressurized gases or fluids be prevented.
can cause injury. Some systems may remain pressurized
Only persons with appropriate training in the
after the engine has shut down.
electrical systems used on the machine are per-
Hydraulic Oil: High pressure mitted to handle battery, electrical connections,
hydraulic leaks can puncture skin and and wiring.
cause blood poisoning. Do not check
for hydraulic leaks by hand. Use card-
board, heavy paper, or other objects to
detect a leak and its source.
Engine Coolant: The engine
radiator coolant reaches scalding
temperatures under pressure. Do
not remove the radiator cap when
the engine is hot.

WORKING SAFELY
Moving Parts locked out, and all components have come to a complete
stop.
Machine parts that move during operation present dan- Maintain rigorous safety procedures in operating the
gerous conditions to avoid. This section covers the fol- drum chipper. If proper safety precautions are not taken,
lowing topics: this equipment can cause serious injury or death.
• Crushing and pinching hazards
• Feed system hazards
Feed System Hazards
• Rotor hazards Hazards associated with the feed system exist at the
• Chip spout hazards feed chain and compression roll.
• Guards and shields Feed Chain Hazards and Precautions

• Drive Tracks (4310B) Be aware of the following hazards and precautions:
• Objects, hands, clothing, or feed
Crushing and Pinching Hazards material may get caught in the
feed chain. The chain may
Keep clear of the following crush and pinch hazards:
reverse direction without warn-
• Pulleys, belts, and feed chain are moving while the ing.
machine is running. Keep all guards in place during
• Do not work on or near the feed
operation.
chain, or place any material by hand on the feed
• The drive belt is moving when the drum is in chain when the engine is running or the feed chain
motion. A belt guard is installed to prevent injury. is moving.
Do not reach into the belt access on the back of the
• When the machine is running, use machinery to
guard while the belt is moving.
move logs in the feed zone. Never allow a person to
• The compression roll housing raises and lowers be in the feed zone to assist feeding logs or to help
during maintenance and operation. unjam logs.
If stray material has blocked the housing, prevent- • Stay at least 300 ft. from the feed deck while the
ing closing or keeping it in its lifted position, machine is operating.
removing that material could place you at risk of
crushing or pinching by allowing the housing to fall Compression Roll Hazards and Precautions
unexpectedly. Be aware of the following hazards and precautions:
• The chip spout parts move when operating the • People working to remove jams
hydraulic system to adjust the spout deflector. near the compression roll can be
Do not place yourself or any part of your body: seriously injured or killed if the
• Under any pivoting component without first install- machine is still operating. Never
ing the safety pins try to remove a jam when the
machine is running.
• Under the machine unless the machine is appropri-
ately supported, or securely blocked or cribbed • When the compression roll is rotating, a pinch point
exists between the compression roll and the hous-
Never remove a safety locking pin while a person is in ing, and the compression roll and frame. Keep
the chipper or near the point of operation. hands clear of the moving parts on the compression
Never attempt to remove any safety locking pin from roll housing (Figure 13 on page 16).
inside or while you or any other person is under the • During operation, the compression roll can sud-
weight it supports. denly and without warning raise or lower, which
Do not climb into the feed chamber until the engine has could crush or severely injure anyone in that area.
been shut down, the main battery disconnect switch is Stay off this area when the engine is running or the
compression roll is turning.

WORKING SAFELY
• Logs can be ejected from the compression roll sud-  To unjam a log from the machine:
denly and seriously injure anyone standing near the 1. Stop the feed system.
feed zone. Do not allow anyone in the feed zone
while the machine is running. 2. Reverse the feed system.
If log is still jammed:
a. Wait for the rotor to stop spinning.
1 b. Follow machine shutdown and lockout proce-
dures.
2
c. Use safety pins to secure the compression roll
housing in the up position.
d. Cut the log and remove it before restarting the
3 machine.
Rotor Hazards
Never operate the chipper or engage
F06550 the clutch without checking to be
1. Pinch Points on Roller Housing Machine Stop absolutely sure all persons are clear of
2. Pinch Points the machine and its drive. If proper
3. Pinch Points on Roller Housing
safety precautions are not taken, this
equipment can cause serious injury or
Figure 13: Pinch Points on Raised Compression Roll
death.
Do not feed materials into the machine other than those
Whenever maintenance or service work is needed in the for which it was originally designed to process.
feed system area, shut down and lock out the machine While performing service or maintenance work, such as
and install the safety pins in the appropriate locations. inspection or changing knives, keep the engine locked
out, and manually turn the rotor slowly and with verbal
Removing Jammed Logs warnings to any others who may be working close to the
If material is jammed anywhere in the rotor.
machine, stop the machine completely.
Never try to remove a jam when the Never perform maintenance or service work on or
machine is running. Turn off and lock around the machine by yourself. Always work with a
out the main battery disconnect switch partner.
before removing the jam.
Chip Spout Hazards
1 WARNING Hazards associated with the chip spout:
Crushing or pinching hazard. • Objects can be thrown up to 300 feet (90 m) from
Never attempt to manually force jammed logs the chip spout.
into the chipper. Never attempt to manually • During machine operation, do not allow anyone in
remove logs from the chipper when the machine the discharge hazard areas as noted in the hazard
is operating.
zone diagrams (See “Hazard Zones” on page 24).
• Keep the chip spout at least 10 feet (3 m) from any
power line or power line support structure.

WORKING SAFELY
1 WARNING Discharge Access Door

Electrocution Hazard. An access door (Figure 14) beneath the chip accelerator
provides access to the discharge area. Open this door to
Watch for overhead power lines. Contacting
electric lines with the chip spout can cause
access the grates and the accelerator. The door is
severe injury or death. equipped with a spring clamp which allows the door to
flex in case of a jam.
Treat any wire as live and dangerous. If possible, have
the power line disconnected before you start work. 1
If you know the chip spout has contacted a live wire or
wires are downed, immediately move away from the
machine. Warn others not to touch any part of the
machine and to keep clear of the area until safe working
conditions are established.
Clearing a jam in the spout 2 3

The spout can become jammed with chips if:
• The engine rpm is too low. The rotor does not have
enough speed to blow the chips out the spout.
• There is interference in the chip spout or at the
accelerator. F08334
4
 To prevent a jam in the spout: 1. Door 3. Spring
• Keep the engine speed above 1750 rpm. 2. Spring Clamp 4. Clamp Bolts
 To clear a jam in the spout: Figure 14: Discharge Area Access Door (4300B Shown)
• Stop the machine and inspect the accelerator.
Remove any jammed material.  To open the discharge access door
• Clean the inside surfaces of the spout. (4300B):
Truck drivers and others must stay clear of the spout 1. Shut down and lockout the machine.
hazard zone when operating the chip spout deflector and 2. Ensure the rotor and the accelerator have come to a
chip spout rotate levers. complete stop.
Truck drivers must wear safety vests, hard hats, and full 3. Place a board or suitable barrier between the engine
eye protection. and the access door. Brace the door.
1 WARNING
Avoid bodily harm.
The discharge access door is heavy. Use caution
when opening the door. Do not stand in the way
of the door when it opens. Brace the door before
removing the clamp.
4. Remove the bolts that secure the spring clamp and
carefully lower the door.

WORKING SAFELY
Drive Tracks (4310B)

Fire Prevention and
Suppression
The drive tracks are controlled by the remote to move
the machine forward, back, and to make turns. When the
track movement alarm sounds, move away and stay
clear of the machine.
Regular cleaning, inspection, and mainte-
1 WARNING nance are the primary means of reducing

the risk of fire. Fire prevention is your
Avoid physical injury. responsibility.
At any time, the machine can move and turn
without warning. Any person can be severely or Daily Fire Prevention
fatally injured if run over by a track or caught in
a track mechanism. Fire prevention starts with the daily prac-
tice of ensuring safe operation before, during, and after
Guards and Shields running the machine. At least once each day, or more
often depending on your operation, clean combustible
The machine includes the following design features to materials from on and under the engine, the exhaust sys-
help prevent personal injury: tem, bearing housings, and other heat sources.
• Guards cover rotating shafts and drive belts. Train new employees in fire prevention and fire emer-
• A wire screen keeps hands and fingers away from gencies. Regularly re-train more experienced personnel
the cooling fans. for fire prevention and emergencies. Get training on
• Two ladders provide safe access to the service deck when and how to use the fire extinguisher from a fire
between the cooling fans and the hydraulic tank. safety specialist. Always place personal safety ahead of
the need to extinguish fires.
• Hand holds and handrails are provided where oper-
ators need support or a convenient grab point when
moving from one part of the machine to another.
Before Operation
Do not clean or lubricate any rotating or moving parts Before starting or operating your machine, do the fol-
while the engine is running. Do not work on or around lowing:
any mechanical drive units, or any rotating or moving
• Read and understand the fire safety statements in
components, such as sheaves, chains, or belts when the
this manual.
machine is running.
• Be sure all items for fire suppression and prevention
are ready for use.
• Be sure all personnel are trained in the use of fire
prevention and suppression equipment.
• Inspect the machine and area for fire hazards.
During Operation
At all times while machine is being operated, main-
tained, or inspected:
• Watch for hot ignitable materials, smoke, or other
signs of fire.
• Extinguish any fire immediately.
• Repair any oil or fuel leaks immediately.
• Clean up any oil or fuel spills immediately.

WORKING SAFELY
1 DANGER Sources and Causes

Explosion hazard.
• Diesel fuel vapors can explode. Keep flames or
of Fires
other ignition sources away. Do not weld, cut,
or grind near diesel fuel. Failure to take precautions can lead to
• Safety regulations prohibit welding or other hot
fires. Pay attention to the following condi-
work in the presence of explosive vapors. tions:
Failure to heed this warning can result in severe Hot Bearings: Accumulations of wood dust on the
burns, injury or death. surface of bearing housings can act as insulation, raising
• Repair faulty electrical wiring and battery cables their temperature. Bearing parts may be hotter than they
immediately. appear. If paint discoloration or smoke appears, do not
touch the parts until the bearing cools.
• Do not permit open flames or sparks near ignitable
materials. Combustable Materials: Risk of fire is always pres-
ent when working with heat sources, ignitable fluids,
• Guard against fire when welding, grinding, or cut-
wood, and other organic wastes.
ting.
The following ignitable materials are likely to be pres-
• Do not allow smoking.
ent on or near the machine: wood dust, chips and debris,
diesel fuel, gasoline, ether, hydraulic oil, lubricants,
After Operation rubber products, and other materials that burn.
After stopping or shutting down your machine: Ignition Sources: Any of the following sources can
• Inspect the machine and the area for hot ignitable start a fire: engine hot exhaust surfaces, friction in bear-
materials or fires. ings or belts, electrical arcing or shorts, smoking mate-
rials, or hot metal in the discharge.
• Clean debris, dust, and all ignitable materials off the
engine and hot surfaces. Clean-up: Daily clean-up is required to avoid fires. If
wood dust, debris, and other combustible materials are
• Move all loose, ignitable materials off and away
allowed to accumulate on a hot engine or on exhaust
from machine.
surfaces, a fire can start. Serious fires have started this
• Remove debris on, under, or around the machine. way.
• Inspect the machine for oil or fuel leaks. Signs of Fire: Watch at all times for smoke or other
• Replace worn or leaky hydraulic hoses, sleeves, and signs of fire and take immediate action to extinguish a
fuel lines. fire or prevent it from starting.
• Prevent open flame or sparks near debris or oils. Small Spills: Small spills of oil or fuel raise the risk of
• Keep fire extinguishers, the on-board water tank, fire if an ignition source (such as a spark, flame, or high
water trucks, and other fire systems maintained and heat point) exists or developed.
near the machine at all times. Electrical Shorts: Electrical shorts caused by cor-
roded or faulty wiring, failed electrical insulation, loose
terminals or connectors, and other sources of sparks and
heat must be avoided. Immediately repair faulty electri-
cal wiring and cables.
Welding: Open flame or sparks near wood debris or
oils are an obvious source of ignition. Welding or torch
cutting can be especially hazardous in an environment
where woody materials are being reduced to small par-
ticles. While your hood or goggles are on, you may not
notice the fire until it is large.

WORKING SAFELY
Smoking: Smoking tobacco in the wood processing

area is a high risk behavior. Carelessness can quickly
Fire Suppression Equipment
lead to a disaster. Maintain a no-smoking policy near the
Keep fire extinguishers, water trucks, and other fire sup-
chipper machines.
pression systems maintained in good operating condi-
Hydraulic Leaks: Replace worn or leaky hydraulic tion and near the machine at all times.
hoses, worn or missing hose sleeves, and fuel lines.
Take notice of pin-hole sized hydraulic or fuel leaks that Fire Extinguishers
may spray a fine mist of oil or fuel near a heat source.
This is a dangerous situation. The red fire extinguisher shipped
with the machine is mounted on
Mufflers: Maintain the muffler and exhaust system to
the frame. It uses a dry chemical
keep sparks from flying out the stack. Regularly inspect
for suppressing Class A, B, and C
the muffler and exhaust system for rust spots and leaks.
fires. Inspect and recharge the
Replace as needed to prevent sparks from escaping.
extinguisher annually. Pressure
Diesel Fuel Vapors: Diesel fuel vapors are present test as required.
in a fuel tank, in a container, near leaking or spraying
diesel fuel, or near a spill of diesel fuel.
F02935
The two fire extinguishers
Diesel fuel generates vapors at
mounted to the front of the 4300B (Figure 15) are for
temperatures above 100°F
suppressing Class A fires. These high pressure extin-
(38°C). Diesel vapors can burn or
guishers have a 55 second discharge time and can spray
explode at ratios of 0.5% to 7%
water up to 55 ft (16 m).
with air if exposed to an ignition
source.
Ignition sources include any activity which would cre-
ate flames, sparks, electrical arcing, or very hot sur-
faces. Keep flames or other ignition sources away from
diesel fuel. Replace damaged fuel tanks.
Diesel Fuel Static Charge: Static charges can
build up in ULSD fuel while it flows through fuel deliv-
ery systems. Static electricity discharge in the presense
of combustible vapors can result in explosion.
To prevent this, the entire system used to refuel your
machine must be properly grounded and bonded.
Spontaneous Combustion: Wood particles com- F08153
bined with oils or greases can burn spontaneously. As
Figure 15: Class A Fire Extinguishers (4300B)
accumulations increase in depth, the likelihood of spon-
taneous combustion increases.
1 WARNING
Fire hazard.
Fires can start in combustible materials around
the machine many hours after it has been shut
down.
If the machine is left unattended after shutdown,
move it away from combustible or flammable
materials.

WORKING SAFELY
Water Pump Sprayer (4310B)

The self-contained, electric water pump sprayer, water 1 2
tank, and hose with nozzle (Figure 16) comprise a sys-
tem designed to help put out fires and to keep the
machine clean of dust and debris which contribute to
machine fires. Table 1 specifies the capacities of the
water sprayer system. 3
Keep the sprayer tank filled with water at all times. Be
prepared to respond to a fire situation.
Table 1: Water Sprayer Specifications

Tank capacity 60 gallons (227
liters)
Max. solid stream spray distance 25 ft (8 m)
1-inch diameter spray hose length 50 ft (15 m)
Minimum full tank discharge time 12 minutes
Nozzle Adjusts solid

stream to fog
The water sprayer can be an effective tool, but is not a

F07037
substitute for other types of fire prevention equipment
1. Coiled Hose For Sprayer
or for good fire safety practices. Always be prepared to 2. Spray Nozzle
respond to a fire. 3. Water Pump Switch
• Use this water sprayer system to wash debris off the Figure 16: Self-Contained Water Sprayer System (4310B)
machine and to wet down the area around it.
• Keep this water tank filled at all times and ready for
emergency use when the machine is operating.  To shut down the water sprayer:
• Fire risk levels and hazards change with conditions 1. Twist to close the spray nozzle.
and job sites. Operations personnel are in the best 2. Turn the water pump switch to OFF.
position to decide how to use the water sprayer most
3. Re-spool the hose.
effectively and how often on each job site. They are
the ones most responsible for job site fire safety and NOTE: The water pumps are powered by the engine bat-
prevention. teries. Do not operate the water sprayer system
• Use this water sprayer to fight Class A combustible continuously.
material fires.
Important
During freezing weather take the system out of ser-
 To use the water sprayer:
vice, drain the tank, the pumps, and the hose.
1. Unspool the hose from the reel.
2. Turn the water pump switch to ON.
3. Twist the nozzle to set the spray pattern.

WORKING SAFELY
Job Site Safety Flying Objects Hazard

Site conditions vary widely. Local or federal safety
codes and the safety rules of your organization may add
1 DANGER
Crushing or pinching hazard.
other safety requirements.
Do not enter the log feed zone. Log movement
One person can start and stop the machine, but it is good and flying objects create high risks.
safety practice to have more than one person at the work
site. See “Operating and Hazard Zones” . Knots and other pieces of wood can sometimes be
thrown as far as 300 feet (90 meters). This could result
Moving Machinery in serious injury if it were to strike an unprotected per-

son. Flying objects are a continuing hazard at any time
material is being processed or the engine is running.
Anyone entering the work area of the machine on foot
must recognize the following conditions:
• 4310B is a remotely-controlled machine.
1 WARNING
Avoid standing near the radiator.
• Several machines and operators may be at work in
the same area. At intervals, the fan reverses to blow dust and
debris from the radiator. Wear eye protection.
• Machines working in the area are not likely to travel
in a predictable path.
• Visibility is limited due to the stacks of material
Noise Hazard
being processed and the size of the machines. Always wear hearing protection
• A person may not be able to hear the approach of a within 50 feet (15 m) of the machine
moving machine because several engines may be when it is running.
running at the same time.
Noise levels can vary widely,
Together these conditions create a potential hazard of depending on the type of material
being hit by a moving machine, a hazard that is greater being processed, the rate of process-
than one finds in ordinary vehicle traffic. It is very ing, the structures near the machine, and the position of
important to your safety that you follow these rules: the listener relative to the noise source.
• Do not enter the work area unless you have a spe- Some directions away from the machine are more quiet
cific purpose. than others. Barriers, such as piled materials and build-
• Make yourself visible by wearing hi-visible clothing walls, can absorb or reflect sounds, which can
ing. reduce or increase the noise.
• Make eye contact and maker your presence with all Noise levels drop with greater distance from the sound
the machine operators in the area. source, eventually reaching safe levels.
• Do not make random or unexpected moves. The noise emission level of the 4300B/4310B has been
• Walk, do not run. determined following the guidelines of ISO 3744:1944
“Acoustics: Determination of sound power levels of
noise sources using sound pressure.”
The sound power level of the 4300B/4310B, while
operating under load, is 127 dB LWA. The sound pres-
sure measurement plane is 2 meters from the machine.
The maximum sound pressure is 110 dBA at the center
of the machine on the left side.

WORKING SAFELY
This decibel data can only approximate the noise condi- In enclosed areas, vent engine exhaust outside. Ensure
tions at your operating site. Take sound level measure- that airborne concentrations of exhaust emissions do not
ments of each site where the machine is operated, and exceed current health standards.
always encourage people to use ear plugs when working
Motor Oil: Used and hot motor oil vapors can be haz-
near the machine.
ardous. Inhaling vapors or swallowing oil can be dan-
gerous. Avoid prolonged contact with used motor oil.
Creating a Safe Workplace Lifting: Avoid heavy lifting to prevent back injury and
muscle strains. Avoid twisting or over-reaching, espe-
For a safe workplace, wear protective gear, avoid unsafe
cially when lifting or carrying heavy weights. When
conditions, and practice safe behaviors.
work requires heavy lifting, get help or use mechanical
assistance.
Wear Protective Gear
Lighting: Ensure that the work site is adequately lit in
Persons near the machine while low light conditions.
it is operating must wear hard
hats, eye protection, and ear Practice Safe Behaviors
protection.
Heavy-soled shoes with toe pro- A safe workplace requires practicing the following
tection and a high visibility vest behaviors:
or other enhanced visibility First aid: Keep a well-stocked, accessible first aid kit
clothing, and other safety equipment are recommended on site.
and may be required by local codes.
Inspect periodically: Consider transporting the
machine to a shop or enclosed area for periodic inspec-
Create Safe Conditions tion.
A safe workplace depends on the following conditions: Double up: Although one person can start and stop
the machine, a good safety practice is to have more than
Training: Do not operate this machine unless you have
one authorized person at a work site.
been trained in its safe use.
Instruct personnel: The owner and operator must
Crowding: Do not stand or walk near the loader when
make sure that support personnel, observers, or others
it is loading the machine with logs.
needing to enter the operating area or work site are
Cleanliness: Use of high pressure air to clean the aware of potential hazards and are properly trained in
machine of debris or for other maintenance activities safe approaches to it. Admit only authorized personnel
can be hazardous. Wear eye protection. to the operating zone.
Debris or small objects can be blown with enough force Communicate visually: Anyone needing to enter
to injure or blind. the work area while the machine is operating must make
Use only reduced pressure nozzles or other means of eye contact or other confirmed communication with the
keeping air pressures at or below 30 psi (2 bar). This operator, signaling their intent to approach. Approach
pressure is recommended by OSHA (in the U.S.) as the the machine only when it is safe to do so.
maximum safe air pressure to use for cleaning dust and Stand at a safe distance: Before starting the
debris from the machine. machine, inspect the area for people and potential haz-
Ventilation: Engine exhaust contains products of ards. Make sure everyone is well away from the operat-
combustion that are harmful to health. The engine uses ing area before starting the diesel engine. Allow only
available oxygen, replacing it with toxic gases. Always trained personnel in hazard zones.
start and operate the engine in a well-ventilated area. To estimate safe distances, see “Operating and Hazard
Zones”

WORKING SAFELY
Shout warnings: Before starting up, follow the rec-

ommended warning procedures of your site. The opera-
Operating and Hazard Zones
tor should look carefully in and around the machine, and
Figure 17 shows areas where material processing activ-
then shout a loud warning, wait and listen for a
ities take place where hazards exist or may be present.
response, repeat and listen, before starting the machine.
The zones offer guidelines for reducing risks and
Stay alert: After the machine is running at the improving productivity while using the machine.
required speed, it can run under the supervision of the Only trained, authorized personnel are permitted to
loader operator who feeds material to it. Other trained enter the work area. They must wear the following pro-
support personnel may need to be in the operating area. tective gear:
Everyone must remain alert and actively avoid hazards.
• Hard hat
Sound the horn: Use the horn as needed to alert oth-
ers. The horn button allows the operator, chip van • Highly visible safety vest
driver, or others to signal to anyone in the area that • Eye and face protection
important safety-related events are about to occur, such • Hearing protection
as starting up the engine or moving a component. The
Horn button is mounted on the main control panel.
Area 4:
Noise and Traffic
Hazard Zone 50 ft (15 m)
Feed
Area 3 and 5: Area 2 and 5:

Falling Material and Thrown Material and
Traffic Hazard Zone Loader Access Zone
F08813
Area 1:
Control
Station
Area 4:
Noise and Traffic
Hazard Zone 50 ft (15 m)
Figure 17: Hazard Zones

WORKING SAFELY
Area 1: Hands-On Control Station Area 4: Noise and Traffic Hazard Zone 50 ft (15 m)
This is the area near the ladders, walkway, engine, and Individuals must not stand near the machine when the
control panel. The operator enters these areas to start the engine is running. Remain at least 50 ft (15 m) from the
engine, unfold the chip spout, check gauges, engage the machine unless authorized by the operator for closer
clutch, check lubricant levels, and perform other func- approach.
tions. Hearing protection is needed at all times. Do not stand
High noise levels occur in this zone. Hot engine sur- inside this area to watch the machine operate.
faces can cause serious, permanent burns. Noise levels, moving parts hazards, and machine activ-
Area 2: Traffic Hazard Zone and Thrown Material ity, including loaders and trucks entering and leaving,
Hazard Zone all combine to make this area a zone that requires spe-
cial alertness to safety hazards by the operator and any-
This is the stockpiling area for the discharged chips or
one else.
loading zone for chip trucks. Loaders or other vehicles
enter and exit this area to move the stack of chips. Only authorized people should enter this zone. No one
should enter the area without specific permission of the
Thrown material coming out of the discharge spout can
machine operator.
hit anyone in this area. Avoid this area while operating
the machine. Also see Figure 18. Everyone should take special notice of traffic hazards at
the work site. Traffic patterns cannot be defined in this
Area 3: Falling Material Hazard Zone and Loader
manual because of differences in the design and work
Access Zone
practices at each job site.
This area is where the loader operator feeds logs into the
Everyone near the operating area should be trained to
machine.
watch for moving loaders, trucks, and other heavy vehi-
Logs can fall off the feed deck, and a possibility of haz- cles. They often drive fast and turn quickly in a noisy,
ardous flying objects also exists in this area. possibly low-visibility environment.
Any authorized person needing to enter this area while Area 5: Travel Hazard Zone (4310B):
the machine is operating should make positive contact
The remote-controlled 4310B tracked vehicle can turn
with the loader operator and machine operator before
rapidly, track forward and back, travel at 2 different
entering the zone. Unauthorized persons should not
speeds, and is very heavy and powerful. Movement of
enter.
the machine can be hazardous.
Normal operating conditions include reversing the
Keep all people at least 20 feet (6 to 7 meters) away
direction of the feed system. The feed may reverse with-
from the machine whenever it is operating or traveling
out warning, and material may spill out during reversal.
on its tracks.
Trucks unload logs in this area. Log piles may become
unstable and suddenly shift or roll. No one is allowed in
this area during machine operation.
Many areas in a storage yard may contain piles of raw
logs awaiting processing. Piles of logs may obstruct
views and can interfere with communication.
Be alert and react to any people or machine entering this
area. Before start-up, check this area to be sure every-
one is at a safe distance.

WORKING SAFELY
Safety Labels
300 feet
Hazard alert, instruction, and safety labels are attached
to the machine. Labels remind operator and other work-
ers not to expose themselves to risks of crushing, pinch-
300 feet
ing, or trapping caused by rotating, moving, or
unguarded parts and other hazards. Some labels serve as
reminders to lock out the power source.
Other labels attached to the machine describe operating
or maintenance activities and other useful information.
A complete list of labels is available in your 4300B or
4310B Parts Book. If the labels have been removed or
become unreadable, call your Peterson distributor for
replacements.
50 feet
15 meters
F03805
300 feet
100 meters
300 feet
100 meters
F03803
Figure 18: Thrown Material and Travel Hazard Zones

WORKING SAFELY
Maintenance Safety 1 WARNING

Keep clear of all moving parts such as pulleys
Good maintenance improves safety. A good mainte- and conveyors while the machine is running.
nance program improves awareness of potential hazards Keep all guards in place during operation. Do not
and reduces the risks of equipment failure, which may rely on guards to protect you from not paying
contribute to accidents. attention.
Safety comes before machine performance. Do not let
the urgency of getting the machine back in working con-
dition jeopardize people’s safety.
1 WARNING
 To work on the machine safely: Do not place yourself or any part of your body
under the machine unless machine is properly
1. Turn off the engine. supported.
2. Turn off the master battery disconnect switch and
remove the key.
3. Close, lock, and tag out the master battery discon-
1 WARNING
nect switch. Pinch point.
4. Tell your supervisor and area workers that you are Do not place yourself or any part of your body
entering the machine. under any pivoting component without first
installing safety pins or support devices.
5. Have someone stand by the machine while you are
inside.
1 WARNING
Do not clean or lubricate any rotating or moving parts
whether the engine is running or not. Keep hands clear of the moving parts of the feed
roll housing. If stray material has blocked normal
Do not work on or around any mechanical drive units or movement of the housing, keeping it in its lifted
any rotating or moving parts, such as sheaves, chains, or position, removal of that material could allow the
belts, when the machine is running. housing to fall unexpectedly.
Always be aware of the following warnings:
1 WARNING
1 WARNING Crushing or pinching hazard.
Crushing or pinching hazard. Keep hands clear of the moving parts of the feed
A damaged or missing guard, safety device, or roll housing while closing the housing after
label can expose operators to risk of injury or maintenance.
death. Maintaining these devices is very import-
ant. Comply with your local and state safety
codes.

WORKING SAFELY

S ECTION 1000
POWER SYSTEM
1000
Clutch
This manual covers clutch sheave removal and installa-
tion, clutch removal and installation, and speed sensor
replacement.
Additional information on clutch servicing and trouble-
shooting can be found in the PT Tech HPTO14 & 15
Installation and Maintenance manual which was sup-
plied in the documentation package with your machine.
Remove the Clutch Sheave F08871
Figure 20: Pull the Expansion Bushing out of the Sheave

1. Remove the outer belt guard and the belts. Instruc-
tions are in the Operator Safety and Maintenance
manual supplied with the machine.
Install the Clutch Sheave
2. Install lifting equipment to the sheave and take up
the slack. 1. Raise the sheave in a sling.
3. Loosen the expansion bushing bolts (Figure 19). 2. Clean the clutch shaft, the inside of the sheave, and
the outer surface of the expansion bushing.
Check for any burrs on the front edge of the shaft.
If any are found, remove them with a file.
3. Loosen the bolts in the expansion bushing. With the
split in the bushing not in line with the keyway,
push the bushing into the sheave.
• It is a very close fit so it will require some
maneuvering. Do not use tools to assist—hand-
install only.
• Keep the wedges from being pushed into the
F08870 bushing housing, otherwise the bushing will
expand.
Figure 19: Loosen the Expansion Bushing Bolts
• Be sure the split in the bushing will not be over
the shaft keyway.
4. Pull the bushing out of the sheave (Figure 20). • The housing of the bushing should end up just
5. Pull the sheave off the clutch shaft. inside the edge of the sheave bore, about 1/32 in.
(0.8 mm).
4. When the bushing is in the sheave, push the sheave
onto the clutch shaft.

SECTION 1000 POWER SYSTEM
• Before tightening the bushing bolts, the distance

from the rear of the sheave and the clutch hous-
Remove the Clutch
ing should be 13 in. (33 cm)
• When the bushing is tightened, the sheave will 1 CAUTION
1000
move about 1/8 in. toward the clutch housing. Crushing hazard.
Then the sheave will be in the correct position
for aligning with the other sheaves (12-7/8 in. Removing and installing the clutch requires a
lifting device for removing the belt guards, drive
[32 cm] from the clutch housing).
sheave, pumps, clutch, and clutch support plate.
5. Hand-tighten the bolts, then keep tightening in an
The clutch weighs over 1000 lb (454 kg). Use lift-
alternating pattern.
ing equipment capable of supporting this
• Tighten gradually and evenly. It will take at least weight.
12 passes on each bolt.
Important
• Keep checking that the bushing wedge is pulling Avoid contaminating the hydraulic circuit. Use
into the bushing housing evenly. If one part of plugs, caps, and covers to protect open ports and
the wedge does not pull into the housing evenly, hoses. Contamination can cause serious damage
tighten the bolts at that location a little more. to hydraulic clutch components. Take precaution-
ary measures to ensure the hydraulic clutch com-
• The wedge must pull in evenly all the way
ponents are clean and free of contaminates.
around. If this does not happen, loosen the bolts
and bushing and try again. Important
6. When you have tightened all the bolts, use a torque When disconnecting hoses, label all the hoses that
wrench to set each bolt to 105 ft-lb. (142 Nm) are going to be reconnected later.
(Figure 21).
 To remove the clutch assembly:
1. Remove the drive sheave from the clutch shaft
according to “Remove the Clutch Sheave” on
page 29.
2. Remove the inner belt guard.
3. Remove the main pump(s) according to “Pump
Removal” on page 49.
4. Remove any air piping as necessary.
5. Drain the clutch oil tank according to “Changing
the Clutch Oil and Filter” in Section 2000 of the
Operator Safety and Maintenance manual supplied
with the machine.
6. Disconnect the hoses from the clutch oil tank
F08872 (Figure 22).
Figure 21: Torque Bushing Bolts to 105 ft-lb (142 Nm). 7. Remove the clutch support plate.

SECTION 1000 P OWER SYSTEM
1000
F08873 F08875
Figure 22: Clutch Drain Hoses and Support Plate (4310B Figure 24: Lifting Bracket (Example)
Shown)
12. Unbolt the clutch from the engine flywheel and dis-
8. Remove all hoses from the clutch. lodge the clutch. The clutch should slide off the
9. Disconnect the speed sensors. back of the engine.
10. If replacing the clutch drive housing or the entire If needed, use bell housing bolts as pusher bolts in
clutch, remove the clutch pump, breather, spline the pusher bolt holes in the top and bottom of the
adapters, all hydraulic fittings, and the speed sen- bell housing (Figure 25).
sors. These can be installed on the new clutch if
they are in acceptable condition.
To dislodge the bell housing, use
one of the mounting bolts here
and on bottom of the housing.
F08876
Figure 25: Pusher Bolt Holes, Bell Housing

F08874
Figure 23: Pump Removal (4310B Shown)
11. Attach lifting equipment to the clutch (Figure 24).

Take up the weight of the clutch.

Install the Clutch

 To reinstall the clutch onto the engine:
1000
1. Make sure all mating parts are clean and free of

burrs or high spots.
Torsional
Coupling
Outer
Ring
Torsional
Coupling
Inner
Ring
F08878
F08879
Figure 26: Clutch Coupler Components
2. Attach appropriate lifting equipment to the clutch

(Figure 24). Fill groove
with lubricant.
3. Raise and align the coupling inner ring in the clutch
assembly with the outer ring on the engine flywheel
(Figure 26).
4. Slide on the clutch until the bell housing is flush
with the engine housing.
5. Install all the bell housing mounting bolts hand- Push O-ring
into groove.
tight, and then tighten to standard torque specifica-
tions.
6. Remove the lifting device.
7. Replace the O-rings in the hydraulic hose couplers
(Figure 27).
8. Install the clutch drain hoses onto the drain ports
(Figure 28 and Figure 30). F08880/F08881
9. Install the clutch drain hoses to the tank. Figure 27: Install O-ring to Hydraulic Coupler

14. Install the pump support bracket (4310B).

15. If removed, install the clutch pump.
16. Install the hoses to the clutch pump.
1000
17. Install the inner belt guard.
18. Install the clutch mounting plate (Figure 30).
F08883
F08882
Figure 28: Installing a Hose End Flange F08873
Figure 30: Clutch Drain Hoses and Mounting Plate (4310B

10. If removed, install the breather. Shown)
11. If removed, install the speed sensors: bottom out the
sensors by hand, and then back them out 2-1/2
turns. 19. Install the drive sheave and bushing on the clutch
shaft according to “Install the Clutch Sheave” on
12. Inspect the spline adapter (Figure 29). If you are in page 29.
doubt as to its condition, replace the spline adapter.
20. Install the drive belt(s). Instructions are in Section
13. Install the main pump(s) according to “Pump Instal- 1000 of the Operator Safety and Maintenance man-
lation” on page 50. ual supplied with the machine.
21. Rotate the drive at least two times by hand to ensure
that sheaves are aligned and the belts are settled in
the grooves.
22. Check belt tension and alignment.
23. Install the outer belt guard.
24. Refill the clutch oil tank with the correct oil.
Instructions are in Section 2000 of the Operator
Safety and Maintenance manual supplied with the
machine.
Spline 25. Operate the clutch at low idle and without a load.
Adapter
Check for proper operation and for leaks.
F08874
Figure 29: Spline Adapter Location

Engine
Removal 4. 4300B: Use the jacking bolts to position the engine
1000
as necessary to facilitate removal.

Engine removal should be attempted only by qualified 5. Unbolt the engine from the engine mounts.
Caterpillar or Peterson technicians, or performed under 6. Lift out the engine using appropriate lifting equip-
their direction. ment. The engine weighs approximately 6,500 lb.
1. Remove the spout. See “Chip Spout” on page 144. (2950 kg).
Installation
2. Remove the clutch according to “Remove the
Clutch” on page 30.
Important Installation is essentially the reverse of the removal
The following steps should be well-documented steps.
with photographs. This will help in re-assembling
parts back onto the engine. Place identification
labels on wires, hoses, and pipes to save time in re-
assembling.
3. In no particular order:
• Drain the coolant from the radiator and engine
block according to the Caterpillar engine man-
ual or the Peterson Operator Safety and Mainte-
nance Manual provided with your machine.
• Disconnect or remove the pipes and hoses that
connect the engine to the radiator.
• As necessary, disconnect or remove the muffler,
turbocharger pipes, and exhaust pipes.
• Disconnect or remove air cleaner hoses, ducting,
and pipes as needed.
• Close the fuel tank valve and disconnect the fuel
lines. Capture fuel in containers before any
spills on the ground. Plug any open lines to pre-
vent spillage during engine removal.
• Remove the alternator guard.
• Disconnect the starter, alternator, and grounding
wires that are connected to the skid or frame.
• Disconnect the ECM connectors at the distribu-
tion box and control box. Remove any grom-
mets holding the wires to the machine.
• At the intake manifolds, disconnect the charge
air cooler piping.

Belt Idler Assembly (4310B)

The idler pulley and shaft are part of the belt tensioner Service: The seal and o-ring can be replaced without
1000
system. removing the idler housing from the shaft.
Inspection: During belt changes, when the belt is off Replacing the idler bearings is not an easy task, so
of the idler pulley, spin the pulley and feel for bearing depending on your available time and resources, return-
damage and listen for bearing noise. Also check for oil ing the assembly to Peterson for replacement might be
leakage around the idler housing plugs and rear seal. preferable.
8 9 10
6 7
2 4
4 5
1
3
F08832
1. Idler Housing 6. O-ring

2. Plug (2) 7. Seal
3. Snap Ring 8. Idler Seal Cap
4. Roller Bearing 9. Bolts and Washers
5. Bearings Spacer 10. Idler Shaft
Figure 31: Belt Idler Shaft Assembly
Idler Shaft Removal b. Loosen the mounting blocks (Figure 32) that
secure the idler shaft.
1. Remove the belts. Refer to the Operator Safety and c. Remove the idler shaft assembly.
Maintenance Manual.
To remove only the pulley:
a. Install lifting equipment to the idler pulley
(Figure 44 on page 40). Take up the slack.
b. Remove the bolts from the idler pulley.
c. Use two 1/2-in coarse thread bolts in the
threaded holes to push the pulley off the bush-
ing.
d. Remove the pulley.
To remove the shaft assembly: : F08849
a. After removing the pulley, install lifting equip- Figure 32: Idler Shaft Mounting Block (1 of 2)
ment to the idler shaft assembly (Figure 42 on
page 40).

To remove the pulley and shaft as an

assembly:
a. Install a lifting sling to both the idler shaft
(Figure 42 on page 40) and the pulley
1000
(Figure 44 on page 40).

b. Take up the slack.
c. Loosen the mounting blocks (Figure 32) that
secure the idler shaft.
d. Remove the assembly.
Seal and O-Ring Replacement

F08837
1. Remove the idler assembly (“Idler Shaft Removal” Figure 34: Installing the Seal
on page 35).
2. Remove the bolts that secure the seal cap to the
housing. 6. Place a new O-ring onto the seal cap (Figure 35).
3. Pull the seal cap off the shaft. 7. Re-install the seal cap onto the idler housing and
tighten the bolts to standard torque specifications.
4. Remove the old seal and O-ring.
5. Install the seal into the seal cap (Figure 33):
a. Check that the spring is installed inside, behind
the rubber seal.
b. Using a proper seal driving tool, tap the seal
into the seal cap (Figure 34).
F08838
Figure 35: O-ring Installed on Seal Cap
8. Re-install the idler shaft assembly (“Idler Shaft

F08834
Installation” on page 40).
Figure 33: Seal and Seal Cap

Bearings Installation
Important
Removal Clean all parts before assembling. Remove any
1000
rust, dirt, burrs, and oil.
1. Secure the assembly in a vise or other arrangement. Handle the bearing with care, otherwise the rollers
2. Drain the oil from the housing, then reinstall the might fall out.
plugs. 1. Take the bearings out of the package and place them
3. Clean off any oil from the assembly. on their side in an oven that has been preheated to
4. Remove the bolts from the cap seal. 225oF (107oC) (Figure 36).
5. Install eye bolts to the housing. Important
6. Attach a hoist or come-along to the eye bolts. Handle the bearing with care, otherwise the rollers
might fall out.
7. Remove the housing from the bearings:
Never attempt to heat bearings with a torch
because that will damage them. Only use an oven
1 WARNING so that the bearings heat gradually and evenly.
Fire and Explosion Hazard. Allow about an hour for the bearing to warm up.
Do not use a flame as a heat source. The oil 2. Clamp the shaft in an upright position.
inside the housing is flammable.
a. Using a non-flame heat source such as a heat
gun, evenly heat the side of the housing while
applying pulling tension with the hoist or come-
along.
b. Use a mallet on the housing to break tension
inside the housing.
NOTE: Depending on the tightness of the original fit,
the housing may not be removable. In this case,
the assembly must be replaced.
8. Remove the snap ring.
9. Remove the bearings. F08843
The bearings must be cut off because the inner races Figure 36: Place Bearings into a 225 F Oven
o
are inaccessable. Be careful to not damage the shaft.

10. Remove the cap with the seal and O-ring from the
shaft. 3. Install the seal into the seal cap (Figure 33):
a. Check that the spring is installed inside, behind
the rubber seal.
b. Using a proper seal driving tool, tap the seal
into the seal cap (Figure 34).
4. Place the seal cap with seal onto the shaft
(Figure 37).

1 CAUTION
Burn Hazard.
The bearings are hot enough to cause third-
1000
degree burns. Use appropriate heat-resistant

gloves when handling hot bearings.
5. While wearing insulated heavy leather gloves, take
the bearing out of the oven and quickly push it onto
the shaft and against the seal cap.
Spacer
Seal cap
with seal F08845
Figure 38: Installing the 2nd Bearing (Typical)
8. Allow the bearings to cool.

9. Install the snap ring into the groove on the shaft.
10. Place the o-ring onto the seal cap (Figure 39).
F08844
Figure 37: Installing the First Bearing (Typical)
6. Install the bearings spacer (Figure 38) onto the

shaft.
7. Take the other bearing out of the oven and quickly
push it onto the shaft and against the seal cap.
F08838
Figure 39: O-ring Installed on Seal Cap
11. Attach lifting eye bolts to the idler housing

(Figure 40). This will allow you to maintain better
control of the install process.
12. Make sure the inside of the housing is clean, then
apply a film of lightweight machine oil to the out-
side of the bearings and inside of the housing.

13. Place the housing onto the top bearing. Using a rub-
ber-faced mallet, begin to drive the housing onto the
bearing.
Keep checking that the bearing is going in straight.
1000
You will ocassionally need to tap the underside of
the outer race to square things up.
Slacken the hoist chains as needed.
F08847
Figure 41: Using Clamps (If Necessary)
15. When the housing is onto the cap, install the bolts
and washers.
If the housing is still very tight on the bearings, the
bolts can be used to assist pulling the housing onto
the bearings.
Tighten to specifications.
16. Install oil:
a. Install the front plug loosely.
b. Fill the idler housing through the plug hole in
the side of the housing with 80W-90 high per-
F08846
formance gear oil until oil just begins to seep
out around the front plug.
Figure 40: Installing the Idler Housing (Typical) c. Tighten the plugs.
14. If the housing does not slip easily over the lower
bearing, install clamps to assist (Figure 41).

Idler Shaft Installation 4. Lift the pulley up to the housing and push it onto the
housing (Figure 44). Push carefully and evenly to
avoid galling anything.
1. Clean the pulley-to-housing mating surfaces.
Remove any burrs, sharp edges, or high spots that 5. Apply blue loctite to the bolts and install all the
1000
might interfere with smooth installation. bolts hand-tight.

If the pulley is new, use a power wire brush to Tighten the bolts in several passes to 170 ft-lb (230
remove any paint from the mating surface with the Nm).
bushing hub.
2. Install the idler shaft into the mounting blocks of the
tensioner assembly (Figure 42).
F08848
Figure 42: Installing the Idler Shaft Assembly

F08869
Figure 44: Installing the Idler Pulley

3. Set the end of the shaft flush with the outside sur-
face of the inside mounting block (Figure 43).
Tighten the bolts so there is an equal gap on each
side of the block halves.
Flush with
block
Gaps equal
F08849
Figure 43: Idler Shaft Installation

Torque Tables
Table 2 and Table 3 provide torques for grade 8 cap During regular maintenance inspections, retighten all
1000
screws, bolts, and standard hex nuts (NC/NF threads). loose nut and bolts to their specified torque.
Table 2: Torque Values, National Fine

Torque Values for National Fine (NF)
Grade 8 Cap Screws, Bolts, and Standard Hex Nuts

Nominal “As Received” Dry Lubricated with Loctite #242 Loctite #271 High Loctite #277 High Crimp-style Locking
Thread Threads Permatex #133 Medium Strength - Strength -Red Strength -Red Nutse,f
Diameter Anti-Seize Blue ftlbb (Nm) ftlbb (Nm)
inches (mm)a ftlbb (Nm) ftlbb (Nm) ftlbb (Nm) ftlbb (Nm)
1/4 (6.4) 14.0 or 168 inlb 9.0 or 108 inlb 11.5 or 138 inlb 15.5 or 185 inlb -NA- c 6.0 or 72 inlb (8.1)
(19.0) (12.2) (15.6) (21.0)
(36.6) (23.0) (29.8) (40.0)
(66.4) (40.7) (53.6) (73.7)
7/16 (11.1) 78.0 (105.8) 47.0 or 564 inlb 62.5 (84.7) 86.0 (116.6) -NA- c 35.0 or 420 inlb (47.5)
(63.7)
1/2 (12.7) 120.0 (162.7) 72.0 (97.6) 96.0 (130.2) 132 (179.0) -NA- c 53.0 or 636 inlb (71.9)
9/16 (14.3) 171.0 (231.8) 102.0 (138.3) 136.5 (185.1) 188.0 (254.9) -NA- c 77.0 (104.4)
5/8 (15.9) 240.0 (325.4) 144.0 (195.2) 192.0 (260.3) 264.0 (357.9) -NA- c 106.0 (143.7)
3/4 (19.1) 420.0 (569.4) 252.0 (341.7) 336.0 (455.6) 462.0 (626.4) 462.0 (626.4) 188.0 (254.9)
7/8 (22.2) 668.0 (905.7)d 400.0 (542.3) -NA- c 735.0 (996.5)d 735.0 (996.5)d 303.0 (410.8)
1 (25.4) 995.0 (1349)d 597.0 (809.4) -NA- c 1095.0 (1489)d 1095 (1489)d 455.0 (616.9)
1-1/8 (28.6) 1444 (1958)d 866.0 (1174)d -NA- c -NA- c 1588 (2153)d 644.0 (873.1)d
1-1/4 (31.8) 2012 (2728)d 1207 (1636)d -NA- c -NA- c 2213 (3000)d 908.0 (1231)d
1-3/8 (34.9) 2712 (3677)d 1627 (2206)d -NA- c -NA- c 2983 (4044)d 1190 (1613)d
1-1/2 (38.1) 3557 (4823)d 2134 (2893)d -NA- c -NA- c 3913 (5305)d 1580 (2142)d
a Nominal diameters are referenced from ANSI B18. Use b foot-pounds (ftlb) except where noted as cNA = Not d Use one or more
approximate dimension in millimeters for identification only. inch-pounds (inlb). Installation with an inch- Applicable torque multipliers to
No exactly equivalent metric fasteners are available. Using pound wrench is recommended for the achieve specified
2.54 mm per inch, an example of this rough conversion of 5/ fasteners where inlb is indicated. torque value.
16 inch is: multiply 2.54 by 5; then divide by 16, yielding
7.9375. Then round to 7.9.
e
Caution! Do not use Loctite with f
Caution! Do not use an air ratchet to assemble or disassemble Refer to Peterson process specification no.
crimp-style locking nuts under any crimp-style locking nuts. Friction-induced heat destroys the nut’s 53500, sheet 3 of 3, Revision A, 082995
circumstance! lubricant coating.
All stated torque values are based on use of through-hardened flat washers under All stated torque values are calculated at 75% of proof load rating,
the bolt head and nut, or only the bolt head in tapped and chamfered hole providing a design safety factor.
applications. This provides a uniform, hard, smooth bearing surface.

Table 3: Torque Values, National Coarse

Torque Values for National Coarse (NC)
1000
Grade 8 Cap Screws, Bolts, and Standard Hex Nuts

Nominal Thread “As Received” Dry Lubricated with Loctite #242 Loctite #271 High Loctite #277 High Crimp-style Locking
Diameter inches Threads Permatex #133 Anti- Medium Strength - Strength -Red Strength -Red Nutse,f
(mm)a Seize Blue ftlbb (Nm) ftlbb (Nm)
ftlbb (Nm) ftlbb (Nm) ftlbb (Nm) ftlbb (Nm)
(16.3) (9.5) (12.9) (17.6)
5/16 (7.9) 25.0 or 300 inlb 15.0 or 180 inlb 20.0 or 240 inlb 27.5 or 330 inlb -NA- c 12.0 or 144 inlb
(33.9) (20.3) (27.1) (37.3) (16.3)
3/8 (9.5) 44.0 or 528 inlb 26.0 or 312 inlb 35.0 or 420 inlb 48.5 or 581 inlb -NA- c 22.0 or 264 inlb
(59.7) (35.3) (47.5) (65.8) (29.8)
7/16 (11.1) 70.0 (94.9) 42.0 or 504 inlb 56.0 or 672 inlb 77.0 (104.4) -NA- c 35.0 or 420 inlb
(56.9) (75.9) (47.5)
1/2 (12.7) 107.0 (145.7) 64.0 (86.8) 85.5 (115.9) 117.5 (159.3) -NA- c 53.0 or 636 inlb
(71.9)
9/16 (14.3) 154.0 (208.8) 92.0 (124.7) 123.0 (166.8) 169.5 (229.8) -NA- c 77.0 (104.4)
5/8 (15.9) 212.0 (287.4) 127.0 (172.2) 169.5 (229.8) 233.0 (315.9) -NA- c 106.0 (143.7)
3/4 (19.1) 376.0 (509.8) 226.0 (306.4) 301.0 (408.1) 414.0 (561.3) 414.0 (561.3) 188.0 (254.9)
7/8 (22.2) 606.0 (821.6)d 364.0 (493.5) -NA- c 667.0 (904.3)d 667.0 (904.3)d 303.0 (410.8)
1 (25.4) 909.0 (1232)d 545.0 (738.9) -NA- c 1000 (1356)d 1000 (1356)d 455.0 (616.9)
1-1/8 (28.6) 1288 (1746)d 773.0 (1048)d -NA- c -NA- c 1417 (1921)d 644.0(873.1)d
1-1/4 (31.8) 1817 (2464)d 1090 (1478)d -NA- c -NA- c 1999 (2710)d 908.0 (1231)d
1-3/8 (34.9) 2382 (3230)d 1430 (1939)d -NA- c -NA- c 2620 (3552)d 1190 (1613)d
1-1/2 (38.1) 3161 (4286)d 1897 (2572)d -NA- c -NA- c 3477 (4714)d 1580 (2142)d
a Nominal diameters are referenced from ANSI B18. Use b foot-pounds (ftlb) except where noted cNA = Not d Use one or more
approximate dimension in millimeters for identification only. No as inch-pounds (inlb). Installation with an Applicable torque multipliers to
exactly equivalent metric fasteners are available. Using 2.54 inch-pound wrench is recommended for achieve specified
mm per inch, an example of this rough conversion of 5/16 inch the fasteners where inlb is indicated. torque value.
is: multiply 2.54 by 5; then divide by 16, yielding 7.9375. Then
round to 7.9.
eCaution! Do not use Loctite with fCaution! Do not use an air ratchet to assemble or disassemble Refer to Peterson process specification
crimp-style locking nuts under any crimp-style locking nuts. Friction-induced heat destroys the nut’s no. 53500, sheet 3 of 3, Revision A,
circumstance! lubricant coating. 082995
All stated torque values are based on use of through-hardened flat washers under All stated torque values are calculated at 75% of proof load
the bolt head and nut, or only the bolt head in tapped and chamfered hole rating, providing a design safety factor.
applications. This provides a uniform, hard, smooth bearing surface.

S ECTION 2000
HYDRAULIC SYSTEM
This section covers the service, troubleshooting, and set-up of pumps, motors, valve assemblies, and cylinders.
Description Pressure Transducers

There are two pressure transducers on the machine, one
at each A port of the control valve for the feed motors.
The 4300B hydraulic system is comprised of one open- These transducers are used by the adaptive control sys-
loop system, powered by a pressure-compensating, tem to adjust machine operation to conditions and
load-sensing pump. desired performance. The sensed pressures can be seen
The 4310B hydraulic system is comprised of two open- on the Feed System information page on the IQAN dis-
loop sub-systems, each powered by a pressure-compen- play.
sating, load-sensing pump. An alert message appears if an over-pressure condition
is sensed by one of the transducers.
Pumps
The 4300B and 4310B pumps are a variable-displace- If an over-pressure condition occurs and is sustained for
ment piston type that supply volume to its valve assem- a programmable period of time, the feed conveyor and
bly as required to maintain function speed. An internal compression roll stop, then rotate in reverse. After a
charge pump allows the pump to supply rated flow at separate programmable time delay, the feed conveyor
higher system pressures. and compression roll return to forward rotation. This
cycle repeats while the over-pressure condition exists.
The pumps are load-sensing with pressure compensa-
tion. Characteristics of load compensation include: System ISO Cleanliness Rating
• Constant pressure and variable flow The oil in the hydraulic system should not exceed a
• High pressure standby mode when flow is not cleanliness rating of 18/16/13. Cleaner oil will extend
needed the life of your hydraulic system components. Test oil
monthly or at each filter change.
• System flow adjusts to meet system requirements
A smaller pump supplies the clutch system. The clutch
system is covered in Section 1000 Power System.
Main Valve Assemblies

The main valve assemblies (manifolds) contain the
pressure limiters and flow controls for the motors, cyl-
inders, and power-beyond for the accessory valve
assembly.
Forward-reverse and speed control is provided by direc-
tional control valves, which are controlled electrically
from the operator controls and by the adaptive control
system. The directional control valves also can be man-
ually actuated for the purposes of testing and trouble-
shooting.

SECTION 2000 HYDRAULIC SYSTEM
Repair Practices and Precautions 1 WARNING

Dirt and contamination are the greatest enemies of Burn hazard.
hydraulic equipment. Before starting any repairs or
Wait until the oil and components have cooled to
removing any hose, filter, valve, or otherwise opening less than 100 deg. F before working on the sys-
the hydraulic system in any way, thoroughly clean the tem.
components.
Important
Cleanliness is the best way to ensure satisfactory life of
For the hydraulic system to function correctly,
hydraulic equipment. Clean the outside of the motor
there must be pressure in the hydraulic tank. Check
thoroughly before disassembly. Take care to avoid con- the gauge on the tank when the engine is running.
tamination of the system ports. Clean parts by using a
If there is no pressure in the tank, make sure the
clean solvent wash and air drying
plugs and breather are tight.
• Replace any O-ring found in a removed part. Apply If pressure is excessive (over 15 psi), replace the fil-
some clean lubricant (petroleum jelly, hydraulic oil, ters and/or clean or replace the breather.
or an O-ring lube product) prior to assembly.
Important
• Cover all holes, hoses and pipe ends with plugs or
Make sure all suction valves are open before start-
seal with clean plastic bags after removal to avoid ing the engine. Lack of oil to hydraulic components
the entry of dirt. can quickly cause major damage to the hydraulic
• Never disassemble hydraulic components outside. system.
• Perform repairs in a workshop on a clean work- Important

bench (covered with clean cloth or newspaper). Never place a load on the hydraulic system until the
oil has warmed up. Placing a load on pumps,
1 WARNING motors, and valves when oil is cold will shorten

their service life and may result in their sudden fail-
Before servicing the machine, review the Safety ure.
section of this manual. Do not operate the
machine unless you have the proper training and Important
are qualified to do so. Oil in a drum or other any container from the man-
ufacturer is not clean filtered oil.
The machine must remain locked out while any
Water and air are considered contamination in oil.
manifold or other hydraulic component is
removed or disconnected. Important
Always inspect the O-rings in the hose and adaptor
1 WARNING fittings. Replace any O-ring that is not in good con-
dition. If in doubt, replace the O-ring.
Hazardous material under pressure—Possible
skin or eye contamination. When replacing an O-ring, coat the O-ring with
clean oil. Never install a dry O-ring.
Before opening any hydraulic line, always
See “Hydraulic Fittings and Torque Tables” on
relieve the pressure in the tank by loosening the
page 81.
tank breather cap.
Always check for pressure in lines before loos- Important
ening components. Always tighten bolts, nuts, fittings, hoses, and car-
tridge valves to the proper torque specification.
Only use hardware that is in good condition.
Before starting the system after servicing, always
double-check connections to make sure they are
tight.

Troubleshooting Tools for Troubleshooting

Have these items on hand when troubleshooting:
Troubleshooting Basics • Hydraulic and electrical schematics for your
machine
The most common problems that occur in hydraulic sys- • Multimeter
tems are:
• Pressure gauges
• Contamination (80%) • Flow meter
• Aeration & Cavitation (10-12%) • Heat gauge
• Over pressure (5-6%)
• Other (poor oil, defective parts, accidental break- Calling Product Support
age, etc.)
Before making hydraulic system adjustments, make When placing a service call, provide the following
sure the problem is not mechanical, such as a loose or information:
missing component, jammed rotor, bent cylinder, etc. • How often the problem occurs, and if it has gotten
Before you begin looking for the cause of a suspected worse
hydraulic system problem, check the following. Any of • Is the problem intermittent or continuous
these can cause poor performance or erratic operation:
• Fluid level and condition (check the color and vis-
• low oil level cosity; if the data is available, note the cleanliness
• incorrect oil viscosity, or oil too hot or cold rating)
• dirty filters, breather, and oil (test the oil) • Fault messages on the display (take a picture to send
to Product Support)
• hose restrictions (tank, pilot, load sense)
• Pressure and temperature readings
• air or other contamination in the system
• What adjustments or other measures have been
• after these basics have been checked, then go to the
attempted
“Troubleshooting Tables” on page 46.
• Are there any unusual vibrations or noise
• Have the schematics in front of you

Troubleshooting Tables
Use the following tables to narrow down the problem.
Table 4: Performance of All Functions Has Deteriorated

Check Action
Pump and system pressures Do the procedure under “Adjusting Pressures (4310B)” on page 62
Pressure limiting valves or “Adjusting Pressures (4300B)” on page 74.
Pump performance. Troubleshoot the pump (“Troubleshooting a Pump” on page 48).
Table 5: Valve Response is Slow for All Functions

Check Action
Contamination Test the oil. Check for evidence of component failure (“In Case of
Pump Failure” on page 48).
Oil too cold or viscosity rating too high Wait until oil is warm before operating or change to a lower viscosity
oil.
Pump load sense (LS) or pressure compensator Do the procedure under “Adjusting Pressures (4310B)” on page 62
(PC) settings out of adjustment; relief valve set or “Adjusting Pressures (4300B)” on page 74.
too low
Restricted pump hose, blocked passage in the Check hoses. Troubleshoot the manifold or remove, disassemble,
manifold and clean the manifold.
Worn out valve assembly components Test and inspect manifold valves.
Table 6: One Function Does Not Respond to Control Panel or Remote Input in One Direction Only
Check Action
1) Operate the actuator manually in both Is there resistance to smooth lever movement? If so, the spool is
directions. NOTE: You must first pull the plug sticking. Remove and inspect the spool or replace the directional
from the actuator. This will cause a control system control valve. See “Replacing a Valve Spool” on page 56.
error which will reset when the plug is re-
connected. If the function operates normally in both directions, the problem is
electrical or hydraulic. Do the next check.
2) While the function is commanded at the If the shaft rotates in only one direction or movement is erratic,
control panel, observe the handle shaft on the the problem is electrical. See “To troubleshoot a 4310B electric
valve’s manual actuator. actuator:” on page 53 or “To troubleshoot a 4300B electric actuator:”
on page 54.
If the shaft rotates normally in both directions, the problem is

hydraulic. Refer to “Cylinders” on page 58 or “Motors” on page 60.

Table 7: One Function Does Not Respond to Control Panel or Remote Input in Either Direction
Check Action
While the function is commanded at the control If the shaft rotates, this means the spool is not stuck and the
panel, observe the handle shaft on the valve’s actuator is receiving an electrical signal. Refer to the troubleshooting
manual actuator. procedures for a cylinder or motor, as applicable.
Valves are identified in Figure 72 on page 67
and Figure 90 on page 76. If the shaft does not rotate, unplug the control valve*, put a lever
on the shaft, and operate the actuator manually:
[4300B only: First check the display for • Is there resistance to smooth lever movement? If so, the spool is
COUT error messages. This means there is a sticking. Remove and inspect the spool. If damaged, replace the
problem in the control valve circuit. The directional control valve. If it looks ok, reinstall and test.
message description will give an indication what
of the problem is. For more information, see the • If the function operates normally, the problem is electrical. See “To
Electrical section.] troubleshoot a 4310B electric actuator:” on page 53 or “To
troubleshoot a 4300B electric actuator:” on page 54.
[4310B only: If the function is proportional
(not on-off), first check the LED on top of the • If the function does not operate normally, the problem is hydraulic.
electric actuator on the directional control Refer to “Troubleshooting Cylinders” on page 58 or “Motors” on
valve. If it is blinking red or steady red, go to “To page 60.
troubleshoot a 4310B electric actuator:” on
page 53.] • If the spool will not move either mechanically or electrically, check
for restricted flow to tank or a damaged spool.
*This will cause a control system error which will reset when the plug is
re-connected.

Pumps • motors
• heat exchanger
• tank
The 4310B pumps are Sauer-Danfoss 130 cc, Series 45,
E frame. • filter housings.
The 4300B pump is a Bosch-Rexroth 145 cc type Use an appropriate solvent. There are screens in
AA11V. Rotation is right-hand, viewed from shaft end. each valve and block that should be backflushed.
The 4300 and 4310 pumps are a variable-displacement 5. Remove the failed pump according to “To remove a
piston type that supply oil to its valve assembly as pump:” on page 49.
required to maintain function speed. They are load- If a replacement pump is not to be installed imme-
sensing with pressure compensation. An internal charge diately, install a cover plate over the opening in the
pump allows the pump to supply rated flow at higher clutch, if applicable.
system pressures. 6. If the pump is to be repaired or returned for war-
Only basic pump repair and troubleshooting informa- ranty, plug the open ports to prevent oil spillage and
tion is presented in this manual. For more extensive dirt from entering the pump.
repair and troubleshooting, refer to the pump manufac- 7. Have the pump inspected by a qualified shop to
turer’s service manual. determine the cause of the failure.
In Case of Pump Failure Troubleshooting a Pump

If a hydraulic pump fails, stop and lock out the machine. The pump is typically not the cause of hydraulic system
If the internal parts have broken apart and migrated into problems. Before removing the pump, make sure the
other areas of the system, the reservoir, filter housings, problem is not elsewhere in the system. See “Trouble-
and associated hydraulic hoses, valves, manifolds, heat shooting Tables” on page 46.
exchanger, motors, and cylinders must be thoroughly
flushed. If this is not done, system operation can be  To inspect and flow-test a pump:
greatly impaired and severe damage can result. In this procedure, the pump is first inspected for internal
NOTE: There are tools available that greatly assist with pump damage. If the pump appears undamaged, then
cleaning hydraulic lines. check the condition of the pump by checking its flow, as
follows:
 To inspect after a pump failure: 1. With the engine stopped and the oil cool, loosen the
1. Loosen the breather cap on the hydraulic tank. breather cap on the hydraulic tank.
2. Close the tank suction line to the pump. 2. Check tank for foaming. If there is foaming, find the
source of the air. First check the pump intake.
3. Remove the hoses from the failed pump and direct
the oil into a suitable container. 3. Inspect for evidence of internal pump damage and
system contamination. See “In Case of Pump Fail-
4. Check the oil, hoses, and pump ports for pieces of
ure” on page 48.
metal.
4. Plumb a flow gauge into the port B plumbing.
If there are metal particles in any hoses or ports:
5. Tighten the breather cap.
Remove the pump hoses at the manifolds and
inspect for metal particles. If any metal is found, 6. Start the engine and allow the hydraulic system to
remove, disassemble, and thoroughly flush all rise to operating temperature.
system components: 7. Listen for any unusual noise from the pump.
• all system hoses 8. Operate all motors, including the tracks and fan(s)
(warm hydraulic system and/or engine) and operate
• manifolds and valve assemblies
no-load, high speed.

Check the flow gauge. The pump should be able to  To install a new pump shaft seal:
supply close to 72 gpm.
1. Remove the pump (“Pump Removal” on page 49).
Important 2. Using a snap-ring pliers, remove the retaining ring
Always inspect the O-rings in the hose and adaptor from the housing.
fittings. Replace any O-ring that is not in good con-
dition. If in doubt, replace the O-ring.
When replacing an O-ring, coat the O-ring with
clean oil. Never install a dry O-ring.
Pump Removal
 To remove a pump:
1. Lock out the machine.
F06393
2. Drain the main hydraulic oil tank according to
“Changing the Hydraulic Oil” in Section 2000 of Figure 45: Shaft Seal and Retaining Ring (Typical)
the Operator Safety and Maintenance manual sup-
plied with the machine.
3. Remove the shaft seal from the bore by using a
3. Remove the air cleaners (4310B).
packing hook or a slide-hammer type puller.
4. Remove the hoses from the pump. Inspect for evi-
4. Inspect the pump housing and new seal for damage.
dence of internal pump damage and system contam-
Inspect the sealing area on the shaft for rust or wear.
ination according to “In Case of Pump Failure” on
Polish the sealing area if necessary.
page 48.
If a groove has been worn into the shaft by the O-
5. Plug the hose ends and pump ports.
ring, replace the shaft or the pump.
1 CAUTION 5. Coat the part of the seal that contacts the shaft with
hydraulic oil.
Falling object hazard. 6. Place a protective sleeve over the shaft end to pre-
The 4310B pumps weigh 125 lb (57 kg) and the vent damage to the seal during installation.
4300B pump weighs 161 lb (73 kg).
Important
Do not attempt to remove a pump without Install the seal with the cupped side toward the
mechanical assistance. Doing so may result in pump shaft bearing. Do not damage the seal.
serious injury.
Important
6. Attach appropriate lifting equipment to the
Press the seal into the housing only far enough to
pump(s). clear the retaining ring groove. Premature bearing
7. Take up the weight of the pump(s) with the lifting failure can result if the seal contacts the bearing.
equipment. 7. Keeping the seal perpendicular to the shaft, press
8. Unbolt the support bracket from the pump (4310B). the new seal into the housing just far enough to
9. Unbolt the pump. There will be oil between the clear the retaining ring groove (or taper, as applica-
pump and the clutch housing (4300B/4310B), and ble).
between the pumps (4310B). 8. Using a snap-ring pliers, install the retaining ring (if
10. Attach a cover plate over the opening on the clutch used) into the housing.
housing or remaining pump. 9. Remove the installation sleeve and install the pump
according to the installation procedure.

Pump Installation 3. Make sure the spline adapter is installed into the
clutch housing (Figure 46).
Important 4. Attach appropriate lifting equipment to the
If you are replacing a failed pump, see “In Case of pump(s).
Pump Failure” on page 48. 5. Bolt the pump to the inner pump or the clutch plate,
The replaced pump’s internal parts may have as applicable.
migrated into other areas of the system. If the sys- 6. Bolt the pump to the support bracket (4310B).
tem is not flushed, operation can be greatly
impaired and severe damage can result. 7. Replace any exposed o-rings on hose connections.
8. Install the hoses to the correct ports on the pump,
Important but do not attach the case drain hose.
Always tighten bolts, nuts, fittings, hoses, and car-
tridge valves to the proper torque specification. Important
Only use hardware that is in good condition. Never start up a pump dry. Always fill the pump and
Before starting the system after servicing, always hoses with oil before operation.
double-check connections to make sure they are 9. Fill the pump with clean, filtered hydraulic oil
tight. through the uppermost case drain port.
1 CAUTION 10. Check for restrictions and make certain all fittings
are tight (except case drain hose).
Falling object hazard. 11. Install the air cleaners (4310B)
The 4310B pumps weigh 125 lb (57 kg) each and 12. Do the air bleed procedure. See “Bleeding Air from
the 4300B pump weighs 161 lb (73 kg). the Hydraulic System” on page 51.
Do not attempt to lift a pump without mechanical 13. At the valve assembly, back out the relief valve sev-
assistance. Doing so may result in serious eral turns. See Figure 64 or Figure 65 on page 63.
injury.
Important
 To install a pump: Back out the relief valves several turns before oper-
ating the hydraulic system. This will ensure that
1. If the pump has been repaired, replace the shaft seal excessive pressures are not placed on the system.
if not already done, according to “To install a new
14. Check the pump standby pressure (if the pump is
pump shaft seal:” on page 49.
new, skip to the set-up procedure):
2. Install a new O-ring between the pumps, if applica-
a. Install a 6000 psi gauge into the test port on the
ble. Lubricate the O-ring with clean hydraulic oil.
pump.
b. Start the engine. Allow the hydraulic system to
warm up.
c. Set engine speed to low idle. Do not place a
load on any functions.
d. Check that the pump is maintaining at least 400
psi (11 bar). If not, determine the cause (see
“Troubleshooting a Pump” on page 48).
Spline
15. Do the set-up procedure: “Adjusting Pressures
Adapter (4310B)” on page 62 or “Adjusting Pressures
(4300B)” on page 74.
F08874
Figure 46: Pump Installation (4310B Shown)

Bleeding Air from the 4. Loosen, slightly, the pump supply fitting at each
main valve assembly. See Figure 49 (4300B) or
Hydraulic System Figure 72 on page 67 (4310B).
Any time the suction manifold has been drained or

partly drained, such as after the hydraulic tank has been
emptied and refilled or a pump has been replaced, prime Pump Supply
Hose Fitting
and bleed the hydraulic system. This will ensure there is
fluid in all hydraulic pumps and circuits and that air is
removed from the system:
1. Place a container under the pump(s) to collect
spilled oil.
2. Begin to fill the hydraulic tank with filtered oil.
3. If not already done, remove the case drain hose
from each pump (Figure 47 and Figure 48).
When oil flows without bubbles from the open port,
re-install the hose.
F09032
Figure 49: Loosen the Pump Supply Fitting (4300B)
5. Turn off the control power.

6. Remove the two plug connectors from the ECM.
This is to prevent the engine from starting.
Important
Do not allow the engine to start while the supply
hose is loose, otherwise the hydraulic pressure will
rupture the o-ring.
F09045
Figure 47: Case Drain Connection (4300B) 7. Turn on the control power.
8. Crank the engine for 30 seconds while someone
observes the loosened fittings.
When oil is flowing from the loosened hoses with-
out spurts or bubbles, stop cranking.
9. Tighten the hoses.
10. Plug the connectors back onto the ECM.
11. Start up the machine according to normal start-up
procedures.
12. Operate all cylinders full-stroke several times.
13. Turn on the feed system and run for at least a min-
ute.
14. Shut down the machine.
F09039
15. Check the oil level and add as necessary.
Figure 48: Case Drain Connection, Top of Pump (4310B)

Valve Assemblies
Directional Control Valves 4300B Actuators
The valves on the 6-section valve assembly are con-
The directional control valves for the main functions are trolled by a 24V, 200mA–800mA (approximately) cur-
electrically controlled by control system input. These rent output from the controller.
valves may also be manually actuated if necessary for Because the output is analog, fault monitoring of each
troubleshooting. control valve circuit is provided. Fault messages will
To determine if a problem may be the result of a faulty appear on the display as COUT or RET errors.
control valve, see “Troubleshooting Tables” on page 46. Fault self-monitoring, however, is not a feature because
For an explanation of tracing the actuator electrical cir- this actuator does not have internal electronics. Another
cuit, see “Tracing an Example Circuit” on page 92. difference between this actuator and the 4310B actua-
tors is that the pilot pressure must be higher.
4310B Actuators
The electric actuators for the valves on the 4-section
valve assemblies are two types: on-off and proportional
(Figure 50).
• The on-off valve is controlled by a 0V–24V signal.
• The proportional valve is controlled by a 2.5V–
7.5V signal. A feature of the proportional type is an
LED which can signal faults of its internal electron-
ics.
You must disconnect

Push this direction the actuator before
for port A flow you can operate the
valve manually
A B Manual Actuator
Electric Actuator (Handle Optional) Pull this direction
for port B flow
Stroke Limiter,
Port B
Solenoid Bridge
(4310B only) Stroke Limiter,
F08884 Port A
Valve Body
Simplified Depiction
Figure 50: Directional Control Valve, Proportional Type (Typical)

 To troubleshoot a 4310B electric actuator: • A steady red light means there is an internal fault
in the actuator electronics. Continue to step 2. If
The on-off valve is controlled by a 0V–24V signal. The
no problem is found in the machine wiring,
proportional valve is controlled by a 2.5V–7.5V signal.
replace the actuator and retest.
A feature of the proportional type is an LED which can
signal faults of its internal electronics. • If the LED is off, go to the next step.
1. Proportional control actuator only (if the function is NOTE: If a stroke limiter has been incorrectly set to
on-off, skip this step): With control power on, check interfere with normal spool movement, this
the LED on top of the actuator (Figure 51). will cause the LED to indicate a fault.
• A steady green light means no internal fault or Also, if the supply or signal voltage drops too
supply voltage problem has been detected. Con- low, the valve will disable itself.
tinue to step 2.
2. Disconnect the plug from the actuator. Inspect the
• A blinking red light means the control signal plug and pins for damage, corrosion, or moisture.
voltage is out of the normal range. Continue to
3. Proportional control actuator only: Check for 24V
step 2. If no problem is found in the machine
at plug terminal 4.
wiring, replace the actuator and retest.
If voltage is zero, check the Electrical Output dis-
play page to verify the switch command is being
received by the controller.
4. Activate the function in both directions at the con-
LED
trol panel while checking for proper signal voltage
(on proportional
valves) at the plug terminals (Figure 51).
5. Turn off the control disconnect switch.
Deutsch
Connector 6. Using an ohmmeter, check resistance between the
plug ground terminal and a good machine ground.
The resistance should be less than 1 ohm.
F08885
7. Isolate the circuit by disconnecting the circuit at the
Top of Electric Actuator
controller (see schematic). Inspect the plug and pins
for damage, corrosion, or moisture.
Proportional On-Off • Using an ohmmeter, check for a short circuit
Control Control
between all plug terminals.
GND GND GND
Not used • Check circuit continuity: At the removed plug at
the controller, jumper the circuit’s terminals.
Resistance between the actuator plug terminals
should be less than 1 ohm.
8. Turn on the control power.
F08886
If no problem is found, troubleshoot the wiring
between the control panel switch and the controller.
24V 2.5V for Port 24V for Port 24V for Port
A Flow B Flow A Flow Also, refer to the Electrical section for more trou-
7.5V for Port 0V for Port 0V for Port bleshooting information.
B Flow A Flow B Flow
5V Neutral
Figure 51: Valve Actuator and Plug Terminals (4310B)

 To troubleshoot a 4300B electric actuator: 5. Check the mA signal:

The valves on the 6-section valve assembly are con- a. Jumper one plug terminal to the corresponding
trolled by a 24V, 200mA–800mA (approximately) cur- pin on the valve actuator.
rent output from the controller. b. Clip one meter lead to the other plug terminal
Fault monitoring of each control valve circuit is pro- and the corresponding valve actuator pin.
vided by the machine’s control system. Fault messages Set a multimeter to measure mA.Without com-
appear on the display as COUT or RET errors. manding the function, you should see zero or
1. Turn off the control power. close to zero mA. If you see significant mA
value, troubleshoot the wiring for a short.
2. Disconnect the plugs from the actuator. Inspect the
plug and pins for damage, corrosion, or moisture c. Operate the function in both directions and
observe the meter. You should see 390-750mA.
3. On the actuator (Figure 52), check resistance
between each set of pins. Resistance should be 20– If an mA signal is absent on any circuit, go to
22 ohms. If not, replace the actuator. the Electrical Outputs display page to verify an
output for that function is being sent by the con-
4. Turn on the control power.
troller.
1 CAUTION If the output on the display is absent, go to the

Electrical Inputs page and verify the signal
Do not command a valve if the wires to the valve from the function switch is received by the con-
are disconnected. Doing so will result in the troller.
valve defaulting to full-flow.
6. Turn off the control power.
7. Isolate the circuit by disconnecting the circuit at the
controller (see schematic). Inspect the plug and pins
for damage, corrosion, or moisture.
• Check for a short circuit between the actuator
plug terminals and ground.
• Check for a short circuit between the plug termi-
nals.
Actuator
Pins • Check circuit continuity: At the removed plug at
the controller, jumper the circuit’s terminals.
390-750mA at Between the actuator plug terminals, resistance
Plug Terminals should be less than 1 ohm.
If no problem is found, troubleshoot the wiring
between the control panel switch and the controller.
Also, refer to the Electrical section for more trou-
F08887/F08888
bleshooting information.
Figure 52: 4300B Valve Actuator Pins and Plug Terminals

Monoblock Valve Assembly NOTE: Another way to test a coil is to energize the coil
as you normally would using the controls. Then
The monoblock assembly has two solenoid-controlled check the coil end for magnetic attraction. A
valves (Figure 53) for the spout cylinders. One valve is good coil will be magnetic when energized.
not used at this time. The 4300B monoblock assembly
NOTE: One common cause of coil burnout is a sticking
has an additional four valves for the landing gear.
valve. Other causes include excessive tempera-
tures and rapid cycling.
4. Activate the function and check across the plug ter-
minals for 24V.
If there is not 24V, go to the Electrical Inputs page
on the display. Activate the function at the control
Manual switch. If the indicator light does not come on for
Actuator that function, troubleshoot the wiring between the
Arm
switch and the controller.
5. Check the wiring between the valve and the control-
ler (Figure 54 and Figure 55). First, isolate the cir-
cuit by disconnecting the circuit’s corresponding
Solenoid
plugs from the controller (see schematic). Then do
Coil the typical checks for opens and shorts. For guid-
ance, see the Electrical section.
F08889
Figure 53: Monoblock Valves
 To troubleshoot a non-responsive spout F08890
cylinder: Solenoid on
Hydraulic
1. Check to make sure the control valve for the power Control Valve Clamping
Diode
beyond function is working. See “To troubleshoot a
4300B electric actuator:” on page 54 or “To trou- Figure 54: Schematic for Monoblock Solenoid Connection
bleshoot a 4310B electric actuator:” on page 53. (Example—See Machine Schematic for Details)
2. Try actuating the valve manually. First disconnect
the coil wires, then insert a handle into the manual
actuator arm. Move the arm forward and back.
Not used
If the cylinder functions normally using the manual
Battery + Battery –
override, go to the next step.
Not used
3. Pull the plug from the solenoid. Check for moisture
or damage.
Connector Type:
Using a multimeter, check the resistance between ISO 4400
the coil terminals on the solenoid. Normal coil F08891
resistance is typically in the 20-22 ohm range.

Figure 55: Plug Terminals for Monoblock Valve Solenoid

Removing a Valve Manifold Replacing a Valve Spool

If a manifold has been contaminated by metal particles,  To replace a valve spool:
the best practice is to remove the manifold to a clean
indoor repair facility with a test bench where it can be 1. Remove the filter from the tank breather cap and
completely disassembled and thoroughly flushed. install vacuum equipment (Figure 56). Apply vac-
uum.
Note that other components in the hydraulic system may
also need to be flushed (see “In Case of Pump Failure”
on page 48).
 To remove a manifold:
1. Shut down and lock out the machine. Allow the
hydraulic system to cool.
2. Loosen the breather cap on the hydraulic tank.
3. Remove the cover located behind the manifold.
4. Disconnect all wiring from the manifold. Label the
wires first.
5. Place a container and rags under the manifold to
collect the hydraulic oil that spills from the opened F08892
hoses and ports.
Figure 56: Vacuum Equipment on Hydraulic Tank
6. Label each hose and its mating port to ensure every-
thing is reinstalled in the correct location.
7. Remove the hoses from the manifold. Plug the hose 2. If a hose is blocking access to the valve, remove,
ends and open ports. disconnect and plug the hose and open port.
3. Back out the top stroke limiter (Figure 57). This
1 CAUTION allows enough play in the manual actuator to detach
the spool once it is removed from the valve.
Falling object hazard.
The larger valve assemblies can be very heavy.
Use mechanical assistance. Not doing so may
result in serious injury.
8. Unbolt the manifold and remove it.
Install in the reverse of this procedure, then do the pump
set-up procedure and adjust the valve assembly pres-
sures.
F08893
Figure 57: Backing out the Stroke Limiter

4. Remove the bolts from the valve cap (Figure 58).

Check to see that the O-rings
on the cap are intact
The spool hooks onto the

actuator inside the cap
F08896
F08894 Figure 60: Detach/Attach Spool

Figure 58: Removing Valve Cap Bolts
7. Slide the new spool into the valve.
5. Remove the cap with the spool still attached (Figure 8. Re-install the cap.
59). 9. If removed, re-install the hose.
10. Remove the vacuum equipment from the tank.
11. Test the function.
F08895
Figure 59: Removing the Valve Cap and Spool
6. Detach the spool from the manual actuator and

attach the new spool (Figure 60).

Cylinders
1 WARNING
Before working on the machine, be aware of the
“Repair Practices and Precautions” on page 44.
Troubleshooting Cylinders
If a cylinder is leaking, operates hot, becomes damaged,
or does not work properly, it is typically replaced.
Therefore, repair procedures are not provided in this
manual. However, some cylinders can often be repaired
if the machine owner wants to do that.
The internal leak test is described on the next page.
Table 8: Hydraulic Cylinder Troubleshooting

Problem Possible Causes Action
One cylinder is much hotter than its Leaking seal and/or damage Inspect rod and cylinder. (Use a heat detection
twin. to one of the cylinders, such tool).
as a bent or scarred rod. • If damaged, replace cylinder.
• If not damaged, do the internal leak test.
Rust or scarring on the cylinder Cylinder worn out. May cause the seal to leak. Do the internal leak
shaft. test.
Long-term storage with no Buff out scarring. If too deep, replace cylinder.
surface protection on the rod.
One cylinder of a pair raises and Leaking seal or damage to Inspect rod and cylinder.
lowers too slowly or not at all. one of the cylinders. • If damaged, replace cylinder.
If not damaged, do the internal leak test.
Both cylinders move slower than Pump, valve, or other See “Troubleshooting Tables” on page 46.
normal. hydraulic component is faulty.
External leakage at the rod seal. Excessive hydraulic pressure. Check the setting of the pressure limiter in the
control valve for the cylinder. See “Pressure
Damaged rod or seal. Limiter Settings” on page 66 or “Pressure
Limiter Settings” on page 78.
Inspect rod and cylinder.

• If damaged, replace cylinder.
• If not damaged, do the internal leak test.
Repaired cylinder soon begins to Poor quality seal. Install a correct seal.
leak again.
Damage. Replace the cylinder.

 To test for internal leakage in a hydraulic

cylinder:
1. Open the hydraulic tank breather cap.
2. Be prepared to collect any oil that spills from the
hose and the cylinder.
3. Start the engine and allow the system to warm up.
4. Extend the cylinder to its full extent.
1 DANGER
Crushing hazard.
The compression roll is extremely heavy. Do not
depend on the hydraulic system to hold the com- F06403
pression roll in a raised position.
Always set BOTH safety locking stops any time Figure 61: Cylinder with Leaking Piston Seal
that:
• Maintenance, inspection, or repair work is to be
9. Stop the engine.
done under a raised compression roll housing.
• The compression roll is to be left in a raised 10. Replace the cylinder or seal if it failed the leak test.
position for any reason After repair or replacement, check the valve pres-
Never attempt to remove the pins from inside or sure limiter settings for that cylinder. See “Pressure
while a person is in the feed chamber, under the Limiter Settings” on page 66 or “Pressure Limiter
weight of the compression roll housing, or near Settings” on page 78.
the point of operation.
If testing a compression roll housing cylinder, insert
the safety pins before working on a cylinder.
5. Stop the engine. For safety, allow the system to cool
to about 100 deg F.
6. Remove the hose from the upper (rod) end of the
cylinder.
Install a plug into the hose.
Direct the cylinder end into a container.
7. Start the engine. Increase speed to high idle.
8. At the controls for the cylinder, operate the control
to extend the cylinder and hold for about 5 seconds,
then release.
If any oil flows from the open port (Figure 61), the
piston seal is bad.

Motors  To test a feed motor:

There are two motor tests: checking the volume of case
drain flow and checking the flow between the motor and
The two feed motors are manufactured by Poclain. the valve. If the motor fails either test, replace the
If there are external oil leaks: motor.
• Hose fittings may be loose or the fitting O-rings
Case Drain Flow Test
may be worn or damaged.
• The case pressure may be too high. Check for
2. Place a container capable of holding 5 gallons of oil
restrictions in the case drain return line.
under the pump.
• The mounting O-ring or shaft seal may be damaged.
3. Disconnect the case drain hose from the motor (Fig-
ure 62).
Troubleshooting a Motor 4. Install a hose to the open case drain port in the
motor. Place the other end of the hose into the con-
First use the “Troubleshooting Tables” on page 46. If all tainer.
signs point to a bad motor, do the following procedure.
5. Tighten the breather cap.
 To troubleshoot a feed system motor: 6. Start the engine and engage the clutch. Set the
engine speed to high idle.
1. Turn on the engine.
7. When the hydraulic system has warmed up, operate
2. Go to the Feed System information page on the the motor full speed, no load.
IQAN display.
When oil begins to flow into the container, start a
3. Activate the function while observing the pressure one-minute timer. At one minute, stop the motor.
on the display. The pressure should spike initially,
then drop to a steady level when the motor speed is 8. Measure the amount of oil that flowed into the con-
steady. If the pressure remains high, there is a tainer. If the amount is more than the specifications
mechanical or hydraulic blockage. below, replace the motor.
4. At the valve assembly, install a 0-6000 psi (414 bar) Feed motors: 5 gallons
gauge on the relief pressure test port. Verify that Fan motors: 3-5 gallons
standby pressure (at no load, high idle) is about 400
psi (27 bar). If not, check the pump and valve set- Main Pressure Flow Test
tings. 1. Loosen the breather cap on the hydraulic tank.
5. Stall the motor and operate the function. Check the 2. Install a flow gauge between the control valve and
pressure on the gauge. The pressure should be about the motor.
4300 psi for a 4300B motor and 4600 psi for a 3. Tighten the breather cap.
4310B motor.
4. Turn on the engine and engage the clutch. Set the
If the pressure is much lower than stated above, engine speed to high idle.
back out the pressure limiter several turns while the
function is operating. This might loosen any debris 5. Go to the display page that monitors the speed of
that may be blocking the valve. Then reset the lim- the motor.
iter to the specifications above. 6. Operate the motor full speed, no load.
6. Check system pressures. See “Adjusting Pressures If the flow to the motor is normal (see list below),
(4310B)” on page 62 or “Adjusting Pressures but the motor cannot maintain its normal speed,
(4300B)” on page 74. replace the motor.
If the motor still performs poorly, or if the specified
pressures cannot be achieved, the motor may be worn
out. Do the motor test procedure.

Maximum flow to the motors Connect and Test a New Feed

4300B: Motor
Fans: 14 gpm
Feed Conveyor: 17 gpm To remove and install a feed drive motor, refer to the
Compression roll: 18 gpm Feed section.
4310B:  To connect and test a new feed motor:
Fan, Engine Cooler: 16 gpm
Fan, Charge Air: 10 gpm Important
Never start up a dry motor. Always fill the motor
Feed Conveyor: 17 gpm
with oil before operation.
Compression roll: 11 gpm
Tracks: 37 gpm 1. Install the high pressure hoses to the correct ports
(Figure 62).
Case Drain
A Port
B Port
F08897
Figure 62: Lower Feed Drive Motor
2. Fill the motor with clean, filtered hydraulic oil

through the case drain port.
3. Install the case drain hose.
4. Tighten the breather on the tank.
5. Start the engine. Allow the system to rise to operat-
ing temperature.
6. Operate the motor for 15 minutes to ensure that the
system is filled and air is purged.
7. Verify that the main valve and pressure limiter set-
tings are correct. See “Adjusting Pressures
(4310B)” on page 62 or “Adjusting Pressures
(4300B)” on page 74.

Adjusting Pressures (4310B)

Main System Pressures  To set the pressures for one pump and
valve assembly:
This procedure should be performed any time that: This procedure will set the:
• a pump or motor is replaced • Pump pressure compensator and standby (LS) pres-
• a manifold component or a relief valve is replaced sure
• when recommended by a troubleshooting proce- • Main relief
dure • Pilot pressure relief
Important • Load sense relief
If a new main relief valve (Figure 64 or Figure 65) or
NOTE: Pressure setting tolerances:
a new pump has been installed, back out the relief
valve several turns before operating the hydraulic above 1000 psi: -0 /+50 psi
system. This ensures that excessive pressures are below 1000 psi: -0/+25 psi
not placed on the system.
Always adjust relief valves UP to the specified
pressure. 2. Stall a function (Figure 63):
• If setting up the outside pump/right-hand valve
Inside Pump assembly, disconnect the port A or B hose at the
The pump that is mounted to the clutch supplies hydrau- feed motor. Cap the open port and plug the hose.
lic oil to the left-hand valve assembly and from there to • If setting up the inside pump/left-hand valve
the following components: assembly, disconnect the port A or B hose at the
• Upper feed lift cylinders upper motor. Cap the open port and plug the
hose.
• Upper feed drive motor
• Radiator/hydraulic oil cooler fan drive motor Important
When installing gauges, be aware that there may be
• Track drive motor, left (drive) side a significant pressure spike when the engine is
started. This can damage some gauges. You might
Outside Pump want to install gauges after the engine is started.
The pump that is mounted to the inside pump supplies
hydraulic oil to the right-hand valve assembly, and from
there to the following components:
• 3-section monoblock valve (discharge spout)
• Feed conveyor drive motor
• CAC fan drive motor
• Track drive motor, right (non-drive) side

Cap on Motor
Port
Relief Pressure
Gauge Connection Main Relief
Valve
Plug in
Hose
Pilot Pressure
Gauge Connection
F08898
Figure 63: Stalled Feed Motor
F08899
3. At the pump, install a 6000 psi (414 bar) gauge to Figure 65: Pilot Pressure Test Fitting (Left-Hand Valve)
the pump pressure gauge connection (Figure 64).
4. At the valve, 5. Tighten the breather cap.
• install a 500 psi (34 bar) gauge to the pilot pres- 6. Start the engine.
sure gauge connection.
7. Allow time for the oil to warm up.
• install a 6000 psi (414 bar) gauge to the relief
pressure gauge connection (Figure 64) 8. On the main relief and load sense relief valves,
loosen the adjusting screw nut.
Main Relief 9. At the pump:
Valve
a. Loosen the set screws (Figure 66).
Load Sense Pressure

Adjustment Screw
Relief Pressure Set screws

Gauge Connection
Pilot Pressure F08901

Gauge Connection Pressure Compensator
Adjustment Screw
Figure 64: Pilot Pressure Test Fitting (Right-Hand Valve)
F08900
Figure 66: Adjustment Screws on the Pump

b. Turn the load sense pressure adjustment screw 15. At the valve assembly:
(Figure 66) gently clockwise until it stops, then a. Adjust the load sense relief valve (Figure 68)
back out 1/2 turn. until the relief pressure gauge reads 4600 psi
10. Increase engine speed to high idle. (318 bar).
11. Manually operate the control valve for the stalled Tighten the nut, recheck pressure, and repeat
function (Figure 67). adjustment if necessary.
b. Decrease engine speed to low idle.
c. Adjust the pilot pressure reducing valve until
the gauge on the pilot pressure test fitting reads
220 (+25/-0) psi (15-17 bar).
Tighten the nut, recheck pressure, and repeat
adjustment if necessary.
Load Sense
Relief Valve
F08902
Figure 67: Manually Actuating a Control Valve Pilot Pressure

Relief Valve
12. On the pump, turn the compensator adjustment
screw until the pump pressure gauge reads 5200 psi
(360 bar). Clockwise rotation increases pressure.
If this pressure cannot be achieved, the main relief F08903
valve may need to be adjusted higher. Figure 68: Load Sense and Pilot Pressure Valves
This is a temporary setting for adjusting pressures at
the valve assembly.
16. Set the load sense pressure (engine speed still at
13. At the valve assembly, adjust the main relief valve low idle):
(Figure 65) down, then up to 5100 psi (352 bar).
a. Unplug the solenoids at the fan control valves.
Tighten the nut, recheck pressure, and repeat adjust-
ment if necessary. b. On the pump, adjust the load sense pressure
until the gauge on the pilot pressure test fitting
If 5100 psi cannot be achieved, the pressure relief reads 400.
valve or the pump may be faulty. Either replace the
valve and retest, or troubleshoot the pump. Tighten the setscrew, recheck pressure, and
repeat adjustment if necessary.
14. On the pump, turn the compensator adjustment
screw until the pump pressure gauge reads 4800 psi Reconnect the fan control valve solenoids.
(331 bar). This sets the system pressure. 17. Make sure the adjustment set screws and valve nuts
Tighten the setscrew, recheck pressure, and repeat have been tightened.
adjustment if necessary.

Important
At this point you can either:
• adjust the pressure limiters according to “Pres-
sure Limiter Settings” on page 66,
• set the pressures for the other pump and valve
assembly, or
• shut down the engine and finish this procedure.
18. Shut down the machine if no other pump or valves

require adjustment.
19. Loosen the tank breather.
20. Remove the motor stall plug and cap and reattach
the hose.
21. Tighten the tank breather.

Pressure Limiter Settings

 To set the lower feed motor pressure: 5. Adjust both pressure
limiters on the valve
1. At the valve assembly, install a 6000 psi gauge in
until the gauge reads
the relief pressure test fitting (Figure 64).
4500 psi (310 bar)
2. Stall the motor: Remove one of the high pressure (Figure 71) in both
hoses from the feed drive motor. Securely plug the directions.
hose and cap the open port (Figure 69).
6. Re-install the hose.
Cap on Motor
Port
Plug in
Hose F08904
Figure 71: Adjusting the Port B
Pressure Limiter
F08898  To set the compression roll motor

Figure 69: Stalled Feed Motor pressure:
1. At the valve assembly, install a 6000 psi gauge in
the relief pressure test fitting (Figure 65).
3. Start and run the engine until the system has
warmed up. Increase speed to high idle. 2. Stall the motor: Remove one of the high pressure
hoses to the compression roll motor. Securely plug
4. Manually operate the feed drive control valve (Fig- the hose and cap the open port.
ure 70) in both directions and check the pressures
on the gauge. 3. Run the engine at high idle.
4. Manually operate the compression roll control
valve (Figure 72) in both directions and check the
pressures on the gauge.
5. Adjust both pressure limiters on the valve until the
gauge reads 4600 psi (317 bar) (Figure 71) in both
directions.
6. Reinstall the caps on the pressure limiters.
7. Stop the engine.
8. When the oil is cool, re-install the hose.
F08902
Figure 70: Manually Operating a Control Valve (Example)

Pump Supply
Hose Fitting Pump Supply
Hose Fitting
Radiator Fan Right Side Track Feed Conveyor Drive
F08905
Left Side Track Compression Compression CAC Fan

Roll Drive Roll Cylinders
Power Beyond
Figure 72: 4310B 4-Section Valve Assemblies, Machine Functions
 To set the compression roll cylinder float  To set the pressure for the monoblock valve
pressure: assembly:
1. Start and run the engine until the system has 1. Start and run the engine until the system has
warmed up. warmed up.
2. Set engine speed to high idle. 2. Set engine speed to high idle.
3. Deadhead the compression roll cylinders. To do 3. Adjust the B port pressure limiter for the mono-
this, raise the compression roll to its full height. block valve (Figure 72) until you reach 2000 psi
4. Adjust the A port pressure limiter (Figure 72) until (138 bar) on the relief pressure test gauge.
the relief pressure gauge reads 1400 psi (97 bar). To set the relief pressure at the monoblock valve,
5. Lower the compression roll fully and observe the see “3-Section Valve Pressure Settings” on page 73.
pressure reading.
6. Adjust the B port pressure limiter until the gauge
reads 1400 psi (97 bar).

 To set the fan speeds (4310B or 4300B):

Two people are required to set up the fans. One person
holds the fan to full speed while the other person mea-
sures the fan speed and adjusts the pressure limiter.
Set the maximum speed of the fans

warmed up.
2. At the IQAN display, go to either the Inlet Air/Hyd
Oil/Clutch Oil Fan page or the Engine Coolant Fan
page (Figure 73).
F08907
Figure 74: Force Fan to Full Speed
4. Using a tachometer, measure the fan speed (Figure

75).
Press F2 to force the fan full reverse

Press F4 to force the fan full forward
F08906
Figure 73: Fan Information Page (1 of 2)
3. At the display, press F4 to force the fan to full for-

F08908
ward or full reverse (Figure 74).
Figure 75: Reading the Fan Speed
5. On the valve for the fan (Figure 72), adjust the pres-
sure limiter for either the A or B port, depending on
the direction of the fan, to:
• Engine coolant fan†(4310B): 2400 rpm
(0 rpm/+100 rpm)
• Inlet air/hyd/clutch fan (4310B): 2100 rpm
(0 rpm/+100 rpm)
• Engine coolant fan†(4300B): 2050 rpm
(0 rpm/–50 rpm)
• Inlet air/hyd/clutch fan (4300B): 2000 rpm
(0 rpm/–50 rpm)

6. At the display, force the fan to full speed in the other 4. Using a tachometer, measure the fan speed.
direction. 5. At the Minimum Speed setting page (Figure 77),
7. Adjust the pressure limiter for the other port to the increase or decrease the value according to your
same value as above. speed measurement.
8. Recheck the fan speed with the fan at full forward
and full reverse. Make the necessary adjustments at
the pressure limiters until the specified speed is
reached.
9. Press OK to save the settings.
Set the minimum speed of the fans

1. Set the engine to low idle.
2. Go to the Adjustments page (wrench icon) and
select Fan Settings.
3. At the Fan Settings menu (Figure 76), select Mini-
mum Speed for the fan you are adjusting.
F08910
Figure 77: Fan Speed Adjustment Page (1 of 2)
6. Continue to measure fan speed and make adjust-

ments at the display until you reach 1000 rpm.
7. Press OK to set the value, then return to the menu
and select the other fan.
8. Set the minimum speed for the other fan.
F08909
Figure 76: Fan Settings Menu

Setting Up the Tracks

NOTE: The track drive motor pressure is set when the
pilot pressure at the valve assembly inlet is
adjusted during the pump set-up.
Setting up the tracks to travel straight requires setting
the spool travel limiters and then making adjustments to
the current output at the IQAN display.
The engine does not need to be on for the following
steps.
 To adjust the spool travel limiters:

1. Go to the valve assembly (Figure 72) and attach a
handle to the valve for the right track.
2. Loosen the locking nut on the spool travel limiter
screw.
Spool travel adjustment
3. Push the handle in toward the valve assembly. This screw for Reverse (B port)
is the forward direction (A port).
4. With the handle pushed in, turn the bottom screw (A
port) all the way in until it contacts the cam. Upon
contact, the handle moves slightly.
Then, turn the screw in 1/4 turn further (this moves
the handle part way toward center).
Spool travel adjustment
Tighten the locking nut. screw for Forward (A port)
5. Pull the handle down, away from the valve assem- F08911
bly, and make the same adjustments for the B screw. Figure 78: Adjust Spool Travel on Track Valves (Example—
6. Repeat the adjustments on the valve for the right Not the Actual 4310B Valve Assembly)
track.
7. Do the procedure “To adjust the track speeds at high
idle:” on page 71.

 To adjust the track speeds at high idle:

The default value for current (mA) output is 100%.
Reducing the current output to the valve slows the track.
Do the following adustments for forward and for
reverse.
Important
Test the adjustments on flat uniform ground to
avoid causing differences between sides.
warmed up.
2. Set engine speed to high idle.
3. Using the remote control, operate the tracks in for-
ward at high speed. Watch to see which direction
the machine may drift. Then stop the machine.
F08913
4. Go to the Adjust menu (Figure 79) on the display Figure 80: Enter PIN Code
and select Tracks High Idle.
6. Select the page for the faster track side.
F08912
Figure 79: Adjust Menu
F08914
5. Enter the PIN code 1999, then press OK (Figure Figure 81: Tracks Adjust Page—High Idle
80).
7. Adjust down the value for the faster track, then

press OK.
8. Operate the tracks again at high idle and watch to
see if the machine travels straight.
Adjust again as necessary.

 To set the low speed for each track: 6. Adjust as necessary to a track until travel to the
specifications in Figure 84.
warmed up.
1. Go to the Adjust menu on the display and select
Tracks Low Idle.
2. Enter the PIN code 1999, then press OK (Figure
80).
3. Select the first menu item on the Tracks Low Idle
page. (Figure 82)
4. Adjust the Value to 40%. Then do the same for the
other three menu items.
F08916
Figure 83: Track Speed Low Idle Forward Adjustment Page

(Right Track Shown)
Specifications for Straight Travel

Specifications for straight travel are shown on Figure
84. The machine must travel within the designated area
for the length specified, without crossing the outer limit.
Do the test in forward and reverse, at low idle and at
F08915
high idle.
Figure 82: Track Low Idle Menu Page
5. Operate the tracks at the adjusted setting and

observe movement.
“X” marks the center, end of feed deck
outer limit
Forward Direction
10 ft. (3 m)
X 100 ft. (30 m) X

10 ft. (3 m)
Reverse Direction
outer limit
Figure 84: Diagram for Travel Test

3-Section Valve Pressure Settings

The 4310B monoblock valve assembly controls the
spout functions.
 To set the valve pressure:

1. Install a 3000 psi gauge where shown in Figure 85.
warmed up.
3. Set engine speed to high idle. Install a 3000 psi
(207 bar) gauge
4. Use the remote control (for convenience) to bottom
out the spout deflector up/down cylinder.
5. Loosen the locking nut on the relief valve adjust-
ment screw.
6. Turn the relief valve adjustment screw until the
gauge on the valve reads 2600 psi (179 bar).
If there is not enough pressure, check the pressure
limiter setting on the main control valve.
Tighten the locking nut, recheck pressure, and
repeat adjustment as necessary.
7. Operate valve controls and observe the correspond-
ing cylinder movement. Relief valve
adjustment
screw
F08917
Figure 85: 3-Section Monoblock Valve (4310B)

Adjusting Pressures (4300B)

Main System Pressures  To set the pressures for the pump and valve
assembly:
The pump and the mid-section block on the 6-section This procedure will set the:
valve assembly are set up together. After the pump is • Pump pressure compensator
set, the pressure limiters on the valve assemblies can be
set. • Load sense
This procedure should be performed any time that: • Main relief
• a pump or motor is replaced • Pilot pressure relief
• a manifold or a relief valve is replaced NOTE: Pressure setting tolerances:

• when recommended by a troubleshooting proce- above 1000 psi: -0 /+50 psi
dure below 1000 psi: -0/+25 psi
Important 1. To access the pilot pressure reducing valve, remove
If a new main relief valve or a new pump has been the box that covers the hoses and wires behind the
installed, back out the relief valve several turns valve assembly.
before operating the hydraulic system. This 2. On the hydraulic tank, loosen the breather cap.
ensures that excessive pressures are not placed on
the system. 3. Stall one of the feed motors (Figure 72):
Always adjust relief valves UP to the specified a. At one of the feed motors, remove a hose from
pressure. port A or port B.
b. Securely cap the open port and plug the hose.
Cap on Motor
Port
High Pressure
Test Fitting Plug in
Hose
F08898
F09004
Figure 87: Stalled Feed Motor
Figure 86: Pump High-Pressure Test Fitting (4300B)
4. On the valve assembly,
• install a 6000 psi (414 bar) gauge to the relief
pressure test fitting (Figure 90 on page 76).
• install a 500 psi (34 bar) gauge to the pilot pres-
sure test fitting.

5. On the pump, install a 6000 psi (414 bar) gauge to

the high pressure test fitting.
6. At the valve assembly, remove the pilot pressure
hose (Figure 88) and cap the hose and port. This
must be done to set the load sense pressure.
Pilot Pressure Pressure Compensator

Hose Connection Adjustment
Load Sense
Adjustment
F09020
Figure 89: Adjustment Screws on the Pump (4300B)
11. Increase engine speed to high idle.

12. While operating the stalled function:
a. On the pump, turn the pressure compensator
adjustment screw clockwise (CW) until the
F09032
gauge reads 5200 psi (358 bar). This is a tempo-
Figure 88: Disconnect and Plug the Pilot Pressure Hose rary setting.
b. At the valve assembly, adjust the main relief
7. Tighten the breather cap. valve to 5075 psi (350 bar).
8. Start the engine. If 5075 psi cannot be achieved, the pressure
9. Allow time for the hydraulic system to warm up. relief valve, the pump, or a motor may be faulty.
10. On the pump: Either replace the valve and retest, or test the
pump or motors.
a. Loosen the jam nuts for the load sense adjust-
ment screw and the pressure compensator Tighten the jam nut, recheck pressure, and
adjustment screw (Figure 89). repeat the adjustment as necessary.
b. Turn the load sense adjustment screw gently c. On the pump, turn the pressure compensator
clockwise (CW) until it stops, then back out 1/ adjustment screw until the pump pressure
2 turn. gauge reads 4700 psi (324 bar).
c. Back out the pressure compensator adjust- Tighten the jam nut, recheck pressure, and
ment screw 3-4 turns. repeat the adjustment as necessary.
13. Set the engine speed to low idle.
14. At the valve assembly, disconnect the plug from
the fan control valves (Figure 90). This shifts the
valves to full flow. Label the plugs.

15. On the pump, turn the load sense adjustment 17. Reconnect the solenoid connectors for the fans.
screw until the pump pressure gauge reads 400 psi 18. Stop the engine, loosen the tank breather, remove
(28 bar). the gauges, and re-connect all hoses.
Tighten the jam nut, recheck pressure, and repeat Tighten the tank breather.
the adjustment as necessary.
16. On the valve assembly, adjust the pilot pressure
relief valve (Figure 91 on page 77) until the pilot
pressure gauge reads 400 psi (28 bar).
Tighten the jam nut, recheck pressure, and repeat
the adjustment as necessary.
Pilot Pressure
Hose Connection
Pilot Pressure
Test Fitting
Relief Pressure Test

Fitting
F09031
Feed Conveyor Motor
Main Relief Valve
CAC Fan
Compression Roll Motor
Radiator Fan
Compression Roll
Housing Cylinders Power Beyond
Figure 90: 6-Section Valve Assembly, Front View (4300B)

Pressure Transducer, Pressure Transducer,

Compression Roll Motor Feed Conveyor Motor
F08918
Pilot Pressure Reducing Valve
Figure 91: 6-Section Valve Assembly, Rear View (4300B)

Pressure Limiter Settings

The following pressure limit procedures are for the  To set the float pressure for the
4300B main control valves. See Figure 90 for identify- compression roll housing cylinders:
ing the function for each valve of the assembly.
1. On the valve assembly, install a 6000 psi (414 bar)
gauge to the relief pressure test fitting (Figure 90).
 To set the motor pressures:
2. Start the engine. Allow the system to warm up.
1. Loosen the tank breather.
3. Run the engine at high idle.
2. Disconnect a hose from the motor and cap the open
port and plug the hose. 4. Using a handle on the control valve, raise the com-
pression roll housing fully and hold the valve open.
3. Tighten the tank breather.
At the same time, adjust the A port pressure limiter
4. On the valve assembly, install a 6000 psi (414 bar) on the cylinders control valve until the gauge reads
gauge to the relief pressure test fitting (Figure 90). 2000 psi (138 bar).
5. Using the handle on the control valve, lower the
6. Run the engine at high idle. compression roll housing fully and hold the valve
7. Operate the motor in one direction and check the open.
pressure reading. At the same time, adjust the B port pressure limiter
As needed, adjust the pressure limiter for that direc- on the cylinders control valve until the gauge reads
tion until the gauge reads 4300 psi (296 bar). 2000 psi (138 bar).
 To set the pressure for power beyond:

1. On the valve assembly, install a 6000 psi (414 bar)
gauge to the relief pressure test fitting.
3. Run the engine at high idle.
4. Adjust the B port pressure limiter on the power
beyond control valve until you reach 3000 psi (207
Pressure
Limiter B bar).
5. Set the monoblock valve pressure (“7-Section
Valve Pressure Settings” on page 79).
 To set the fan speeds:

The procedure is the same as for the 4310B. See “To set
F09002
the fan speeds (4310B or 4300B):” on page 68.
Figure 92: Adjusting a Pressure Limiter (4300B)
8. Operate motor in the other direction and check the

pressure reading.
As needed, adjust the pressure limiter for that direc-
tion until the gauge reads 4300 psi (296 bar).
9. Install the plastic cap back onto the pressure limiter.
10. Stop the engine, loosen the tank breather, and re-
install the hose.

7-Section Valve Pressure Settings

On the 4300B, the power-beyond control valve supplies 4. Turn the relief valve adjustment screw until the
oil to the 7-section monoblock valve. gauge on the valve reads 2500 psi (172 bar).
5. Repeat steps 3 and 4 until 2500 psi is consistently
 To set the 7-section, monoblock valve seen on the gauge.
pressure:
Tighten the jam nut, recheck pressure, and repeat
1. Run the engine at low idle. Allow the hydraulic oil the adjustment as necessary.
to warm up.
6. Operate each function and observe the correspond-
2. Install a 3000 psi gauge where shown in Figure 93. ing cylinder movement.
3. Operate a landing gear cylinder fully in one direc-
tion and hold. Check the pressure on the gauge.
Relief valve adjustment screw Landing gear control levers
Install a 3000 psi (207 bar) pressure gauge

F08130
Figure 93: 7-Section Monoblock Valve (4300B)

System Pressures
4300B 4310B
Pressure setting tolerances: Pressure setting tolerances:
above 1000 psi: -0 /+50 psi above 1000 psi: -0 /+50 psi
below 1000 psi: -0/+25 psi below 1000 psi: -0/+25 psi
Table 9: 4300B System Pressures Table 10: 4310B System Pressures
Component PSI Bar Component PSI Bar
Pump Pumps
Compensator @ Engine Working Compensator @ Engine Working

Speed 4700 324 Speed 4800 331
Load Sense (Standby) 400 27.6 Load Sense (Standby) 400 27.6
Valve Assembly, 6-Section Valve Assembly 1
Relief Valve @ Mid Inlet Test Port 5075 350.0 Relief Valve @ Inlet 5100 351.6
Pilot Pressure Relief 400 27.6 Load Sense Limiter @ Inlet 4500 310.3
Pilot Pressure Limiter @ Inlet 220 15.2
Feed Cylinder, Up 2000 138

Feed Cylinder, Press Down 2000 138 Track (Either Direction) No Adjustment
Compression Roll, Forward 4300 296.5 Feed Chain Drive, Forward @ Inlet 4500 310.3
Compression Roll, Reverse 4300 296.5 Feed Chain Drive, Reverse 4500 310.3
Feed Chain Drive, Forward 4300 296.5 Feed Cylinder, Up 1400 96.5
Feed Chain Drive, Reverse 4300 296.5 Feed Cylinder, Press Down 1400 96.5
Charge Air/Hyd/Clutch Fan, Pull 3800 262.0
Charge Air/Hyd/Clutch Fan, Pull 3500 241.3 Charge Air/Hyd/Clutch Fan, Push 3800 262.0
Charge Air/Hyd/Clutch Fan, Push 3500 241.3 Valve Assembly 2
Engine Coolant Fan, Pull 3150 217.2 Relief Valve @ Inlet 5100 351.6
Engine Coolant Fan, Push 3150 217.2 Load Sense Limiter @ Inlet 4500 310.3
Power Beyond 3000 206.8 Pilot Pressure Limiter @ Inlet 220 15.2
Monoblock Valve Assembly, 7-Section

Relief 2500 172.4 Track (Either Direction) No Adjustment
Compression Roll Drive, Forward 4600 317.2
Compression Roll Drive, Reverse 4600 317.2
Engine Coolant Fan, Pull 3000 206.8
Engine Coolant Fan, Push 3000 206.8
Power Beyond 2000 137.9
Monoblock Valve Assembly, 7-Section
Relief 2600 179.3

Hydraulic Fittings and Torque Tables

The hydraulic fittings described in this section are used
on Peterson machines.
Note the widely varying torque specifications for the
same thread sizes across the different fitting types.
To avoid seal damage and to ensure a long-lasting seal,
tighten fittings to the torque specified in the torque
tables. Use a torque wrench designed to tighten hydrau-
lic fittings.
Avoid overtightening. Overtightening can damage O-
rings and the sealing surfaces of flared connectors.

Straight Thread O-Ring Boss (ORB) Straight Thread O-Ring Boss (ORB)
Low Pressure with 37o Seat High Pressure with ORS
Standard: SAEJ514 Standard: J1453
Male connector: Straight thread with O-ring Male connector: Straight thread with O-ring, O-ring in
Female port: Straight thread, 37o coned seat face
The seal is accomplished by compressing the O-ring Female port: Flat face with swivel nut
into the chamfer on the female nut. The seal is accomplished by the O-ring male end being
The following torque specifications are for both jam nut pressed against the flat-faced female end, and by com-
and straight fittings. pressing the O-ring into the chamfer on the female nut.
The following torque specifications are for both jam nut
and straight fittings.
1 2
1 2 3
F08919
1. Straight thread with 37 coned seat

o
2. Straight thread with O-ring F08920
1. Straight thread with O-ring
Figure 94: Example of a Straight Thread ORB Low Pressure 2. O-ring in face
3. Flat face with swivel nut
with 37o
Figure 94: Example of a Straight Thread ORB High Pressure
with ORS
Table 11: Recommended Torque, Straight Thread ORB Low
Pressure with 37o
Table 12: Recommended Torque, Straight Thread ORB High
Size Thread (inch) lb-ft Nm Pressure with ORS
–04 3/8–24 8–9 12–13 Size Thread (inch) lb-ft Nm
–05 7/16–20 13–15 18–20
–04 3/8–24 14–16 20–22
–06 9/16–18 23–24 32–33
–05 7/16–20 18–20 24–27
–08 3/4–16 40–43 55–57
–06 9/16–18 24–26 33–35
–10 7/8–14 43–48 59–64
–08 3/4–16 50–60 68–78
–12 1-1/16–12 68–75 93–101
–10 7/8–14 72–80 98–110
–14 1-3/16–12 83–90 113–122
–12 1-1/16–12 125–135 170–183
–16 1-5/16–12 112–123 152–166
–14 1-3/16–12 160–180 215–245
–20 1-5/8–12 146–161 198–218
–16 1-5/16–12 200–220 270–300
–24 1-7/8–12 154–170 209–230
–20 1-5/8–12 210–280 285–380
–32 2-1/2–12 218–240 296–325
–24 1-7/8–12 270–360 370–490

ORS (O-Ring Seal) SAE 37o (JIC)

Male connector: Straight thread, O-ring in face Male connector: Straight thread, 37o flared face
Female port: Flat face with swivel nut Female port: Straight thread, 37o coned seat with swivel
The seal is accomplished by the O-ring being pressed nut
against the flat-faced female end. The seal is accomplished by seating the flared male end
Assembly instructions: When you are ready to make the into the coned female end.
connection, lubricate and install an ORS-type O-ring
into the male fitting. Tighten to the specifications
below. 1
2 F06820
1. Coned Female Fitting 2. Flared Face, Male Fitting
Figure 95: Example of an SAE 37o (JIC) Fitting

F06405
1. O-rings, Male Fitting 2. Flat Face, Female Fitting
Table 15: Recommended Torque, SAE 37o (JIC) (Swivel Nut)

Figure 94: Examples of ORS Fittings
Size Thread (inch) lb-ft Nm
–04 7/16–20 11–12 15–16
Table 13: Recommended Torque, ORS (Swivel Nut) –05 1/2–20 15–16 20–22
Table 14: –06 9/16–18 18–20 24–28
Size Thread (inch) lb-ft Nm –08 3/4–16 38–42 52–58
–04 9/16–18 10–12 14–16 –10 7/8–14 57–62 77–85
–06 11/16–16 18–20 24–27 –12 1-1/16–12 79–87 108–119
–08 13/16–16 32–35 43–47 –16 1-5/16–12 108–113 148–154
–10 1–14 46–50 62–68 –20 1-5/8–12 127–133 173–182
–12 1-3/16–12 65–70 88–95 –24 1-7/8–12 158–167 216–227
–16 1-7/16–12 92–100 125–136 –32 2-1/2–12 245–258 334–352
–20 1-11/16–12 125–140 170–190

–24 2–12 150–165 204–224

Metric BSPP
The seal is accomplished by the 0-ring being pressed Male connector: Straight thread, coned seat
into the retaining washer. The compression is controlled Female port: Tapered nose/globeseal with swivel nut
by the thickness of the retaining washer. The port may
be of spot faced or a flat machined surface. The seal is accomplished by the tapered nose/globe seal
of the female swivel which seals on the cone seat of the
male connector. The O-ring is pressed into the retaining
washer.
F08922
1 2
4 2
F08921
1. Retaining washer
3 3
2. O-ring
Figure 96: Example of a Metric Fitting
F08923
1. Swivel nut
Table 16: Recommended Torque, Metric (Straight Adapter or 2. Tapered nose/globeseal
Locknut) 3. Straight thread
4. Coned seat
Size lb-ft Nm
Figure 97: Example of a BSPP Fitting
M10 x 1 13–15 18–20
M12 x 1.5 15–19 20–25
M14 x 1.5 19–23 25–30 Table 17: Recommended Torque, BSPP (Straight Adapter or
Locknut)
M16 x 1.5 33–40 45–55
M18 x 1.5 37–44 50–60 Size lb-ft Nm
M20 x 1.5 52–66 70–90 G 1/8–28 13–15 18–20
M22 x 1.5 55–70 75–95 G 1/4–19 19–23 25–30
M26 x 1.5 81–96 110–130 G 3/8–19 33–40 45–55
M27 x 2 96–111 130–150 G 1/2–14 55–70 75–95
M33 x 2 162–184 220–250 G 3/4–14 103–118 140–160
M42 x 2 170–192 230–260 G 1–11 162–184 220–250
M48 x 2 258–347 350–470 G 1-1/4–11 170–192 230–260

G 1-1/2–11 258–347 350–470

S ECTION 3000
ELECTRICAL
The machine’s electrical system can be a troubleshooting tool for technicians. Wiring can be checked for shorts and
opens, and the display can be used to get information from pressure transducers and every switch on the machine.
Troubleshooting Battery: Make sure the connections at the battery neg-

ative terminals are tight and in good condition.
Machine Circuits Starter: The primary grounding point is at the engine

starter (Figure 98). The battery negative terminals are
wired directly to this point. Check that the nut on the
starter is tight and that the wire lugs are tight on their
Required Tools respective wire or strap.
To effectively troubleshoot an electrical circuit, the

most essential tools are:
Multimeter: A good quality multimeter with alligator
clips is essential.
Also, extra long test leads and a variety of pigtails and
jumpers would also be very useful.
Electrical schematics: The Peterson schematics
make troubleshooting the machine much easier. They
show the machine circuits clearly and with color cod-
ing, wire labels, terminal identification, type of circuit
(power, signal, ground, etc.), and much more. Examples
can be seen in Figure 109 through Figure 112.
If you cannot locate the schematics that were provided F08924
with the machine (hard copy and CD), call your Peter- Figure 98: Grounding Point on the Starter
son dealer or Peterson Product Support.
Other important tools:
Machine frame and engine: Check that the
• common electrician’s hand tools grounding straps that are attached to the machine frame
• flashlight and to the engine are tight and in good condition. Both
• magnifying glass straps are connected to the starter.
Control boxes: Check the resistance between the
Ground Connections grounding terminals in the control boxes and the engine
starter or a good machine ground. Resistance should be
Ground connections should be checked periodically for less than 0.5 ohm.
condition, tightness, and resistance. If the controls or
control system are not functioning properly, or if you
see intermittent error codes, check the ground connec-
tions. For details, see “Return Circuits” on page 104.

SECTION 3000 ELECTRICAL
Alternator 60A Circuit Radio Status Lights

Breaker The Omnex R170 receiver has status lights to indicate
what is occuring with the remote control system. There
The circuit breaker that protects the charging circuit is a User Configuration/Installation manual available
(between the alternator and the battery) is located on a from the manufacturer which explains the status light
plate secured to the alternator. codes. If you suspect trouble with this system, call
If the batteries become discharged for no apparent rea- Peterson Product Support.
son, check this circuit for a short. The breaker can be
reset by pressing in the blue button. IQAN System Control
Modules
The IQAN display module is the master controller. It
decides what received messages mean and which mes-
sages to transmit, shows system status, and allows for
adjustable parameters to be set for various components.
The IQAN expansion modules are slave controllers.
They receive the information from the various sensors
and switches. Then, the message is sent to the IQAN
display module where it is processed.
F08925
Both the display module and the expansion modules
Figure 99: 60A Breaker for the Charging Circuit perform their own internal self-checks. If an internal
error is detected, it may be shown as a message on the
display module or signaled by the LEDs on the back of
Important
the expansion modules.
If a breaker trips or a fuse blows, always investigate
the cause of the overload.
Control Power
ECM Faults If the control system does not
come on, check the 30A
ECM faults are shown on the display in the J1939 for- breaker (CB100) on the dis-
mat. For a list of the engine faults that the Peterson tribution box.
IQAN checks for, refer to the Operator Safety and
Maintenance Manual for the machine. After CB100, each control
module power supply circuit
There are many possible ECM faults that can only be is fused before leaving the
accessed via the J1939 port on the control box cover. distribution box (Figure 115). The display module is
The J1939 port is provided for Peterson and Caterpillar fused again in the control box (Figure 108). Check these
technicians to connect to the ECM. fuses if you get a message like the one shown on
Figure 105.
Clutch Controller Faults The clutch controller power circuit is fused inside the
grey plug at the clutch controller. The ECM is fused
Clutch controller faults are shown on the display in the internally.
in the J1939 format and are explained in the Operator
Safety and Maintenance Manual for the machine.

Peterson Devices that

IQAN System communicate using
J1939
Service J1939 protocols
Connection
IQAN Display
Module Plug Plug
C2 C1
(MD3)
T9 Omnex Radio
T10 (Remote Control)
USB Port T11
Engine Control
Modem Module
XA2.1 XA2.0 Clutch

Terminal Controller
Blocks
Magnatek
(4310B)
Figure 100: Diagram of the 4300/4310B Controlled Area Network
Troubleshooting with the IQAN

Display
The display module can be an aid in troubleshooting
machine circuits. By using the Electrical Inputs and
Electrical Outputs display pages (Figure 101), you can
see if a switch or sensor signal is received by the control
module or if the module is sending a signal to a compo-
nent.
If a problem is seen, troubleshoot the circuit wires.
Refer to the electrical schematic.
F08926
Figure 101: Electrical Inputs Display Page

Control System Faults

There is a problem
in the main display
The IQAN display and expansion modules monitor pin 18, plug C1
their inputs, outputs, and controlled area network circuit.
(CAN) circuits for shorts or opens that may be in the
wiring or in the module itself.
If the IQAN system detects a control system fault
(Figure 102), the associated message will indicate if it is
an open, short, or a fault with the CAN terminating
resistor, and on which circuit or module. Then you can
check the schematic to find the correct wire to trouble-
The function
shoot. associated with this
problem circuit is the
NOTE: System faults are not the same as machine faults. compression roll
Machine faults are covered in the Operator position sensor.
Safety and Maintenance Manual.
F08927
Depending on the fault, the IQAN system will do noth- Figure 102: Typical IQAN System Fault Message
ing, the module might internally turn off the problem
circuit, or the module might turn itself off.
Communication faults between modules is explained in
“System Communication and Module Faults” on
page 90.
The pin number associated

with the fault is indicated in
the fault message.
Check the wiring of the

circuit attached to that pin.
Digital Output (DOUT)
circuits.
On-off 0–24V mostly used
for on-off coils, small
relays, lights, etc..
Current Output (COUT)

circuits.
mA mostly used for
proportional coils.
F08928
Figure 103: DOUT and RET Fault Messages

Digital Input (DIN) circuits.

for on-off 0–5V and 0–24V
devices.
The pin number associated

with the fault is indicated in
the fault message.
Check the wiring of the

circuit attached to that pin.
Voltage Input (VIN) circuits.

Variable 0V–5V used with
analog devices.
F08929/F08930
Figure 104: DIN and VIN Fault Messages

System Communication and Module Faults  To troubleshoot a communication fault:

The IQAN system monitors its modules and controlled 1. Write down the complete fault message or take a
area network (CAN) circuits (Figure 100) for opens and picture of the screen. The message includes a fault
shorts. The associated fault message will indicate if it is code used for diagnostics.
an open, short, or a fault with the CAN terminating
2. Obtain the machine electrical schematic.
resistor, and on which circuit or module. Then you can
check the schematic to find the correct wire to trouble- 3. Turn off the control power disconnect switch.
shoot. Important
Turn off the control power disconnect switch
before removing a connector from any control
module. Removing a connector from an energized
module can damage it.
4. Find the terminating resistor (Figure 106). Isolate
the resistor and check its resistance. It should be
Type of 120 ohm.
fault
5. Using the fault message and the schematic, deter-
mine which are the CAN-H and the CAN-L wires,
F08931 or the J1939 wires, for the circuit that is presenting
the error.
Address tag—each expansion module
has a resistor that identifies the module 6. Isolate the circuit by disconnecting all the wires and
to the main controller (MDL). connectors in the suspected circuit.
If it is not clear by the error message which CAN or
J1939 circuit is faulty, disconnect all wires at J9,
J10, J11, and unplug every controller connection in
the control box.
F08932 7. Check continuity of the disconnected wiring.
If the wiring and connectors are ok, check the con-
nections at the controller.
If no problems are found, reconnect all wires.
F08933 8. Turn on the control power. If the original fault mes-
Figure 105: Communication Lost with 1st XA2 Module sage indicated a particular expansion module,
check the error code lights on that module (Figure
107).
In the event of a communication or module fault, check If you are certain that the wiring is ok, replace the
for: control module that is producing the error.
• a blown fuse for the affected module (Figure 115) Important
• a faulty control module (Figure 100) Do not try to swap a control module from one
• an open or short in the CAN wiring or connection machine to another. The machine will not run cor-
rectly or may not run at all.
(see schematic)
9. Reconnect any removed wires, connectors, or
• a missing or faulty terminating resistor (Figure 106)
jumpers.
Troubleshooting a fault consists primarily of checking
the terminating resistor, the continuity of the wiring,
and the condition of pins and terminals.

J1939 Communication Faults A list of non-IQAN controller faults is in the Operator

The control module will display faults generated by the Safety and Maintenance Manual. Troubleshooting the
non-IQAN controllers, such as the ECM and the clutch wiring is essentially the same as described for the IQAN
controller. The messages will show the ISO designated communication faults.
numbers that identify the particular fault.
Terminals 9A and 9B:

J1939 shield black wires

CAN-H and J1939 (+),
yellow wires
Terminals 10C:
Terminating Resistor,
120 ohm

CAN-L and J1939 (–),
green wires
F08934
Figure 106: Communication Wires at the Terminal Block
Table 18: Expansion Module Error Codes

LEDs on the top XA2 module
can be viewed with a mirror Error Primary Flash Secondary Flash
(Red) Error Code (Green) Error Code
From MD3  
FRAM Memory  
error
CAN Error  
Address Error  
Memory Error  
Fatal Error 
F08935
In normal operation, the green LED green indicates
To check the LEDS on the lower XA2 module, either uninstall power on, and the yellow slowly blinking LED indi-
the module from the mounts in the control box or observe cates normal operation.
the blinking LEDs in the reflection on the back of the box.
Figure 107: Checking XA2 Module LEDs

Tracing an Example Circuit

The series of illustrations on the following pages lead Feed the wire inside the terminal hole until it bottoms
you through a circuit on the machine. The circuit used out, and press down the lock to install. The wires do not
is for a 4310B electrical actuator located on the control require the insulation to be stripped off because the wire
valve manifold. locks pierce the insulation to make the connection.
The actual steps for troubleshooting this actuator is in If you suspect trouble with the terminal blocks, check
the Hydraulics section under “Valve Assemblies” on for loose or damaged wires or terminal locks in the open
page 52. position.
When troubleshooting, before disconnecting wires look
first with good light and a magnifying glass for clues to Terminal Jumpers
the problem, such as burn marks, mosture, corrosion, Terminal jumpers are used to bridge power to the adja-
damaged rubber seals, broken pins or connections. cent terminal block. If you suspect a problem with a ter-
Also, tug on the wires at terminals to check for loose- minal jumper, note its position and remove it from the
ness. terminal block. Check the jumper for damaged pins, and
reinstall, making sure that it is fully seated in the hole.
Terminal Blocks .
The terminal blocks are located in the control box and

distribution box. The wires connect into the terminals
by opening the lock with a small, flat-blade screwdriver.
It is not necessary to
Terminal strip the wire end. To open the terminal,
shown in open Slots for Contact is made when insert a small
position Terminal Jumpers the terminal is closed. screwdriver here and
pivot the lock.
F04841
Bus connects all 4 terminals
Figure 108: Terminal Block

Wire Color Plug 207 (at

May not stay the control box)
same throughout
A black line indicates a ground or shield the circuit
circuit.
4310B shown, Plug terminal 312.3 at the actuator is
4300B similar where you would check the ground
circuit.
A magenta* line indicates a voltage (0-5V

or 0-24V) supply circuit.
Plug terminal 312.1 at the actuator is
where you would check the 24V supply.
A light blue* line indicates a 24V control

circuit.
Plug terminal 312.4 at the actuator is
where you would check for a 24V control
signal.
Wire Harness
Plug at Control Valve
Actuator (Figure 51 on
page 53)
F08936
F08937 These numbers indicate the

destination of the wire
(terminal to which the wire
is connected at the other
end.)
The feed conveyor

circuit continues on
Figure 110.
* If you are working with a black-

and-white schematic, the kind of
circuit is also shown in text form.
See Figure 110.
F08939
Figure 109: Using the Electrical Schematic to Trace the Feed Conveyor Circuit—Control Valve to Control Box

The feed conveyor circuit

continues on Figure 111.
The kind of circuit
4310B shown, is shown here.
4300B similar
F08938
Feed conveyor
circuit terminals Stationary These are locations on
Junction the terminal block. See
Figure 113.
J203 J207
J201
Radio
Antenna
J206
J200 J202
F08940
Figure 110: Using the Electrical Schematic to Trace the Feed Conveyor Circuit—At the Control Box Junction

Connector pins on the Plugs P205 and P206 Wiring between the controller
Magnatek control and the terminal pins on the
module (4310B only). control box (Figure 110).
4310B shown,
4300B similar
These are locations on

the terminal block. See
Figure 113.
Wire tag information

matches the
schematic.
Destination: Terminal
block 11B, position 3
F08941
Feed conveyor actuator

circuits.
J206
J205
F08942
F08943
Figure 111: Using the Electrical Schematic to Trace the Feed Conveyor Circuit—At the Control Module

Feed conveyor switch

4310B shown, Feed conveyor switch
4300B similar circuit terminals at MD3
(display controller) plug
C2.
Disconnect to check the
wiring to the switch.
F08944
Voltage Inputs—These
are shown on the
These are locations on Electrical Inputs page on
the terminal block. See the display.
Figure 113.
CAN circuits. For

troubleshooting, see “System
Communication and Module
Faults” on page 90. When a voltage input is received
from a control panel switch or
push button, 24V is applied to the
circuit for the LED in that switch or
push button.
F08945
Figure 112: Using the Electrical Schematic to Trace the Feed Conveyor Circuit—Between the Switch and the Controller

FU1: Control power (Figure 128)
FU2: Display module RTC (real time clock)
See the schematics for

Diode details on all circuits.
Your machine may not
FU3: Display module exactly match this
photo.
FU8: Modem
This terminal map is

These red items are on the schematic,
jumpers. along with a
description of each
block’s purpose and
color code.
CAN terminals
See Figure 106
Diode
Resistors for LED circuits

(on operator controls)
GND A—return wire to dist.

box for the control module
ground wires
GND C—return wire to dist.

box for the ground wires
below
CR1 remote stop
CR2 start solenoid and key switch

power
F08947
F08949
Figure 113: Control Box Terminals and Components (4310B Shown)

IQAN Module
XA2.1 Master Control
Relay (MCR)
Terminal blocks
(Figure 108)
IQAN Module
XA2.0
Radio for
remote control
Magnatek CAN-
M1 Module
(4310B)
F08948
Figure 114: Inside the Control Panel (4310B Shown)

FU100, 20A If the LED is on, the fuse is good.

XA2.0 module power FU101, 20A
XA2.1 module power
FU102, 15A
Control module power FU104 (4310B only), 20A
Magnatek module power
FU105, 15A
ECM power (FU104 on 4300B) FU106, 5A
Clutch module power
FU103, 1A
Work light switch
Power circuits
Ground circuits
Circuit breakers:
Engine start switch

See the schematics for
positive identification. Water pumps (Optional)
Your machine may not
exactly match this
photo. Work lights
Work lights
On-Off relay for

work lights
Terminal block for ground
circuits:
Terminal block grounds in the To grounding
control box point on starter
Terminal block grounds in the
distribution box
Clutch controller
Water pumps
Distribution box and control
panel enclosures
F08946
J103 from
disconnect
switches
J101
J102 J100
F08950
Figure 115: Distribution Box (4310B Shown)

Updating the
Machine Control
Software
Occasionally the machine code needs to be updated.
IQAN Run is the program that is used to perform this
update.
You will also need a standard USB cable (2.0 A-B)
(Figure 116).
F08953
1. Connect the USB cable to your laptop and the other
end to the port on the front of the control panel. Figure 117: Log-In Window
3. After you logon, select “Get Clone” on the left side

of the screen (Figure 118).
Save this to your hard drive as a backup and include
in the file name the machine serial number.
F08951
F08952
Figure 116: USB Connection F08954
Figure 118: Select Get Clone

2. Open IQAN Run and select “Login” (under “Secu-
rity”). 4. Select “Get Settings” (Figure 119). Save to your
Log in using the Username and Password hard drive (this is another backup).
(Figure 117) that was provided with the new
machine code.

F08955
F08957
Figure 119: Select Get Settings
Figure 121: Select Application Window
5. Inside the control panel, use the yellow plastic key

on the relay to maintain power to the system. Oth- 7. A window will ask for the machine code password
erwise, the Master Control Relay (MCR) will open that was provided with the update (Figure 122).
during the software update.
Override
Key
Insert key
here and turn
90 degrees
F08958
Figure 122: Password Window
F08956
Figure 120: MCC Override 8. At the Confirmation window, select Yes to save the
password to your computer.
9. At the next Confirmation window, select Yes to
6. Select “Update” (Figure 121) under “File opera- update the MD3.
tions.” At the Select Application window, select the 10. A warning window (Figure 123) will appear to
file you want and select Open. make sure that the machine is not moving and the
engine is shut down. Select OK if this has been
done.

F08959
Figure 123: Warning Window
11. At the Send Application Window (Figure 124),

select OK to start the upload.
F08961
While the new code is being uploaded, the IQAN Figure 125: Application Updated Message
display shows the status of the upload.
When the upload is completed (Figure 125), select
OK. 12. Disconnect the USB cables and close IQAN Run.
Test machine functions for proper operation.
F08960
Figure 124: Sending Application Window


Return Circuits However, the connection must also be tight. A loose or

frayed connection may test acceptable with the very low
amount of current output of an ohmmeter, but the point
All machine electrical devices and controls require a of contact may be too minimal for the circuit’s opera-
low-resistance return path to the battery (–) post. If there tional current.
is high resistance in a return path, the function or device High resistance can be caused by:
may work intermittently, poorly, or not at all.
• Loose or frayed connection
Although the terms “return” and “ground” are often
• Broken wire
used interchangably, strictly speaking, “return” circuits
have a wired connection back to the battery negative • Disconnected wire
post and “grounded” circuits use the machine frame or • Bent or broken plug junction pin
engine skid as the return path to the battery. • Corrosion in a plug
Currently, no 4300B/4310B circuits intentionally • Corrosion at a terminal
employ the machine or skid as a return path. However,
the machine return path is important because it picks up A visual check and a wire-pull check can often reveal a
stray currents, radio frequencies, and shorts that come point of high resistance. If the point of high resistance is
into contact with the machine. not readily apparent, then use of an ohmmeter is
required.
The maximum resistance in most return circuits should
be 0.5 ohm or less. Large gauge connections, such as at Additionally, the IQAN system monitors many return
the starter (Figure 98) and battery, should show less circuits. For example, a COUT OPEN LOAD fault on the
than 0.1 ohm resistance. display means there is a problem with the current return
circuit for the function indicated in the fault message.
Control Box (see Figure 113)
Terminal
Blocks
Distribution Box (see Figure 115)
Terminal
Block Enclosure
Ground
MDL
Dist Box Grounds GND A
GND A/GND B GND B XA2.0
GND C
XA2.1
thru
Enclosure Ground Plug Connections GND P
Individual Control
Circuit Returns
ECM Battery –
Engine
S
Simplified diagram.
See machine
schematic for
details.
Machine Frame Skid
Figure 126: Machine Ground/Return Paths

Checking the Primary Return Circuits 4. Using an ohmmeter, check points 1–7 (one at a
The path to the battery negative post for the control time) directly to point 8.
modules include at least 16 connections, any one of If any check shows more than 0.5 ohm, check the
which can potentially become a point of high resistance. connection and test to all points between, including
Individual control circuits have even more connections plug connections, to find the point of high resis-
until they are grounded at the battery. tance.
To verify the most critical return paths (Figure 127), use The above checks require extra-long meter leads. If you
the procedure below. The checks should take just a few only have normal-length leads, you can use a good
minutes. machine ground test point. However, before relying on
1. Open either the battery disconnect or the control the machine frame as a ground, first verify the
power disconnect switch. braided strap connections between the starter and
the machine frame.
2. Make sure the connections at the starter post are
clean and tight. It is a good idea to occasionally (once every 6-12
months) check the return circuits to find potential trou-
3. Make sure the connection at the battery negative
ble areas before they affect production.
post is clean and tight.
Control Box (see Figure 113)
Terminal
Blocks
Distribution Box (see Figure 115)
Grounding
Block Enclosure
Ground
MDL
Dist Box Grounds GND A
1 2 GND B XA2.0
GND A/GND B
GND C
3 thru XA2.1
Enclosure Ground GND P

Individual Control
Circuit Grounds
ECM Battery –
Engine 4 1–8 = Primary connection and test points.
5
8 Verify these if a problem is suspected to be due to
S poor grounding. If all test good, check individual sus-
pected circuit(s).
6 7
Machine Frame Skid
Figure 127: Primary Ground/Return Paths

MCR Circuit 2. The powered-up master display sends power to the

MCR coil, keeping the coil circuit energized.
3. The operator can now allow the CONTROL POWER
The master control relay is the 24VDC power supply button to raise. The control system is powered.
gateway for the start control, control panel switches,
If an E-stop is pushed in: The 24V output from
control modules, radio, modem, etc. The power-up sce-
the master display is prevented from completing the cir-
nario is as follows:
cuit to the coil. If the operator holds down the CONTROL
1. The operator pushes the CONTROL POWER button POWER button, the LED on the control panel E-stop
and holds for 3 seconds. During this time, button will come on to alert the operator that an E-stop
a. The master display receives a 24V input. somewhere on the machine is pushed in.
b. The master display sends a 24V output to ener- If the remote transmitter stop button is
gize the MCR coil. pressed: A signal is sent to the master display which
c. The MCR coil closes the 24V power circuit to then unlatches the output to the coil. The effect is the
the control system, including the master dis- same as if an E-stop were pressed.
play.
Battery
Disconnect Distribution Box
30A Control Box
Module Power
Supplies
Control
Power
Disconnect
T1 MD power supply,
FU1 switches, radio, etc.
T2 T6
LED on E-stop
Control
Power RED
Button Machine
(PB3) E-Stops
T4 T5
MCR
LED on Control Power Button
T3
GRN
Output
Power
Input Supply
T6 Simplified diagram.
See machine
schematic for
details.
IQAN Master
Display (MD)
Figure 128: Master Control Relay Circuit (Coil De-energized)

S ECTION 4000
FEED SYSTEM
Tail Drum and Bearings
Removal Installation
1. Remove the feed chains (“Removal and Installa- 1. Clean the shafts on each end of the drum.
tion” on page 109). 2. Using appropriate lifting equipment, place the drum
2. Place a lifting sling around the drum (Figure 129). into the machine, but keep it suspended (Figure
3. Using appropriate lifting equipment, take up the 129).
weight of the drum.
4. Loosen the setscrews in the bearing collars and
remove the collars.
5. Remove the bolts that secure the bearings.
6. Pull the bearings off the shaft ends.
7. Remove the drum from the machine.
F08822
Figure 129: Installing the Tail Drum
3. Lightly coat the shafts with never-sieze.

4. Install the bearings. On each end of the drum:
a. Push the bearings onto the shaft.
b. Using the hoist controls, maneuver drum to
position the bearing housings in the bearing
mount spacers, but keep most weight sus-
pended.
c. Hold the nut plate where shown in Figure 130.
d. Install the bolts through the washer, bearing
housing, cradle/tray, nut plate, and lock nut (no
washer under the nut).
Leave the bolts loose until everything is
adjusted.

SECTION 4000 FEED SYSTEM
F08962
Figure 130: Nut Plate Under the Bearing F08963
Figure 132: Bearing Installed on the Bearing Mount Spacer
5. Measure each side from frame to drum. Use a pry-

bar to move the drum side to side until the distance 8. Install the collars onto the bearings (Figure 144 on
is equal. page 114):
a. Push the collar against the bearing and turn the
collar until you meet firm resistance.
b. Using a punch in the set screw hole, set a divot
in the shaft for the setscrew to set into.
c. Install the setscrews with blue locktite.
F08823
Figure 131: Checking that the Tail Pulley is Centered
6. Remove the lifting equipment. Check that the hous-

ings are still properly seated in the bearing mount
spacers.
F08824
7. Tighten the bearing bolts. Figure 133: Tightening Setscrews in Bearing Collar
9. Install the feed chain (“Feed Chains” on page 109).

Feed Chains 7. Attach the ropes to the ends of the new chains. Also,
be sure to line up the chain ends so they will engage
the drive pulley teeth simultaneously. This will
make pinning easier. Note the center set of pulley
Removal and Installation teeth are offset from the others.
8. Pull the three chains together underneath the hopper
Method I—Remove Old Chain First floor and up to the drive pulley.
During the pull, check that the chain does not catch
1. Raise the compression roll. Lock the roll using the on anything such as the bolt heads under the hopper
safety locking pins. Then shut down the machine. floor.
2. Adjust the tail pulley as far as possible toward the 9. Pull the chain ends to the tail pulley and remove the
drive pulley. ropes.
3. At the tail pulley, cut and remove a link pin from 10. Use a hoist to raise the lower link to the upper link
each chain. (Figure 135).
4. Install three ropes to pull the chains: Starting at the 11. Pin together the chain ends:
head pulley, pull the ropes under the deck through
to the end of the hopper, and over the drive pulley a. Insert a link pin through the end links.
(Figure 138). b. Heat the pin end until it is red hot.
Center the ropes between the pulley teeth. c. Have an assistant brace the cold end of the pin.
d. Hammer the hot end until it is flattened.
Brace Air Powered

Hammer
Pull
chain this
direction
F08829
Figure 134: Chain Pull Ropes F08828
Figure 135: Flattening the Link Pin
5. Place the rolls of new chain at the front of the feed

deck. 12. Check that the chains are correctly positioned on
6. Using appropriate lifting and rigging equipment, each pulley.
unroll the chains onto the ground in front of the feed 13. Tighten the chains using the adjusting bolts on the
deck. The chain teeth are downward. tail pulley.
The length of exposed thread on the two adusting
bolts must be the same.
To check the chains for proper tension, grab the
chain from the center of the feed deck and lift up.

The top of the chain should be 6–8 in. (15–20 cm) 13. Pin together the chain ends (Figure 135):
off of the feed deck. a. Insert a link pin through the end links.
14. Start the machine, lower the compression roll, and b. Heat the pin end until it is red hot.
test operate the feed drive.
c. Have an assistant brace the cold end of the pin.
15. Stop the machine and re-check the chain tension.
d. Hammer the hot end until it is flattened.
Adjust as necessary. New chains will stretch. Check
frequently until their length stabilizes.
Brace Air Powered
Hammer
Method II—Use Old Chain to Pull On
New Chain
You can either remove one chain at a time or all four at
once.
1. Raise the compression roll. Pin the housing in the
raised position using the safety locking pins. Then
shut down the machine.
2. Adjust the tail pulley as far as possible toward the
drive pulley.
3. At the tail pulley, cut and remove a link pin from F08828
each chain. Figure 136: Flattening the Link Pin
4. Place the rolls of new chain at the front of the feed
deck.
14. Check that the chains are correctly positioned on
5. Using appropriate lifting and rigging equipment,
each pulley.
unroll the chains onto the ground in front of the feed
deck. The chain teeth are downward. 15. Tighten the chains using the adjusting bolts on the
tail pulley.
6. Hoist the chain ends up to the tail drum and tempo-
rarily pin the new chains to the old chains. The length of exposed thread on the two adusting
bolts must be the same.
Note: You will be pulling the chain underneath the
deck, over the drive pulley, and back across the top To check the chains for proper tension, grab the
of the feed deck. chain from the center of the feed deck and lift up.
The top of the chain should be 6–8 in. (15–20 cm)
7. Attach the rigging to the old chain. Use a mobile
off of the feed deck.
hoist to keep the old chain off the new chain while
the new chain is pulled into the machine. 16. Start the machine, lower the compression roll, and
test operate the feed drive.
8. Start the engine and engage the clutch. Keep the
engine at idle speed. 17. Stop the machine and re-check the chain tension.
Adjust as necessary. New chains will stretch. Check
9. Operate the feed drive slowly in reverse to pull the
frequently until their length stabilizes.
new chain into the machine.
10. Pull the (new) chain ends to the tail pulley and
remove the ropes.
11. Unpin the old chains from the new chains.
12. Use a hoist to raise the lower link to the upper link.

Feed Drive 1 CAUTION

Falling object hazard.
The feed motor is heavy. Do not attempt to lift the
Remove the Feed Drive motor without mechanical assistance. Doing so
may result in serious injury.
1. Raise the compression roll and install the safety 11. To remove the motor, place a lifting sling around
locking pins. the motor (Figure 138). Remove the motor mount-
2. Remove a link from each chain and move the chains ing bolts.
off the feed drive roll. The bolts that secure the motor to the roll were
3. Install two lifting slings around the roll and apply installed with red locktite. You will need to heat the
upward tension. bolts to remove them.
4. At the non-drive side, loosen the set screw in the
bearing collar and remove the collar (Figure 144).
5. Remove the mounting bolts from the non-drive side
bearing and pull off the bearing.
6. Remove the motor cover plates and shims (Figure
142). Note the location of each shim so they can be
re-installed in the same place.
Important
Note the location of each shim so they can be re-
installed in the same place.
7. Loosen the breather on the hydraulic tank.
8. Remove the hydraulic hoses and plug all ports and
open hose ends.
9. Remove the drive roll:
a. Raise the assembly move it out the drive side as
far as possible.
b. Remove the sling closest to the outside and
reinstall it around the motor as shown in
Figure 141.
c. Move the assembly out as far as possible, then
once again bring the sling around to the outside
of the machine and reinstall it to the roll.
d. Pull the roll the rest of the way out.
10. Place the assembly on a sturdy work bench and
secure as shown in Figure 137.

Remove the Motor (Only) Install the Feed Drive or Motor

1 CAUTION NOTE: Although the photos for the motor installation
procedure show a bench installation, the on-
Falling object hazard. machine installation is essentially the same.
The feed motor is heavy.
Do not attempt to lift the motor without mechan- 1 CAUTION
ical assistance. Doing so may result in serious Falling object hazard.
injury.
The feed motor is heavy.
1. Install lifting slings and place upward tension on the Do not attempt to lift the motor without mechan-
roll. ical assistance. Doing so may result in serious
2. Remove the motor cover plates and shims (Figure injury.
142). Note the location of each shim so they can be 1. If installing the motor on a bench, secure the feed
re-installed in the same place. drive roll (Figure 137). Otherwise, go to the next
Important step.
Note the location of each shim so they can be re-
installed in the same place. This will save a lot of
time instead of trying to determine where the shims
should be located.
3. Loosen the breather on the hydraulic tank.
4. Remove the hydraulic hoses and plug all ports and
open hose ends.
5. Install a lifting sling around the motor and take up
the slack.
6. Remove the motor mounting bolts.
The bolts that secure the motor to the roll were
installed with red locktite. You will need to heat the
bolts to remove them. F08964
You will need to rotate the drive roll to access all the Figure 137: Feed Conveyor Drive Secured to Bench
bolts.
7. Remove the motor with the motor mounting plate. 2. Clean:
• the threaded holes in the drive roll. If necessary,
run in a tap, then blow out with compressed air.
• the motor-to-roll mating surfaces.
3. Lift the motor and install it onto the roll (Figure
138). Start one or two bolts to align bolt holes.

F08967
Figure 140: install the Mounting Plate to the Motor

F08965
Figure 138: Installing Feed Drive Motor

6. If the entire drive assembly was removed, lift the
assembly and install it into the machine (Figure
4. Apply red locktite to the bolt threads, then quickly 141) in the same way it was removed.
install the bolts with a flat washer. Tighten in incre-
ments and in an alternating pattern to 336 ft-lb (455
Nm) (Figure 139).
F08968
F08966
Figure 141: Removing or Installing the Feed Drive Assembly
Figure 139: Torqueing the Motor Mounting Bolts
7. Re-install the same number and size shims behind
the motor mounting plate.
5. Install the mounting plate (Figure 140):
If the previous location of the shims is not known or
a. Hold the mounting plate in position and tempo-
you are installing a new roll, start with one 1/4 in.
rarily install two bolts loosely. shim and two 1/8 in. shims on each side.
b. Apply blue locktite to the bolt threads and
8. Install the plastic and metal shims next to each side
install the bolts (without washers).
of the mounting plate (top, bottom, sides) in the
c. Tighten the bolts to 192 ft-lb (260 Nm). same location as they were removed from.
If the previous location of the metal shims is not
known, start with one 1/8 in. shim and two 1/16 in.
shims on each side.

Shims behind the

mounting plate (1/4 in.
and 1/8 in.)
Plastic shims (3/8 in.) and

Metal shims (1/16 in.)
Shims in front of the

mounting plate (1/4 in.
and 1/8 in.)
F08970
Figure 143: Clamping the Mounting Plate
F08969 13. Check the clearances between the feed drive roll
Figure 142: Shims and Motor Cover Plates and the hopper floor plate. For specifications and
adjusting instructions, refer to the Operator Safety
and Maintenance Manual.
9. If there was a shim pad under the non-drive-side As needed to achieve the proper clearances, remove
bearing housing, place it onto the mounting pad. the clamp and adjust the position of the shims at the
10. Install the non-drive-side bearing (Figure 144): motor mount plate. Then apply the clamp again.
a. Clean the shaft and bearing bore. 14. Install the collar onto the bearing (Figure 144):
b. Apply some never-seize onto the shaft. a. Place the collar tight against the bearing and
c. Push the bearing housing onto the shaft. Place turn the collar until you meet firm resistance.
the housing onto the mounting plate in the same b. Using a punch in the set screw hole, set a divot
location as before it was removed. in the shaft for the setscrew to set into.
d. Install the hold-down bolts. c. Install the setscrews with blue locktite.
11. Remove the lifting equipment.
12. Clamp the motor housing to the mounting plate on
the machine frame (Figure 143). This stabilizes the
position of the roll.
F08971
Figure 144: Installing the Bearing Collar

15. Remove the clamp.

16. Place the same number and size shims to the front
face of the motor mount plate and install the motor
cover plates (Figure 142 and Figure 145).
F08972
Figure 145: Shims and Motor Cover Plates Installed
17. Install the feed chains (“Feed Chains” on page 109).

Compression Roll
Remove the Motor and
Bearing
1. Remove the compression roll housing (“Remove
the Compression Roll Housing” on page 120).
2. Remove the bolts holding the compression roll to
the housing. Note that these factory-installed bolts
were installed using red locktite.
3. Remove the tube guard plate.
4. Disconnect the hydraulic fittings from the motor.
5. Remove the retaining nut from the bearing. Then,
using a pipe slightly larger than the shaft, drive the F08973
bearing toward the inside. Figure 146: Drive Cap Bolted to the Motor (Typical)
6. Lift the compression roll housing off the compres-
sion roll. 13. Remove the bolts that secure the motor adapter
7. Pull the bearing with adapter off the shaft. plate to the roll (Figure 153). Note that these fac-
8. Remove the bearing from the adapter. tory-installed bolts were installed using red locktite
The motor is removed in the following steps. 14. Install eye bolts to the motor.
9. Set the compression roll on its shaft end. See Figure 15. Lift out the motor.
149 for an example of lifting equipment attachment
to the roll.
10. Remove the bolts that secure the drive cap to the
roll.
11. Remove the bolts that secure the drive cap to the
motor (Figure 146):
a. Remove the two bolts that are installed with the
special large washers (Figure 148).
b. Using standard washers, reinstall the two bolts
(Figure 150).
c. Remove the other bolts that secure the drive cap
to the motor.
12. Install eye bolts into the drive cap and then lift off
the drive cap (Figure 147).
F08974
F08975
F08976
Figure 147: Remove the Drive Cap and Motor

Install the Motor and Bearing

If you are only installing the bearing, skip to step 11.
Important
Prior to assembling parts, always clean the mating
surfaces. Remove any paint, burrs, or high spots.
1. Assemble the motor to the adaptor plate (Figure
148) by installing the fasteners in the same orienta-
tion as when removed.
• Use an SAE flat washer under the nuts. There
are no washers under the bolts.
• Use blue locktite and tighten the nuts to the F08978
proper torque. Figure 149: Detail of Lifting Equipment Attached to

Compression Roll
Blue locktite and Special

530 ft-lb torque Washers 3. Make sure the adaptor plate and roll mating sur-
faces are clean.
4. Install the threaded retainer and lifting eye bolts to
the motor (Figure 150).
Threaded
Retainer
Eye Bolt Eye Bolt
F08977
Temporary bolts
Figure 148: Motor Assembled to Adapter Plate and washers
2. Set the compression roll on its shaft end. See Figure

149 for an example of lifting equipment attachment
to the roll.
Threaded
Retainers
F08979
Figure 150: Eye Bolts for Lifting the Motor (Typical)

5. Lower the motor/adaptor plate assembly into the

compression roll (Figure 151).
Motor with
Adapter
Plate
Adapter Plate
Bolts
F08981
Figure 153: Motor Installed in Compression Roll (Typical)
6. Install eye bolts to the drive cap.

7. Install the drive cap onto the motor (Figure 154).
F08974
F08975
Make sure the slot in the cap is aligned with the
hydraulic ports on the motor.
Figure 151: Lowering the Motor into the Compression Roll
a. Align the bolt holes.

b. Apply red locktite or equivalent to the adapter Drive Cap
plate bolt threads.
Red locktite
on threads
Motor
F08763
Figure 154: Installing the Drive Cap onto the Motor (Typical)
8. Install the bolts and tighten to specifications

(Figure 155). Be sure to use the special washers
F08730 under two of the bolts. No washers under the other
Figure 152: Apply Red Locktite onto Adapter Plate Bolts bolts.
See Figure 148 for the actual 4300B/4310B bolt and
washer arrangement.
c. Install and tighten the adapter plate bolts (Fig-
ure 153, no washers).
d. Remove the eye bolts.

Bearing
Tapered
Sleeve
Bearing
Adapter
F08973
F08982
Figure 155: Drive Cap Bolted to the Motor (Typical)
Figure 156: Bearing Installed onto the Adapter
9. Place the compression roll onto its side.
10. Assemble the bearing:
a. Clean all bearing components.
b. Apply a light coat of machine oil to the inside
and outside of the tapered sleeve.
c. Install the tapered sleeve into the bearing.
d. Install the tabbed washer and retaining nut
(hand-tight) onto the sleeve threads.
11. Install the bearing.
a. Clean the mating surfaces of the adapter and
bearing.
b. Apply machine oil to the mating surfaces. F08984
c. Install the bearing onto the adapter (Figure Tabbed

156). Install and tighten bolts to specifications. Washer and
Retaining Nut
d. Apply a thin coating of never-seize to the shaft.
e. Push the bearing with adapter onto the shaft
(Figure 157).
The retaining nut will be tightened after the roll
is installed to the housing.
F09050
Figure 157: Install the Bearing with Adapter onto the Shaft

12. Place the roll into the compression roll housing.

Remove the Compression
13. Install the bolts that secure the compression roll to
the housing (use red locktite on all bolts): Roll Housing
a. Bolt the drive cap to the housing.
1. Remove the hydraulic hoses from the pipes on the
b. Bolt the housing to the bearing adapter (If housing.
needed, use longer bolts temporarily to pull the
adapter toward the housing).
c. Tighten all bolts to specifications.
14. Tighten the bearing retaining nut (Figure 158) to Remove and plug
325 ft-lb (440 Nm). hoses. Cap the
pipes.
Run up with an air tool, then use a torque wrench.
F09079
Figure 159: Hydraulic Hoses for the Upper Feed Motor
2. Detach the lift cylinders from the housing.
F09046
Remove pin from

both cylinder
rod clevises.
F09080
F09046
Figure 160: Feed Roll Housing Lift Cylinder
Figure 158: Tightening the Bearing Retaining Nut (Typical)
15. Install the hydraulic tube fittings to the motor.

16. Install the compression roll housing back into the
machine according to “Install the Compression Roll
Housing” on page 121.

3. Attach shackles, rigging to the two lifting points on

the compression roll housing (Figure 161). Attach a Threaded
hole for eye Grease
hoist to this rigging. bolt Fitting
Attach a second hoist and rigging to the front of the
housing.
Attach a tag line to the housing.
Lock Bolt
F08987
Figure 162: Pivot Pin
Install the Compression Roll

Housing
1. Attach a hoist and rigging to the two lifting points
on the compression roll housing (Figure 161).
Attach a second hoist to the front of the housing.
Attach a tag line to the housing.
2. Lift the housing and lower it into the machine
frame.
Keep the housing suspended.
3. Put a mark near the end of each pivot pin (Figure
F08827 163) in line with the holes for the set screw and
Figure 161: Three-Point Lift on Compression Roll Housing grease fitting. This is to help you install the pin in
correct alignment with the corresponding holes in
the pin housing.
4. Remove the lock bolts and grease fittings from the
pivot pins (Figure 162).
5. Install an eye bolt in each pivot pin.
6. Take up the weight of the housing.
7. Attach rigging to the eye bolts. Use mechanical
assistance pull the pivot pins from the housing.
There are one or two centering shims located
between the housing and one of the the machine
side walls. These will fall out when you remove the
pivot pins. Find the shims for reuse.
Note on which side of the housing they were
installed. This will save you time during installa-
tion. Replace them if missing or damaged. F08826
8. Lift and remove the compression roll housing from Figure 163: Mark the Pivot Pin in Line with the Lock Bolt
the machine. Holes

4. Using the hoist controls, maneuver the roll housing b. Push the housing as far as it will go to the other
so the housing pin holes line up with pin housings side.
on the machine. At the high, mid, and low point, measure the
Using a flashlight, look into the pin hole on one side distance between the housing and the frame.
to see if the housing holes are centered on the
machine frame holes (Figure 164).
F09035
Figure 166: Measure Distance Between Housing and Frame

F08830
Figure 164: Check that Both Housing Holes are Centered on c. Determine which side one or two shims need to
the Machine Frame Holes be installed in order to achieve 1/4-3/8 in. (6-8
mm) at the closest point between the housing
and the machine frame.
5. Slide in the pivot pins (Figure 165) until they are If the gap is equal on both sides, install one
about 2 inches into the compression roll housing. shim on each side.
The shims will be installed in the next steps.
7. Install the pins and two shims:
a. Withdraw one pin until it is free of the housing.
b. Using the tab on the shim(s), hold the shim(s) in
position (Figure 167) so the pivot pin can be
pushed through the shim(s) and into the hous-
ing.
Note that one side might need two shims and
the other no shim, or both sides may need one
shim.
F08831
c. Push in the pivot pin until it is inside the hous-
Figure 165: Installing the Pivot Pins ing. If necessary, use a soft-faced mallet.
Make sure the grease fitting threads line up with
6. If the original location of the shims is not known, the corresponding holes in the frame.
determine placement of the centering shim(s):
d. Repeat steps a.–c. to install the other pin and
a. Using a pry bar, push the housing as far as it any shims.
will go to one side.
At the high, mid, and low point, measure the
distance between the housing and the frame
(Figure 166).

Install a
grease fitting
Lock Bolt
F08987
Figure 169: Installed Pivot Pin

F09033
Figure 167: Installing a Shim 10. Attach the lift cylinders using the correct pins and
cotter pins. Replace the bushings if they are worn.
8. Use the awl end of a pry bar in the set screw hole
(Figure 168) to rotate the pin as needed so the lock 11. Reconnect the hydraulic hoses to the pipes.
bolt can be reinstalled. 12. Remove the lifting equipment.
13. To purge air from the system, operate the lift cylin-
ders fully several times and operate the compres-
sion roll motor for 10 minutes. Check for leaks.
14. Install the pipe guard back onto the end of the com-
pression roll.
15. Check the pressure limiter setting on the motor’s
control valve. Refer to the Hydraulics section under
Pressure Limiter Settings.
F09033
Figure 168: Line-up the Lock Bolt Holes
9. Install the lock bolts and grease fittings (Figure

169) into the pins.


S ECTION 5000
PROCESSOR SYSTEM
Rotor Sheave and 3. Remove the four sheave bolts.
4. To push the sheave off the bushing, install two of
Bushing
the bolts into the pusher holes. Turn the bolts evenly
until the sheave is free.
5. Mark the shaft with a scribe or marker pen to indi-
cate the location of the bushing for re-installation.
Removal
Mark position of
1. Remove the belt guard and the belts. For instruc- bushing on the shaft
tions, refer to the machine’s Operator Safety and
Maintenance Manual.
2. Install a lifting strap to the sheave and take up the
weight of the sheave (Figure 170).
F08989
Figure 171: Mark the Bushing Location on the Shaft
6. Remove the setscrew (Figure 172).
Hole for pusher

bolt (1 of 2)
F08990
Figure 172: Removing/Installing Setscrew
F08988 7. Install a thin wedge (Figure 171) into the slot in the
Figure 170: Removing/Installing the Sheave Bolts bushing and then remove the bushing.

SECTION 5000 PROCESSOR SYSTEM
Installation Alignment should be within 1/16 in. (1.5 mm)

of parallel. Note that final tightening can move
the sheave an additional 1/16 inch toward the
1. Install the sheave bushing onto the shaft to the mark
machine.
you made before removing the bushing.
To aid in installation, use a thin wedge in the slot as
shown in Figure 171. String
Important
Tap the wedge in just enough to allow installation,
otherwise the bushing will crack.
2. Install the key into the keyway.
F08733
3. Apply blue locktite to the setscrew and install the
setscrew (Figure 173). Figure 174: Checking for Parallel Alignment—String Method
5. As needed to move the sheave in or out:

a. Remove the sheave bolts and use pusher bolts
to back the sheave from the bushing. Keep the
sheave supported by the lifting equipment. It is
not necessary to completely remove the sheave.
b. Loosen the setscrew, install the wedge in the
bushing slot, then move bushing in or out as
needed.
c. Remove the wedge, reinstall the sheave, and re-
F08990
check alignment. Repeat as necessary.
6. Tighten the four sheave bolts to specifications.
Figure 173: Removing/Installing Setscrew
7. Install the belts (for instructions, refer to the
machine’s Operator Safety and Maintenance Man-
4. Install the sheave: ual).
a. Raise the sheave and bring it to the shaft (Fig-
ure 170).
b. Turn the shaft so that the puller holes in the
sheave are 90 degrees to the keyway.
c. Install the four bolts and tighten in a circular
pattern to about 100 ft-lb (135 Nm).
d. Using the string method (do not use a laser on
this sheave due to casting imperfections), align
the rotor sheave with the face of the clutch pul-
ley.
Do this by holding one end of a length of string
to the far side of the sheave and the other end
tight across the face of the clutch pulley
(Figure 174).

Rotor
Removal
1. Remove the sheave and bushing (“Rotor Sheave
and Bushing” on page 125).
2. Remove the belt guard plate (Figure 186 on
page 130).
3. Remove both bearing covers (Figure 175).
4. Remove the rotor lockout assembly (non-drive
side).
F09071
Rotor Hood Cover
Figure 176: Hood Platform Lifting Hardware
b. Unbolt the hood assembly.

c. Attach lifting eye bolts to two corners of the
hood assembly as shown in Figure 177.
Rotor Lockout
Assembly
Bearing Cover
F08991
Figure 175: Rotor Lockout Assembly and Bearing Cover
5. Disconnect the proximity switch (drive side). F09070
6. Remove the slot cover (drive side) (Figure 178). Figure 177: Rotor Hood Lifting Hardware
7. Remove the rotor hood:
a. Remove the platform from the hood. Use the 8. If you want to remove the bearing seal protectors
hole in the center of the platform to attach a lift- from the shaft, the screws were installed with red
ing eye bolt (Figure 176). loctite so you will need to heat the threads.

Installation
1. Use appropriate rigging to lift the rotor assembly.
Use a 2-point lift and tagline. See Figure 179 for
hardware.
NOTE: The rotor assembly weighs approximately 3,400
lb (1542 kg).
Slot Cover 2. Lift the rotor and guide it down into the slots in the
machine sidewalls (Figure 180).
Seal Protector Make sure a 1/8-in shim plate is on each bearing
mount. This helps keep the knives the correct dis-
tance from the anvil.
Bearing
Mounting Bolts
F08992
Figure 178: Seal Protector and Slot Cover (Drive Side)
9. Remove the bearing mounting bolts. They were

installed with red loctite so you will need to heat the
threads.
10. Remove a bolt from two outside knife assemblies.
Using a 7-inch bolt, install lifting hardware as
shown in Figure 179. F08836
Figure 180: Lowering/Raising the Rotor

7 in. bolt in two
outside knife
assemblies 3. Lower the rotor nearly onto the mounts, but keep
suspended.
4. Install the bearing housing mounting bolts and
washers, but do not tighten.
5. Lower the bearings onto the mounts between the
gibs (Figure 184).
NOTE: If a new bearing housing was installed, casting
variability may result in the housing not fitting
F08833 between the gibs. If this happens, remove the
Figure 179: Lifting Hardware (Example) gibs, center the rotor shaft in the slot, and weld
on new gibs.
11. Using a 2-point lift and tagline, raise the rotor out of
the machine (Figure 180). 7. Remove the bolts from the bearing housing cap,
then remove the cap.
NOTE: The rotor assembly weighs approximately 3,400 8. Center the bearing in the housing.
lb (1542 kg).

Use a screwdriver in the slots between the bearing 11. Adjust the bearing runout (mounting bolts loose).
and the housing as shown in Figure 181. The bear- a. Zero the dial at the 3 or 9-o’clock position (Fig-
ing pictured is centered. A visual check is sufficient. ure 182). Turn the rotor half-way around to the
opposite side.
Note the reading on the gauge.
The acceptible runout is 0.000 to -0.003, or
0.000 to +0.003.
b. Adjust the bearing housing as needed to
achieve the acceptible runout. Do this by lightly
tapping either the right or left side of the hous-
ing as in Figure 183. Then turn the rotor back
one-half rotation and recheck the runout.
c. Repeat the above steps until the runout specifi-
cation is achieved.
F09030
Figure 181: Centering the Bearing in the Housing
9. Wipe the grease from the end of the shaft and from
the face of the outer race.
10. Set up a dial indicator with magnetic base onto the
end of the shaft (Figure 182).
Set the plunger tip against the face of the outer race
as shown, at the 3 or 9-o’clock location. F09029
NOTE: The bearing housing hold-down bolts should Figure 183: Adjusting the Bearing Housing Position
still be loose.
12. Install the bearing housing mounting bolts and

Wipe off grease
tighten to specifications.
Tighten in steps and in an alternating pattern.
13. Adjust the bearing runout (mounting bolts tight).
Do the same procedure as before. The only differ-
ence is you will need to strike the bearing housing
much more aggressively and with a steel mallet as
shown in the figure.
The acceptible runout is the same: 0.000 to -0.003,
or 0.000 to +0.003.
14. Remove the dial indicator set-up, install the housing
F09029 cap and bolts, and tighten to specifications.
15. Apply red locktite to the mounting bolt threads.
Figure 182: Checking that the Non-Drive-Side Bearing is
Parallel to the Shaft 16. Install the mounting bolts, washers, and nuts and
tighten to specifications.

17. Using red locktite on the screw threads, install the 22. Install the hood platform (Figure 176 on page 127).
bearing seal protectors (Figure 184 and Figure 185). 23. Install the belt guard plate onto the inner belt guard
(Figure 186).
Seal Protector
Belt Guard Plate
Inner Belt Guard
Mounting Bolts
Gib
1/8 in. Shim Plate
F09036
Figure 184: Bearing on Mounting Plate (Drive Side) F09072
Figure 186: Belt Guard Plate
18. Install the slot cover (drive side) (Figure 178 on

page 128). 24. Install the sheave and bushing (“Rotor Sheave and
19. Install the rotor lockout assembly (non-drive side). Bushing” on page 125).
20. Install the bearing covers.
Bearing Cover
Seal Protector
F07846
Figure 185: Bearing Seal Protector and Cover
21. Install the hood (Figure 177 on page 127).

Bearings Installation
1. Remove the bearings from the packaging and place
Removal them in a preheated 250oF oven (Figure 188). Let
them heat up for 1-2 hours.
For additional illustrations, see the installation proce-
dure on the next page.
1. Remove the rotor (“Rotor” on page 127) and place
it on a suitable work stand.
2. Install lifting equipment to the bearing housing
(Figure 187).
F09010
Figure 188: Placing the Bearings into an Oven
2. Thoroughly clean both shafts. Remove any high

spots or burrs on machined edges.
3. Unpack the bearing housings and move them to a
F09017
suitable workbench (Figure 189). Use mechanical
assistance when lifting the housings.
Figure 187: Lifting Equipment Installed onto Housing
3. Remove the housing cap bolts and the housing cap.

4. Lower the housing away from the bearing and set it
aside.
5. Wipe off excess grease.
6. Remove the end cover and stabilizing ring (Figure
198, drive side bearing).
7. Pull off the outer seal.
8. Remove the retaining nut and tabbed washer.
9. Use appropriate bearing pulling equipment to
remove the bearing. Alternatively, it may be easier
to cut the bearing off. F09007
10. Pull off the inner seal. Figure 189: Moving the Housings to a Workbench
11. Install a new bearing (“Installation” on page 131).
4. If replacing both bearings, match-mark the outside
of the housing halves and their caps to ensure they
do not become switched. Each housing must be
installed with the cap it was packaged with.

5. Pry apart the caps from the housings. 10. Check that the bearing retaining nut will thread all
6. Thoroughly clean the inside of the housings and the the way onto the end of the shaft, then remove the
caps. (Figure 190) . nut.
F09008 F09011
Figure 190: Cleaning the Housings and Caps Figure 192: Installing the First Seal
7. Pack the housing bases with EP2 lithium-base

grease. Fill about 1/3 full as shown in Figure 191.
1 CAUTION
Keep the center area where the bearing rests clear of Burn Hazard.
grease. The bearings are hot enough to cause third-
8. Place a bead of grease in the slots for the seals. Then degree burns. Use insulated heavy leather
cover the parts using clean rags to keep out dirt. gloves or other appropriate material when han-
dling hot bearings.
Also place grease 11. When the bearings are sufficiently warmed, remove
in the slots for the one from the oven and quickly push it onto the
seals (both ends). shaft, firmly against the machined stop.
F09009
Figure 191: Packing the Housing with Grease

F09015
Figure 193: Pushing a Hot Bearing onto the Shaft

9. Install the larger seal onto the shaft to the position
shown.

12. Allow the bearing to cool for a few minutes, then

wrap the bearing with a clean cloth to prevent con-
tamination.
13. When the bearing is cool (about an hour), remove
the cloth covering.
14. Install the tabbed retaining washer and nut:
a. Apply grease to the face of the retaining washer
that contacts the nut.
b. Apply grease to the threads on the shaft.
c. Install the retaining washer against the bearing
(Figure 194).
d. Install the retaining nut and tighten. Use a ham-
mer and chisel to get the nut as tight as possible F0
(Figure 195).
F09014
e. Turn down one of the washer tabs into a slot in
the nut. Bend the tab only halfway in case the Figure 195: Tightening the Retaining Nut
nut needs to be loosened later.
15. Check the clearance between the outer ring and the
bearing rollers. At the 12-o’clock position, there
must be at least 0.003 in. clearance to allow suffi-
cient space for grease to keep the bearings lubri-
cated.
F09012
Figure 194: Installing Tabbed Washer and Retaining Nut
F09013
Figure 196: Checking Roller-to-Outer Race Clearance
16. Thoroughly pack the bearing with grease.

17. On the drive-side shaft, install the second (smaller
diameter) seal (can be seen in Figure 198).
The drive-side bearing is assembled with different
parts because it needs to be a non-expansion type.

18. Install the bearing housing. Use mechanical assis- 20. On the non-drive-side, install the end cover onto the
tance to move and hold the housing in place (Figure housing (Figure 199).
196).
• Adjust the position of the seals as necessary.
• The non-drive side bearing should be located in
the center of the housing.
• The drive-side bearing should be located so
there is room to install the stabilizing ring (Fig-
ure 198).
F09018
Figure 199: End Cover Installed onto the Housing (Non-

Drive-Side Only)
21. Wipe the mating surfaces clean, then install the cap,
washers, and bolts (Figure 200). Tighten to specifi-
F09019
cations.
Figure 197: Installing the Housing to the Bearing
NOTE: The cap bolts can also be tightened to spec-
ifications during the runout-checking step
19. On the drive-side shaft, install the stabilizing ring during the rotor installation procedure.
against the bearing (Figure 198). Turn the ring so
the ends are facing up.
F09017
Figure 200: Cap Installed onto Housing

F09016
Figure 198: Installing the Stabilizing Ring (Drive Side Only).

22. Remove the lifting equipment. Wipe off excess
grease.

S ECTION 6000
DISCHARGE SYSTEM
Chip Accelerator
Removing the Accelerator Bearing Removal
To replace the drive-side bearing, remove the accelera- The non-drive-side bearing can be replaced without
tor sheave, bushing, and accelerator assembly: removing the accelerator assembly.
1. Remove the belt guard and the belts. Instructions To remove the drive-side bearing, the accelerator
are in the Operator Safety and Maintenance man- assembly must be removed from the machine.
ual.
2. Remove the accelerator guard (hood).  To remove the non-drive-side bearing only:
3. Remove the sheave (Figure 218 on page 142). 1. Put a sling around the shaft behind the bearing and
take up the slack.
Use two pusher bolts, 6 x 3/4 coarse thread, in the
two threaded holes. 2. Remove the bearing cover.
4. Remove the bushing. 3. Remove the mounting bolts from the bearing.
With a marker pen, mark the shaft where it meets 4. Loosen the setscrews in the retaining nut.
the rear of the bushing. This will save time later 5. Bend the tab of the lockwasher out of the retaining
when you align the accelerator sheave to the drive nut.
sheave. 6. Remove the retaining nut and bearing:
To aid removal, insert a thin wedge into the groove a. Tap several places on the nut using a drift and
(Figure 217 on page 142). soft-faced mallet.
Important b. Rotate the nut one turn, then tap around the nut
Open the bushing only as much as necessary for again.
installation, otherwise you might crack the bush- c. Repeat the above instruction until the nut is
ing.
loose, then remove the nut.
5. Remove the shaft guard plate (Figure 217 on
7. Pull off the bearing.
page 142).
8. Remove the bearing sleeve from the shaft.
6. Attach lifting equipment to the accelerator.
7. Remove the bolts from the bearing mounts.  To remove the drive-side bearing or both
8. Lift out the accelerator assembly. bearings:
1. Remove the accelerator assembly (“Removing the
Accelerator” on page 135). Secure the assembly to
a work stand or table.
2. Loosen the setscrews in the retaining nut.
3. Non-drive-side only: Bend the tab of the lock-
washer out of the retaining nut.

SECTION 6000 DISCHARGE SYSTEM
4. Remove the retaining nut and bearing:

Bearing Installation
a. Tap several places on the nut using a drift and
soft-faced mallet. The non-drive side bearing is a single-taper type which
b. Rotate the nut one turn, then tap around the nut uses one tapered sleeve. This bearing must be modified
again. to allow for shaft expansion.
c. Repeat the above instruction until the nut is The drive side bearing is a double-taper, non-expansion
loose. type which uses two tapered sleeves.
d. On the drive-side bearing, break the taper lock
by using prybars as shown in Figure 206. Non-Drive-Side Bearing
e. Remove the retaining nut. 1. Loosen all setscrews enough to prevent damage
5. Pull the bearing off the shaft. during bearing installation (Figure 201).
NOTE: The drive-side bearing is a double-taper type. It
can be very difficult to break free both taper
Setscrews in
locks. You may need to apply heat and other Housing
measures to remove. For assistance, call Peter-
son Product Support or your Peterson distribu-
tor.
6. Remove the bearing sleeve from the shaft. Setscrews in
Retaining Nut
F08993
Figure 201: Loosen Setscrews
2. Remove the threaded sleeve (Figure 202) from the

bearing.
3. Clean the bearing bore, shaft, and the inside and
outside surfaces of the sleeve.
4. Apply a film of lightweight machine oil to both sur-
faces of the sleeve (Figure 202).
F08983
Figure 202: Apply Machine Oil to Sleeve (Inside and Outside)

5. Push the sleeve onto shaft, thread side toward shaft 9. Push the housing against the spacer.
end. It will go on part way as shown in Figure 202. 10. Install the tabbed washer.
6. Modify this (non-drive-side) bearing to allow for 11. Install the retaining nut part way, leaving about 1/4
expansion of the shaft: in. between the back side of the nut and the washer.
a. Matchmark the slot in the retaining ring and
housing (Figure 203). 2-1/8 in.
b. Turn the retaining ring 1 full turn counter- (5 cm)
spacer
clockwise. To loosen, use a chisel in one of the
grooves to tap the ring counterclockwise.
Slot in
Retaining
Ring
F08995
Figure 205: Installing the Washer and Retaining Nut

F08994
Figure 203: Matchmark and Turn the Retaining Ring

12. Seat the internal bearing rollers:
a. Set two small pry bars behind the washer
7. Install the bearing housing onto the sleeve (Figure 206). Apply pressure against the
(Figure 204). washer to seat the bearing tightly onto the
sleeve.
b. Turn the retaining nut until hand-tight.
c. Remove the spacer from behind the housing.
F09049
Figure 204: Installing the Housing onto the Sleeve F08985
Figure 206: Seating the Bearing onto the Sleeve

8. Place a 2-1/8 in. (5 cm) spacer against the accelera-
tor weldment. See the example in Figure 205. This
will keep the bearing in the correct location in the
next steps.

13. Tighten the retaining nut:

a. Matchmark the nut and the inner race at the
center of a tab (Figure 207).
b. From there, count the washer tabs clockwise.
At the eleventh tab, matchmark the nut and
outer race.
F09048
Matchmarks
Figure 208: Using a Mallet when Tightening the Retaining Nut
14. Install the retaining nut setscrews with blue locktite

Targets and tighten.
(10th or 11th
Tabs)
F08996
Figure 207: Matchmark and Tighten the Retaining Nut
c. Tighten by alternating between setting the nut

with a brass mallet (Figure 208) and turning the
nut until you have reached the matchmarks.
A drift can also be used, as shown in
Figure 216.
Important
Do not strike next to the setscrew holes.
If the nut cannot be turned enough to reach the
11th tab, align the slot on the nut to the 10th tab.
d. Turn down the tab into the slot in the nut.
Do not seat the tab fully. Leave room to pry up
the tab for the next bearing change.

Drive Side Bearing 6. Push the sleeve onto shaft, thread side toward shaft
end (Figure 211).
1. Loosen all setscrews enough to prevent damage
during bearing installation (Figure 209).
Setscrews in
Housing
Setscrews in
Retaining Nut
F09042
F08993 Figure 211: Installed Inner Sleeve

Figure 209: Loosen the Setscrews
7. Place a 2-1/8 in. (5 cm) spacer against the accelera-

2. Remove both tapered sleeves from the bearing. tor weldment (Figure 214). This will keep the bear-
ing in the correct location in the next steps.
3. Discard the tabbed washer.
8. Install the bearing housing onto the sleeve
4. Clean the bearing bore, shaft, and the inside and
(Figure 212).
outside surfaces of the inner sleeve.
5. Apply a film of lightweight machine oil to both sur-
faces of the inner sleeve (Figure 210).
F09049
F09042
Figure 212: Installing the Housing onto the Inner Sleeve
Figure 210: Apply Machine Oil to Inner Sleeve

9. Install the outer tapered sleeve and retaining nut 11. Seat the bearing onto the sleeve:
(Figure 213). a. Set two small pry bars behind the nut. Apply
pressure against the nut to seat the bearing
Outer tightly onto the sleeve.
Tapered
Inner Sleeve b. Turn the retaining nut until hand-tight.
Tapered
Sleeve c. Remove the spacer.
2-1/8 in. (5 cm) spacer
The shaft is not shown in this F09042

view in order to better illustrate
component assembly Retaining Nut
F09037
Figure 214: Seating the Bearing
12. Tighten the retaining nut by alternating between

turning the nut (Figure 215) and setting the nut with
a brass mallet and drift (Figure 216).
F09040
Figure 213: Assembly of Tapered Sleeves
10. Install the retaining nut part way, leaving about 1/4
in. between the back side of the nut and the bearing.
F08998
Figure 215: Tightening the Retaining Nut

Important
Do not strike next to the setscrew holes.
Turn the nut until the outside of the nut is flush with
the end of the sleeve.
F08997
Figure 216: Using a Drift when Tightening the Retaining Nut
13. Install the retaining nut setscrews with blue locktite

and tighten.

Installing the Accelerator 10. Install the sheave.

a. Clean the mating surfaces. If the pulley is new,
1. Attach lifting equipment to the accelerator. use a power wire brush to remove any paint
from the mating surface with the hub.
2. Move the accelerator assembly to the machine.
b. Lift and install the sheave onto the bushing
3. Set the bearing housings between the gibs and flush
(Figure 218).
with the edge of the mounts.
Important
The bearing housing must make flush contact with
the mount surface. Be sure the housing does not
sit on the weld at the back of the mount.
4. Install the mounting bolts, washers, and lock nuts.
Tighten to 455 ft-lb (617 Nm).
6. Check for proper clearances between the paddles
and the discharge floor.
7. Install the shaft guard plate (Figure 217) onto the
inner belt guard.
8. Install the bushing. Tap a wedge into the slot so that
the bushing can be pushed on.
F08723
Important
Figure 218: Installing the Accelerator Sheave onto Bushing
Tap the wedge only as much as necessary for
installation, otherwise you might crack the bush-
ing.
c. Install the mounting bolts hand-tight (no lock-
NOTE: The bushing tightens onto the shaft when the tite), then tighten in several passes and in an
sheave bolts pull the sheave onto the bushing. alternating pattern to about 100 ft-lb (136 Nm).
9. Install the key into the keyway. d. Using a laser tool, align the sheave with the
clutch pulley.
Shaft Guard Plate If a laser tool is not available, use the string
method:
Do this by holding one end of a length of string
to the far side of the sheave and the other end
tight across the face of the clutch pulley
(Figure 219).
String
F08733
F08999 Figure 219: Checking for Parallel Alignment—String Method

Figure 217: Installing the Key

Alignment should be within 1/16 in. (1.5 mm)

of parallel. Note that final tightening can move
Replacing Paddles
the sheave an additional 1/16 inch toward the
Accelerator paddles are supplied in sets of ten paddles
machine.
which have been weight-adjusted to within 0.10 lb of
Finally, tighten to 225 ft-lb. (305 Nm) each other.
(Figure 220).
Never replace fewer than all ten paddles, otherwise the
accelerator will be unbalanced. Use new fasteners as
specified in the parts manual for use with paddles.
Remove and replace all

10 paddles and 50 sets
of fasteners.
F08738
Figure 220: Torquing the Accelerator Sheave Bolts

F09084
11. Install the accelerator guard (hood). Check for Figure 221: Accelerator Paddles
equal paddle clearances around the inside of the
hood. Slotted mounting holes allow the hood posi-
1. Shut down the machine and wait for the drive belts
tion to be adjusted.
come to a stop. Lock out the machine.
12. Install the proximity sensor.
2. Unbolt and open the accelerator hood door.
13. Install the drive belts and belt guard. Instructions
3. Remove the old paddles. You can turn the accelera-
are in the machine’s Operator Safety and Mainte-
tor by hand.
nance Manual.
4. Clean the mating surfaces, then install the new pad-
14. Test the accelerator.
dles.
5. Tighten the crimp-style lock nuts to 106 ft-lb. (144
Nm). Do not tack-weld.
6. Turn the accelerator and check for equal clearances
between the paddles and the hood, and between the
paddles and the floor of the chute.
7. Close and bolt down the hood.

Chip Spout
For assembly details, refer to the parts manual supplied
for your machine.
Lift Points
End Load Spout (4300B)
Removal
1. Using the spout control pushbutton, lower the dis-
charge end as far as possible.
F09085
2. Disconnect the electrical plug for the engine start-
ing aid (ether) cylinder. Remove the wire grommet Figure 223: Lift Points—End Load Spout (4300B)
from the spout.
3. Disconnect the hydraulic hoses from the pipes on
5. Unbolt the spout from the discharge chute and from
the spout support (Figure 222). Plug the hose ends
the spout support.
and cap the pipe ends.
6. Remove the spout assembly from the chipper.
Installation
Installation is the reverse of the removal procedure:
raise spout to machine, bolt in place, and reattach hoses.
Disconnect
these hoses.
F09073
Figure 222: End Load Spout (4300B)
4. Attach lifting equipment to three points on the spout

as shown in Figure 223.
Using an overhead crane, take up the weight of the
spout assembly.

End Load Spout (4310B)

Removal Mounting bolts
1. Lower the discharge end as far as possible.

Remove and plug
these hoses. Cap
the valve fittings.
F09078
F09077
2. Disconnect the hydraulic hoses from the locking

valve on the spout (Figure 225). Plug the hose ends
and cap the pipe ends.
3. Attach lifting equipment to two points on the spout
as shown in Figure 226.
Using an overhead crane, take up the weight of the
F09075
spout assembly.
4. Unbolt the spout from the discharge chute and from
the cooler assembly frame.
5. Remove the spout assembly from the chipper.
Installation
Installation is the reverse of the removal procedure:
raise spout to machine, bolt in place, and reattach hoses.
F09081
Figure 226: Lift Point Detail (4310B)

Top Load Spout Lower Assembly
Removal (4310B) 1. Attach 3-point lift rigging to the upper assembly

and take up the slack.
Upper Assembly with Support Frame 2. Disconnect the hydraulic hoses from the lower
spout assembly. Cap all open hoses and fittings.
3. Unbolt the lower assembly and remove from the
1. Lower the spout all the way to the bumpers on the
machine.
pivot frame.
2. Disconnect the hydraulic hoses between the upper
and lower spout assembly. Cap all open hoses and
fittings.
3. Attach lift rigging to the upper assembly
(Figure 228). Take up the weight of the assembly.
Pivot Pin
F09076
F09074
Figure 227: Lower Assembly, Top Load Spout (4310B)
4. Apply penetrating oil to the pivot pin at the bush-

ings.
5. Remove the pivot pin (Figure 227 and Figure 229)
from the upper and lower assembly.
6. Unbolt the support frame from the mounting brack-
F09082
ets on the machine. Inspect the bushings.
Figure 228: Lift Point Detail, Upper Assembly
7. Move the spout away from the machine.

Installation
1. Install the lower spout and attach the hydraulic
hoses.
2. Bring the upper spout to the lower spout. Install the
pivot pin and cotter pin (Figure 229).
3. Install the support frame to the machine using
crimp-type lock nuts.
4. Reconnect the hydraulic hoses.
5. Remove rigging. Test-operate the spout cylinders.
F09086
Figure 229: Spout Pivot Pin


I NDEX
INDEX
Symbols D
"Important and "Note" messages dB 22
how used in manual 3 dBA 22
Diesel vapor 14
Numerics Discharge access door 17
Disconnect switches
0V–24V signal 52 lockout/tagout 8
2.5V–7.5V signal 52 Drum rotor
precautions 11
A securing 11
Alert messages 3
Alternator E
surge damage 7 ECM
ANSI 6 surge damage 7
ANSI B18 42 Electric actuator, hydraulic valve 52
Electrical
B hazards 14
Battery disconnect switch 7 shorts 19
Bearings Emergency stop buttons 9
fire, source of 19 Engine
shut down, disconnect switches 7
C Expansion bushing, clutch 29
Chip accelerator F
hood door 13
Chipper hood 12 Falling hazard zone 25
Clutch Falling objects, safety 14
spline adapter 33 Feed system
torsional coupling 32 hazards and precautions 15
weight 30 Fire
Coil burnout 55 prevention 18
Coil testing 55 sources and causes 19
Compression roll suppresion equipment 21
hazards and precautions, 15 suppression equipment 20
precautions 10 Fire prevention
safety pins, removal 11 training 18
COUT or RET errors 52 Flow test, motor 60
Flying objects hazard 22
Ft-lb torque, abbreviation 4

INDEX
G LED
on actuator 53
Grates Limited warranty 5
access 17 Loader access zone 25
Guards and shields 18 Lubrication
near moving parts 18
H
Hands-on control station 25 M
Hazard messages, how used in manual 3 Machine Stop, remote 9
Hazard zones 24 Maintenance
Hazards safety practice 27
crushing and pinching 15 Measurement units 4
drum rotor 16 Muffler, inspect 20
electrical 14
electrical, power lines 17 N
feed system 15
gases and fluids 14 Noise 22
moving machinery 22 hazard zone 25
noise 22
spout 16 O
Hearing protection 22
Horn 9 Operators, qualification 6
Horn, safety uses 24 O-rings 44
Hydraulic control valves, types 52 OSHA 6
Hydraulic coupler 32
Hydraulic system P
leaks 20 Power
Hydraulic tank, pressure 44 disconnect switches 7
lockout/tagout 8
I Protective gear 23
Ignition sources 19 Proximity sensors 13
Inertia, drum rotor 11 Pump
Internal leak, cylinder 58 water sprayer 21
ISO cleanliness rating 43 Pump failure 48
J R
Jams Remote transmitter

blockage 14 stop button 9
removing 16 Rotor
spout 17 lock-out 11
motion, hazards 11
L precautions 11
rotating manually 12
Labels
safety 26

I NDEX
S Standby pressure 50
Safe behaviors 23 T
Safety
clean up 19 Tanks
cleanliness 23 water sprayer 21
control power disconnect 7 Tensioner
controls 7 pulley installation 40
discharge access door 17 shaft installation 40
disconnect switches 7 Torque values
drive tracks 18 chart, national coarse thread 42
drum rotor, precautions 11 chart, national fine thread 41
emergency stop buttons 9 Traffic hazard zones 25
fire extinguisher 20
fire prevention 18 U
fire, source and cause 19
gases and fluids 14 Units of weight and measure 4
guards and shields 18
hazards, flying objects 22 W
hazards, moving machinery 22 Warning messages, definitions 3
horn 24 Warranty 5
inertia, drum rotor 11 Water pump sprayer 21
job site 22 Welding
lifting 23 hazards 19
lockout/tagout 8
maintenance 27
motor oil 23
operating the machine 7
protective gear 23
proximity sensors 13
responsibility 6
safe conditions 23
stored energy 10
travel hazard zone 25
unsafe conditions 6
ventilation 23
visibility 22
water sprayer 21
Safety locking pins
compression roll 10
rotor 11
Shields and guards 18
Smoking 20
Sound levels, chipper 22
Spills 19
Spontaneous combustion 20

INDEX

4300B - 4310B Service Manual (Standard) 113050

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4300B - 4310B Service Manual (Standard) 113050

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4300B/4310B Service

The Manual Set Important Messages and

113050 4300B/4310B DRUM CHIPPER SERVICE MANUAL 3

Units of Weight and Measure Small Numbers on Figures

4 4300B/4310B DRUM CHIPPER SERVICE MANUAL 113050

113050 4300B/4310B DRUM CHIPPER SERVICE MANUAL 5

6 4300B/4310B DRUM CHIPPER SERVICE MANUAL 113050

113050 4300B/4310B SERVICE MANUAL 1

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Pressure Limiter Settings . . . . . . . . . . . . . . . . 66

2 4300B/4310B SERVICE MANUAL 113050

SECTION 4000 Replacing Paddles . . . . . . . . . . . . . . . . . . . . 143

113050 4300B/4310B SERVICE MANUAL 3

4 4300B/4310B SERVICE MANUAL 113050

Introduction Hazards, Techniques,

113050 4300B/4310B DRUM CHIPPER SERVICE MANUAL 5

Safety First! Use Only for the Designed

6 4300B/4310B DRUM CHIPPER SERVICE MANUAL 113050

Safe use of the machine during normal operation, main-

stop buttons. 1. Main Battery Disconnect

113050 4300B/4310B DRUM CHIPPER SERVICE MANUAL 7

Disconnect Lockout/Tagout Everyone maintaining or servicing the

Figure 2: Disconnect Switches Lockout/Tagout 3

The battery disconnect switch must be in the Off posi-

1 WARNING key, close the cover, lock, and tag out.

8 4300B/4310B DRUM CHIPPER SERVICE MANUAL 113050

• When more than one person is working on or Remote Machine Stop

Figure 4: Remote Transmitter OFF & STOP Button

113050 4300B/4310B DRUM CHIPPER SERVICE MANUAL 9

• Pressurized gases and fluids Figure 5: Compression Roll in Raised Position

10 4300B/4310B DRUM CHIPPER SERVICE MANUAL 113050

113050 4300B/4310B DRUM CHIPPER SERVICE MANUAL 11

Figure 8: Shaft Collar Used for Turning the Rotor

1 WARNING Chipper Hood

12 4300B/4310B DRUM CHIPPER SERVICE MANUAL 113050

 To open the chipper hood: 1 WARNING

Figure 9: Spring Latches, Chipper Hood Access F08284

Figure 11: Proximity Sensor, Accelerator Hood

F08283 Figure 12: Proximity Sensor, Chipper Hood

113050 4300B/4310B DRUM CHIPPER SERVICE MANUAL 13

Jams or Blockage Diesel Vapor: Diesel fuel

Falling Objects 1 WARNING

14 4300B/4310B DRUM CHIPPER SERVICE MANUAL 113050

• Guards and shields Feed Chain Hazards and Precautions

113050 4300B/4310B DRUM CHIPPER SERVICE MANUAL 15

16 4300B/4310B DRUM CHIPPER SERVICE MANUAL 113050

1 WARNING Discharge Access Door

Clearing a jam in the spout 2 3

113050 4300B/4310B DRUM CHIPPER SERVICE MANUAL 17

Drive Tracks (4310B)

1 WARNING nance are the primary means of reducing

18 4300B/4310B DRUM CHIPPER SERVICE MANUAL 113050

1 DANGER Sources and Causes

113050 4300B/4310B DRUM CHIPPER SERVICE MANUAL 19

Smoking: Smoking tobacco in the wood processing

20 4300B/4310B DRUM CHIPPER SERVICE MANUAL 113050

Water Pump Sprayer (4310B)

Table 1: Water Sprayer Specifications

Max. solid stream spray distance 25 ft (8 m)

1-inch diameter spray hose length 50 ft (15 m)

Minimum full tank discharge time 12 minutes

Nozzle Adjusts solid

The water sprayer can be an effective tool, but is not a

113050 4300B/4310B DRUM CHIPPER SERVICE MANUAL 21