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1410D Forwarder

Serial Number
WJ1410D000475-

OPERATORS MANUAL
1410D Forwarder
OMF064197 (ENGLISH)

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
If this product contains a gasoline engine:

WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects or other reproductive harm.
The State of California requires the above two warnings.

Worldwide Construction
And Forestry Division
Published in Finland

Contents
Page

Introduction
Operators manual for Timberjack 1410D
Forwarder . . . . . . . . . . . . . . . . . . . . . . . . . . .
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Timberjack Contact Information . . . . . . . . . . . .
Technical Information Feedback Form . . . . . . .

Page

Fire Prevention . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-9


What To Do If the Machine Catches Fire . . . . . 3-3-9
1-1-1
1-1-2
1-1-2
1-1-3

Safety - Maintenance Precautions


Service Machines Safely . . . . . . . . . . . . . . . . .
Using the Xenon Worklamp . . . . . . . . . . . . . . .
Securing the Service Position. . . . . . . . . . . . . .
Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prevent Acid Burns. . . . . . . . . . . . . . . . . . . . . .
Service Cooling System Safely. . . . . . . . . . . . .
Prevent Battery Explosions. . . . . . . . . . . . . . . .
Service Tires Safely . . . . . . . . . . . . . . . . . . . . .
Work in Clean Area . . . . . . . . . . . . . . . . . . . . .
Illuminate Work Area Safely . . . . . . . . . . . . . . .
Use Proper Tools . . . . . . . . . . . . . . . . . . . . . . .
Use Proper Lifting Equipment. . . . . . . . . . . . . .

Warranty
Standard warranty clauses . . . . . . . . . . . . . . . . 2-1-1
250 Hour Service . . . . . . . . . . . . . . . . . . . . . . . 2-1-1
Safety - Safety Features
1410D Forwarder Safety Features . . . . . . . . . . 3-1-1
Safety - General Precautions
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recognize Safety Information. . . . . . . . . . . . . .
Understand Signal Words. . . . . . . . . . . . . . . . .
Replace Safety Signs . . . . . . . . . . . . . . . . . . . .
Maintain Safety Cabin . . . . . . . . . . . . . . . . . . .
Driving and Service . . . . . . . . . . . . . . . . . . . . .
Use of Radio-transmitters . . . . . . . . . . . . . . . . .
Prepare for Emergencies . . . . . . . . . . . . . . . . .
Handle Fluids SafelyAvoid Fires . . . . . . . . . .
Handle Chemical Products Safely. . . . . . . . . . .
Dispose of waste properly . . . . . . . . . . . . . . . .
Avoid High-Pressure Fluids . . . . . . . . . . . . . . .
Wear Protective Clothing . . . . . . . . . . . . . . . . .
Daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2-1
3-2-1
3-2-1
3-2-2
3-2-2
3-2-3
3-2-3
3-2-4
3-2-4
3-2-5
3-2-5
3-2-6
3-2-7
3-2-7

Safety - Operating Precautions


General operating instructions . . . . . . . . . . . . .
Handle Starting Fluid Safely . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary exit . . . . . . . . . . . . . . . . . . . . . . . . .
Travel Safely . . . . . . . . . . . . . . . . . . . . . . . . . .
Do Not Short Starter. . . . . . . . . . . . . . . . . . . . .
Operating the Machine . . . . . . . . . . . . . . . . . . .
Loading the Machine . . . . . . . . . . . . . . . . . . . .
Driving on Frozen Water. . . . . . . . . . . . . . . . . .
Driving/Transporting on Public Roads. . . . . . . .
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3-1
3-3-2
3-3-2
3-3-3
3-3-3
3-3-4
3-3-4
3-3-5
3-3-6
3-3-6
3-3-7
3-3-8

3-4-1
3-4-2
3-4-3
3-4-4
3-4-5
3-4-5
3-4-6
3-4-6
3-4-7
3-4-7
3-4-8
3-4-8

Operators Station
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1
Front Dashboard . . . . . . . . . . . . . . . . . . . . . . . 4-1-2
Start Key Positions . . . . . . . . . . . . . . . . . . . . . . 4-1-3
Window Washers and Wipers. . . . . . . . . . . . . . 4-1-4
Signal Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5
Left Arm Control Panel . . . . . . . . . . . . . . . . . . . 4-1-5
Right Arm Control Panel. . . . . . . . . . . . . . . . . . 4-1-6
Using Boom Control Levers . . . . . . . . . . . . . . . 4-1-7
Overhead Panel Switches . . . . . . . . . . . . . . . . 4-1-8
Warning Lamps and Buzzer . . . . . . . . . . . . . . . 4-1-9
Preparedness for telephone . . . . . . . . . . . . . . . 4-1-9
Air Conditioner Controls . . . . . . . . . . . . . . . . . 4-1-10
Operators seat. . . . . . . . . . . . . . . . . . . . . . . . 4-1-11
Operating the Machine, Control System
TMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-1
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-1
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-2
Operating the machine, Operation
Function of Seat Safety Switch. . . . . . . . . . . . . 5-2-1
Emergency Stopper . . . . . . . . . . . . . . . . . . . . . 5-2-1
Operating the Boom . . . . . . . . . . . . . . . . . . . . . 5-2-2
Continued on next page

All information, illustrations and specifications in this manual are based on


the latest information available at the time of publication. The right is
reserved to make changes at any time without notice.
COPYRIGHT 2002
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual

101702

PN=1

Contents

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Frame Brake . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High/Low Gear and Rear-Wheel Drive . . . . . . .
Using the Differential Lock-Up . . . . . . . . . . . . .
Operating the Decking Blade (Optional
Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating the Clambunk. . . . . . . . . . . . . . . . . .

Page

Page

5-2-3
5-2-4
5-2-5
5-2-6
5-2-7

Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-16


Cab lift pump . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-17
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-17
Maintenance - Periodic
Maintenance intervals. . . . . . . . . . . . . . . . . . . . 6-1-1

5-2-7
5-2-7

Maintenance - Every 10 hours or Daily


Check the hydraulic oil level . . . . . . . . . . . . . . .
Check the engine oil level . . . . . . . . . . . . . . . .
Check the Fuel Pre-Filter . . . . . . . . . . . . . . . . .
Check engine coolant level. . . . . . . . . . . . . . . .
Check the windshield washer fluid level . . . . . .
Check the radiator grille cleanness. . . . . . . . . .
Check the driving brake oil level. . . . . . . . . . . .
Check the air filter . . . . . . . . . . . . . . . . . . . . . .
Check the tires for air pressure and
overall shape. . . . . . . . . . . . . . . . . . . . . . . . .
Fill up the fuel tank. . . . . . . . . . . . . . . . . . . . . .
Maintain the boom . . . . . . . . . . . . . . . . . . . . . .
The following service and checks are to
be made at the end of each workday . . . . . .

Lifting and Lowering the Cab


How to Lift the Cab . . . . . . . . . . . . . . . . . . . . . 5-3-1
How to Lower the Cab . . . . . . . . . . . . . . . . . . . 5-3-2
Transportation of the Machine
Use hold-down straps. . . . . . . . . . . . . . . . . . . .
Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Minilevers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4-1
5-4-1
5-4-1
5-4-2

Starting and Turning Off the Engine


Before Starting the Engine for the First
Time in a Working Day . . . . . . . . . . . . . . . . .
Normal Start . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold engine starting . . . . . . . . . . . . . . . . . . . . .
After starting. . . . . . . . . . . . . . . . . . . . . . . . . . .
A normal operation of the engine . . . . . . . . . . .
Turning off the engine . . . . . . . . . . . . . . . . . . .

5-5-1
5-5-2
5-5-3
5-5-4
5-5-5
5-5-6

Maintenance - Every 50 hours or Weekly


Grease the center hinge bearings and
steering cylinder bearings. . . . . . . . . . . . . . .
Grease the decking blade1 . . . . . . . . . . . . . . . .
Check the air conditioner . . . . . . . . . . . . . . . . .
Maintain the Boom . . . . . . . . . . . . . . . . . . . . . .
Check the fire extinguisher system . . . . . . . . . .

Driving the Machine


Off-Road Driving. . . . . . . . . . . . . . . . . . . . . . . . 5-6-1
Driving on Road . . . . . . . . . . . . . . . . . . . . . . . . 5-6-2

Maintenance - Every 250 hours


Clean the machine . . . . . . . . . . . . . . . . . . . . .
Check the high/low gear oil level. . . . . . . . . . . .
Check Differential Oil Level . . . . . . . . . . . . . . .
Check Single Axle Wheel Ends ( Hub gear)
Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Bogie Housings Oil Level . . . . . . . . . . .
Grease Bogie Bearings . . . . . . . . . . . . . . . . . .
Check Wheel Nut Torque . . . . . . . . . . . . . . . . .
Check the cabine air filters . . . . . . . . . . . . . . . .
Check the air conditioner . . . . . . . . . . . . . . . . .
Maintain the boom . . . . . . . . . . . . . . . . . . . . . .

Towing the Machine


Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7-1
Stowing a Disabled Boom . . . . . . . . . . . . . . . . 5-7-4
Maintenance - Machine
Service, General. . . . . . . . . . . . . . . . . . . . . . . . 6-0-1
Servicing Safety Precautions . . . . . . . . . . . . . . 6-0-2
General Maintenance Instructions . . . . . . . . . . 6-0-3
Welding Instructions . . . . . . . . . . . . . . . . . . . . . 6-0-4
Cleaning the Cab windows . . . . . . . . . . . . . . . . 6-0-4
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-5
Changing Wheels . . . . . . . . . . . . . . . . . . . . . . . 6-0-6
Anti slips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-7
Fitting bogie tracks . . . . . . . . . . . . . . . . . . . . . . 6-0-8
Recommended Lubricants and Fluids. . . . . . . 6-0-10
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-11
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-12
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-13
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-14
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-15
Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-16

Maintenance - Every 500 hours


Change engine oil and replace oil filter. . . . . . .
Change the fuel filters . . . . . . . . . . . . . . . . . . .
Clean crankcase vent tube . . . . . . . . . . . . . . . .
Check the air intake system . . . . . . . . . . . . . . .
Checking belt tensioner spring tension and
belt wear . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2-1
6-2-2
6-2-2
6-2-3
6-2-4
6-2-5
6-2-6
6-2-6
6-2-7
6-2-7
6-2-8
6-2-8

6-3-1
6-3-2
6-3-2
6-3-2
6-3-3

6-4-1
6-4-2
6-4-3
6-4-4
6-4-5
6-4-6
6-4-7
6-4-7
6-4-8
6-4-8

6-5-1
6-5-3
6-5-4
6-5-4
6-5-4

Continued on next page

ii

101702

PN=2

Contents

Page

Page

Check engine speeds . . . . . . . . . . . . . . . . . . . . 6-5-6


Control engine grounding . . . . . . . . . . . . . . . . . 6-5-6
Remove sediment and water from the
fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-6
Renew the pressure filter of the drive
hydraulic system . . . . . . . . . . . . . . . . . . . . . . 6-5-7
Check the batteries for charge . . . . . . . . . . . . . 6-5-7
Checking cooling system . . . . . . . . . . . . . . . . . 6-5-8
Control of the diesel engine coolant . . . . . . . . . 6-5-9
Filling supplemental coolant additives
(SCA) between coolant changes . . . . . . . . . . 6-5-9
Pressure control of the cooling system . . . . . . 6-5-10
Grease the driveshafts . . . . . . . . . . . . . . . . . . 6-5-10
Maintenance - Every 1000 hours
Renew the hydraulic oil. . . . . . . . . . . . . . . . . . .
Replace the hydraulic return filter . . . . . . . . . . .
Replace the hydraulic tank breather . . . . . . . . .
Renew the high/low gear (transfer case) oil . . .
Check and tighten the screw and bolt
connections. . . . . . . . . . . . . . . . . . . . . . . . . .
Check the exhaust manifold . . . . . . . . . . . . . . .
Check the air conditioner . . . . . . . . . . . . . . . . .
Maintain the boom . . . . . . . . . . . . . . . . . . . . . .

Have the proper function of the atomizers


checked . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the Fuel Tank Filler Filter . . . . . . . . . . .
Replacing fan/alternator belt . . . . . . . . . . . . . .
Maintain the Boom . . . . . . . . . . . . . . . . . . . . .
Check the air conditioner . . . . . . . . . . . . . . . .

Cooling System Maintenance


Replenishing Supplemental Coolant
Additives (SCAs) Between Coolant
Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11-1
Pressure Testing Cooling System. . . . . . . . . . 6-11-3
Hydraulic System: Hydraulic Oil Change
Hydraulic tank and the vacuum pump. . . . . . . . 7-1-1
Checking the oil level in hydraulic tank. . . . . . . 7-1-1
Renew the hydraulic oil. . . . . . . . . . . . . . . . . . . 7-1-2

6-6-1
6-6-2
6-6-3
6-6-4

Hydraulic System: General


Working hydraulic system. . . . . . . . . . . . . . . . . 7-2-1
Hydrostatic system . . . . . . . . . . . . . . . . . . . . . . 7-2-1

6-6-5
6-6-6
6-6-6
6-6-6

Hydraulic System: Bleeding


General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding Drive Hydraulic System . . . . . . . . . . .
Bleeding Work Hydraulic System . . . . . . . . . . .
Bleeding the Brake System . . . . . . . . . . . . . . .

Maintenance - Every 2000 hours


Check Valve Clearance - Engines
(200,000- ) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7-1
Checking Crankshaft Vibration Damper . . . . . . 6-7-3
Changing the Coolant. . . . . . . . . . . . . . . . . . . . 6-7-4
Change Bogie Axle Differential Oil . . . . . . . . . . 6-7-7
Change Bogie Housings Oil . . . . . . . . . . . . . . . 6-7-8
Change Single Axle Differential Oil. . . . . . . . . . 6-7-9
Change Single Axle Wheel Ends Oil . . . . . . . 6-7-10
Check and tighten the bolts for the joints
between axles and frame . . . . . . . . . . . . . . 6-7-11

7-3-1
7-3-1
7-3-3
7-3-5

Hydrostatic System: Drive Pump adjusting


Checking and adjusting the charge pressure . . 7-4-1
Checking and adjusting the pressure
cut-off valve setting of the drive pump. . . . . . 7-4-2
Hydrostatic System: Drive Motor adjusting
Checking the function of hydrostatic
flushing valve . . . . . . . . . . . . . . . . . . . . . . . . 7-5-1
Checking and adjusting drive motors
pressure cut-off settings . . . . . . . . . . . . . . . . 7-5-2

Maintenance - Every 6 months


Service the fire extinguisher . . . . . . . . . . . . . . . 6-8-1

Work Hydraulic System: Check and Adjust


Adjustment of Pressure Difference . . . . . . . . . .
Adjusting the Maximum Pressure . . . . . . . . . . .
Adjusting the Boom Pressure . . . . . . . . . . . . . .
Adjusting Auxiliary Functions . . . . . . . . . . . . . .
Adjusting Frame Brake . . . . . . . . . . . . . . . . . . .
Adjusting Proportional Decking Blade . . . . . . . .
Adjusting Optional Equipment. . . . . . . . . . . . . .

Maintenance - Every 12 months


Have the fire extinguisher system (opt. eq.)
checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9-1
Maintenance - As required
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding the fuel system . . . . . . . . . . . . . . . .
Have the proper function of the
turbocharger checked . . . . . . . . . . . . . . . . .
Have the proper function of the alternator
checked . . . . . . . . . . . . . . . . . . . . . . . . . . .
Have the proper function of the starter
motor checked . . . . . . . . . . . . . . . . . . . . . .

6-10-5
6-10-5
6-10-6
6-10-6
6-10-6

6-10-1
6-10-2
6-10-4

7-6-1
7-6-1
7-6-2
7-6-4
7-6-4
7-6-5
7-6-5

6-10-4

Brake System: Check and Adjust


Checking the brakes. . . . . . . . . . . . . . . . . . . . . 7-7-1
Mechanical adjustment of brakes . . . . . . . . . . . 7-7-2

6-10-4

Continued on next page

iii

101702

PN=3

Contents

Page

Page

Brake Charging Pressure . . . . . . . . . . . . . . . . . 7-7-3


Checking the Work Brake. . . . . . . . . . . . . . . . . 7-7-3
Checking the Drive Brake (Brake Pedal) . . . . . 7-7-4

Boom, Maintenance every 250 hours


Clean the boom.. . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Check boom structures. . . . . . . . . . . . . . . . . . 10-4-1
Check the extension booms for vertical
clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-2
Check the tightness of boom fastening
bolts, hydraulic cylinder covers, and other screw
joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-2

Electrical System
Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-1
Location of ECU and engine sensors . . . . . . . . 8-1-2
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-3
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-5
Fuses on the Left-Hand Side in the Engine
Compartment . . . . . . . . . . . . . . . . . . . . . . . . 8-1-7
Instrument Box Fuses and Relays . . . . . . . . . . 8-1-8
The RPM Sensor of the Drive
Hydrostatics Motor . . . . . . . . . . . . . . . . . . . . 8-1-9
Hydraulic Tank Sensors . . . . . . . . . . . . . . . . . 8-1-10
Transmission
Operating Power Transmission. . . . . . . . . . . . .
High/Low Gear . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic System. . . . . . . . . . . . . . . . . . . . . .
Control of Transmission . . . . . . . . . . . . . . . . . .

Boom, Maintenance every 1000 hours


Clean the magnetic plug of rotator . . . . . . . . . 10-5-1
Change the boom slewing system oil . . . . . . . 10-5-1
Clean the boom extension boom chains
(depending on the model) . . . . . . . . . . . . . . 10-5-2
Boom, Maintenance as required
Adjusting the rotator link brakes . . . . . . . . . . . 10-6-1

9-1-1
9-1-1
9-1-2
9-1-3

Boom, Technical Data


Boom CF7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7-1
Rotator and Grapple . . . . . . . . . . . . . . . . . . . . 10-7-1
Boom CF7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7-3

Boom, General
A General Description of the Boom . . . . . . . . 10-0-1
Operating Safety Precautions . . . . . . . . . . . . . 10-0-2
General Operating Instructions . . . . . . . . . . . . 10-0-4

Equipment, Air Conditioner


Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1-1
Main Parts of Air Conditioning System . . . . . . 11-1-1
Risks and Counter-Measures . . . . . . . . . . . . . 11-1-4
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1-5
Air Conditioner, Using. . . . . . . . . . . . . . . . . . . 11-1-6
Maintenance and Inspections: Check the
refrigerant level. . . . . . . . . . . . . . . . . . . . . . 11-1-8
Check the service moisture indicator of
the dryer every 50 hours . . . . . . . . . . . . . . .11-1-11
Service the compressor V-belt every 250
hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1-11
Service the compressor every 1000 hours . . .11-1-11
Service the evaporator element every
1000 hours . . . . . . . . . . . . . . . . . . . . . . . . .11-1-12
Service the condenser element every
1000 hours . . . . . . . . . . . . . . . . . . . . . . . . .11-1-12
Service the hoses and connectors every
1000 hours . . . . . . . . . . . . . . . . . . . . . . . . .11-1-13

Boom Maintenance, General


Assembly Instructions. . . . . . . . . . . . . . . . . . . 10-1-1
Bleeding the Hydraulic System . . . . . . . . . . . . 10-1-1
Maintenance Schedule . . . . . . . . . . . . . . . . . . 10-1-2
Boom, Maintenance every 10 hours
Grease the grapple and link. . . . . . . . . . . . . . 10-2-1
Check boom structures. . . . . . . . . . . . . . . . . . 10-2-1
The following service and checks are to
be made at the end of each workday . . . . . 10-2-2
Boom, Maintenance every 50 hours
Check the boom slewing housing oil level . . .
Check that the joint pins of the boom
are secured. . . . . . . . . . . . . . . . . . . . . . . . .
Check the sideways clearance of the
extension booms. . . . . . . . . . . . . . . . . . . . .
Check the boom extension boom chains for
tightness. . . . . . . . . . . . . . . . . . . . . . . . . . .
Grease the rocker and cylinder bearings
of the boom and the slewing system
bearing.. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricate the extension boom chains
with oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the grapple . . . . . . . . . . . . . . . . . . . . .
Lubrication and Maintenance Chart . . . . . . . .

10-3-1
10-3-1
10-3-2

Equipment, Engine Preheater


Operation and maintenence . . . . . . . . . . . . . . 11-2-1

10-3-2

Equipment, Fire Extinguisher System


General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3-1
Fire Alarm and Actions . . . . . . . . . . . . . . . . . . 11-3-2
After a fire . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3-5

10-3-3
10-3-3
10-3-3
10-3-4

Continued on next page

iv

101702

PN=4

Contents

Page

Control unit. . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3-6


Hand-held fire extinguishers . . . . . . . . . . . . . . 11-3-8
Equipment, Decking Blade
Using the Decking Blade . . . . . . . . . . . . . . . . 11-4-1
Lowering the Decking Blade . . . . . . . . . . . . . . 11-4-2
Decking Blades Float. . . . . . . . . . . . . . . . . . . 11-4-3
1410D Specifications
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . .
Decals and Signs . . . . . . . . . . . . . . . . . . . . . .
Load area. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission . . . . . . . . . . . . . . . . . . . . . . . . .
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic system . . . . . . . . . . . . . . . . . . . . . .
Electrical System . . . . . . . . . . . . . . . . . . . . . .
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12-0-1
12-0-2
12-0-3
12-0-4
12-0-5
12-0-5
12-0-5
12-0-6
12-0-6
12-0-6
12-0-6
12-0-7

Hydraulic Diagrams, F622627


Hydraulic Diagrams, F622627 . . . . . . . . . . Hydraulic
Diagrams-1
Boom Hydraulics . . . . . . . . . . . Hydraulic Diagrams-2
Transmission Hydraulics . . . . . Hydraulic Diagrams-6
Brake Hydraulics . . . . . . . . . . . Hydraulic Diagrams-8
Extra Equipment Hydraulics . . . . . . . . . . . Hydraulic
Diagrams-10
Options Hydraulics . . . . . . . . Hydraulic Diagrams-12
Wiring Diagrams, 1410D
General . . . . . . . . . . . . . . . . . . . . Wiring Diagrams-1
TMC
TMC CONTROL SYSTEM ver 3G+ . . . . . . . . TMC-1

101702

PN=5

Contents

vi

101702

PN=6

Introduction
Operators manual for Timberjack 1410D Forwarder
Manufacturer:
Timberjack Oy
P.O. Box 474
FIN-33101 Tampere, Finland
Telephone int: +358 205 84 162
Fax int: +358 205 84 163

Table to enter Machine Serial Number and Dealer information:


Machine Serial No.
Dealer

The information contained in this manual is comprised


of regulations and instructions which will assist the
operator to operate the machine in a safe and efficient
manner. Make sure this manual is always close at
hand and available to all who work on the machine.
Should this manual be lost or should it deteriorate to
an unintelligible state, contact Timberjack or your
nearest Timberjack dealer for a replacement manual.

CAUTION: Only persons whose training has


been approved by Timberjack are permitted
to operate Timberjack machinery.
Improper operation and maintenance of this
machine can be hazardous and could result
in serious injury or death.

If you sell the machine, be sure to give this manual to


the new owners.
Continuing improvements in the design of this machine
can lead to changes in detail which may not be
reflected in this manual. Consult Timberjack or your
local Timberjack dealer for the latest available
information of your machine or for questions regarding
information in this manual.

Therefore, it is of paramount importance that


all the instructions given in this manual and
during training be followed when the
machine is operated or serviced.
Read the safety rules from Section 3.

EL62757,0000159 1919APR021/1

1-1-1

101702

PN=4

Introduction

Foreword
This manual provides you with the instructions for the
operation and maintenance of Timberjack Forwarder.
Please read the entire manual before you start
operating the machine. The instructions given will
assist you in becoming familiar with many features of
Timberjack Forwarder, showing you how to operate the
machine and how to carry out periodic maintenance
procedures and some basic adjustments.
However, we strongly advise you to contact the
nearest repair shop authorized by Timberjack when
complicated maintenance tasks or repairs come up.
Our service people have the experience and tools
needed for the job.

Do not pollute the environment. It is imperative that


you do not allow oil to leak into the ground or water
because it only takes one liter of mineral oil to
contaminate one million liters of water. Should you see
a leaky joint, fix it immediately.

We designed the forwarder to carry cross-cut timber


on its deck from the logging site to the roadside.
NOTE: See Section 12 for information about maximum
payload and log length.
NOTE: Skidding long logs is only permitted with
machines specially equipped for the purpose.
The machine must not be used for other
purposes.

We designed the forwarder to operate under difficult


off-road circumstances. Still it is important that you
always adapt your driving speed and load to the
surroundings. Use chains and tracks if necessary.
Take a good look at your forwarder always when
having a short break or when maintaining the machine.
It is worth bearing in mind that even a small failure, if
left unattended, may soon result in major problems
and a long downtime.

Remember fire prevention. Keep the machine clean at


all times for this reduces the risk of overheating and
chance of a fire starting.
See Section 12, for technical information of the
machine.

EL62757,000015A 1919APR021/1

Timberjack Contact Information


Please, contact our web site: www.Timberjack.com.

EL62757,000015B 1919APR021/1

1-1-2

101702

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Introduction

Technical Information Feedback Form


We need your help to continually improve our Operators
Manuals please FAX or mail your comments, ideas and
improvements on this comment sheet.
SEND TO:

Timberjack Oy
P.O. Box 474
FIN-33101 Tampere
Finland
Attn: Publications Supervisor

FAX NUMBER: +358 205 84 6160


Ideas, Comments, (Please state Page Number):

OVERALL, how would you rate the quality of "ALL" Operators Manuals provided to you? (Check one)
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1

Fair
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Good
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Company Name
Address
Phone
FAX No.
Dealer Acct. No.

THANK YOU!

EL62757,000015C 1919APR021/1

1-1-3

101702

PN=6

Warranty
Standard warranty clauses
The machine is covered by Timberjacks guarantee in
compliance with the standard warranty clauses accepted
by the Timberjack group.
The manufacturer will not assume responsibility for the
machines delivered should the following conditions be
violated:
The forwarder is exclusively operated and maintained
by experienced personnel who have been trained by
Timberjack or by a dealer authorized by Timberjack.
The forwarder must be operated and maintained in
accordance with the instructions provided in this
manual.
Only fuels and lubricants specified in this manual are
used.
Only genuine spare parts are used

EL62757,000015D 1919APR021/1

250 Hour Service


The forwarder was checked and test driven before
delivery, and it can be put to use immediately. However,
to ensure good reliability it is very important to thoroughly
service the machine once it has been put to use.
The warranty given by Timberjack will be valid provided
that the machine is handed over for after sales
maintenance after appr. 250 running hours, the service
shop being one authorized by Timberjack.

EL62757,000015E 1919APR021/1

2-1-1

101702

PN=7

Safety - Safety Features

T160087

UN03OCT02

1410D Forwarder Safety Features

1Secondary exit. The


right-hand cap window can
be used as a secondary
exit from the cab.
2ROPS. Integrated rollover
and operator protective
structures fully enclose
and protect the operator
3Central warning light and
alarms (+buzzer).Alarm
when malfunctions occur.

4Seat safety switch. No


function can be engaged
before somebody sits on
the seat.
5Safety signs. Warn and
give safety information for
the operator.
6Back-up alarm (opt). Allerts
bystanders when machine
is reversing.

7Frame brake. Locks the


horizontal hinge of the
machine.
8Hand-held fire
extinguishers and fire
extinguisher system (opt.)

9Emergency stop Stops the


machine and engages the
parking brake.
10Stairs, anti-slips on the
steps, handrails. Help to
climb into the machine.

Please remember, the Operator is the key to


preventing accidents.

OUTJ003,00005CF 1910MAY011/1

3-1-1

101702

PN=8

Safety - General Precautions


General
Comply with instructions in this manual and also your
companys regulations.
Should there be any information or instructions in this
manual that are not in compliance with local laws and
regulations in force in the country or region where this
equipment is operated, the local laws and regulations
must take precedence.
This machine should not be operated or maintained by
personnel other than those who have been thoroughly
trained.
As the maintainer ensure that you become familiar with all
occupational safety regulations pertaining to forest
machinery as well as all safety instructions pertaining to
this equipment. Observe the instructions provided in this
manual and on all hazard and information decals on the
machine.

OUTJ003,00004A0 1915FEB011/1

This is a safety-alert symbol. When you see this symbol


on your machine or in this manual, be alert to the
potential for personal injury.

T133555

Follow recommended precautions and safe operating


practices.

UN28AUG00

Recognize Safety Information

DX,ALERT 1929SEP981/1

Understand Signal Words

TS187

DANGER or WARNING safety signs are located near


specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.

1930SEP88

A signal wordDANGER, WARNING, or CAUTIONis


used with the safety-alert symbol. DANGER identifies the
most serious hazards.

DX,SIGNAL 1903MAR931/1

3-2-1

101702

PN=9

Safety - General Precautions

Replace Safety Signs

More specific measures are illustrated with pictographs


which may also be attached to the machine in locations
pertinent to their respective message.

TS201

Keep safety signs in good condition. Repair or replace


damaged signs.

UN23AUG88

Carefully study all of the safety messages that are in this


manual and on the machine.

DX,SIGNS1 1904JUN901/1

Maintain Safety Cabin


Cabin is safety tested according to international ROPS,
FOPS and OPS standards.
Do not operate the machine with the door open or any of
the safety covers or protective devices removed.
It is important to keep the operator protective structure in
place (doors, screens, windows, windshield, etc.) to
minimize hazards from whipping or intruding objects.
The protection offered by ROPS, FOPS and OPS will be
impaired if cabin
is subjected to structural damage
is involved in an overturn incident
is in any way altered by welding, bending, drilling, or
cutting
To maintain ROPS, FOPS and OPS protection, replace
damaged cabin parts immediately. A damaged structure
should be replaced, not reused.
Do not attach any parts on the cabin by welding nor drill
any holes on it because it is a safety cabin. It is forbidden
to modify the window fastening.

AK12300,000010A 1905NOV011/1

3-2-2

101702

PN=10

Safety - General Precautions

Driving and Service

Carry no passengers. The vehicle is provided and


approved with seating for the operator only.
Use the handrails and steps provided when mounting
and dismounting from the machine. Do not climb onto
the machine in any other fashion.
The machine must not be operated by anyone under
the influence of alcohol or drugs.
Avoid operating the machine if you are tired or ill, as
there is a greater risk of accident. Take sufficient breaks
and observe local regulations on working hours.

T152788

IMPORTANT: Do not let an untrained person operate


the machine.

UN20MAR02

The machine may only be used or repaired by personnel


who have received training that is approved by
Timberjack.

EL62757,000015F 1919APR021/1

Use of Radio-transmitters
IMPORTANT: Any use of equipment containing a
radio transmitter (e.g., telephone,
communications radio) that has an
antenna inside the cab is strictly
prohibited.
Such equipment must be permanently installed in a proper
manner with an antenna on a suitable grounded plate
outside the cab.
Never mount an antenna inside the cabin because it may
cause malfunction in electrical devices!
CAUTION: Never use a headset when there is
thunder or lightening. Observe the danger of an
outer antenna so that it does not come into
contact with power lines.

EL62757,000005B 1924SEP011/1

3-2-3

101702

PN=11

Safety - General Precautions

Prepare for Emergencies


Be prepared if a fire starts.

TS291

Keep emergency numbers for doctors, ambulance service,


hospital, and fire department near your telephone.

UN23AUG88

Keep a first aid kit and fire extinguisher handy.

DX,FIRE2 1903MAR931/1

Handle Fluids SafelyAvoid Fires

Store flammable fluids away from fire hazards. Do not


incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris.

TS227

Do not store oily rags; they can ignite and burn


spontaneously.

UN23AUG88

When you work around fuel, do not smoke or work near


heaters or other fire hazards.

DX,FLAME 1929SEP981/1

3-2-4

101702

PN=12

Safety - General Precautions

Handle Chemical Products Safely

Check the MSDS before you start any job using a


hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.

TS1132

A Material Safety Data Sheet (MSDS) provides specific


details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.

UN26NOV90

Direct exposure to hazardous chemicals can cause


serious injury. Potentially hazardous chemicals used with
your machine include such items as lubricants, coolants,
paints, and adhesives.

See your authorized dealer for MSDSs on chemical


products used with your machine.

TX,05,DH2500 1902OCT921/1

Dispose of waste properly

Do not pour waste onto the ground, down a drain, or into


any water source.

TS1133

Use leakproof containers when draining fluids. Do not use


food or beverage containers that may mislead someone
into drinking from them.

UN26NOV90

Improperly disposing of waste can threaten the


environment and ecology. Potentially harmful waste used
with equipment include such items as oil, fuel, coolant,
brake fluid, filters, and batteries.

Air conditioning refrigerants escaping into the air can


damage the Earths atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.
Inquire on the proper way to recycle or dispose of waste
from your local environmental or recycling center, or from
your authorized dealer.

EL62757,0000160 1919APR021/1

3-2-5

101702

PN=13

Safety - General Precautions

Avoid High-Pressure Fluids

Search for leaks with a piece of cardboard. Protect hands


and body from high pressure fluids.

X9811

Avoid the hazard by relieving pressure before


disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.

UN23AUG88

Escaping fluid under pressure can penetrate the skin


causing serious injury.

If an accident occurs, see a doctor immediately. Any fluid


injected into the skin must be surgically removed within a
few hours or gangrene may result. Doctors unfamiliar with
this type of injury should reference a knowledgeable
medical source.

CED,TX14740,7088 1930JUN001/1

3-2-6

101702

PN=14

Safety - General Precautions

Wear Protective Clothing

Wear a suitable hearing protective device such as


earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.

TS206

Prolonged exposure to loud noise can cause impairment


or loss of hearing.

UN23AUG88

Wear close fitting clothing and safety equipment


appropriate to the job.

Safety face shield, glasses, or goggles should always be


used as protection from pressurized fluid spray, flying
debris, and other airborne matter when working with tools,
power tools, welding equipment, and corrosive or
dangerous chemicals.
Wear protective clothing as required by the job. Use a
rubber apron and rubber gloves when working with
corrosives and wear heavy work gloves and safety shoes
when handling large heavy or sharp objects and cables.
Operating equipment safely requires the full attention of
the operator. Do not wear radio or music headphones
while operating machine.

OUTJ003,00005AA 1909MAY011/1

Daily checks
inspect the machine daily for signs of damage, unusual
wear, fluid leaks, or faulty operation.
Repair all defects.
Keep windows clean.
Keep floors, steps, and running boards clean and free of
oil, ice, mud, and loose objects.
NOTE: Adhere to the maintenance schedule in the
operators manual. This will contribute to a safe
working environment.

EL62757,0000161 1919APR021/1

3-2-7

101702

PN=15

Safety - Operating Precautions


General operating instructions
Operate the machine only from a seated position in the
operators seat. Always use the seat belt.

UN23AUG88

Before lifting or lowering the hydraulic stairs make sure


that they dont hit any obstacles.
Keep the door closed when driving the machine.

TS205

Do not operate the machine with any of the safety covers


or protective devices removed.

CAUTION: A danger zone of 20 metres (70 ft.)


applies when the machine is in operation. The
operator is personally responsible for
maintaining this safety rule in the absence of
the foreman.

T139370

Maintain a safe operating distance between the equipment


and other personnel. Never swing the boom over the
heads of bystander

UN06JUN01

When the engine is running, allow no one in the risk zone


of the machine. Bystanders who are close to the machine
may be injured by moving implements.

IMPORTANT: The manufacturer shall assume no


responsibility for any alterations made
to the electrical system of the machine
if the changes are not in compliance
with service bulletins. There is a risk
that the function of the safety systems
of the machine is jeopardized.

EL62757,0000162 1919APR021/1

3-3-1

101702

PN=16

Safety - Operating Precautions

Handle Starting Fluid Safely


Starting fluid is highly flammable.

TS1356

To prevent accidental discharge when storing the


pressurized can, keep the cap on the container, and store
in a cool, protected location.

UN18MAR92

Keep all sparks and flame away when using it. Keep
starting fluid away from batteries and cables.

Do not incinerate or puncture a starting fluid container.

OUTJ003,000068F 1914MAY011/1

Controls
Prior to commencing work, make sure that all machine
and crane controls function correctly.
IMPORTANT: It is not permissible to operate the
machine if there is something wrong
with the controls of the machine or if
they have not been properly adjusted.
Check the operation of the emergency stop every day.
Check the braking capacity before each shift:

Choose low gear.


Select the driving direction
Press the foot-brake
Increase engine speed to about 1500 r/min. The
machine shall not move.

EL62757,0000163 1919APR021/1

3-3-2

101702

PN=17

Safety - Operating Precautions

Alarms
A warning light and alarm light will be activated in the
event of machine faults. See Section 4.
Never continue running a machine when the alarm has
been given, unless you have checked the cause and
taken necessary action.

EL62757,0000164 1919APR021/1

Secondary exit
There is an emergency exit through the front right hand
side window.
IMPORTANT: Remove the lock pin (1) from behind the
window latch before you start to work.
CAUTION: Always remember to remove the lock
pin before you start the machine. If not, the
window cant be opened from the outside in
case of emergency.
IMPORTANT: In case of emergency the window can
be opened from outside and inside.
From the inside : Pull the hinge pin (2) entirely out and
push the window fully open.

T152785

IMPORTANT: Replace the lock pin (1) again when


locking the cab. That is to prevent
unauthorized access to the cab through
the window

UN20MAR02

From the outside (the lock pin has to be removed):


Push in the releasing handle (4). The window can be
opened so much that you are able to pull the hinge pin (2)
out and open the window fully.

1Lock pin
2Hinge pin
3Window hatch
4Releasing handle

EL62757,0000165 1919APR021/1

3-3-3

101702

PN=18

Safety - Operating Precautions

Travel Safely
Know the location of bystanders before moving the
machine.
UN20DEC88

Always keep the reverse warning alarm, if equipped, in


working condition. It warns people when the machine
starts to move in reverse.

T6964AD

Use a signal person when moving the machine in


congested areas. Coordinate hand signals before starting
the machine.

TX,05,FF3319 1908FEB931/1

T139380

Start the engine from the operators seat only. Never


attempt to start the engine by shorting across the starter
terminals as this can cause dangerous situations with risk
of serious injury or death to bystanding personnel.

UN06JUN01

Do Not Short Starter

EL62757,0000169 1919APR021/1

3-3-4

101702

PN=19

Safety - Operating Precautions

Operating the Machine


Choose low gear and adapt driving speed to prevailing
ground conditions. Where necessary use anti-skid device,
e.g. chains.
On steep slopes always try to drive directly uphill or
downhill and avoid changes in direction or driving
diagonally (risk of toppling).
CAUTION: Do not jump from the cab. If the
machine tips over hold on to the armrests.
If you find yourself in a precarious situation, dont take any
risks, call for towing assistance.
In the event of strong wind, trees leaning over or are
otherwise difficult to reach, take care and longer time
rather than taking greater risk.
When you stop working, even temporary (for example
while using the phone), lower the crane and engage the
parking brake.
NOTE: ALWAYS put the direction selector in neutral and
apply the parking brake before leaving the cab
Never leave the machine unattended while the engine is
running.
Turn the main switch off if the machine is to stand still for
a prolonged period of time (overnight, for example).

EL62757,0000166 1919APR021/1

3-3-5

101702

PN=20

Safety - Operating Precautions

Loading the Machine


CAUTION: Do not overload the machine.
Likewise, do not carry a load that exceeds the
limits of the headboard. A load that is stacked
too high can cause the machine to overturn, or
the topmost logs may slide over the headboard
and cause a fatal injury to the driver.
The crane grapple must be supported on the load carrier
frame or on top of the load. Do not ever leave the boom
and grapple unsupported or resting on the ground.
CAUTION: A load that exceeds the limits of the
headboard may cause serious or fatal injury.

EL62757,0000167 1919APR021/1

Driving on Frozen Water


Pay extra attention while driving on frozen water:
Be ready for quick evacuation from the cabin before
driving on a frozen lake, etc.
Release your safety belt.
Ensure that the doors are unlocked.
Ensure that there is nothing to obstruct quick
evacuation.
Restore the above precautions on reaching firm ground.
CAUTION: Never park the machine on a frozen
lake, etc.

EL62757,000005E 1924SEP011/1

3-3-6

101702

PN=21

Safety - Operating Precautions

Driving/Transporting on Public Roads


When traveling on public roads, use accessory lights and
other cautionary devices to bring your approach to the
attention of other vehicle operators. Ensure that the
vehicle meets all regulatory requirements.
If the machine must be transported, make sure it is
adequately secured to the transporting vehicle. Even
though the brakes may be fully engaged, the wheels must
be blocked and the machine secured with chains, wire, or
rope to prevent movement during transport.
Position and secure the implement attachment, including
the boom, so that the equipment will not move and cause
imbalance during transport.
Ensure that the overall height does not exceed local or
state maximum height regulation.

OUTJ003,00004B0 1915FEB011/1

3-3-7

101702

PN=22

Safety - Operating Precautions

Power Cables

UN03OCT02

When planning the work, check with the local power


company to find out if there are any overhead cables in
the working zone and the safe distance to them.

T152796

NOTE: Avoid operating under overhanging electrical


powerlines for a high voltage can jump over a
distance of several meters in the air.
Safety distances to electric lines
Rated voltage
kV
1

Min. distance (m)


under

Min. distance (m)


on the side

1...45

110

220

400

Normally stay in the cab and back up away from a


powerline.
If the engine stops and the machine comes into contact
with a powerline and you have to come out of the
machine do as follows:
grapple firmly with a bare hand on the wrist of the other
hand holding a handle while pushing the door open.
Jump out of the cab both feet together.
Keep on jumping feet together until you are at least 10
meters from the machine and the powerline.
If you fall earlier do not stand up, but keep on rolling on
the ground toward the same direction.
You run the greatest risk if you are in simultaneous
contact with the machine and the ground.
Jump clear from the machine to the ground.

EL62757,0000168 1919APR021/1

3-3-8

101702

PN=23

Safety - Operating Precautions

TS227

Clean dust and debris from the machine regularly.


Clean the radiator and oil cooler regularly to ensure
components operate at efficient working temperatures.
Inspect the machine daily for potential fire hazards and
make any necessary repairs immediately.
Inspect electrical wiring and connections, fuel and
hydraulic hose runs to ensure they are secure and not
rubbing against other components.
Clean up any excess grease, oil accumulation, and
spillage immediately.
Use only nonflammable solutions for cleaning the
machine or components.
Store rags and other combustible materials in a safe,
fireproof location.
Before starting repair work, such as welding, the
surrounding area should be cleaned and a fire
extinguisher should be close by.
Maintain a charged fire extinguisher on the vehicle at all
times and KNOW HOW TO USE IT.

UN07SEP00

To reduce the chance of a fire starting, observe the


following instructions:

T133553

When working in a forest environment, it is impossible to


prevent combustible debris from collecting in tight corners
of the machine. This debris, in itself, may cause a fire;
however, when mixed with fuel, oil, or grease in a hot or
confined place, the danger of fire is very much increased.

UN23AUG88

Fire Prevention

OUTJ003,00004B1 1915FEB011/1

T133554

Turn the engine off.


Turn the master disconnect switch off
If possible, fight the fire using the portable fire
extinguisher or other fire suppression equipment.
Ensure that the fire does not spread to the surrounding
area.
Call for help!

UN07SEP00

What To Do If the Machine Catches Fire

OUTJ003,00004B2 1915FEB011/1

3-3-9

101702

PN=24

Safety - Maintenance Precautions


Service Machines Safely
Prior to servicing or repairing the machine, ensure that the
machine is level and the parking brake is engaged.
If repairing the brakes, make sure that the machine
cannot start moving.
CAUTION: You are strictly prohibited from
carrying out service on the machine while the
diesel engine is running.
Position the boom firmly and safely on the ground so that
it cannot move.
Keep clear of the raised boom.

Disconnect the negative (-) battery cable from the battery,


if you work on electrical equipment.

T152787

UN20MAR02

NOTE: When handling the battery beware of the risk of a


short-circuit and watch out for the corrosive acid
in the battery.

TS218

Shut the engine down and turn the main switch off.

UN23AUG88

Make sure that unauthorized persons are not allowed near


the machine.

DX,LOOSE 1904JUN901/1

3-4-1

101702

PN=25

Safety - Maintenance Precautions

Using the Xenon Worklamp


When using the lamp, please notice the following:
Avoid looking directly into the intensive light
The lens may occasionally be cleaned
No aggressive or abrasive cleaners may be used
IMPORTANT: Do not wash the lens with liquid
substances while switched on or
while the lens is still warm, as the
lens might crack.

Safety instructions for replacing the Xenon bulb


Please observe the following safety instructions when
replacing the Xenon bulb:
Always switch off the headlamp before exchanging
bulbs and disconnect from the power supply.
Never insert foreign objects of fingers into the bulb
holder.
The electrician connection between headlamp and
lamp ballast is under high voltage and must not be
disconnected.
The ballast unit must never be operated without a
bulb, as dangerous voltage spark-over, which leads
to damage, may occur at the bulb holder.

Allow the bulb cool off.


Wear safety goggles and gloves when exchanging
bulb.
CAUTION: The glass body of the Xenon bulb
is filled with various gasses and metal
gasses under pressure (danger of
splintering).
Never touch the glass bulb of the Xenon lamp, touch
the bulb at its base only.
Use a clean cloth and alcohol to remove any
fingerprints from the glass bulb.
The Xenon lamp has to be operated only in the
closed work lamp.
IMPORTANT: If a Xenon bulb breaks in a closed
room (workshop), the room is to be
aired and everyone must leave the
room for 20 minutes to exclude any
danger to health due to escaped gas.
Dispose of used Xenon bulbs as hazardous waste.

EL62757,0000050 5416SEP021/1

3-4-2

101702

PN=26

Safety - Maintenance Precautions

Securing the Service Position

UN06JUN01

Before dismantling parts subjected to load, hydraulic


cylinders, stays, wheels, etc., they must be supported and
relieved so as to eliminate the risk of injury.

T139371

Having raised the cab to its full height, always lock the
safety support in place. Do not use any middle position.
Make sure that nobody comes close to the cab when
raising or lowering it.
CAUTION: When lowering cab, its lowering
speed may accelerate when the cab is appr. 5
centimeters from the fastening studs. Make
sure that nobody comes too close to the cab
when lowering it.
CAUTION: The use of engine hoods and belly
pans may have been facilitated by means of lift
supports. Should these supports become
defective, the cover may unexpectedly come
down. Do not go under these parts when
lifting/lowering them or before they are properly
secured in the uppermost position.

Likewise, also secure the horizontal hinge, if necessary,


as applicable under the circumstances.
If the machine breaks down in difficult terrain, and cannot
be moved prior to being repaired, take extra care to fully
immobilize the machine and all rotating or moving parts.

T152685

UN19MAR02

Before disconnecting any load-bearing parts, secure the


vertical hinge of the machine.

1Frame lock

Install the frame lock (1) to prevent accidental articulation


of the machine.
Read the manual carefully and follow the maintenance
procedures provided.
NOTE: The operator and serviceman are responsible for
safety on and around the machine.

EL62757,000016A 1919APR021/1

3-4-3

101702

PN=27

Safety - Maintenance Precautions

Fluids
Fluid leaks under pressure may not be visible.
Pressure can be maintained in a hydraulic system long
after the power source and pump have been shut down.
Lower the implements to the ground and relieve trapped
pressure before performing maintenance work on
components.
Do not disconnect any hoses before making sure that all
pressure has been eliminated.
Do not fill up the oil tanks or fuel tank if the engine is
running.
Do not modify any pressure adjustments without a
permission from the manufacturer.
Use extreme caution when draining hot fluids from the
machine. Splashing hot fluid can cause serious burns.
Open the expansion tank cap slowly if the cooling system
is hot. This allows the pressure to even out.

EL62757,000016B 1919APR021/1

3-4-4

101702

PN=28

Safety - Maintenance Precautions

Prevent Acid Burns


Sulfuric acid in battery electrolyte is poisonous. It is strong
enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.
Avoid the hazard by:
1.
2.
3.
4.
5.

Filling batteries in a well-valveated area.


Wearing eye protection and rubber gloves.
Avoiding breathing fumes when electrolyte is added.
Avoiding spilling or dripping electrolyte.
Use proper jump start procedure.

If you spill acid on yourself:

UN23AUG88

1. Flush your skin with water.


2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 1530 minutes. Get
medical attention immediately.
If acid is swallowed:

TS203

1. Do not induce vomiting.


2. Drink large amounts of water or milk, but do not
exceed 2 L (2 quarts).
3. Get medical attention immediately.

DX,POISON 1921APR931/1

Service Cooling System Safely

TS281

Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
to relieve pressure before removing completely.

UN23AUG88

Explosive release of fluids from pressurized cooling


system can cause serious burns.

DX,RCAP 1904JUN901/1

3-4-5

101702

PN=29

Safety - Maintenance Precautions

Prevent Battery Explosions


Keep sparks, lighted matches, and open flame away from
the top of battery. Battery gas can explode.

UN23AUG88

Never check battery charge by placing a metal object


across the posts. Use a voltmeter or hydrometer.

TS204

Do not charge a frozen battery; it may explode. Warm


battery to 16C (60F).

DX,SPARKS 1903MAR931/1

Service Tires Safely


Explosive separation of a tire and rim parts can cause
serious injury or death.
Do not attempt to mount a tire unless you have the proper
equipment and experience to perform the job.
Always maintain the correct tire pressure. Do not inflate
the tires above the recommended pressure. Never weld or
heat a wheel and tire assembly. The heat can cause an
increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.

TS211

Check wheels for low pressure, cuts, bubbles, damaged


rims or missing lug bolts and nuts.

UN23AUG88

When inflating tires, use a clip-on chuck and extension


hose long enough to allow you to stand to one side and
NOT in front of or over the tire assembly. Use a safety
cage if available.

DX,RIM 1924AUG901/1

3-4-6

101702

PN=30

Safety - Maintenance Precautions

Work in Clean Area

If you dont have an exhaust pipe extension, either work


outside, or open the shop doors.

TS220

If it is necessary to run the engine in an enclosed area,


use an exhaust pipe extension to remove exhaust fumes.
Run the engine only when it is necessary for testing or
adjustments.

UN23AUG88

Work in a valveated area only.

DX,CLEAN 1904JUN901/1

TS223

Illuminate your work area adequately but safely. Use a


portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.

UN23AUG88

Illuminate Work Area Safely

DX,LIGHT 1904JUN901/1

3-4-7

101702

PN=31

Safety - Maintenance Precautions

Use Proper Tools


Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards.

UN08NOV89

Use power tools only to loosen threaded parts and


fasteners.

TS779

For loosening and tightening hardware, use the correct


size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping
wrenches.
Make sure that jack stands and lifting equipment are in
good condition and of adequate capacity. Repair or
replace worn or damaged tools, including lifting
equipment, before initiating repair work on your machine.
Use only service parts meeting manufacturers
specifications.

OUTJ003,00005AB 1909MAY011/1

Use Proper Lifting Equipment


Lifting heavy components incorrectly can cause severe
injury or machine damage.

TS226

UN23AUG88

Follow recommended procedure for removal and


installation of components in the manual.

DX,LIFT 1904JUN901/1

3-4-8

101702

PN=32

Operators Station
General
Warning lights are located on the front dashboard.
Bear in mind that should a warning light go on or the
central warning light blink, this always indicates that there
is something that does not function properly within the
system. This being the case, discontinue loading and turn
off the engine. See the Instructions for use of Timberjack
TMC (Total Machine Control), Appendix.
The operation of the alarm system is detailed in the
Instructions for use TMC.

T152190

UN12SEP02

1Front dashboard
2Signal lights
3TMC-display
4Left control panel
5Right control panel
6Drive pedal
7Brake pedal
8Heater/AC controls
9Warning lamps
10Light switch
11Engine preheater
12Control unit for fire extinguisher system
13Radio

Cab Component Locator

TMC is a registered trade mark of Timberjack.

EL62757,000016C 1919APR021/1

4-1-1

101702

PN=33

Operators Station

Front Dashboard

T152191

UN17OCT02

1Hazard lights
2Horn
3In reserve
4 Stairs
5In reserve
6Rear wheel drive; engagement (when high gear is
on)
7Windscreen washer *
8Windscreen wiper *
9Left side window wiper *
10Right side window wiper*
11Rear window washer
12Rear window wipe *
13Emergency stop
14Cigarette lighter (24 V)
15Ignition switch
16In reserve
17Decking blade float1
18Head lamp; high beam/low beam
19Switch, headlights
20Turn indicator lights
21Ministick steering on/off; opt. eq
22In reserve
23Parking brake

See: Equipment, Decking blade


EL62757,000016D 1919APR021/1

4-1-2

101702

PN=34

Operators Station

Start Key Positions


PVacuum pump (opt. eq.)

UN05MAR02

STOPEngine turn-off
IPower on
II Empty

T152192

STARTStarting.
In positions Start and II the load on the working
hydraulic pump is relieved making it easier for the
engine to run

EL62757,000016E 1919APR021/1

4-1-3

101702

PN=35

Operators Station

T152193

UN05MAR02

Window Washers and Wipers

1Switch for Windscreen


wiper

2Windscreen washer
3Windscreen wiper

The wiper switches on the side panel activate a


continuous function of the wipers.
Control of the wiper interval action:
You can control the wiper action with a key (1) on the
right arm-rest panel.

4Left side window wiper


5Right side window wiper

6 Rear window washer


7Rear window wiper

1 press on key (1).


The windscreen wiper makes a single move.
2 presses (the 2nd press within 30 seconds) on key
(1).
Time between these two presses determines the wiper
interval.
3rd press on key (1).
The 3rd press stops the wiper action.

A single move of the windscreen wiper can be


engaged when the seat is facing forward and a rear
single move (optional) can be engaged when the seat
is facing backward.

EL62757,000016F 1919APR021/1

4-1-4

101702

PN=36

Operators Station

Signal Lights

T152194

UN20SEP02

1Turning signal
2High beam
3Work spot lights
4Battery charging
5Glow light
6Parking brake
7Brake system charge pressure
8Supply pressure of driving hydraulics

EL62757,0000170 1919APR021/1

Left Arm Control Panel

T160562

UN17OCT02

1Steering
2Boom control lever, left
3Front differential lock,1
4Rear differential lock
5Working rpm
6Frame brake release
7 Headboard up
8 Headboard down
9Load space spreading
10Load space narrowing

see section 5-2, Using differential locks


EL62757,0000171 1919APR021/1

4-1-5

101702

PN=37

Operators Station

Right Arm Control Panel

T152196

UN15OCT02

1Driving direction switch


2Boom control lever, right
3High/Low gear
4Boom functions on/off
5For optional equipment use
6Windscreen wiper
7Blade up1
8Blade down
9Seat lock (used when the power in ON)
A, B, C , D, E = Multifunction buttons for TMC use

Operation of the decking blade, see section 11, Decking blade


EL62757,0000172 1919APR021/1

4-1-6

101702

PN=38

Operators Station

T152197

UN05MAR02

Using Boom Control Levers

1. LEFT BOOM LEVER

2. RIGHT BOOM LEVER

+Y

Outer boom out

+Y

Main boom down / Blade down

-Y

Outer boom in

-Y

Main boom up / Blade up

+X

Boom slew clockwise

+X

Grapple rotation clockwise

-X

Boom slew counterclockwise

-X

Grapple rotation
counterclockwise

+Z

Extension boom out

+Z

Grapple open

-Z

Extension boom in

-Z

Grapple press together

EL62757,0000173 1919APR021/1

4-1-7

101702

PN=39

Operators Station

T152198

UN05MAR02

Overhead Panel Switches

1Cab light
2Service light under the cab
3Track light, (opt. eq.)
4Work spot light; front

5Work spot light; left side


6Work spot light; left and
right sides, (opt. eq.)
7Work spot light; right side

8Work spot light; rear


9Work spot light; bottom
corner of cab, (opt.eq.)
10Work spot light; boom,
(opt. eq.)

11Inside air recirculation,


(opt. eq.)

EL62757,0000174 1919APR021/1

4-1-8

101702

PN=40

Operators Station

T152199

1. Buzzer and TMC warning lamp (yellow), give warning


that something is wrong. The TMC display indicates
what is wrong.
2. Fire alarm lamp (red) The fire alarm flashes and the
alarm sounds if fire is registered by the detectors. You
should then trigger the fire extinguisher1 system. See
section 11-4.
3. Control unit for fire extinguisher system.

UN12SEP02

Warning Lamps and Buzzer

in certain markets / optional equipment


EL62757,0000175 1919APR021/1

Preparedness for telephone


A mobile phone or a radiotelephone can be mounted into
the cabin. Preparedness for the phone consists of 12 V
power transmission which can be connected to connection
X17 in the instrument box.
The end of aerial lead (50 W) is situated close to
connection X17 in the instrument box.
The other end of aerial lead (50 W) is on the roof

EL62757,0000176 1919APR021/1

4-1-9

101702

PN=41

Operators Station

Air Conditioner Controls


Instructions for use, see section 11-1.

T152201

UN02OCT02

1Fan speed
2Temperature control
3Inside air recirculation / outside air brought in;
selector switch (For the outside air, turn the
switch clockwise to its extreme position)
4Air vent control
5Max. defrost (eliminates humidity)

EL62757,0000177 1919APR021/1

4-1-10

101702

PN=42

Operators Station

T159289

UN12SEP02

Operators seat

Kab 544, 564, 569

The function is ON when the power is ON.

1. Armrest
The armrest is adjustable i all directions
2. Control Panel
There is a push button on the right side of the
right control panel. Button is used to release or
stop the swing of the seat.

3. Chair module
Most of the controls and swithes are installed to
the Chair2-module.
4. Seat safety switch
Continued on next page

4-1-11

EL62757,000004D 5415SEP021/2
101702

PN=43

Operators Station
Function of the seat safety switch is explained in
group 5-2.

The height could be set in 5 positions


Pull rear handle for adjustment of the rear part
of the seat
Pull from handle for adjustment of the front part
of the seat

5. Weight setting with a mechanical knob (depending


on model)
Turn knob for appropiate weight.
6. Mechanical swing (depending on model)
7. Ventilation
8. Weight setting (depending on model)
Push for harder suspension
Pull for softer suspension
9. Heater
Adjustable
Temperature between +27 to 42 C.
10. Heightriser

11. Backrest angle


Could be adjusted forward of backwards
Pull handle for required position
12. ACS - Air Comfort System (depending on the
model)
a. Thight support
b. Side support, seat
c. Side support, back
d. Trippel lumbar support
More support, press +
Less support, press -

EL62757,000004D 5415SEP022/2

4-1-12

101702

PN=44

Operating the Machine, Control System


TMC
DM

The TMC control system is used for controlling the


boom and the hydrostatic power transmission of the
forwarder, as well as the auxiliary functions related to the
boom and the hydrostatic power transmission.

Hub

Ch
Cr

Tr
When operating the machine in an ordinary manner, the
TMC display is in the run-time mode and it shows you
data that is necessary for usage.

ECUEngine Control Unit


TrTransmission module
HubHub module
DMDisplay module
ChChair module
CrCrane module

UN12SEP02

For the instructions for the adjustment of parameters


related to the operation of the system see the TMC
instruction manual (attached).

T159329

ECU

Placing of TMC modules and Engine Control Unit in 1410D

EL62757,0000179 1921APR021/1

ECU
ECU (Engine Control Unit) is a controlling unit that guides
and controls the functions of the engine.
The flow of information between TMC and ECU goes
through CAN-bus.
ECU adjusts the engine rpms according the instruction
that comes from TMC (from the accelerator or the rpm
switch).

EL62757,000017A 1921APR021/1

5-1-1

101702

PN=45

Operating the Machine, Control System

Alarms
The TMC control system is equipped with a
condition-monitoring system that greatly facilitates the use
and maintenance of the system. The alarms are recorded
in the alarm log.
The alarms are registered in ECU but they can bee
glanced only in TMC.
There are two kind of alarms: active and previous active
(see the TMC manual1 attached).

See alarms -section in TMC manual.


EL62757,000017B 1921APR021/1

5-1-2

101702

PN=46

Operating the machine, Operation


Function of Seat Safety Switch
The activation of the seat safety switch is a prerequisite
for all other functions. What this means is that no function
can be engaged before somebody sits on the seat.
When you are operating the boom controls, articulated
frame steering, or the pedal, you can stand up for a
moment and the operation will not be interrupted, but the
TMC system will sound an alarm together with instructions
displayed on screen.
When you are sending a new control input you have to sit
on the seat.

EL62757,000017C 1921APR021/1

The emergency stopper (1) is in the right side panel. If the


knob is pushed down the engine will stop, all functions of
the machine will terminate, and the parking brake will be
engaged. The emergency stopper can be released by
turning the knob clockwise.

T152202

1Emergency stopper

UN05MAR02

Emergency Stopper

EL62757,000017D 1921APR021/1

5-2-1

101702

PN=47

Operating the machine, Operation

UN05MAR02

Operating the Boom


The boom can be operated if:

T152203

1. The operator sits on the seat.


2. The parking brake has been released
3. The boom has been engaged.
If these conditions have been met, the boom is
automatically engaged when the seat is turned to face the
rear of the machine.

1Machine rpms
2Boom symbol

If the seat faces the front of the machine, the boom can
be activated if necessary by means of the boom switch in
the right-hand-side control panel.
The boom can always be used when the TMC-display
shows the boom symbol. It is also possible to move the
machine while operating the boom.
For instructions for safe and efficient boom operation see
Section 10..

EL62757,000017E 1921APR021/1

5-2-2

101702

PN=48

Operating the machine, Operation

Brakes
The brake system of the machine involves the following:

T152204

UN05MAR02

1. Drive brake
The drive brake functions by means of hydraulic
pressure. The brake is operated with a pedal.
2. Work brake
Also the work brake functions by means of hydraulic
pressure. The brake is automatically engaged always
when the machine stops, and it is disengaged when
the machine is moved again.
When the work brake is engaged, an S symbol is
shown on the TMC display.
3. Parking brake
The parking brake is operated with the switch (1)
located in the side panel. The warning light of the
switch is on when the brake is engaged.
IMPORTANT: It is important to engage the brake
always when you leave the cab.
1Switch, park brake

The engagement of the parking brake is


spring-actuated, and the brake is released by means of
hydraulic pressure.
If there is no hydraulic pressure the parking brake
stays engaged. When the parking brake is engaged,
an P symbol is shown on the TMC display.
NOTE: Dont use the brake pedal while the work/parking
brake is engaged.

EL62757,000017F 1921APR021/1

5-2-3

101702

PN=49

Operating the machine, Operation

Frame Brake
The frame brake is a means to lock the horizontal hinge
of the machine. The frame brake is always automatically
engaged when the machine stops, and the brake is
disengaged when the machine starts moving again. The
brake can also be entirely disengaged through a key (1).
IMPORTANT: Bear in mind that the frame brake is
always open when loading during
driving.

T160561

UN16OCT02

1Switch, frame brake

EL62757,0000180 1921APR021/1

5-2-4

101702

PN=50

Operating the machine, Operation

Steering
The machine is steered by means of a ministick (1) in the
left control panel. If the stick is turned in the desired
direction the machine will turn in the same direction. This
is also the case when the seat faces the rear of the
machine.
The moving speed of the steering cylinders is slowed
down by the end damping function of the steering system
at both extreme turning positions when the limit switch is
activated.
If the machine is equipped with hydraulic steering stick
(optional equipment) the ministick steering can be
disengaged through the switch (2) on the side instrument
panel.
NOTE: On certain markets the use of ministick steering is
not possible when driving with the high gear.
The hydraulic steering stick (3) is located in the right side
panel. When the stick is pushed forward the machine will
turn to the left. When the stick is pulled backward the
machine will turn to the right.
In some machines, there is a back-up alarm which goes
on when reversing.

T160564

UN16OCT02

1Ministick
2Switch, ministick operation
3Hydraulic steering stick

EL62757,0000181 1921APR021/1

5-2-5

101702

PN=51

Operating the machine, Operation

High/Low Gear and Rear-Wheel Drive


The machine is equipped with mechanical high/low gear
and with an adjustable speed range (%). These can be
engaged through the selector switch (2) in the right control
panel.
Shifting the high/low gear is only possible when the
machine stands still, the work brake has been engaged
(and the switch (1) for driving direction is in the center
position).
The high gear will be replaced by the low gear when the
seat is turned to face to rear of the machine.
When shifting the pump receives short pulses (forward
and backward), which is to make sure that the gear has
been engaged.
Wait five seconds. If the high gear cannot be engaged,
the low gear is on.
NOTE: If the gear (high or low) is not properly engaged
(the gear symbol is not visible in the display), the
work brakes will remain engaged on and the
machine will not move.
If the driving direction has been selected and the switch
(2) is pressed, the system enters the adjustable speed
range (snail) (%) or leaves it.
When operating with the low gear on, the rear-wheel drive
is always engaged. If the high gear is selected the
rear-wheel drive is automatically disengaged.
If necessary, the rear-wheel drive can be engaged also
when the high gear is on. This is done with a switch (3)
on the side panel.
NOTE: Use low gear when the machine is loaded

T152207

UN05MAR02

1Driving direction
2Switch, adjustable speed range
3Rear-wheel drive engagement

EL62757,0000182 1921APR021/1

5-2-6

101702

PN=52

Operating the machine, Operation

Using the Differential Lock-Up


The switches (1 and 2) for the lock-up of the front axle
and rear axle differential are located on the left-hand-side
control panel.
NOTE: The locks can only be engaged when the machine
stands still.

T160563

IMPORTANT: Exercise great caution when using the


locks, and keep them engaged for short
periods only. When the differential is
locked, avoid turning the machine
sharply.

UN16OCT02

The switch has to be held down until the machine


moves. They will stay on until the machine is brought
to a halt again. When the locks are engaged a lock
symbol is flashing on the TMC display.
The letter F in the upper left corner of the symbol
indicates that the front differential lock is engaged.
The letter R in the upper right corner of the symbol
indicates that the rear differential lock is engaged.

1Switch, differential lock-up


2Switch, differential lock-up

A flashing symbol in the TMC display indicates that the differential


locks are engaged.

EL62757,0000183 1921APR021/1

Operating the Decking Blade (Optional


Equipment)
See ssection 11-4. Equipment, Decking Blade.
EL62757,0000184 1921APR021/1

Operating the Clambunk


See section 11-4. Equipment, Clambunk.

EL62757,0000185 1921APR021/1

5-2-7

101702

PN=53

Lifting and Lowering the Cab


How to Lift the Cab
IMPORTANT: See to it that nobody comes too close
to the machine when you lift or lower
the cab.

UN05MAR02

1. Remove the cab attaching bolts (1).


There is one bolt for each cab corner
2. Turn the up/down valve (2) clockwise until it stops in
the extreme position.
3. Pump up the cab by means of the lever (3) until it does
not rise anymore.
4. Secure the cab with the lock bar (4) before you start
working under the cab

T152216

IMPORTANT: Do not lift the cab if the machine is not


standing on level ground. Do not drive
the machine if the cab is in the upper
position. You can run the engine while
the cab is up (if you are adjusting the
pressures, for instance).
1Attaching bolts
2Up/down valve
3Pumping lever

EL62757,0000187 1921APR021/1

5-3-1

101702

PN=54

Lifting and Lowering the Cab

T152217

UN05MAR02

How to Lower the Cab

4Lock bar

1.
2.
3.
4.

Lower the lock bars (4) of the cab


Turn the up/down valve (2) counterclockwise
Pump the cab down by means of the lever
Fit the cab attaching bolts again.

Specification
Cab attaching boltsTorque ................................ 100 Nm (73.7 lbt-ft)

EL62757,0000188 1921APR021/1

5-3-2

101702

PN=55

Transportation of the Machine


Use hold-down straps
Make sure that the tracks, fuel container, and other loose
items on the load area of the machine are properly
secured for the transport (use heavy-duty hold-down
straps, for instance).

EL62757,0000189 1921APR021/1

Positioning
When positioning the forwarder onto the trailer, ensure
that the machine is laterally as well centered as possible.
Similarly, when positioning the machine and the boom
bear in mind the maximum axle loads permitted for the
truck or trailer as well as the maximum width and height.
If necessary, the values must be checked by measuring
before transporting.

EL62757,000018A 1921APR021/1

Minilevers
For the transport minilevers are clamped to the extreme
position with rubber loops situated on outer side of control
panels.

EL62757,000018B 1921APR021/1

5-4-1

101702

PN=56

Transportation of the Machine

Chains
Ensure that the machine or boom will not move during the
transport. The machine must be secured by at least two
chains (you can use a ratchet tensioner, for example). It is
good to utilize any support provided by, for instance, the
fenders of the truck or trailer if the tires of the machine
can be positioned against these. The chains secured to
the front frame and Rear frame must provide longitudinal
support for the machine both fore and aft, as well as
lateral support at suitable angles. Make sure that the
chains are not twisted after tightening to prevent the
tensioners from coming loose during the transport. In
addition, when securing the chains make sure that they
will not damage the forwarder. Finally, fit clearance lights
as stipulated by local laws.
NOTE: When travelling on public roads, all regulatory
requirements must be met in full.

EL62757,000018C 1921APR021/1

5-4-2

101702

PN=57

Starting and Turning Off the Engine


Before Starting the Engine for the First Time
in a Working Day

Turn on the main switch (the switch is located on the


left-hand side, under the cab).
Check the fire extinguishing system. See separate
instructions by the manufacturer (optional equipment).
Check the fuel level.
Remove the lock pin of the emergency exit.

T152211

1Main switch

UN05MAR02

Take an overall look at the machine (joints, hoses, etc.


Check the engine oil level.
Check the coolant level.
Check the hydraulic oil level.

EL62757,000018D 1921APR021/1

5-5-1

101702

PN=58

Starting and Turning Off the Engine

Normal Start

UN07OCT02

NOTE: Make sure that there are no people within the


danger zone around the forwarder.

T160198

1. Engage the parking brake (1) (the forwarder will start


only if the parking brake is on).
2. Check that the switch for driving direction (3) is in the
middle position and the emergency stopper (2) in the
upper position.
IMPORTANT: Do not start the engine when the
preheater is on.

Allow the starter motor to cool down for


appr.2 minutes. After that, try again.
Should the engine still refuse to start
after four tries, find out what is wrong.

T160197

IMPORTANT: Dont operate the starting motor longer


than 30 seconds at the time. The starter
may overheat.

UN16OCT02

3. Make sure that working RPMs (4) is disengaged.


4. Turn the start key to the I position. Check that the
warning lights function properly.
5. Wait until you hear the TMC signal and the basic menu
appears in the display module.
6. Turn the ignition key to start (position START).
7. Release the ignition key immediately when the engine
fires.
8. See that the oil pressure signal light disappears from
the TMC display.

UN05MAR02

NOTE: The engine and starter motor must be at a


complete standstill before you try to start again.

T152192

9. Check that all gauges function correctly.

EL62757,000018E 1921APR021/1

5-5-2

101702

PN=59

Starting and Turning Off the Engine

Cold engine starting


CAUTION: Never use a liquid starting aid to
start the engine. The use with the pre-heat
device will cause an explosion in the intake
manifold.
NOTE: When the temperature drops below 5C we
strongly recommend that you use the pre-heating
(optional equipment) of the engine coolant 1/2 ...
1 hour before starting the engine.
Using correct grade oil is critical to achieving adequate
cold weather cranking speed!
1. When the temperature is below 0 C the engine is
basically started as described above but:
2. Use the pre-heating of the engine intake air. Turn the
ignition key to position II. Use the glow operation for 5
... 15 seconds before starting, depending on the
outside temperature.
3. Turn the ignition key to position III (start). Press the
accelerator pedal all the way down. Release the key
when the engine fires and decrease the throttle to
prevent the engine speed from exceeding 1000 rpm.
4. If the engine fails to fire repeat the glow procedure
before attempting to start again.
5. Once the engine has started you may, where
necessary, release the ignition key to position II and
keep it there for around 10 seconds. In this case the
load on the working hydraulic pump is relieved making
it easier for the engine to run.
NOTE: (Grid heater) glowing discharges the batteries a
great deal. If the indicator light for glowing stays
on after glowing, turn the master disconnect
switch off.

EL62757,000005C 1915OCT021/1

5-5-3

101702

PN=60

Starting and Turning Off the Engine

After starting
1. After starting, operate the engine for 1 ... 2 minutes at
appr. 1200 rpm before full loads are applied.
Make the time longer if the outside temperature is
beyond the freezing point.
2. Therefore, do not operate the engine at speeds beyond
1400 rpm before the hydraulic oil has warmed up.
When the hydraulic oil is still cold, too high an engine
speed results, among other things, in excessive
pressures in the pumps and motors. This may inflict
damage on shaft packings etc.
NOTE: NOTE! Avoid prolonged idling periods (more than
5 minutes). Carbon deposits will appear in the
engine and the lubrication of various components
will not be efficient.
IMPORTANT: Never turn off the main switch while the
engine is running (with the exception of
a potential emergency).

EL62757,000018F 1921APR021/1

5-5-4

101702

PN=61

Starting and Turning Off the Engine

A normal operation of the engine


Observe engine coolant temperature and engine oil
pressure. Temperatures and pressures will vary between
engines and with changing operating conditions,
temperatures, and loads.
NOTE: Normal engine coolant operating temperature
range is 82...94 C (179...201F) If coolant
temperature rises above 105 C (221 F), TMC
will give an alarm (alarm 38).
Unless temperature drops quickly, stop all
operations and let the engine idle..
Determine cause before resuming operation
NOTE: When coolant temperature is excessive (above
115 C (239 F) engine will reduce power (40 %)
automatically.
NOTE: Contact your local Timberjack service for more
information.
Operate the engine under a lighter load and at slower
than normal speed for first 15 minutes after start-up. DO
NOT run engine at slow idle.
Stop engine immediately if there are any signs of part
failure. Symptoms that may be early signs of engine
problems are:

Sudden drop in oil pressure


Abnormal coolant temperatures
Unusual noise or vibration
Sudden loss of power
Excessive black exhaust
Excessive fuel consumption
Excessive oil consumption
Fluid leaks

EL62757,0000190 1921APR021/1

5-5-5

101702

PN=62

Starting and Turning Off the Engine

Turning off the engine


1. First, make sure that the switch for driving direction is
in the middle position.
2. Ensure that the parking brake is engaged.
3. Let the engine idle for appr. 30 seconds to even out
the temperature in the turbocharger. If you are about to
stop the engine immediately after operating with full
loads, you should even out the temperatures in the
main components of the engine by letting the engine
idle for 2 ... 4 minutes before switching off.
4. Make sure that the boom will not move freely once the
engine has been turned off
5. Turn the start key to STOP-position

EL62757,0000191 1921APR021/1

5-5-6

101702

PN=63

Driving the Machine


T152212 UN05MAR02

Off-Road Driving
During off-road operation the low gear is engaged
(all-wheel-drive mode is on).
NOTE: The stairs must be in the upper position when the
driving direction is selected, or the machine will
not start moving.
Operating under difficult conditions it is recommended to
switch on the adjustable speed range (%).

EL62757,0000192 1921APR021/3
T152213 UN05MAR02

Off-Road Driving with the Working rpm


1. Engage the low gear (the driving direction switch has
to be in neutral position).
2. Select the driving direction with the direction switch,
which will make the diesel engine working rpm turn to
constant speed (see TMC).
3. Press the accelerator pedal. This will automatically
disengage the work brake and the machine will start
moving.
4. The speed of the machine is controlled with the drive
pedal. As soon as the pedal is pressed past the
constant speed position, the speed of the diesel engine
starts also picking up in relation to the position of the
pedal

Continued on next page

5-6-1

EL62757,0000192 1921APR022/3

101702

PN=64

Driving the Machine

T152214

UN05MAR02

5. If the switch of the high/low gear is pressed after the


driving direction has been selected, the system will
move to the adjustable speed range (%). What will be
shown as a speed range symbol on the TMC display is
a snail underneath of which can be seen the driving
speed setting. Speed can be adjusted through the Z
movement of the right ministick.
6. The machine is steered by means of the ministick of
the left control panel.
Off-Road Driving with the Working rpm off
If you do not want to use the working rpm in off-road
driving, the operation is similar to what has been
described above, but:
Regulating the machine speed with the drive pedal has
a direct impact on the speed of the diesel engine
You cannot operate the boom.

EL62757,0000192 1921APR023/3

Driving on Road
The high gear can be used for driving on road. This is
when the rear-wheel drive is disengaged.
However, it is possible to engage the rear-wheel drive
with a separate switch.
NOTE: The high gear cannot be engaged if the seat is
facing the back of the machine.
1. Disengage working rpm.

Continued on next page

5-6-2

EL62757,0000193 1921APR021/3

101702

PN=65

Driving the Machine


T152215 UN05MAR02

2. Engage the high gear (the driving direction switch has


to be in neutral position).
3. Select the driving direction with the direction switch
4. Press the pedal, which will automatically disengage the
work brake. The machine will start moving.
5. The speed of the machine is regulated by means of
the accelerator pedal. This will simultaneously adjust
the diesel engine speed and the gear ratio of the
hydrostatic system.

EL62757,0000193 1921APR022/3

T152214

NOTE: There are countries where the use of the ministick


for driving on public roads (with the high gear
engaged) is forbidden (Germany) or blocked
(Sweden) because of road traffic regulations

UN05MAR02

6. The adjustable speed range (%) can be used as when


driving off-road.
7. When driving on road the machine is steered with
The ministick
A hydraulic stick (optional equipment)

8. Before you embark on driving on public roads,


remember the following:
Install the rear lights and front turn indicators and
check their function.
Adjust the side-view mirrors

EL62757,0000193 1921APR023/3

5-6-3

101702

PN=66

Towing the Machine


Towing
As a result of a machine failure it may be necessary to
tow the machine when it comes to a halt on a public road
or if you have to transfer the machine to proper repair
facilities.
The machine cannot be towed unless some or all of the
following actions are taken:
1.
2.
3.
4.

Release
Release
Release
Release

the
the
the
the

parking brake.
driving power transmission system
work brake.
steering.

EL62757,0000194 1921APR021/5

UN18JUL01

CAUTION: Once the above steps have been


taken, the machine cannot be properly
controlled anymore. Therefore, it is of utmost
importance to ensure that nobody is placed in
jeopardy during the towing process or during
installation work. Make sure that no outsider
enters the risk zone around the machine.

T144065

NOTE: We strongly recommend you use a rigid towing


linkage for towing. Make sure that the machine is
adequately supported before anybody embarks on
repairing the machine.
How to Release the Parking Brake

T142813

UN13JUN01

Open the underpan.


Remove the cover at the end of the brake cylinder.
Screw down the release screw (under the cover) to
release the brake.
Repeat the procedure for each brake cylinder.
After towing, the release screws must be removed.
There are four brake cylinders in all. Two of these are for
the front axle and two for the rear axle.
1Brake cylinders
2Brake cylinder cover
3Release screw of the brakes

Continued on next page

5-7-1

EL62757,0000194 1921APR022/5
101702

PN=67

Towing the Machine


How to Disengage the Power Transmission System
(bypass function)

UN16OCT02

Lift up the cabin


Turn the screw (1)) of shock pressure valves (209),
(211) of the drive pump to such an extent that the valve
cartridge is released and free oil circulation is possible.

T160481

NOTE: When towing short distances (< 20 m /65 ft)),


release the power transmission system. Otherwise
release the drive shafts.
Drive pump, Drive pressure relief valves

Once towing is over the valves need to be closed again.


Torque to 200 10 Nm (148 7,4 lb-ft)

T156362

UN

T156362

EL62757,0000194 1921APR023/5

How to Release the Work Brake

UN08OCT02

Lift up the cabin.


Disconnect the solenoid valve Y41W coupler of the
work brake

T159878

NOTE: Re-connect the connector after towing

Continued on next page

5-7-2

EL62757,0000194 1921APR024/5

101702

PN=68

Towing the Machine


Disconnecting the steering cylinders
The steering valve block Y66 is located in the loader
valve.
Open the relief valve plug and remove the spring (1)
and cartridge (2)
Install the plug with gasket and tighten.
After towing, install the spring and cartridge

T152221

UN05MAR02

NOTE: Secure all loose parts and the valve housing


against dirt

EL62757,0000194 1921APR025/5

5-7-3

101702

PN=69

Towing the Machine

Stowing a Disabled Boom


If the engine is stopped with the boom in an extended
position it may be necessary to manually retract and stow
the boom before the Forwarder can be towed.
The boom hydraulics are released by by-passing the port
reliefs in the Loader Control Valve and the boom is
maneuvered using a second Forwarder or a suitable lifting
device.
CAUTION: If the boom is stopped in a raised
position it must be completely supported in that
position before the hydraulics are released.
If the boom load is not completely disabled, oil
might be pressurized and the oil flow is heavy
at the beginning.
Failure to follow proper safety precautions may
lead to personal injury or damage to the
machine.
Securely block the wheels. Support the boom using blocks
or a second machine. Each boom function is controlled
from its spool section on the Crane valve. Each spool
must be by-passed in order to move the boom in that
direction.

Continued on next page

5-7-4

EL62757,0000195 1921APR021/2

101702

PN=70

Towing the Machine


At each spool section:
Remove the pressure relief valves. Open the relief valve
plug and remove the spring (1) and cartridge (2).
Replace the valves with by-pass plugs. Install the plug
with gasket and tighten.
Maneuver the boom using a second forwarder boom or
suitable lifting device.
Replace the valves.
NOTE: Do not mix the valves after they have been
removed. Replace the valves as originally
installed.

T152221

Support the boom in position carefully. There must not


be any pressure in a cylinder when a relief valve plug is
opened.
By-pass the sixth spool section.
Lift or lower the main boom using a suitable lifting
device
Replace the pressure relief valves

UN05MAR02

For example, to raise or lower the main boom:

NOTE: Secure all loose parts and the valve housing


against dirt.

EL62757,0000195 1921APR022/2

5-7-5

101702

PN=71

Maintenance - Machine
Service, General
This maintenance section contains a number of servicing
and checking procedures that are performed regularly.
Some of these are carried out by the operator.
When it comes to maintenance and repairs that require
special skills and tools, contact the nearest authorized
repair shop.
Any defect or shortcoming that compromises the
operational safety must be remedied immediately.
If the aim is a reliable and safe operation, the most
important (and the most inexpensive) contribution is
regular machine checks and maintenance.
Maintenance periods have been categorized as follows:

Daily maintenance or after every ten running hours


Weekly maintenance or after every fifty running hours
Maintenance after every 250 running hours.
Maintenance after every 500 running hours
Maintenance after every 1000 running hours.
Maintenance after every 2000 running hours

60 1922APR021/1

6-0-1

101702

PN=72

Maintenance - Machine

Servicing Safety Precautions


Carefully study the safety instructions in section 3-4
before starting maintenance work.
Make sure the machine is level and cannot move
(brakes applied) and wheels chocked if necessary
Keep clear of the raised boom
Make sure that no outsiders come close to the machine
during servicing or repairs
The operator and serviceman are responsible for safety
on and around the machine.
IMPORTANT: The operator, mechanic, and foreman
must be familiar with the safety rules
and regulations provided in this service
manual and in the decals of the
machine, as well as with those related
to national road traffic and occupational
safety. All safety rules and regulations
in effect pertaining to the machine and
workplace must be obeyed.
CAUTION: The use of engine hoods and belly
pans has been facilitated by means of lift
supports. Should these supports become
defective, the cover may unexpectedly come
down. Do not go under these parts when
lifting/lowering them or before they are properly
secured in the uppermost position.

EL62757,0000146 1918APR021/1

6-0-2

101702

PN=73

Maintenance - Machine

General Maintenance Instructions


When the machine is new, check all bolted joints daily,
especially those between the boom and the frame and
those between the axles and the frame.
Keep tightening until the bolts maintain their tightness.
Check the hose joints, too. During ordinary operation, the
joints should be frequently checked in addition to
scheduled maintenance.
Bolt torque values
JOINT

QTY

SIZE

GRADE

TORQUE
Nm

Wheel bolts

550
( 405 lb -f t)

Cab fastenings

100
( 74 l b -f t )

Cab base fastenings

170
( 125 lb -f t)

Joints between axles and frame


Horizontal bolts

950
(700 lb -f t)

Vertical bolts

950
( 700 lb -f t)
BOOM

Fastening

M24x100

12.9

1120
( 826 lb -f t)

Base, support plate

M10x25

8.8

49
( 36 lb -f t)

M12x40

12.9

137
( 101 lb -f t)

12.9

110
( 81 l b -f t )

Slewing cylinder

4x12

M12x70

Main boom cylinder

M65x2

1890
( 1394 lb -f t)

Outer boom cylinder

M65x2

1890
( 1394 lb -f t)

M40x2

440
( 325 lb -f t)

M20x1.5

200
(147,5 lb -f t)

Extension boom cylinder

EL62757,0000147 1918APR021/1

6-0-3

101702

PN=74

Maintenance - Machine

Welding Instructions
See welding instructions from Section 8-1.

EL62757,0000148 1918APR021/1

Cleaning the Cab windows


When washing the cab windows, use mild detergent only
that is environmentally friendly. Use lots of water for
rinsing. Soft towels are recommended for wiping and
drying the windows. Always when you use the wipers,
operate the washer, too.
NOTE: Never clean the windows with gasoline or any
other solvents.
NOTE: Do not clear the windows of ice and snow with a
sharp scraper because the safety glass made of
polycarbonate is easily scratched.

EL62757,0000149 1918APR021/1

6-0-4

101702

PN=75

Maintenance - Machine

Tires
Tire pressures
Check tire pressures visually every day. If in doubt, use a
pressure gauge to check the pressure.
Tire pressures
8-wheel
FRONT

PRESSURE

REAR

PRESSURE

710/45-26.5 20PR
Nokian

300..350 kpa
(43,5...50,8 psi)

710/45-26.5 20PR
Nokian

500... 550
72,5...79,8 psi)

800/40-26.5 20PR
Nokian

300..350
(43,5...50,8 psi)

800/40-26.5 20PR
Nokian

450... 500
65,3...72,5 psi)

700/50-26.5 20PR
Nokian

300...350
(43,5...50,8 psi)

700/50-26.5 20PR
Nokian

500...550
72,5...79,8 psi)

220...230
31,9...33,4 psi)

710/45-26.5 20PR

500...550
72,5...79,8 psi)

800/40-26.5 20PR

450...500
65,3...72,5 psi)

700/50-26.5 20PR
Nokian

500...550
72,5...79,8 psi)

6-wheel
700/55-34 14PR
Nokian

NOTE: When operating with heavy loads in harsh, rugged


terrain, it is good to use maximum tire pressures.
NOTE: When operating with heavy loads in harsh, rugged
terrain, it is good to use maximum tire pressures.
Running a tire with too low pressure can lead to
immediate tire failure.
NOTE: Too low pressure can lead to sidewall damage
and rim chafing, possible even to rim slippage.
NOTE: Min.pressures must be found in wheels even in
cold winter days (cold weather reduces the tire
pressures about 10 kPa / 10C).

EL62757,000014A 1918APR021/1

6-0-5

101702

PN=76

Maintenance - Machine

Changing Wheels
Park the machine on firm, level and smooth ground.
Position the jack underneath the flat part of the axle or
bogie casing, see figures. Make sure neither the machine
nor the jack can move during the lift.
It is especially important to retighten the wheel nuts if the
rims or wheel axle flanges have been painted recently, or
the machine is new.
Periodically see to it that there are no dents or cuts in the
rims. Replace badly damaged rims.
CAUTION: Always apply the parking brake
before leaving the cab.
Item

Measurement

Specification

Wheel nuts

Torque

550 Nm (405 lb-ft).

EL62757,000014B 1918APR021/1

6-0-6

101702

PN=77

Maintenance - Machine

Anti slips

T152223

UN05MAR02

Ensure that the anti-slips are in good condition.


Turn them the right way.
Lay the anti-slip out in front of the wheel, see fig
Tie a 1.5 metre (5 ft) long piece of rope, or something
similar, to the anti-slip and place it over the tire as
illustrated
Carefully move the machine. If needed stop the
machine and adjust the anti-slip. Continue until the ends
of the anti-slip lie near each other, and connect the
ends together with the coupling links.

T152224

UN02MAY02

Choose fairly smooth ground when fitting the anti-slip.

EL62757,000014C 1918APR021/1

6-0-7

101702

PN=78

Maintenance - Machine

Fitting bogie tracks


Useful tool: A chain or cable about 5,5 m (18 ft) long.

UN05MAR02

1. Lay the bogie track on the ground with track plates as


shown in fig. 1.
2. Secure the chain or cable to the first track plate as
shown in figs. 1 and 2.
3. Then lay the chain over both bogie wheels, and wedge
it under the front bogie wheel as shown in figs. 1 and
2.
4. Drive forward slowly, watching the chain all the time to
make sure it stays in the centre of the wheel and does
not slide off, see fig. 3.
5. Drive forward until one track plate lies free behind the
rear bogie wheel, see fig 4.
6. Fit the chains, fig. 5 and fig. 6, to the links between the
second and third track links on each side of the joint.
Make sure the chains are the same length on both
sides. Make sure you tighten both sides equally,
otherwise the track will be unbalanced.

T152225

NOTE: Do not over-tighten the tracks.

Continued on next page

6-0-8

EL62757,000014D 1918APR021/2

101702

PN=79

Maintenance - Machine
7. Reverse the machine carefully until the joint is midway
between the wheels. The track is now stretched and
the chain 1 in the middle should be slack. If the track
needs to be tightened more, shorten these, reverse
and fit a suitable track lock, see fig. 7.
CAUTION: Make sure no-one is nearby when
you tighten the tracks.
8. Fit the track lock with the loop on the inside against the
tire.
9. Then drive forward until the tensioning chains are
slack. Remove them.
10. Drive the machine forward and back a couple of
times. Check the track tension as shown in fig. 8.
Dimension A should be 50...100 mm (2...4 in).
Tip! If the tensioning chains do not pull the track together
enough: Fit an extra chain between the ends and then
drive forward again. This will now hold the track together
so that the tensioning chains can be tightened more, see
fig. 5.

T152227

UN05MAR02

Positioning of track lock shown in fig. 9. (Nut must face


tire).

EL62757,000014D 1918APR022/2

6-0-9

101702

PN=80

Maintenance - Machine

Recommended Lubricants and Fluids


General instructions for checking oil levels and fill-ups:
The machine must stand on level ground when you
check any of the oil levels
Check the oil level in the morning for that is when the
oil is cold and it has seeped down into the lower parts
of the component.
Renew the oil while the engine is warm. Thus it is
easier to remove the old oil
To even the pressure at the oil space, open a plug
located above the oil level (e.g. filling plug) before
opening the drain plug.
Avoid direct contact with oil, particularly heated oil.
NOTE: Oil on the skin should be washed off immediately.
Basic rules when changing oil and filters, checking
hydraulic pressures, repairing etc.:
Clean thoroughly the area around the components to be
opened to ensure that no dirt enters the system.
Keep the hydraulic hoses plugged as well as the filters
in their packs until they are installed to the machine.
Plug removed components
Ensure that all parts are clean before assembly

EL62757,000014E 1918APR021/1

6-0-10

101702

PN=81

Maintenance - Machine

Capacities
Fluids and lubricants

Liters

Gallons

25

6.6

Coolant

27.5

7.3

High/low gear

4.5

1.2

Differential; front - 6-wheeled

27

7.1

Differential; front - 8-wheeled

12

3.1

Engine oil + filter

Differential; rear

12

3.1

2x4

2 x 1.05

Bogie housing/each

52

13.7

Boom slew housing

9.5

2.5

Hydraulic fluid - max. level

150

39.6

Hub gearings - 6-wheeled

Hydraulic fluid - min. level

79

20.9

Fuel tank

165

43.5

Windshield washer fluid tank

2x5

2x1.3

Cab lift

0.8

0.2

Driving brake oil level (ATF oil)

0.5

0.1

The filling capacities given are guidelines only. Having


changed the oil it is always necessary to check the final
correct oil level through the check opening or by means of
the oil dipstick.

EL62757,000014F 1918APR021/2

The drain hoses are located on the underpan under the


engine. The hose clamps have been numbered:

T152229

UN05MAR02

1Hydraulic oil; hydraulic tank


2The drainage of the hydraulic suction hose.
3Engine oil; draining
4Fuel tank; draining

EL62757,000014F 1918APR022/2

6-0-11

101702

PN=82

Maintenance - Machine

Diesel Fuel
Capacity

Fuel tank

165 l
(43.6 gal)

Recommended quality requirements for diesel fuel:


1. Cetane number of 40 minimum. Cetane number
greater than 50 is preferred, especially for
temperatures below -20C (-4 F).
2. Sulfur content:
Sulfur content should not exceed 0.5%. Sulfur
content less than 0.05% is preferred.
The period for changing the engine oil must be
reduced by half if diesel fuel containing more than
0.5% sulphur is used.
Do not use diesel fuel with sulfur content greater
than 1.0%.
Bio-diesel fuels may be used ONLY if the fuel properties
meet DIN 51606 or equivalent specification.
When operating in cold circumstances use fuel that is
suitable for winter operation and has a cloud point
appearing at a lower level than the operating
temperatures.
Avoid condensation by keeping the fuel tank full. Alcohol
may not be added to the fuel, even a small amount could
damage the fuel system.
IMPORTANT: Use only pure fuel. DO NOT mix used
engine oil or any other type of lubricant
with diesel fuel.

EL62757,0000151 1918APR021/1

6-0-12

101702

PN=83

Maintenance - Machine

Engine Oil
25 l
(6.6 gal)

NOTE: Change the oil after the first 250 operating hours.
After that a normal oil change every 500 hours.

SAE 5W-40

SAE 5W-30

122F

40C

104F

30C

86F

20C

68F

10C

50F

0C

32F

-10C

14F

-20C

-4F

-30C

-22F

-40C

-40F

TS1668

2. OIL CHANGE EVERY 500 HOURS


John Deere preferes following oils:
John Deere PLUS-50
ACEA E4
ACEA E5

SAE 10W-40

1. ENGINE BREAK-IN OIL


New engines are filled at the factory with John Deere
ENGINE BREAK-IN OIL.
Within the first 250 operating hours, use:
John Deere ENGINE BREAK-IN OIL :
or oil that meets the requirements of API CE or
ACEA E1

SAE 15W-40

NOTE: Consult your Timberjack service for use and


availability of John Deere engine oils.

50C

UN05OCT01

Engine

SAE 30

Capacity

3. OIL CHANGE EVERY 250 HOURS


when using following oil qualities:
ACEA E3
API CH-4
API CI-4
if diesel fuel with sulfur content greater than 0.5% is
used
NOTE: Always use the original oil filter at oil changes.
Multi-viscocity oils are preferred.
Use oil viscosity based on the expected air temperature
range during the period between oil changes.
IMPORTANT: It is forbidden to use other oils (except
during the break-in period).

PLUS-50 is a registered trademark of Deere & Company.

EL62757,0000152 1918APR021/1

6-0-13

101702

PN=84

Maintenance - Machine

Coolant
Capacity

Engine cooling
system

27,5 l
(7,3 gal)

The engine cooling system is filled to provide year-round


protection against corrosion and cylinder liner pitting, and
winter freeze protection to -37C (-34F).
Use a coolant mixture consisting of 50 percent of water
and 50 percent of antifreeze in the system all year round.
The antifreeze must consist of ethylene glycol or
propylene glycol and that complies with grade ASTM4985
or ASTM5345.
Coolant chart
Antifreeze, in percents

Freezing point of volume, C

40

-24 (-11 F)

50

-37 (-34 F)

The anti-freezing ability will be reduced if the content of


glycol is greater than 60%.
If it is necessary to add coolant to the system make sure
that the new coolant is similar to the original. Allow the
engine to cool down before adding new coolant.
Check the coolant concentration before the ambient
temperature drops below 0C (32F).

EL62757,0000153 1918APR021/1

6-0-14

101702

PN=85

Maintenance - Machine

Hydraulic oil
Capacity

Hydraulic tank

min. 79 l (20.9 gal)


max. 150 l (39.6 gal)

If you use mineral oil:


Comply with SH 68 (SMR classification) in summer.
Comply with SHS 32 (SMR classification) in winter.
Comply with SHS 46 (SMR classification) for year-round usage.

If you use synthetic biodegradeable oil:


Neste Biohydrauli SE 46

IMPORTANT: Do not mix different types of oils as this


will cause degradation of their
properties when mixed. When in doubt,
contact the manufacturer. Abuse will
result in the revocation of the warranty.

EL62757,0000155 1918APR021/1

6-0-15

101702

PN=86

Maintenance - Machine

Gear oil
Capacity

High/low gear

4.5 l
(1.2 gal)

Differentials, rear

12 l
(3.2 gal)

Differentials, front, 8-wheel

12 l
(3.2 gal)

Differentials, front, 6-wheel

27 l
(7.1 gal)

Hub gears, 6-wheel

2x4l
2 x 1.05 gal)

Bogie casings

52 l
(13.7 gal)

Boom slew housing

9.5 l
(2.5gal)

Use hypoid oil that complies with the classification: API


GL-5 or MIL-L-2105 B or D.
The following viscosity categories can be used:

SAE
SAE
SAE
SAE

90
85W/90
80W/90
75W/90

EL62757,0000157 1918APR021/1

Brake fluid
Capacity

Brake fluid tank

appr.0.5 l
(0.1 gal)

Use ATF-oil.

EL62757,0000156 1918APR021/1

6-0-16

101702

PN=87

Maintenance - Machine

Cab lift pump


Capacity

Cab lift pump

0.8 l
(0.2 gal)

Factory has filled the pump with Biohydr. 15 oil.


NOTE: Dont mix oils together.
If the pump is emptied, it can also be filled with ATF-oil.

EL62757,0000158 1918APR021/1

Grease
IMPORTANT: Contact Timberjack service about
availability of John Deere greases.
Apply lithium grease, some examples:

Neste Yleisrasva EP 2
Esso Beacon EP2
Shell Retinax LX Lithium
Mobilgrease
Castrol LM Grease
Texaco Molytex Grease EP 2

NOTE: Use enough grease!


NOTE: Dont mix different type of grease together.

EL62757,0000154 1918APR021/1

6-0-17

101702

PN=88

Maintenance - Periodic
Maintenance intervals
Service the machine according to following maintenance
intervals:
NOTE: Bear in mind that, when servicing the machine,
the maintenance that comes after every 2000
running hours, for example, also includes the daily
maintenance as well as the maintenance that
comes after every 50, 250, 500 and 1000 running
hours.
Maintenance - Every 10 hours or Daily
Check the hydraulic oil level

Check the radiator grille cleanness

Check the engine oil level

Check the air filter

Check pre-fuel filter

Check the tires for air pressure and overall shape.

Check engine coolant level.

Fill up the fuel tank

Check the windshield washer fluid level

Maintain the Boom, see Section 10-2

Check the driving brake oil level


Maintenance - Every 50 hours or Weekly
Grease the center hinge bearings and steering cylinder bearings.
Grease the decking blade

Check the air conditioner, see


Check the fire extinguisher system, see .
Maintain the Boom, see Section 10-3

Maintenance - Every 250 hours


Clean the machine

Grease Bogie Bearings

Check the high/low gear oil level.

Check Wheel Nut Torque

Check Differential Oil Level

Check the cabine air filters

Check Single Axle Wheel Ends ( Hub gear) Oil Level.

Check the air conditioner, see section 11-1

Check Bogie Housings Oil Level

Maintain the Boom, see Section 10-4


Maintenance - Every 500 hours

Change the engine oil and filter

Remove sediment and water from the fuel tanks

Change fuel filters

Checking cooling system

Clean crankcase vent tube

Renew the pressure filter of the drive hydraulic system

Check the air intake system

Check the batteries for charge

Checking belt wear

Grease the driveshafts

Check engine speeds


Control engine grounding

Continued on next page

6-1-1

61 1921JAN021/2

101702

PN=89

Maintenance - Periodic
Maintenance - Every 1000 hours
Renew the hydraulic oil.

Check and tighten the screw and bolt connections

Replace the hydraulic return filter

Check the exhaust manifold

Replace the hydraulic tank breather

Check the air conditioner, see section 11-1

Renew the high/low gear (transfer case) oil

Maintain the Boom, see Section 10-5


Maintenance - Every 2000 hours

Change Coolant

Change Bogie Housings Oil

Check valve clearance

Change Single Axle Differential Oil

Flushing the cooling system

Change Single Axle Wheel Ends Oil

Change Bogie Axle Differential Oil

Check and tighten the bolts for the joints between axles and frame

Control of the vibrations damper


Maintenance - Every 6 months
Service the fire extinguisher
Maintenance - Every 12 months
Have the fire extinguisher system (opt. eq.) checked
Maintenance - As required
Bleeding the fuel system

Have the proper function of the starter motor checked

Replacing fan/alternator belt

Clean the Fuel Tank Filler Filter

Have the proper function of the atomizers checked


Have the proper function of the turbocharger checked

Check the air conditioner, see section 11-1

Have the proper function of the alternator checked

Maintain the Boom, see Section 10-5

61 1921JAN022/2

6-1-2

101702

PN=90

Maintenance - Every 10 hours or Daily


Check the hydraulic oil level

NOTE: Do not exceed the MAX mark. There always has


to be enough air space in the hydraulic oil tank,
because the fluid level goes up and down during
the operation.

T152230

3. During the fill up, open venting screw (2). Do not forget
to close the screw.

UN05MAR02

1. Check the hydraulic oil level in the sight glass (1) of


the tank.
When you do this, the lift and jib cylinders have to be
in the innermost position.
2. If necessary add oil through the quick coupler (4) with
the hydraulic fill-up pump (3) (optional equipment).
The quick coupler is mounted in a way that the new
oil enters the system through the filter.
Also a manual pump can be used.

See section 7-1, Vacuum pump (opt. equipment)


NOTE: Do not mix different type of oils.
Capacities

Hydraulic tank

min. 79 l (20.8 gal) /


max. 150 l (39.6 gal)

Mineral oil

Summer oil

SMRs norm SH 68

Winter oil

SMRs norm SHS 32

Year-round oil

SMRs norm SHS 46


Neste Biohydrauli SE
46

UN07APR02

If you use synthetic


biodegradeable oil:

T152231

1Oil level sight class


2Venting screw
3Switch, fill-up pump
4Quick coupler - oil fill
5Switch, vacuum pump

EL62757,00000E8 1910APR021/1

6-2-1

101702

PN=91

Maintenance - Every 10 hours or Daily

Check the engine oil level


IMPORTANT: DO NOT add makeup oil until the oil
level is BELOW the ADD-mark.
UN16JUN00

The most accurate oil level reading is obtained when the


engine is cold before starting the engine for the days
operation.

RG8009A

The oil dipstick is located on the left-hand side of the


engine
If needed add oil through the oil filler cap (A).
RG8028 UN15JAN99

IMPORTANT: DO NOT fill above the top mark on the


dipstick. Oil level is in the acceptable
operating range within the crosshatch
area of the dipstick.
Capacities

Engine oil + filter

25 l (6,6 gal)

See information about Break-in Oils and oils which are preferred every
500 hours or 250 hours. Chapter 6-0.

EL62757,00000F4 1910APR021/1

Check the Fuel Pre-Filter

IMPORTANT: Drain the fuel into a suitable container


and dispose of properly.

To drain water or depris, proceed as follows:

After draining water from the fuel filter the filter must be
primed by bleeding air from the fuel system.

4
1. Loosen the air bleed vent screw (3) two full turns by
hand on final fuel filter base.
2. Operate fuel supply pump prime lever (4) until fuel flow
is free from air bubbles.
3. Tighten bleed plug securely, continue operating hand
primer until pumping action is not felt. Push hand
primer inward engine as far as it will go.

T160017

UN01OCT02

1. Turn the start key to position I, to open the stop


solenoid and the tank valve.
2. Loosen drain plug (1) in the bottom of bowl two or
three turns.
3. Loosen air bleed vent screw (2) two full turns on fuel
filter mounting and drain water from bottom until fuel
starts to drain out.
4. Tighten drain plug securely.

EL62757,000005F 6716OCT021/1

6-2-2

101702

PN=92

Maintenance - Every 10 hours or Daily

Check engine coolant level.


With the engine cold, coolant level must be between MAX
and MIN marks on the expansion tank (A).
If coolant is below the MIN mark, add coolant to the tank.

NOTE: If the expansion tank is full and radiator is low,


check for leaks in the radiator. Check the hose
connections between radiator and coolant surge
tank.

T159304

Coolant level must be at bottom of the radiator filler neck.

UN17SEP02

If expansion tank is empty, check for leaks. Repair as


required. Add coolant to the radiator and the expansion
tank.

EL62757,00000F5 1910APR021/2

Cooling system

27,5 l (7,3 gal)

50% Water /50%


Antifreeze

Ethylene or
Propylene glycol

ASTM4985 or ASTM
D5345

T6642EK

Capacities

UN01NOV88

CAUTION: Prevent possible injury from hot


spraying water. DO NOT remove expansion tank
filler cap or radiator cap unless engine is cool.
Then turn cap slowly to the stop. Release air to
relieve all pressure before you remove cap.

EL62757,00000F5 1910APR022/2

6-2-3

101702

PN=93

Maintenance - Every 10 hours or Daily

Check the windshield washer fluid level

T159303

UN11SEP02

The windshield washer tank is located in the engine


compartment. Ensure that there is enough of the fluid.

EL62757,00000F6 1910APR021/1

6-2-4

101702

PN=94

Maintenance - Every 10 hours or Daily

Check the radiator grille cleanness


NOTE: Depending on the operating conditions, it is
important to clean the radiator grille frequently in
order to prevent the engine and hydraulic system
from overheating.

4. Clean the radiator grille with a brush or compressed


air. Lightly clean the condenser, too.

T159302

CAUTION: Prevent possible injury from flying


chips if compressed air is more than 210 kPa
(2.1 bar) (30 psi). Clear area of bystanders,
guard against flying chips, and wear personal
protection equipment including eye equipment.

UN11SEP02

1. The grille can be removed by opening the fasteners (1)


.
2. Take off and clean the net (2).
3. Open the wing nuts (see figure) of the air conditioner
condenser (3) and lift up the condenser.

NOTE: Do not cover the grille when the engine is


running.

T159301

UN11SEP02

1Fasteners
2Net
3Condenser
4Cooling element

EL62757,00000F8 1910APR021/1

6-2-5

101702

PN=95

Maintenance - Every 10 hours or Daily

Check the driving brake oil level


Check the driving brake oil level (ATF oil) in the tank (1)
located in the front wall of the cab.

T152233

UN05MAR02

1ATF oil tank

EL62757,00000F7 1910APR021/1

Check the air filter


When the red warning area of the restriction indicator (A)
of the air filter (1) is fully visible after the engine is
stopped, the air filter element must be cleaned or
replaced.
Having changed the filter element press the button at the
bottom of the restriction indicator. This will make the red
area disappear.

UN11SEP02

The air filter element (B) can be cleaned with compressed


air three times. After that, the element and the safety
insert (C) inside the element must be replaced.

T159300

NOTE: When replacing the air filt er element it is


important to make sure that no dirt enters the
intake manifold.
Clean also the inside of the filter casing.
Remove dust from the valve (D). Ensure that the sides of
the valve close completely together and they can separate
freely.

T159299

UN11SEP02

IMPORTANT: In dusty circumstances the air filter


must be controlled more often.

EL62757,00000F9 1910APR021/1

6-2-6

101702

PN=96

Maintenance - Every 10 hours or Daily

Check the tires for air pressure and overall


shape.

T152362

UN06MAR02

Check tire pressures visually every day. If in doubt, use a


pressure gauge to check the pressure. See section 6-0.

EL62757,00000FA 1910APR021/1

Fill up the fuel tank


UUse only clean fuel to make sure that the diesel engine
will not run erratically.
If necessary, drain the dirt deposited in the fuel tank
through the fuel tank drain hose (4).
Fill up the tank every evening. This prevents
condensation from accumulating in an empty tank.
Specification
Fuel tankVolume ............................................................. 165 l (43,5 gal)

Clean the area around the top (1) before you open it for
the fuel filling hose.
Fuel can be added through the top (1) or through the
quick coupler (2).

UN07OCT02

A fixedly mounted fuel fill-up pump (opt. eq.) is available


as an extra equipment.

T160196

Automatic stop is engaged when the tank is full. After the


stop a manual use is also possible. The pump stops when
turning the switch in the opposite direction.
NOTE: TMC has to be ON as a pre-requisite for
automatics.
1Top
2Quick coupler
3Drain hose

EL62757,00000FB 1910APR021/1

6-2-7

101702

PN=97

Maintenance - Every 10 hours or Daily

Maintain the boom


See Section 10-2
1. Grease the grapple and link.
2. Check boom structures

EL62757,00000FC 1910APR021/1

The following service and checks are to be


made at the end of each workday
Clean the machine
Inspect all covered compartments, including engine
bay, belly plates etc. It is particularly important to
clean the machine in the winter because snow and
debris easily gets stuck to the machine
Make sure that there are no defects or leaks
Check the machine in daylight
Repair any defects found or contact the service
personnel.
Renew oils and grease (if necessary) the machine
while it is still warm.
Check the tightness and mounting of the possible
chains.
Replace the lock pin of the emergency exit
Lock the cab door
Turn off the main switch.
If the machine is equipped with an automatic fire
extinguishing system (optional equipment), the
system will be engaged when the main switch is
turned off.

EL62757,00000FD 1910APR021/1

6-2-8

101702

PN=98

Maintenance - Every 50 hours or Weekly


Grease the center hinge bearings and
steering cylinder bearings.
CAUTION: Crushing injury may result to
persons in the hinge area if machine is turned.
Install frame locking bar before working in this
area.

T152346

UN06MAR02

There are five greasing points at the hinge pivot and four
at the steering cylinders. When greasing the hinge pivot,
also check visually the hinge pivot clearances.

T152347

UN06MAR02

Center hinge bearing, left

Center hinge bearing, right

EL62757,00000E9 1910APR021/1

6-3-1

101702

PN=99

Maintenance - Every 50 hours or Weekly

Grease the decking blade1

NOTE: Working in difficult circumstances, if necessary,


grease the decking blade daily.

T152349

NOTE: There are six greasing points for the decking


blade. Four greasing points are external and two
are inside the frame. The belly pan must be
lowered to access the greasing points inside the
frame. Use a 1/2 wrench to lower the belly pan.

UN06MAR02

Grease the decking blade pins.

Decking blade is an optional equipment.


EL62757,00000FE 1910APR021/1

Check the air conditioner


Check the service moisture indicator.
See section, 11-1.

EL62757,00000FF 1910APR021/1

Maintain the Boom


1.
2.
3.
4.
5.

Check the boom slewing housing oil level


Check that the joint pins of the boom are secured
Check the sideways clearance of the extension booms.
Check the boom extension boom chains for tightness
Grease the rocker and cylinder bearings of the boom
and the slewing system bearing.
6. Lubricate the extension boom chains with oil
See section 10-3.

EL62757,0000101 1910APR021/1

6-3-2

101702

PN=100

Maintenance - Every 50 hours or Weekly

Check the fire extinguisher system


Fire extinguisher system is an extra equipment. See
section 11-4.
EL62757,0000100 1910APR021/1

6-3-3

101702

PN=101

Maintenance - Every 250 hours


Clean the machine
Remove dirt and wash the machine
Use a spray of warm water to clean the cooling ducts
(1). Clean from the engine side, blowing against the
normal flowing direction of the cooling air. Do not
employ a strong pressure when cleaning the air
conditioner condenser (2).
If you operate under dusty circumstances, clean the ducts
with compressed air more frequently, even daily if
necessary.

T152350

UN06MAR02

1Cooling ducts
2Condenser

EL62757,00000EA 1910APR021/1

6-4-1

101702

PN=102

Maintenance - Every 250 hours

Check the high/low gear oil level.


1. Park the machine on a level surface. Lower decking
blade to the ground and secure grapple to Rear frame.
2. Engage park brake. Turn key switch OFF.
CAUTION: Prevent possible injury from
unexpected machine movement. Install frame
locking bar before working in frame pivot area.

NOTE: To vent the high/low gear while adding oil, pull up


dipstick.
Capacities

High / low gear

Hypoid oil

API GL-5 or MIL-L-2105 B or D

Viscosity

SAE
SAE
SAE
SAE

T152348

UN06MAR02

3. Install frame locking bar.


4. Check oil level dipstick that the oil level stays between
the MIN and MAX marks.
Dipstick is placed between the hydraulic tank and the
fuel tank.
5. If necessary add oil through the dipstick hole or
through the filler plug (3) on top of the high/low gear
High/ low gear can be accessed by moving the fuel
tank aside. Remove two bolts (2).

4.5 l (1.2 gal)

90
85W/90
80W/90
75W/90

T152824

UN20MAR02

1Dipstick
2Bolts
3Filling plug

EL62757,0000102 1910APR021/1

6-4-2

101702

PN=103

Maintenance - Every 250 hours

Check Differential Oil Level


NOTE: The differential is similar on the single axle and
the bogie axle.
The oil levels in the differential and wheel ends or
bogie housings must be checked separately.
1. To access the dipstick and filler plugs on the rear axle,
remove the service covers on top of the Rear frame.

UN21JUN01

2. To access the dipstick and filler plugs on the front axle,


tilt the cab to the service position.

T142883

3. Check the oil level in the differential gear on the


dipstick.
4. If required, add oil through one of the filler plugs on top
of the axle. Alternatively, add oil through the level plug
on the differential.

Differentials, rear

12 l (3.1 gal)

Differentials, front,
8-wheel

12 l (3.1 gal)

Differentials, front,
6-wheel

27 l (7.1 gal)

Hypoid oil

API GL-5 or MIL-L-2105 B or D

Viscosity

SAE
SAE
SAE
SAE

T142884

Capacities

UN21JUN01

NOTE: Any time a plug is removed, replace the O-ring


seal or copper washer.

90
85W/90
80W/90
75W/90

1Differential Oil Level Dipstick


2Filler Plugs
3Level Plug

OUTJ003,00006A8 1916MAY011/1

6-4-3

101702

PN=104

Maintenance - Every 250 hours

Check Single Axle Wheel Ends ( Hub gear)


Oil Level
NOTE: Although oil can pass from the differential to the
wheel ends, it is necessary to check the oil level
in the differential and each wheel end separately.
1. Position the wheel end so that the drain port (1) is on
the horizontal centerline of the axle.
2. Remove the drain plug. The oil level must be up to the
drain port.
3. Add oil, if necessary, through the fill port (2).
4. Install the drain plug.

Hub gears, 6-wheel

Hypoid oil

API GL-5 or MIL-L-2105 B or D

2 x 4 l (2 x 1.05 gal)

Viscosity

SAE
SAE
SAE
SAE

T144162

Capacities

UN19JUL01

NOTE: Any time a plug is removed, replace the O-ring


seal or copper washer.

90
85W/90
80W/90
75W/90

1Drain Plug
2Fill Plug

OUTJ003,00006F6 1917JUL011/1

6-4-4

101702

PN=105

Maintenance - Every 250 hours

Check Bogie Housings Oil Level


1. Clean the area around the plugs.

UN21JUN01

2. Remove the filler plug to vent the bogie housing.

T142885

3. Remove the inspection plug. The oil level must be up


to the inspection port.
NOTE: The oil levels in the differential and both bogie
housings must be checked separately.
4. If necessary, add oil to the bogie housing through the
filler port.

1Filler Plug
2Inspection Plug

NOTE: Any time a plug is removed, replace the O-ring


seal or copper washer.
Capacities

Bogie housing

52 l (13.7 gal)

Hypoid oil

API GL-5 or MIL-L-2105 B or D

Viscosity

SAE
SAE
SAE
SAE

90
85W/90
80W/90
75W/90

OUTJ003,00006A9 1916MAY011/1

6-4-5

101702

PN=106

Maintenance - Every 250 hours

Grease Bogie Bearings

UN13JUN01

Each bogie housing has ten grease fittings on each side


of the housing which must be greased to properly
lubricate the bogie bearings.
Cover the grease fittings with white plastic caps.

T142886

1Grease Fittings

T142887

UN13JUN01

Bogie Housing Grease Points, 3 Upper Ports

T142888

UN13JUN01

Bogie Housing Grease Points, 3 Lower Ports

Bogie Housing Grease Points, 4 Side Ports

OUTJ003,00006AA 1916MAY011/1

6-4-6

101702

PN=107

Maintenance - Every 250 hours

NOTE: It is important to retighten the wheel nuts if the


rims or axle flanges have been recently painted or
if the forwarder is new. Check wheel nut torque
after first 250 Hours, then at 1000 Hour intervals.
Check the wheel nuts torque.

T142843

Replacement hardware should be tightened to


specification.

UN04DEC01

Check Wheel Nut Torque

Specification
Wheel NutTorque ..................................................... 550 Nm (405 lb-ft)

Check wheel rims for dents and cuts. Replace damaged


wheel rims.

OUTJ003,00006AB 1916MAY011/1

Check the cabine air filters


1. The hatch for the cabine outside and inside air filter is
located underneath the first side window.
Open the hatch on the right-hand side of the cabin.
2. Inside the cabine, at the back side of the floor, there is
a filter (2)for cabines heater.
3. Controll and clean the filters, replace if necessary.
NOTE: If necessary, due to circumstances, the filters
must be checked and cleaned or replaced even
more often.

T159298

UN11SEP02

1Cabine Air Filter


2Heaters Air Filter

EL62757,0000107 1910APR021/1

6-4-7

101702

PN=108

Maintenance - Every 250 hours

Check the air conditioner


See section 11-1.
1. Check AC Compressor V-belt
2. Check fresh outside air filter and inside filter.
3. Check AC Compressor

EL62757,0000108 1910APR021/1

Maintain the boom


See Section 10-4.
1.
2.
3.
4.

Clean the boom.


Check boom structures.
Check the extension booms for vertical clearance.
Check the tightness of boom fastening bolts, hydraulic
cylinder covers, and other screw joints.

EL62757,0000109 1910APR021/1

6-4-8

101702

PN=109

Maintenance - Every 500 hours


Change engine oil and replace oil filter

Capacities

Engine oil + filter

UN05MAR02

IMPORTANT: Change the engine oil and filter for the


first time after 250 hours maximal of
operation, then every 500 hours
thereafter.
25 l (6.6 gal)

T152229

John Deere PLUS-50, ACEA E5, ACEA E4. See also chapter 6-0.

1. Run engine approximately 5 minutes to warm up oil.


Shut engine off.
2. Lower the belly pan. Open the plug of the drain hose
(3) and drain the oil into a container.
3. Oil filter (A) is placed at the right side of the engine.

UN24OCT01

Clean the area around the filter bowl.

RG11616

4. Remove old oil filter element turning it


counterclockwise. Make sure the old seling comes off
with filter. Clean the sealing surface of the filter foot.
IMPORTANT: Filtration of oils is critical to proper
lubrication. Always change filter
regularly. Use filter meeting John Deere
performance specifications

6. Install oil pan drain plug (3) with a new seal when
equipped.

Y01

Specification
Oil pan drain plugTorque ............................................. 80 Nm (59 lb-ft)

T160264

UN08OCT02

5. Oil new packing and the sealing of the filter using


clean engine oil. Turn the filter element back and
tighten 3/4...1-1/4 turn after packing contacts filter
housing.

3Oil drain hose


AOil filter

7. Fill engine crankcase with engine oil through oil filler


cap.

Continued on next page

6-5-1

DPSG,OUOE003,8005 1918JUN991/2

101702

PN=110

Maintenance - Every 500 hours


IMPORTANT: Immediately after completing any oil
change, crank engine for 30 seconds
without permitting engine to start. This
will help insure adequate lubrication to
engine components before engine
starts.
9. Detach the connection (Y01) from the control unit of
the fuel pump and operate the engine by means of the
starter motor about 30 seconds. Reconnect the
connector again. Start engine and run to check for
possible leaks.
10. Stop engine and check oil level after 10 minutes. Oil
level reading should be within crosshatch of dipstick.

DPSG,OUOE003,8005 1918JUN992/2

6-5-2

101702

PN=111

Maintenance - Every 500 hours

Change the fuel filters


1. Clean dirt and debris from and around the fuel filter
assembly
2. Open drain plug (1) in the bottom of the filter and vent
screw (2) on the filter. Drain the fuel into a container.
NOTE: Lifting up on retaining ring as it is rotated helps to
get it past raised locators.

4. Inspect filter mounting base for cleanliness. Clean as


required.
5. Remove filter element from water separator bowl (4).
Drain and clean separator bowl. Dry with compressed
air. Check also O-ring; change if needed. Install water
separator bowl onto new element. Tighten securely.

T160018

UN01OCT02

3. Firmly grasp the retaining ring (3) and rotate it


counterclockwise 1/4 turn. Remove ring with filter
element.

6. Fill the new filters with clean fuel. Fit the filters back.
7. Install retaining ring onto mounting base making certain
dust seal is in place on filter base. Hand tighten ring
(about 1/3 turn) until it snaps into the detent. DO
NOT overtighten retaining ring.

BFuel Pre Filter


AFinal Fuel Filter
1Drain plug
2Vent screw
3Retaining ring
4Water bowl

T160019

4
1

UN01OCT02

8. Bleed the fuel system. See chapter: Maintenance as


required.

EL62757,0000060 6716OCT021/1

6-5-3

101702

PN=112

Maintenance - Every 500 hours

Clean crankcase vent tube


If the engine has been operated in dusty circumstances,
clean the tube(A) more often.

RG8017A

UN19JUN00

1. Remove and clean crankcase vent tube (A).


2. Install the vent tube. Be sure the O-ring fits correctly in
the rocker arm cover for elbow adapter. Tighten hose
clamp securely.
ACrankcase Vent tube

EL62757,000010A 1910APR021/1

Check the air intake system


IMPORTANT: The air intake system must not leak

T138992

UN20JUL01

Inspect the intake piping and aftercooler for cracked


hoses or loose clamps which can allow dirt and debris to
enter the engine. Clean and fix if necessary.

EL62757,000010B 1910APR021/1

Checking belt tensioner spring tension and


belt wear
Checking belt wear
UN18NOV97

Visually inspect cast stops (A and B) on belt tensioner


assembly.

RG8098

If the tensioner stop (A) on swing arm is hitting the fixed


stop (B), check mounting brackets (alternator, belt
tensioner, idler pulley, etc.) and the belt length. Replace
belt as needed.
ATensioner Stop
BFixed Stop

Continued on next page

6-5-4

EL62757,000010F 1910APR021/3
101702

PN=113

Maintenance - Every 500 hours

1. Release tension on belt using a long-handle 1/2 inch


breaker bar in tension arm. Remove belt from pulleys.
2. Release tension on tension arm and remove breaker
bar

RG7977

A belt tension gauge will not give an accurate measure of


the belt tension when automatic spring tensioner is used.
Measure tensioner spring tension using a torque wrench
and procedure outlined below:

UN14NOV97

Checking tensioner spring tension

RG12054

UN08JAN02

3. Put a mark (A) on swing arm of tensioner as shown.

EL62757,000010F 1910APR022/3

4. Measure 21 mm (0.83 in.) from mark (A) and put a


mark (B) on tensioner mounting base.

UN28JAN02

5. Install torque wrench (C) so that it is aligned with


center of pulley and tensioner. Rotate the swing arm
with the torque wrench until marks (A and B) are
aligned.

RG12065

6. Record torque wrench measurement and compare with


specification below. Replace tensioner assembly as
required
Specification
Spring TensionTorque ..................................... 18-22 Nm (13-16 lb-ft)

RG7381

UN28NOV97

AMark On Swing Arm


BMark On Tensioner Mounting Base
CTorque Wrench

EL62757,000010F 1910APR023/3

6-5-5

101702

PN=114

Maintenance - Every 500 hours

Check engine speeds


Check the engine rpms at the TMC display.

EL62757,0000114 1910APR021/1

Control engine grounding


Check engine ground connection to be sure it is secure
and clean. This will prevent electrical arcing which can
damage engine.

EL62757,0000115 1910APR021/1

Drain water and sediment from the sediment cup of the


tank through the fuel tank drain hose (4) at the front belly
pan.

T152229

4Fuel tank drain hose

UN05MAR02

Remove sediment and water from the fuel


tanks

EL62757,000011B 1910APR021/1

6-5-6

101702

PN=115

Maintenance - Every 500 hours

Renew the pressure filter of the drive


hydraulic system
1. Lower down the belly plate. The transmission filter is
located under the transmission pump.
2. Turn filter counterclockwise to remove.
3. Clean mounting surface. Apply thin film of oil to gasket
of new filter.

UN22SEP02

4. Install new filter. Turn the filter by hand until the seal
makes contact with the base. Use a filter wrench to
turn the filter 30 further.

T159654

5. Start engine. Check for leaks around the filter base.


Tighten filter only enough to stop leaks.
6. Stop engine.
7. Check oil level at sight glass on hydraulic tank. Add oil,
if necessary. See Section 6-0, for recommended
hydraulic fluids.

1Pressure filter

EL62757,0000117 1910APR021/1

Check the batteries for charge


CAUTION: Keep sparks, lighted matches, and
open flame away from the top of battery.
Battery gas can explode.

TS203

UN23AUG88

Sulfuric acid in battery electrolyte is poisonous. It is strong


enough to burn skin, eat holes in clothing, and cause
blindness if splashed into eyes.

Continued on next page

6-5-7

EL62757,000011A 1910APR021/2
101702

PN=116

Maintenance - Every 500 hours


Measure the specific gravity of the battery electrolyte.

NOTE: The electrolyte of a discharged battery can freeze


at temperatures as high as -10C (14F.),
destroying the battery.

T142899

If the density (specific gravity) of the electrolyte has


dropped below 1.23, the battery must be recharged.

UN13JUN01

The density (specific gravity) of the electrolyte must be


between 1.23 and 1.28.

Make sure the battery cable are correctly connected. Look


at the electrical scheme.

EL62757,000011A 1910APR022/2

IMPORTANT: Air must be expelled from cooling


system when system is refilled. Loosen
temperature sending unit fitting at rear
of cylinder head or plug in thermostat
housing to allow air to escape when
filling system. Retighten fitting or plug
when all the air has been expelled.

TS281

CAUTION: Explosive release of fluids from


pressurized cooling system can cause serious
burns. Shut off engine. Only remove filler cap
when cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve
pressure before removing completely.

UN23AUG88

Checking cooling system

1. Check entire cooling system for leaks. Tighten all


clamps securely
2. Thoroughly inspect all cooling system hoses. Replace
hoses when hard, flimsy, or cracked

EL62757,0000110 1910APR021/1

6-5-8

101702

PN=117

Maintenance - Every 500 hours

Control of the diesel engine coolant


Maintaining adequate concentrations of glycol and
inhibiting additives in the coolant is critical to protect the
engine and cooling system against freezing, corrosion,
and cylinder liner erosion and pitting.
Test the coolant solution at intervals of 12 months or less
and whenever excessive coolant is lost through leaks or
overheating.
Coolant Test Strips:
Coolant test strips are available from your local dealer.
These test strips provide a simple, effective method to
check the freeze point and additive levels of your engine
coolant.
Compare the results to the supplemental coolant additive
(SCA) chart to determine the amount of inhibiting
additives in your coolant and whether more John Deere
COOLANT CONDITIONER should be added.

EL62757,0000111 1910APR021/1

Filling supplemental coolant additives (SCA)


between coolant changes
IMPORTANT: Do not add supplemental coolant
additives when the cooling system is
drained and refilled with John Deere
ANTIFREEZE/SUMMER COOLANT or
COOL- GARD
NOTE: If system is to be filled with coolant that does not
contain SCAs, the coolant must be precharged.
Determine the total system capacity and premix
with 3% John Deere Coolant Conditioner.
See Section 6-11: Filling supplemental coolant additives
(SCA) between coolant changes

EL62757,0000112 1910APR021/1

6-5-9

101702

PN=118

Maintenance - Every 500 hours

Pressure control of the cooling system


CAUTION: Explosive release of fluids from
pressurized cooling system can cause serious
burns. Shut off engine. Only remove filler cap
when cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve
pressure before removing completely.
See Section 6-11: Pressure control of the cooling system
EL62757,0000113 1910APR021/1

T159651

UN02OCT02

Grease the driveshafts

Nipples (1), (2) and (3) Front driveshaft, grease


through the service openings under the frame.

Nipples (4) and (5) Center driveshaft

Continued on next page

6-5-10

EL62757,0000119 1910APR021/2

101702

PN=119

T159652

UN02OCT02

Maintenance - Every 500 hours

T159653

UN02OCT02

Short rear frame

Long rear frame

Nipples (6) (7), (8) and (9) Rear driveshafts


Rear driveshaft, grease through the service
openings on top of the frame (nipple (6) and nipples
(7) and (8) and (nipple 9).
EL62757,0000119 1910APR022/2

6-5-11

101702

PN=120

Maintenance - Every 1000 hours


Renew the hydraulic oil.
NOTE: Change hydraulic oil when it is warm and
contaminants are in suspension.
You can use a vacuum pump (optional equipment) to
drain the hydraulic tank. The vacuum pump is used to
avoid oil spill, e.g., in the event of hose rupture or other
leakage. See section 7-1 for instructions to use a vacuum
pump.
You can use a hydraulic fill-up pump (optional equipment)
to add oil to the tank. Oil is added through a quick coupler
which is mounted in a way that the new oil enters the
system through the filter. Also a manual pump can be
used.
See section 7-1 for instructions to renew the hydraulic oil.
IMPORTANT: Do not mix oils.

EL62757,00000EC 1910APR021/1

6-6-1

101702

PN=121

Maintenance - Every 1000 hours

Replace the hydraulic return filter


CAUTION: Before working on the hydraulics,
park the machine on a level surface, lower the
decking blade, grapple to the ground, shut off
the engine.
IMPORTANT: When replacing the filter make sure that
no dirt enters the hydraulic system.
1. Open the vent screw (1) on top of the tank
2. Remove the screws of cover (10)
CAUTION: The filter cover is under spring
tension. Hold cover down while removing
screws
Clamp guarantees that the filter functions properly.
NOTE: Filter assembly consists of a filter element (7) and
a canister (6). Filter is in lock position inside the
canister.

UN11SEP02

IMPORTANT: The filter and the canister must be lifted


together from the tank to prevent the
contamination to flow into the tank.

T159297

3. Put the filter element and the canister into an oil


collecting sump
4. Unlock the filter element by twisting it counterclockwise
5. Remove the filter element and clean the canister

1Vent screw
2Lock position
3O-ring
4Spacer ring
5O-ring
6Canister
7Filter element
8Spring
9O-ring
10Cover
11Screw

6. Replace the filter element and put it inside the canister.


Twist the filter element clockwise and check that it
is locked inside the canister! You maybe need to
press the filter while twisting it.
7. Place the filter assembly in the tank together with the
spring (8). Screw the cover (10) on.
8. Start the engine and run for 5 minutes. Stop the engine
9. Check for any leakage at filter cover.

Continued on next page

6-6-2

EL62757,000011C 1910APR021/2
101702

PN=122

Maintenance - Every 1000 hours


10. Close the vent screw.
11. Check oil level in tank. Add oil if necessary.
The filters are equipped with a pressure sensor. If the
pressure sensor sets off an alarm, renew the filter.
Otherwise, stick to maintenance periods.

EL62757,000011C 1910APR022/2

Replace the hydraulic tank breather


Check the hydraulic oil tank breather. Clean the breather
if necessary.

T152538

UN08MAR02

1Hydraulic tank breather.

EL62757,000011D 1910APR021/1

6-6-3

101702

PN=123

Maintenance - Every 1000 hours

Renew the high/low gear (transfer case) oil


1. Park machine on a level surface. Lower decking blade
to the ground and secure grapple to Rear frame.
2. Engage park brake. Turn key switch OFF.
CAUTION: Prevent possible injury from
unexpected machine movement. Install frame
locking bar before working in frame pivot area.
3. Install frame locking bar.
UN20MAR02

4. To access the bottom of the transfer case, remove the


cover on the underside of the front frame.

T152797

5. Remove the drain plug and drain the transfer case oil
into a suitable container.
NOTE: Dispose of waste properly.

6. After draining, install the plug and replace the access


cover.
NOTE: To vent transfer case while adding oil, pull up
dipstick.

T152824

UN20MAR02

1Drain plug
3Fill plug

Continued on next page

6-6-4

EL62757,000011E 1910APR021/2

101702

PN=124

Maintenance - Every 1000 hours


8. Check oil level on dipstick. Oil level must be at the
FULL notch.
9. Install fill plug.
Capacities

High / low gear

Hypoid oil

API GL-5 or MIL-L-2105 B or D

4.5 l (1.2 gal)

Viscosity

SAE
SAE
SAE
SAE

UN06MAR02

90
85W/90
80W/90
75W/90

T152348

1Dipstick
2Screws

EL62757,000011E 1910APR022/2

Check and tighten the screw and bolt


connections

UN04DEC01

It is especially important to retighten the wheel nuts if the


rims or wheel axle flanges have been painted recently, or
the forwarder is new.

T142843

Periodically see to it that there are no dents or cuts in the


rims. Replace badly damaged rims.

Item

Measurement

Specification

Wheel nuts

Torque

550 Nm (405 lb-ft)

EL62757,0000122 1910APR021/1

6-6-5

101702

PN=125

Maintenance - Every 1000 hours

Check the exhaust manifold


IMPORTANT: Allow exhaust system to cool before
service
See to it that all attaching bolts are firmly secured, all
joints are tight, and that there are no breaks in the
manifold.

EL62757,0000121 1910APR021/1

Check the air conditioner


See Section 11-1. .
1.
2.
3.
4.
5.

Service
Service
Service
Service
Service

the
the
the
the
the

compressor
compressor clutch
evaporator element
condenser element
hoses and connectors

EL62757,0000120 1910APR021/1

Maintain the boom


See section 10-5.
1. Clean the magnetic plug of rotator
2. Change the boom slewing system oil

EL62757,000011F 1910APR021/1

6-6-6

101702

PN=126

Maintenance - Every 2000 hours


Check valve clearance

UN06AUG96

CAUTION: To prevent accidental starting of


engine while performing valve adjustments,
always disconnect NEGATIVE () battery
terminal or connector Y01.

RG7408

IMPORTANT: Valve clearance MUST BE checked and


adjusted with engine COLD.
1. Remove rocker arm cover and crankcase ventilator
tube.
ATiming/Rotation Hole
BTiming Pin Hole

IMPORTANT: Visually inspect contact surfaces of


valve tips and rocker arm wear pads.
Check all parts for excessive wear,
breakage, or cracks. Replace parts that
show visible damage.
Rocker arms that exhibit excessive
valve clearance should be inspected
more thoroughly to identify damaged
parts.
2. Remove plastic plugs or cover plate from engine
timing/rotation hole (A) and timing pin hole (B).
3. Using JDE83 or JD81-1 Flywheel Turning Tool, rotate
engine flywheel in running direction (clockwise viewed
from front) until No. 1 cylinder is at TDC compression
stroke. Insert JDG1571 or JDE81-4 Timing Pin in
flywheel.
If the rocker arms for No. 1 (front) cylinder are loose,
the engine is at No. 1 TDC-Compression.
If No. 1 cylinder rocker arms are not loose, rotate
engine one full revolution (360) to No. 1 TDC
compression.

Continued on next page

6-7-1

RG41165,0000032 1912DEC001/2

101702

PN=127

Maintenance - Every 2000 hours

5. Rotate flywheel 360 until No. 6 piston is at TDC of


its compression stroke. Rocker arms for No. 6 piston
should be loose.

RG4777

Specification
Intake Valve Clearance Checking
(Rocker Arm-to-Valve Tip With
Engine Cold)Clearance ................................................... 0.31..-0.38 mm
(0.012...0.015 in.)
Exhaust Valve Clearance
Checking (Rocker Arm-to-Valve
Tip With Engine Cold)
Clearance ........................................................................... 0.41...0.48 mm
(0.016...0.019 in.)

UN31OCT97

4. With engine lock-pinned at TDC of No. 1 pistons


compression stroke, check valve clearance on Nos. 1,
3, and 5 exhaust valves and Nos. 1, 2, and 4 intake
valves.

AFront of Engine
BNo. 1 Piston TDC Compression
CNo. 6 Piston TDC Compression
EExhaust Valve
IIntake Valve

6. Check valve clearance to the same specifications on


Nos. 2, 4, and 6 exhaust and Nos. 3, 5, and 6 intake
valves.
7. If valve clearance needs to be adjusted, let an
authorized workshop do that.
8. Install rocker arm cover with vent tube and tighten cap
screws to specifications in order shown.

RG41165,0000032 1912DEC002/2

6-7-2

101702

PN=128

Maintenance - Every 2000 hours

Checking Crankshaft Vibration Damper

UN15JAN99

IMPORTANT: The vibration damper assembly is not


repairable and should be replaced every
4500 hours or 60 months, whichever
occurs first.
1. Remove belts (shown removed).

RG8018

2. Grasp vibration damper with both hands and attempt to


turn it in both directions. If rotation is felt, damper is
defective and should be replaced.
3. Check vibration damper radial runout by positioning a
dial indicator (A) so probe contacts damper outer
diameter.

UN23NOV97

4. Rotate crankshaft using JDE83 or JD81-1 Flywheel


Turning Tool.
5. Note dial indicator reading.

Item

Measurement

Damper

Radial Runout

RG7508

If runout exceeds specifications, replace vibration


damper.

Specification

1.50 mm (0.060 in.)

EL62757,0000116 1910APR021/1

6-7-3

101702

PN=129

Maintenance - Every 2000 hours

Changing the Coolant

UN23AUG88

CAUTION: Explosive release of fluids from


pressurized cooling system can cause serious
burns.

TS281

Shut off engine. Only remove filler cap when


cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
before removing completely.
NOTE: Drain the initial factory fill engine coolant after the
first 3000 hours or 3 years of operation.
Subsequent drain intervals are determined by the
coolant used for service.

High Pressure Fluids

RG8019A

UN19JUN00

When John Deere COOL-GARD is used, the drain


interval is 3000 hours or 3 years. The drain
interval may be extended to 5000 hours or 5
years of operation provided that the coolant is
tested annually AND additives are replenished
as needed, by adding a supplemental cooling
additive (SCA).
If COOL-GARD is not used, the drain interval is
reduced to 2000 hours or 2 years of operation.

Cooling System Drains

Drain old coolant, flush the entire cooling system, replace


thermostats, and fill with recommended clean coolant.

UN07OCT02

1. Make sure that the machine is standing horizontally.


Set the cabin heating control to its maximum open
position.

3. Open engine coolant drain valve (A) on left side of engine


Drain all coolant from engine block.
fOpen radiator drain valve (C) and
drain coolant from radiator.

T159296

2. Carefully open the expansion tank cap to relieve


pressure and allow coolant to drain faster.

APump Drain Valve


CRadiator Drain Valve

4. Remove thermostats. Install cover and tighten cap


screws to 20 Nm (15 lb-ft).

Continued on next page

6-7-4

AK12300,000001A 1930JAN021/3
101702

PN=130

Maintenance - Every 2000 hours


5. Close all drain valves and fill the cooling system with
clean water. Run the engine about 10 minutes to stir
up possible rust or sediment.
6. Stop engine and immediately drain the water from
system before rust and sediment settle.
7. After draining water, close drain valves and fill the
cooling system with clean water and a heavy duty
cooling system cleaner such as FLEETGUARD
RESTORE or RESTORE PLUS. Follow
manufacturers directions on label.
8. After cleaning the cooling system, drain cleaner and fill
with water to flush the system. Run the engine about
10 minutes, then drain out flushing water.
9. Close all drain valves on engine and radiator. Install
thermostats using a new gasket.
IMPORTANT: Never pour cold liquid into a hot
engine, as it may crack cylinder head or
block.
IMPORTANT: Air must be expelled from cooling
system when system is refilled. Loosen
temperature sending unit fitting in
cylinder head or plug in thermostat
housing to allow air to escape when
filling system. Retighten fitting or plug
when all the air has been expelled.
10. When adding coolant to the system, use the
appropriate coolant solution.

FLEETGUARD is a trademark of Cummins Engine Company, Inc.


RESTORE is a trademark of Fleetguard Inc.
RESTORE PLUS is a trademark of Fleetguard Inc.

Continued on next page

6-7-5

AK12300,000001A 1930JAN022/3

101702

PN=131

Maintenance - Every 2000 hours


Add coolant via expansion tank. Ensure that the coolant
level stays between the MIN and MAX marks.
Capacities

Cooling system

27.5 l (7,3 gal)

50% Water /50%


Antifreeze

Propylene glycol

ASTM4985 or ASTM
D5345

11. Run engine until it reaches operating temperature


82- 94C (180 - 202F). This mixes the solution
uniformly and circulates it through the entire system.

T159304

UN17SEP02

12. After running the engine, check coolant level and


entire cooling system for leaks.

AK12300,000001A 1930JAN023/3

6-7-6

101702

PN=132

Maintenance - Every 2000 hours

Change Bogie Axle Differential Oil


NOTE: Change the oil while it is warm.
1. Park the machine on a level surface. Engage the
parking brake. Install the frame lock.
2. To access the dipstick and filler plugs on the rear axle,
remove the service covers on top of the Rear frame.
3. Clean the area around the plugs.
UN21JUN01

4. Lift the dipstick or remove one of the filler plugs to vent


the differential.

T142883

5. Remove drain plug. Drain oil into suitable container.


NOTE: Dispose of waste properly. Do not dump oil on
ground or in sewers.
6. Clean and install the drain plug.
NOTE: Any time plugs are removed, the O-ring seals or
copper washers should be replaced.
UN15JUN01

7. Add new oil through one of the filler plugs on top of the
axle. Alternatively, add oil through the level plug on the
differential.

T142920

8. Check oil level on dipstick. Install the filler plug.


NOTE: Any time plugs are removed, the O-ring seals or
copper washers should be replaced.
Capacities

Differentials, rear

12 l (3.1 gal)

Differentials, front,
8-wheel

12 l (3.1 gal)

Hypoid oil

API GL-5 or MIL-L-2105 B or D

Viscosity

SAE
SAE
SAE
SAE

1Differential Oil Level Dipstick


2Filler Plugs
3Level Plug
4Drain Plug

90
85W/90
80W/90
75W/90

OUTJ003,00006B9 1916MAY011/1

6-7-7

101702

PN=133

Maintenance - Every 2000 hours

Change Bogie Housings Oil

UN13JUN01

NOTE: Before changing the bogie housing oil, let the


machine stand for 30 minutes to allow impurities
to settle to the bottom.
1. Park the machine on a level surface. Engage the
parking brake. Install the frame lock.

T142919

2. Clean the area around the plugs.


3. Remove the filler plug to vent the bogie housing.
4. Remove the inspection plug.
5. Remove the drain plug. Drain a sample of oil (5 l / 1,3
gal) into a suitable container.

1Filler Plug
2Inspection Plug
3Drain Plug

Check the condition of the oil. If the oil is clear, add


new oil.
NOTE: The oil sample taken from the bogie housing is
not reusable.
If the oil is cloudy, replace all the oil in the bogie
housing.
NOTE: Dispose of waste properly. Do not dump oil on
ground or in sewers.
6. Install the drain plug. Add oil to the bogie housing
through the filler port until the oil level is up to the
inspection port.
7. Install the filler and inspection plugs.
NOTE: Any time plugs are removed, the O-ring seals
should be replaced.
8. Repeat the procedure at each bogie.
Capacities

Bogie housing

52 l (13.7 gal)

Hypoid oil

API GL-5 or MIL-L-2105 B or D

Viscosity

SAE
SAE
SAE
SAE

90
85W/90
80W/90
75W/90

OUTJ003,00006B8 1916MAY011/1

6-7-8

101702

PN=134

Maintenance - Every 2000 hours

T144163

UN19JUL01

Change Single Axle Differential Oil

1Dipstick
2Axle Beam Fill Ports

3Differential Level Port

NOTE: Change the oil while it is warm.


1. Park the machine on a level surface. Engage the
parking brake. Install the frame lock.
2. To access the dipstick and filler plugs on the rear
axle, remove the service covers on top of the Rear
frame.
3. To access the dipstick and filler plugs on the front
axle, tilt the cab to the service position.

4Axle Beam Drain Ports

5Differential Drain Port

7. Remove drain plugs from the differential and both


axle beams. Drain oil into suitable container.
NOTE: Dispose of waste properly. Do not dump oil on
ground or in sewers.
8. Clean and install the drain plugs.
NOTE: Any time plugs are removed, the O-ring seals
or copper washers should be replaced.

4. Open the bellypan to access the underside of the


differential.

9. Add new oil through one of the filler plugs on top of


the axle beams. Alternatively, add oil through the
level plug on the differential.

5. Clean the area around the plugs.

10. Check oil level on dipstick. Install the filler plug.

6. Lift the dipstick or remove the differential filler plug


to vent the differential.

Continued on next page

6-7-9

OUTJ003,00006F7 1917JUL011/2
101702

PN=135

Maintenance - Every 2000 hours


NOTE: Any time plugs are removed, the O-ring seals
or copper washers should be replaced.
Capacities

Differentials, front,
6-wheel

27 l (7.1 gal)

Hypoid oil

API GL-5 or MIL-L-2105 B or D

Viscosity

SAE
SAE
SAE
SAE

90
85W/90
80W/90
75W/90

OUTJ003,00006F7 1917JUL012/2

Change Single Axle Wheel Ends Oil

UN19JUL01

NOTE: Although oil can pass from the differential to the


wheel ends, it is necessary to change the oil level
in the differential and each wheel end separately.
NOTE: Change the oil while it is warm.

T144165

1. Position the wheel end with the drain plug at the


bottom.
2. Clean the area around the plugs.
Wheel End - Drain Position

3. Remove the filler plug to vent the wheel end.

1Drain Plug
2Filler Plug

4. Remove drain plug. Drain oil into suitable container.


NOTE: Dispose of waste properly. Do not dump oil on
ground or in sewers.

Continued on next page

6-7-10

OUTJ003,00006F8 1917JUL011/2

101702

PN=136

Maintenance - Every 2000 hours


5. Position the wheel end with the drain plug on the
horizontal centerline of the axle.

UN19JUL01

6. Add new oil through the filler port until the level is at
the drain plug.
7. Clean and install the drain plug and the filler plug.

T144166

NOTE: Any time plugs are removed, the O-ring seals or


copper washers should be replaced.
8. Repeat the procedure at each wheel end.
Wheel End - Fill Position
Capacities

Hub gears, 6-wheel

Hypoid oil

API GL-5 or MIL-L-2105 B or D

2 x 4 l (2 x 1.05 gal)

Viscosity

SAE
SAE
SAE
SAE

1Drain Plug
2Filler Plug

90
85W/90
80W/90
75W/90

OUTJ003,00006F8 1917JUL012/2

Check and tighten the bolts for the joints


between axles and frame
Item

Measurement

Specification

Horizontal and Vertical bolts

Torque

1000 Nm (737.5 lb -ft)

Check and tighten the bolts for the joints between axles
and frame every 2000 h.

EL62757,0000123 1910APR021/1

6-7-11

101702

PN=137

Maintenance - Every 6 months


Service the fire extinguisher
The fire extinguishers must be checked, serviced and
stamped by an authorized dealer. On certain markets fire
insurance terms stipulate that fire extinguishers must be
checked after every six months.

T152581

UN11MAR02

Contact your insurance company for all the details.

EL62757,00000EE 1910APR021/1

6-8-1

101702

PN=138

Maintenance - Every 12 months


Have the fire extinguisher system (opt. eq.)
checked
The system is to be inspected once a year by authorized
service personnel.
This inspection is a condition of the insurance companies.
See section 11-4, annual inspection.

EL62757,00000EF 1910APR021/1

6-9-1

101702

PN=139

Maintenance - As required
General
IMPORTANT: Do not modify fuel system!
CAUTION: Modification or alteration of the
injection pump, the injection pump timing, or
the fuel injectors in ways not recommended by
the manufacturer will terminate the warranty
obligation to the purchaser. In addition,
tampering with fuel system which alters
emission-related equipment on engines may
result in fines or other penalties, per EPA
regulations or other local emission laws. Do not
attempt to service injection pump or fuel
injectors yourself. Special training and special
tools are required. (See your authorized
servicing dealer or engine distributor.)

EL62757,000013C 1911APR021/1

6-10-1

101702

PN=140

Maintenance - As required

Bleeding the fuel system


Bleeding the fuel system:

UN23AUG88

Whenever the fuel system has been opened up for


service (lines disconnected or filters removed), it will be
necessary to bleed air from the system.

X9811

CAUTION: Escaping fluid under pressure can


penetrate the skin causing serious injury.
Relieve pressure before disconnecting fuel or
other lines. Tighten all connections before
applying pressure. Keep hands and body away
from pinholes and nozzles that eject fluids
under high pressure. Use a piece of cardboard
or paper to search for leaks. Do not use your
hand.
Small amounts of air will be vented automatically from the
injection pump supply line. However, manual bleeding will
be required if:
The fuel tank is drained during ordinary operation
A part of the fuel supply line has leaked. Fuel filters are
not filled prior to installation.
Injection pump or high pressure fuel lines are replaced.
In order to eliminate air from the fuel system, proceed as
follows:

Continued on next page

6-10-2

EL62757,0000136 1910APR021/4

101702

PN=141

Maintenance - As required
1. Turn the start key to position I, to open the stop
solenoid and the tank valve.

2. Loosen the air bleed vent screw (1) two full turns by
hand on fuel filter base.
3. Operate supply pump primer lever (2) until fuel flow is
free from air bubbles.
4. Tighten bleed plug securely, continue operating hand
primer until pumping action is not felt. Push hand
primer inward (toward engine) as far as it will go.

6. If engine will not start, it may be necessary to bleed air


from fuel system at fuel injection pump or injection
nozzles as explained next.

T160020

UN01OCT02

5. Start engine and check for leaks.

1Primary filter vent screw


2Hand primer

EL62757,0000136 1910APR022/4

At Fuel Injection Pump


1. Turn the start key to position I, to open the stop
solenoid and the tank valve.
UN03NOV97

2. Slightly loosen fuel return line connector (A) at fuel


injection pump.

RG6264

3. Operate fuel supply pump primer lever until fuel,


without air bubbles, flows from fuel return line
connection.
Stanadyne Rotary Fuel Injection Pump

4. Tighten return line connector to 27 Nm (20 lb-ft).


5. Primer lever is spring-loaded and will return to normal
position.

Continued on next page

6-10-3

EL62757,0000136 1910APR023/4

101702

PN=142

Maintenance - As required
At Fuel Injection Nozzles

RG7725

1. Using two open-end wrenches, loosen fuel line


connection at injection nozzle as shown.
2. Crank engine over with starter motor, (but do not start
engine), until fuel free from bubbles flows out of
loosened connection. Retighten connection to 27 Nm
(20 lb-ft).
3. Start the engine

UN08JAN97

IMPORTANT: Always use a backup wrench when


loosening or tightening fuel lines at
nozzles and/or injection pump to avoid
damage.

Fuel Line Connection

EL62757,0000136 1910APR024/4

Have the proper function of the turbocharger


checked
Let an authorized service person do this check.
EL62757,00000F0 1910APR021/1

Have the proper function of the alternator


checked
Let an authorized service person do this check.
EL62757,000012A 1910APR021/1

Have the proper function of the starter motor


checked
Let an authorized service person do this check.
EL62757,0000129 1910APR021/1

6-10-4

101702

PN=143

Maintenance - As required

Have the proper function of the atomizers


checked
Let an authorized service person do this check.
The first indications of a faulty atomizer are as follows:

The engine runs erratically


The engine knocks
The engine overheats.
There is not enough power
The exhaust smoke is black.
Fuel consumption is high
CAUTION: Ensure that the high-pressure fuel
does not spray onto your skin.

NOTE: Even if only one of the atomizers is defective,


allow an authorized repair shop to check and
adjust the entire set.

EL62757,0000128 1910APR021/1

Clean the Fuel Tank Filler Filter


When the fuel tank is not full, the filler filter (1) can be
cleaned with a vacuum cleaner through the filler opening.
If it is necessary to remove the filter, first remove the
cover (2) on which the filter has been attached.
When installing the cover, make sure that the sensor pipe
(3) meets the guide at the bottom of the tank.

T152580

UN11MAR02

1Filler filter
2Cover
3Sensor pipe

EL62757,0000127 1910APR021/1

6-10-5

101702

PN=144

Maintenance - As required

Replacing fan/alternator belt

3. Install new belt, be sure that belt is correctly seated in


all pulley grooves.
4. Apply tension to belt with tensioner. Remove ratchet

RG8098

2. Remove belt from pulleys and discard belt.

UN18NOV97

1. Release tension on belt

5. Start engine and check belt alignment

RG,RG34710,3602 1930AUG961/1

Maintain the Boom


1. Adjusting the rotator link brakes
Sea section 10-5.

EL62757,000013B 1911APR021/1

Check the air conditioner


See Section 11-1.
Maintenance every 24 months:
The filter-dryer-receiver must be replaced always when
the hoses are replaced or if the service moisture indicator
has turned to pink.

EL62757,0000140 1912APR021/1

6-10-6

101702

PN=145

Cooling System Maintenance


Replenishing supplemental coolant additives
(SCAs) between coolant changes
IMPORTANT: Do not add supplemental coolant
additives when the cooling system is
drained and refilled with John Deere
ANTIFREEZE/SUMMER COOLANT or
COOL-GARD

UN05DEC97

NOTE: If system is to be filled with coolant that does not


contain SCAs, the coolant must be precharged.
Determine the total system capacity and premix
with 3% John Deere Coolant Conditioner.

RG6262

Through time and use, the concentration of coolant


additives is gradually depleted during engine operation.
Periodic replenishment of inhibitors is required, even when
John Deere ANTIFREEZE/SUMMER COOLANT is used.
The cooling system must be recharged with additional
supplemental coolant additives available in the form of
liquid coolant conditioner.

JTO7298 Coolant/Battery Tester

Maintaining the correct coolant conditioner concentration


(SCAs) and freeze point is essential in your cooling
system to protect against rust, liner pitting and corrosion,
and freeze-ups due to incorrect coolant dilution.
John Deere LIQUID COOLANT CONDITIONER is
recommended as a supplemental coolant additive in
John Deere engines.
DO NOT mix one brand of SCA with a different brand.
Test the coolant solution at 600 hours or 12 months of
operation using either John Deere coolant test strips or a
COOLSCAN analysis. If a COOLSCAN analysis is not
available, recharge the system per instructions printed on
label of John Deere Liquid Coolant Conditioner.

COOL-GARD is a trademark of Deere & Company


COOLSCAN is a trademark of Deere & Company

Continued on next page

6-11-1

DPSG,OUOD002,1921 1912DEC001/2

101702

PN=146

Cooling System Maintenance


IMPORTANT: ALWAYS maintain coolant at correct
level and concentration. DO NOT
operate engine without coolant even for
a few minutes.
If frequent coolant makeup is required,
the glycol concentration should be
checked with JTO7298 Coolant/Battery
Tester to ensure that the desired freeze
point is maintained. Follow
manufacturers instructions provided
with Coolant/Battery Tester.
Add the manufacturers recommended concentration of
supplemental coolant additive. DO NOT add more than
the recommended amount.
The use of non-recommended supplemental coolant
additives may result in additive drop-out and gelation of
the coolant.
If other coolants are used, consult the coolant supplier
and follow the manufacturers recommendation for use of
supplemental coolant additives.
See DIESEL ENGINE COOLANTS AND
SUPPLEMENTAL ADDITIVE INFORMATION for proper
mixing of coolant ingredients before adding to the cooling
system.

DPSG,OUOD002,1921 1912DEC002/2

6-11-2

101702

PN=147

Cooling System Maintenance

RG6557

UN20JAN93

UN20JAN93

Pressure testing cooling system

RG6558

Test Radiator Cap


Test Cooling System

1. Allow engine to cool, then carefully remove radiator


cap.

CAUTION: Explosive release of fluids from


pressurized cooling system can cause
serious burns.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands.
Slowly loosen cap to first stop to relieve
pressure before removing completely.
Test Radiator Cap

2. Fill radiator with coolant to the normal operating


level.
IMPORTANT: DO NOT apply excessive pressure to
cooling system, doing so may
damage radiator and hoses.
3. Connect gauge and adapter to radiator filler neck.
Pressurize cooling system to 67 kPa (0.7 bar) (10
psi)1.

1. Remove radiator cap and attach to D05104ST


Tester as shown.
2. Pressurize cap to 67 kPa (0.7 bar) (10 psi)1. Gauge
should hold pressure for 10 seconds within the
normal range if cap is acceptable.

4. With pressure applied, check all cooling system


hose connections, radiator, and overall engine for
leaks.
If leakage is detected, correct as necessary and
pressure test system again.

If gauge does not hold pressure, replace radiator


cap.

If no leakage is detected, but the gauge indicated a


drop in pressure, coolant may be leaking internally
within the system or at the block-to-head gasket.
Have your servicing dealer or distributor correct this
problem immediately.

3. Remove the cap from gauge, turn it 180, and


retest cap. This will verify that the first
measurement was accurate.
Test Cooling System
NOTE: Engine should be warmed up to test overall
cooling system.

Test pressures recommended are for all Deere OEM cooling


systems. On specific vehicle applications, test cooling system and
pressure cap according to the recommended pressure for that
vehicle.
RG,RG34710,4083 1901JAN961/1

6-11-3

101702

PN=148

Hydraulic System: Hydraulic Oil Change


Hydraulic tank and the vacuum pump
Using the vacuum pump
The vacuum pump is used to avoid oil spill, e.g., in the
event of hose rupture or other leakage.
IMPORTANT: Before starting and using the vacuum
pump, make sure the machine is level
and that the hydraulic fluid is not above
maximum level, see the sight glass.

UN07APR02

Otherwise the hydraulic fluid might


reach up to the suction connection in
the tank!

UN23SEP02

2. Run for 2 or 3 minutes before doing anything with the


hydraulic system
3. After the vacuum pump has been turned off start the
engine and let it idle for a couple of minutes.

T159295

NOTE: The vacuum pump will be disconnected


automatically if the machine is started

T152231

1. Stop the engine.


Set the ignition lock to the vacuum pump mode (P)
before activating switch (5)

3Switch, fill-up pump (optional equipment)


4Quick coupler
5Switch, vacuum pump

EL62757,000004F 5415SEP021/1

Checking the oil level in hydraulic tank


1. Check the hydraulic oil level in the sight glass (1) of
the tank. When you do this, the lift and shift cylinders
have to be in the innermost position.
2. If necessary add oil.
Capacities

Hydraulic tank

min. 79 l (20.9 gal) / max. 150 l (39.6 gal)

Mineral oil

Summer oil

SMRs norm SH 68

Winter oil

SMRs norm SHS 32

Year-round oil

SMRs norm SHS 46

If you use synthetic biodegradeable oil:

Neste Biohydrauli SE 46

EL62757,0000131 1910APR021/1

7-1-1

101702

PN=149

Hydraulic System: Hydraulic Oil Change

Renew the hydraulic oil.


NOTE: Change hydraulic oil when it is warm and
contaminants are in suspension.
During the oil change, open the vent tap (2) first.

T152230

UN05MAR02

1Sight glass
2Vent tap

EL62757,00000EC 1910APR021/3

Draining the oil


The oil tank drain hose (1) is located at the front belly
pan.

T152229

UN05MAR02

1. Open the plug at the end of the drain pipe


2. The hydraulic oil of the working hydraulic pump is
drained by opening the plug (2) at the end of the drain
pipe
NOTE: Dispose of waste properly.
3. Clean the hydraulic tank.
4. After every 1000 hours: change the hydraulic return
filter and the breather. See section 6-6.
5. Close the plug of the drain pipe.

1Drain hose, hydraulic oil from the tank


2Drain hose, hydraulic oil from work pump

Continued on next page

7-1-2

EL62757,00000EC 1910APR022/3

101702

PN=150

Hydraulic System: Hydraulic Oil Change


Filling the oil
IMPORTANT: Do not exceed the MAX mark.
There always has to be enough air
space in the hydraulic oil tank, because
the fluid level goes up and down during
the operation.
IMPORTANT: Do not mix different type of oils.

UN07APR02

Add oil through the quick coupler (4) with the hydraulic
fill-up pump (3) (optional equipment). The quick coupler is
mounted in a way that the new oil enters the system
through the filter.

T152231

NOTE: During the fill up, open the vent tap of the
hydraulic tank.
1. Clean the filling hose and remove the dust cap.
2. Place the hose into the canister containing new
hydraulic oil.
3. Start the filling pump with switch (3).
4. Close the vent tap.

3Switch for hydraulic fill-up pump


4Quick coupler
5Switch for vacuum pump

NOTE: Also a manual pump can be used.

EL62757,00000EC 1910APR023/3

7-1-3

101702

PN=151

Hydraulic System: General


Working hydraulic system
The working hydraulics system includes all other hydraulic
functions except driving hydrostatics.
The hydraulic system is load sensing, i.e., it senses how
much pressure is required when a particular function is
activated.
The pump supplies only the amount of fluid required in
each situation, and no fluid is circulated by the pump
when all functions are at rest.

EL62757,0000196 1921APR021/1

Hydrostatic system
The hydraulic part is a hydrostatic link between the engine
and gearbox, consisting of a hydraulic pump and a
hydraulic motor. Infinitely variable speed control and gear
shifting between forward and reverse is achieved.
See also Section 9.

EL62757,0000197 1921APR021/1

7-2-1

101702

PN=152

Hydraulic System: Bleeding


General
If air enters the working or driving hydraulic system while
parts are changed, the air must be eliminated from the
components affected before the machine can be operated
again.
Follow the instructions provided on the next pages.

EL62757,0000199 1921APR021/1

Bleeding Drive Hydraulic System


Air must be eliminated from the drive hydraulics after the
system has been serviced or repaired, before the machine
is used again.

UN02OCT02

1. If necessary, add first clean, filtered hydraulic oil to the


housings of the drive pump and drive motor through
the bleed connects (1) / (B), until the housings are half
full.
2. Fill up the hydraulic tank.
Make sure that the low-pressure hose of the drive
pump is also filled with oil (loosen the hose
connector for the fill-up).

T159885

3. Press down the emergency stopper in the instrument


panel to ensure that the engine will not start during the
air bleeding process
4. Make sure that the switch for driving direction is in the
center position. This ensures that the drive pump stays
at a zero angle
BDrive pump bleed connect, Drive motor bleed
connect

Continued on next page

7-3-1

EL62757,000019A 1921APR021/2

101702

PN=153

Hydraulic System: Bleeding

6. Operate the starter motor for appr. five seconds


7. Repeat the starting procedure after waiting one minute
(do this 3 ... 5 times), until no more air comes out of
the bleed hoses.
8. Disconnect the bleed hoses

T153143

(204)Supply pressure
(206)Drive pressure backwards
(214)Drive pressure forward

UN01SEP02

5. Connect bleed hoses to the measuring points of the


drive hydraulics:
Supply pressure (204)
Driving pressure (206) and (214)

EL62757,000019A 1921APR022/2

7-3-2

101702

PN=154

Hydraulic System: Bleeding

Bleeding Work Hydraulic System


Before the machine is used again air must be eliminated
from all hydraulic system components that have been
serviced or repaired.

UN08OCT02

NOTE: If necessary, add first clean, filtered oil to the


housing of the working pump through the bleed
connect (B) until the housing is half full.
1. Next, fill up the hydraulic tank.

T160060

Make sure that the low-pressure hose of the working


pump is also filled with oil (loosen the hose connector
for the fill-up).
2. Start the engine and allow it to idle.
3. Connect bleed hoses to the following measuring points
in the working hydraulic system:

UN01OCT02

a. The working pump pressure (111)

T159884

b. The reduced pressure of the auxiliary functions


(114)
c. Pilot pressure of the crane valve (123)
Attachement valve

4. Disconnect the bleed hoses as soon as no more air


comes out of them.

BWork pump bleed connect


111Work pump pressure
117Work pump LS pressure
114Reduced pressure of the auxiliary functions

5. Connect a bleed hose to the measuring point (114) of


the LS pressure line going to the working pump.
6. Operate the rotator for appr. one minute in the other
direction.
7. Disconnect the bleed hose as soon as no more air
comes out of it.
8. Stop the engine and let air be removed from the oil
tank (for appr. five minutes).

Continued on next page

7-3-3

EL62757,000019B 1921APR021/2

101702

PN=155

Hydraulic System: Bleeding


Bleeding the solenoids of the loader valve
1. Loose the bleeding screws (A) on top of the solenoids
and operate the boom movements for appr. one
minute.
2. Close the screws.

T159882

1. Slowly operate the functions all the way to their


extreme positions. Do this at least twice.
2. If necessary, you can also check the directions of
travel for the various functions at the same time.
Stop the engine and let air be removed from the oil
in the tank (for appr. five minutes).
Add oil until the level reaches the upper mark in the
measuring glass

UN13OCT02

Bleeding the cylinders

123Measuring crane valve pilot pressure


AVent screws

EL62757,000019B 1921APR022/2

7-3-4

101702

PN=156

Hydraulic System: Bleeding

Bleeding the Brake System

UN06JUN01

CAUTION: With the engine running, the brake


system pressure is 10 MPa (1450 psi). Use
extreme caution when opening the vent screws
to bleed air from the system.
Bleeding the brake cylinders

T139063

1. Start the diesel engine.


2. Release the parking brake (see the symbol on TMC
display).
3. Bleed the work brake cylinders through vent screws
RB6, RB7, RB8 and RB9

T139065

UN06JUN01

T139064

UN06JUN01

1Vent screw of work brake cylinder

Continued on next page

7-3-5

EL62757,000019C 1921APR021/3

101702

PN=157

Hydraulic System: Bleeding


4. Bleed the parking brake cylinders through vent screws
RB2, RB3, RB4 and RB5.

T139068

UN06JUN01

T139067

UN06JUN01

T139066

UN06JUN01

1Vent screw of parking brake cylinder

Continued on next page

7-3-6

EL62757,000019C 1921APR022/3

101702

PN=158

Hydraulic System: Bleeding


Bleeding the brake pedal
If necessary, the brake pedal circuit can be bled as
follows:
NOTE: Two people are needed for bleeding of the brake
pedal.
NOTE: Do not start the diesel engine.

Press the pedal several times,


Keep the pedal pressed and open the bleed screw (1).
Close the bleed screw and release the pedal.
Repeat until no air comes out with fluid.
Do the same procedure for the other brake pedal.
Check that air is properly removed from both of the
brake pedals by driving the machine when the brake is
on.

UN01OCT02

3ATF tank
1Bleed screw

T159877

1.
2.
3.
4.
5.
6.

T152820

The process is the same as for a normal fluid brake

UN20MAR02

NOTE: Check that there is sufficient brake fluid in the


fluid bottle (3)

EL62757,000019C 1921APR023/3

7-3-7

101702

PN=159

Hydrostatic System: Drive Pump adjusting


Checking and adjusting the charge pressure

T138248

UN22AUG01

1. Disconnect the parking brake solenoid Y41 from the


valve block. After this, the parking brake will stay
engaged
2. Connect a pressure gauge (0 ... 6 MPa) (0... 870 psi)
to pressure measuring point (204). When the engine
RPM is 1600, the pressure should be 2.8 ... 3.2 MPa
(406 ...464 psi).
3. If necessary, adjust the pressure with adjusting screw
(207).
4. Fit the solenoid into the valve and tighten the
lockscrew hand tight.

T153143

UN01SEP02

Y41Park brake solenoid


(204)Measure point
(207)Adjust screw

EL62757,000019D 1921APR021/1

7-4-1

101702

PN=160

Hydrostatic System: Drive Pump adjusting

Checking and adjusting the pressure cut-off


valve setting of the drive pump

UN22AUG01

1. Disconnect the parking brake solenoid Y41 from the


valve block . After this, the parking brake will stay
engaged.

T138248

2. Connect pressure gauges (60 MPa) (8702 psi) to


measuring points (214) (forward) and (206) (reverse).
3. Engage high gear.
4. Drive the machine both forward and backward even
though the brake is on. Do not do this longer than for
five seconds at a time.
5. The pressure should rise to 45,0 + 0,5 MPa (6526,70
psi) (both directions).
6. If necessary, adjust the pressure with adjusting screw
(210) (forward/reverse).
7. After making the adjustment, check the pressures once
again.

UN28MAR02

8. Fit the solenoid into the valve and tighten the


lockscrew hand tight.

T153143

UN01SEP02

T153142

(206)Measure point, drive pressure backwards


(210)Adjust screw
(214)Measure point, drive pressure backwards

EL62757,000019F 1921APR021/1

7-4-2

101702

PN=161

Hydrostatic System: Drive Motor adjusting


Checking the function of hydrostatic flushing
valve

2. First, press the brake pedal all the way down


3. Press the accelerator pedal until the machine tries to
start moving.
4. The very moment the machine should start moving
(i.e. the pressure measuring point (206) rises) the
pressure at the measuring point (204) must drop by
appr. 0,1...0,6 MPa (14...87 psi).

T153143

1. Connect a pressure gauge to measuring points (204)


(0 ... 6 MPa) (0...870 psi) and (206) (0 ... 60 MPa)
(0...8702 psi) .

UN01SEP02

The function of hydrostatic flushing valve is checked by


measuring the supply pressure (204).

(204)Measure point, supply pressure


(206)Measure point, drive pressure backwards

NOTE: The hydrostatic flushing valve cannot be adjusted.

EL62757,000019E 1921APR021/1

7-5-1

101702

PN=162

Hydrostatic System: Drive Motor adjusting

Checking and adjusting drive motors


pressure cut-off settings
The tools needed: 3-mm hex key and 10-mm wrench
1. Disconnect the parking brake solenoid Y41 from the
valve block. After this, the parking brake will stay
engaged.
2. Connect a pressure sensor to measuring point (206)
(...60 MPa) (0...8702 psi) and a pressure gauge to
measuring point (216) (...60 MPa) (0...8702 psi)
3. Disconnect the connector of the motor steering (pos.
C)

4. Connect a 24 V tension with a separate cable from the


power outlet next to the main switch to the motor
steering (pos.C).

5. Start the engine

T152684

216

6. Engage high gear and rear wheel drive. Let the engine
idle.

UN19MAR02

217

7. Select the driving direction forward.


8. Set the adjustable speed range (snail) to 15 %
9. Press smoothly the drive pedal, the pressure will first
start to rise at measuring points (216) and (206).

UN01SEP02

10. The engine rpm and the pressures are increasing, but
at a certain point the pressure of (216) stops to
increase and finally it starts to decrease.

T153143

11. When the pressure at (206) reaches 31 MPa (4496


psi) the pressure at (216) should then be 14 2 MPa
(2030 290 psi).
a. If (206) reaches 33 MPa (4786 psi) and the value
at (216) is higher than 14 2 MPa (2030 290
psi) , turn the adjusting screw (217)
counterclockwise in small increments and repeat
the test.

CAdjusting screw
(216)Measure point,
(217)Adjusting screw, cut-of

Continued on next page

7-5-2

EL62757,00001A0 1921APR021/3
101702

PN=163

Hydrostatic System: Drive Motor adjusting


b. If (206) reaches 33 MPa (4786 psi) and the value
at (216) is lower than 14 2 MPa (2030 290
psi), turn the adjusting screw (217) clockwise in
small increments and repeat the test.
EL62757,00001A0 1921APR022/3

12. Disconnect the cable between the power outlet and


the position C

UN22AUG01

13. Connect back the connector of the motor steering


(pos. C) .
14. After making the adjustment, fit the solenoid into the
valve and tighten the lockscrew hand tight

T152801

UN20MAR02

T138248

24VCurrent
Y41Solenoid

24V Current
EL62757,00001A0 1921APR023/3

7-5-3

101702

PN=164

Work Hydraulic System: Check and Adjust


Adjustment of Pressure Difference

UN01OCT02

1. Connect pressure sensors (0 ... 30 MPa) (0...4351 psi)


to measuring points (111) and (117) (pump main
pressure and signal lines).
2. Engage the working rpm and boom

4. Rotate the rotator freely and simultaneously check the


pressure at measuring points (111) and (117). The
pressure at (117) must be lower than that of (111) by
2.5...2.7 MPa (362...391 psi).

T159884

3. Lift the loader free of the load area.

111Measure point, work pumps pressure


117Measure point, work pumps signal pressure

NOTE: When checking at measuring point (111) the


pressure should not rise over 15 MPa (2175 psi).
5. If necessary, adjust the pressure with adjusting screw
(102).
NOTE: Turning the screw clockwise will increase the
pressure difference

EL62757,00001A1 1921APR021/1

Adjusting the Maximum Pressure


1. The sensors are still connected to measuring points
(111) and (117).
2. The working rpm is engaged.

The pressure at measuring point (111) must be


240,5 MPa (348072 psi).
4. If necessary, adjust from adjusting screw (101).
Turning the screw clockwise will increase the pressure.

T160061

UN02OCT02

3. Increase the pressure to maximum. For example by


using the extension in movement.

101Max-pressure adjustment
102Pressure difference adjustment

EL62757,00001A2 1921APR021/1

7-6-1

101702

PN=165

Work Hydraulic System: Check and Adjust

Adjusting the Boom Pressure

UN13OCT02

What can be measured at the loader valve is the pilot


control pressure of the valve as well as the pressures
specific for each function.
Measuring the pressures for each function

T159883

The pressures of each movement can be measured


through measuring point (116)
First, connect a (0...30 MPa) (0...4351 psi) pressure
transducer to quick coupler (116).
Engage the working rpm and boom
1. Grapple close
a. Operate the grapple close function.
The pressure must rise up to 18.3 MPa (2654 psi)
as the movement is operated to extreme.
b. If necessary, adjust from adjusting screw (135)

UN01OCT02

2. Grapple open
a. Operate the grapple open function.
The pressure must rise up to 16.3 MPa (2364 psi)
as the movement is operated to extreme.
b. If necessary, adjust from adjusting screw (136)
3. Other functions

T159881

Operate the function you want to check.


The pressure must rise up to the maximum level (21.5
MPa) (3118 psi) as the movement is operated to
extreme
Steering:
a. Operate steering function to right / left
b. The pressure must rise up to 20.4 MPa (2959 psi) as
the movement is operated to extreme
c. If necessary, adjust from adjusting screw (139) /
(140)

116Measure point, pilot pressure


129Adjusting screw, reduced pressure,
slew
130Adjusting screw, reduced pressure,
slew
135Adjusting screw, reduced pressure,
closed
136Adjusting screw, reduced pressure,
open
139Adjusting screw, reduced pressure,
140Adjusting screw, reduced pressure,

Boom Slew:

boom
boom
grapple
grapple
steering
steering

a. Operate slewing function to right / left


b. The pressure must rise up to 20.4 MPa (2959 psi)
MPa as the movement is operated to extreme

Continued on next page

7-6-2

EL62757,00001A3 1921APR021/3
101702

PN=166

Work Hydraulic System: Check and Adjust


c. If necessary, adjust from adjusting screw (129) /
(130)

EL62757,00001A3 1921APR022/3

Checking the pilot pressure


1. Connect a (0...30 MPa) (0...4351 psi) pressure sensor
to measuring point (123).
2. Next, engage the loader and working RPMs (1500 ...
1700 rpm).
3. Increase the pressure up to the maximum level by
means of the extension in function, for instance
At measuring point (123), the pressure should be 3.5
0.5 MPa (507 72 psi).
The pressure relief valve cannot be adjusted.

T159882

UN13OCT02

123Pressure measure point


ABleed screws

EL62757,00001A3 1921APR023/3

7-6-3

101702

PN=167

Work Hydraulic System: Check and Adjust

Adjusting Auxiliary Functions

UN13OCT02

Differential locks.
High/low gear.
Rear-wheel drive engage when the high gear is used.

T159880

The functions listed above operate with a reduced


pressure of 3.0 MPa (435 psi). The pressure is measured
at measuring point (114).
If necessary, the pressure is adjusted from adjusting
screw (113). This can be done while the engine is idling.
NOTE: Though the pressure is lower than the delta
pressure of the pump, the adjustment should be
checked by increasing the pressure up to the
maximum by engaging the extension in
movement, for instance. The pressure at quick
coupler (114) must remain the same.

113Adjusting screw
114Pressure measuring point
(409)Adjusting screw for frame brake.

Stairs operate with a reduced pressure of 3.0 MPa (435


psi).

EL62757,00001A4 1921APR021/1

Adjusting Frame Brake

The boom and working rpm are engaged


Grap for instance a stake with the grapple.
Use the main lift and keep it engaged.
Check the pressure at measuring point (411).
The pressure should be 21.0 MPa (3045 psi).
5. If necessary, adjust the pressure from adjusting screw
(409)

T152779

1.
2.
3.
4.

UN15APR02

The pressure used for the same frame brake is provided


by the lift cylinder, not directly from the pump.

T159616

UN20SEP02

(411)Pressure measure point


409Adjusting screw

EL62757,00001A5 1921APR021/1

7-6-4

101702

PN=168

Work Hydraulic System: Check and Adjust

Adjusting Proportional Decking Blade


The pressure for the proportional decking blade can be
measured from measuring point (116).

T160364

UN14OCT02

1. Operate cylinder function to in / out


2. The pressure must rise up to 20.3 MPa (2944 psi) MPa
as the movement is operated to extreme.
3. If necessary, adjust from adjusting screw 516, located
on the workpump.

EL62757,0000061 6716OCT021/1

Adjusting Optional Equipment


Headboard movement
Decking blade
Preparedness for clambunk
All optional equipment (as installed at the factory) operate
with the maximum pressure. There are no separate
pressure adjustments.

EL62757,00001A6 1921APR021/1

7-6-5

101702

PN=169

Brake System: Check and Adjust


Checking the brakes

1. Release the parking brake


2. Insert the calliper (A) through the aperture and take a
measurement at the adjusting screw (B)
3. Make a note of the measurement.
4. Reconnect the parking brake and repeat the
measurement.
The difference between the two measurements must
not exceed 5,25 mm (0.2 inc).
If the difference is greater than this, the cylinder should
be adjusted.

T153524

You can check that the cylinders are correctly adjusted by


taking measurements through the release screw aperture
(8), for example using a slide calliper.

UN04APR02

IMPORTANT: Before you start the servicing work, the


machine has to be parked on a level
surface.

EL62757,00001A7 1921APR021/1

7-7-1

101702

PN=170

Brake System: Check and Adjust

4. Loosen the locking nut (4). Hold the piston (6) in


position.
5. Fully open the adjusting screw (1). Clean the thread
and the locking nut (4).
6. Turn the locking nut (4) to the end of the adjusting
screw. Lock the adjusting screw thread (1) by applying
locking fluid (Loctite 242).
NOTE: If the locking fluid comes into contact with other
areas than the adjusting screw and the locking
nut, the excess fluid should be cleaned away.
7. Insert the adjusting screw (1) and turn it clockwise until
a significant resistance is felt (8...15 Nm) (5,9...11
lb-ft). Turn the adjusting screw (1) 3 1/2 turns
counterclockwise while holding the piston (6) in
position.
8. Tighten the locking nut (4) to approx. 40 Nm (29.5 lb-ft)
while holding the piston (6) in position.
9. Reinstall the cylinder. Ensure that the O ring (7) is in
good condition and is correctly positioned. Tighten the
four screws (5).
10. Fit the protective cover (2). Check that the O ring is in
good condition and is correctly positioned
11. Connect the electrical contact Y41W to the brake
valve. Adjust all the cylinders in the same way

T159878
UN04APR02

NOTE: The smaller Allen screws (2 screws, key size 6


mm) should not be loosened

T153523

1. Disconnect electrical contact Y41W, from the work


brake valve.
2. Remove the protective cover (2). Note the loose
release screw (3) under the cover
3. Open the larger Allen screws (5) (4 screws, key size 8
mm) and remove the cylinder.

UN08OCT02

Mechanical adjustment of brakes

EL62757,00001A8 1921APR021/1

7-7-2

101702

PN=171

Brake System: Check and Adjust

Brake Charging Pressure


CAUTION: Do not ever disconnect any brake
system hose joints before all pressure has been
eliminated from pressure accumulators.
Connect a pressure sensor (0...30 MPa) (0...4351 psi) to
pressure measuring points (307) and (301).

T152793

1. Turn the start key to I position and wait until you hear
the TMC signal. Start the engine.
2. Disengage the parking brake and wait until the
pressure has risen to 15,0...16,0 MPa (2175...2320
psi).
3. Engage and disengage the parking brake a number of
times.
The pressure reading measured from measuring points
(307) and (301) should drop

UN01SEP02

NOTE: The pressure is the same with that of the


pressure accumulators

301Measure point
307Measure point

The charging system of the pressure accumulators should


be activated as soon as the pressure drops to 13,0 ...
14,5 MPa (1885...2103 psi), and disengaged when the
pressure has risen to 16,0 MPa (2320 psi).

EL62757,00001A9 1921APR021/1

NOTE: The pressures cannot be adjusted.

T152794

1. Connect a pressure sensor (0...30 MPa) (0...4351 psi)


to measuring points (305) and (304).
2. Start the engine
3. Disengage the parking brake. Symbol P on the TMC
display will be replaced by S.
4. Make sure that the maximum pressure reading from
the pressure measuring points (305) and (304) are 9.5
... 10.0 MPa (1377...1450 psi).

UN13OCT02

Checking the Work Brake

EL62757,00001AB 1921APR021/1

7-7-3

101702

PN=172

Brake System: Check and Adjust

1. Connect a pressure sensor (0...30 MPa) (0...4351 psi)


to measuring points (305) and (304)
2. Start the engine and keep engaged the parking brake
3. Press the brake pedal and ensure that the pressure
reading from the (305) and (304) rises to 9.5 ... 10.0
MPa (1377...1450 psi).

T152794

NOTE: The pressures cannot be adjusted.

UN13OCT02

Checking the Drive Brake (Brake Pedal)

EL62757,00001AC 1921APR021/1

7-7-4

101702

PN=173

Electrical System
Main Switch
The main switch (1) is behind a cover on the left-hand
side of the machine.

UN01OCT02

The main current coming from the battery is divided


between two 60 A fuses.
The fuses can be found in a fuse box under the cab.

T159876

There is a socket serving as a power outlet (24 V) next to


the main switch. If the machine is equipped with an
automatic fire extinguishing system (opt. eq.) the system
will be switched on to the automatic mode when the main
switch is turned off.
1Main Switch
2Triggering handle for fire extinguisher
3Quick coupler for hydraulic oil filling
4Tap for decking blades floating system
5Switch, hydraulic oil filling pump
6Switch, vacuum pump
724V Current

EL62757,00001AD 1921APR021/1

8-1-1

101702

PN=174

Electrical System

T159875

UN01OCT02

Location of ECU and engine sensors

AOil pressure sensor


BPump control solenoid
CEngine Control Unit (ECU)

DCrank position sensor


EFuel temperature sensor
FEngine coolant temperature
(ECT) sensor

GManifold air temperature


(MAT) sensor

HLoss of coolant
temperature sensor

ECU, engine control unit, is placed at the left side of


the machine.

EL62757,00001AE 1921APR021/1

8-1-2

101702

PN=175

Electrical System

Batteries

UN23AUG88

CAUTION: Gas given off by battery is explosive.


Keep sparks and flames away from battery. Use
a flashlight to check battery electrolyte level.

TS204

Never check battery charge by placing a metal


object across the posts. Use a voltmeter or
hydrometer.
Always remove grounded (-) battery clamp first
and replace it last.
CAUTION: Sulfuric acid in battery electrolyte is
poisonous. It is strong enough to burn skin, eat
holes in clothing, and cause blindness if
splashed into eyes.

RG4698

UN14DEC88

The machine has a negative earth electrical system. It


is equipped with two 12 volt batteries connected in
series to provide 24 volts and a capacity of 140 Ah.
The batteries are located under the cab on the left-hand
side of the machine.
When disconnecting the batteries always uncouple the
ground wire first. When connecting the batteries couple
the ground wire last.
When quick charging the batteries disconnect the
ground wire and positive cable. Do not mix up the
battery terminals. An incorrect connection may seriously
damage the alternator. Do not disconnect the battery
cables while the engine is running.
NOTE: Do not ever disengage the electronic system or
display when the power is on.
Using booster batteries:

Continued on next page

8-1-3

EL62757,00001AF 1921APR021/2

101702

PN=176

Electrical System
NOTE: In case you need an outside power source to start
the machine, it is recommended to use a similar
machine as a power source.
NOTE: If you need an outside power source to start the
machine, be careful not to short-circuit the battery
while handling the cables.
NOTE: Power source, stronger than 140 A (like an
auxiliary battery), can be used only as a quick
charger for batteries.
Connecting auxiliary cable:
First, connect the auxiliary positive cable, coming from a
24-volt power source, to the positive cable of the machine
to be started, and then connect the auxiliary negative
cable to the power source and the other end to the
negative cable or frame of the machine to be started.
Bear in mind this order of connection when using auxiliary
batteries because a full battery is more sensitive to
sparks.
Disconnect the cables in reverse order, beginning by
disconnecting the negative cable from the machine to be
started.
IMPORTANT: Make sure, that the polarity is correct
before you make any connections.
Contrarious polarity violates the
electrical system.
CAUTION: The manufacturer shall assume no
responsibility for any alterations made to the
electrical system of the machine if the changes
are not in compliance with service bulletins.
There is a risk that the function of the safety
systems of the machine is jeopardized.

EL62757,00001AF 1921APR022/2

8-1-4

101702

PN=177

Electrical System

Welding
Before you start arc welding the machine, do the following

T152800

UN20MAR02

1. The first actions


turn the master disconnect switch off
disconnect the wire (1) between the battery and the
frame.
disconnect central unit wires of the automatic fire
extinguishing system (A) and the tripping of the
extinguisher (F).
Ground cable

T159364

UN13SEP02

Cables to be disconnected

Continued on next page

8-1-5

EL62757,00001B0 1921APR021/2

101702

PN=178

Electrical System
disconnect ECUs cable
disconnect Hubs cables (5 cables)
2. Grounding
Connect the ground wire as close to the welding
point as possible.
The welding current must never pass through
bearings, joints, electrical equipment, or hydraulic
systems.

T159874

UN01OCT02

3. The parts that must never be welded:


boom fastening bolts
control valves
hydraulic pipes
4. The parts that must not be welded without the
manufacturers instructions:
castings
cylinder loops.

ECUs cable

T159362

6. Welding.
Weld inside, if possible, in facilities reserved for this
purpose where the temperature is at least 10 degrees
centigrade. If welding in other places, pay attention to
local regulations and to circumstances as well as to the
environment before you start welding.
The welder must possess adequate skills and the
permits required.
7. Assessment of damage.
In case a component or structure has been damaged
as a result of an accident, excessive load, or fatigue, it
is first necessary to determine whether the structure
requires reinforcements or is ordinary repair sufficient.
8. Instructions.
Before you start welding you can also contact the
manufacturer who has detailed instructions for each
case.
Possibility of major damage is reduced by regularly
cleaning and checking the machine and the boom.

UN13SEP02

5. The points and components to which it is forbidden to


attach other parts by welding:
castings
boom ends
cylinder fastening lugs
corners of box girders

Hub in the cabine

EL62757,00001B0 1921APR022/2

8-1-6

101702

PN=179

Electrical System

Main fuse

(60 A)

F52

Main fuse

(60 A)

F41

Preheater (opt. eq.)

(20 A)

F42

Preheater (opt. eq.)


and Timer (opt. eq.),
Radio and
Radio-telephone

(15 A)

F43

Air conditioner (opt.


eq.)

(25 A)

F44

Grid heater signal


light

(7,5 A)

F45

Socket 24 V
Hydraulic pump
(fill-up) (opt. eq.)

(20 A)

F46

, Socket 24 V Fuel
pump (fill-up) (opt.
eq.)

(20 A)

F47

Fire extinguishing
system (opt.eq.

(10 A)

F48

Fire extinguishing
system (opt.eq.

(10 A)

T160565

F51

UN16OCT02

Fuses on the Left-Hand Side in the Engine


Compartment

Relay K3, Starting motor


Relay K15, Engine preheater & AC unit

EL62757,00001B1 1921APR021/1

8-1-7

101702

PN=180

Electrical System

Instrument Box Fuses and Relays


F1-F13

Work Lights

F14

Head light switch

F15

Ignition

F16

Parking lights

F17

Brake switch

F18

Air conditioner, Seat compressor (opt.


eq.)

F19

Horn

F20

Indicator lights

F21

TMC

F22

Windscreen wipers

F23

Cigarette lighter

F24

Stairs

F25

Vacuum pump

F26

ECU

F27

Rear window wipers

F28

Fuel valve, stopping solenoid, motor


ECU

F29

Air conditioner, valve (opt. eq.)

F30

Hydraulics vacuum pump , (opt. eq.)

F31

Low beam

F32

Voltage transformer

F33

High beam

F34

Parking brakes

F35

Parking brakes

F36

Working pumps drop


Electricity controlled by ignition switch

K2

Intermittent rear window wiper

K4

Blinker relay

K6

Seat compressor

K9

Hourmeter

K12

Intermittent windshield wiper

K14

Engine starting prevent

K20

Radio

K21

Pressure switch, Air conditioner,


compressor (opt. eq.)

K22

Air conditioner, (opt. eq.)

K23

Seat compressor

T152823

UN17JUN02

K1

Continued on next page

8-1-8

EL62757,00001B2 1921APR021/2
101702

PN=181

Electrical System
Other relays
Relay K3, Starting motor
Relay K4, Blinker relay in the instrument box
Relay K24, Grid heater, Front frame

EL62757,00001B2 1921APR022/2

The RPM Sensor of the Drive Hydrostatics


Motor
The sensor (A4) is located on the left-hand side of the
drive hydrostatics motor. The sensor has an impact on the
function of the speedometer and odometer as well as on
the coupling of the work brake.

T159873

UN01OCT02

ARPM Sensor

EL62757,00001B5 1921APR021/1

8-1-9

101702

PN=182

Electrical System

Hydraulic Tank Sensors


Hydraulic Oil Level Sensor
The sensor (5) trickers the alarm if the hydraulic oil levels
drops below the acceptable limit.
Hydraulic Oil Temperature Sensor
The sensor (6) sets off the alarm if the hydraulic oil
temperature exceeds the acceptable limit.
Hydraulic Oil Return Filter Sensor
The sensor (7) triggers the alarm if the hydraulic oil filter
has clogged.

T152795

UN20MAR02

5Level Sensor
6Temperature Sensor
7Return Filter Sensor

EL62757,00001B6 1921APR021/1

8-1-10

101702

PN=183

Transmission

T152540

UN11MAR02

Operating Power Transmission

The hydrostatic-mechanical power transmission can be


divided into three main parts: mechanical, hydraulic,
and electrical part.

The hydraulic section consists of a hydraulic motor


connected to the high/low transfer case and of a
hydraulic pump connected to the diesel engine.

The mechanical part consists of the high/low transfer


case, drive shafts, differentials, and bogies.

EL62757,00001B7 1921APR021/1

High/Low Gear
The high/low transfer case is located at the back of the
front frame. The power generated by the hydraulic motor
is distributed by the high/low transfer case (through the
drive shafts) to the front differential and rear differential.
The gear is shifted with the switch on the right-hand-side
control panel (see Section 4). The switch controls a
hydraulic cylinder via an electrical valve.

EL62757,00001C3 1922APR021/1

9-1-1

101702

PN=184

Transmission

T152541

UN08MAR02

Hydrostatic System

The main components of the system are a hydraulic


pump and a hydraulic motor. These components make
up a closed loop circuit in which the oil flowing from
the pump to the motor will return to the pump from the
motor. Both the pump and the motor are of the
variable displacement piston type.

The direction of rotation and speed of the motor


depend on the direction and magnitude of the flow
generated by the pump.

The direction of rotation of the pump shaft is always


the same. The displacement of the pump is regulated
by means of two electrically controlled proportional
valves. One of the valves adjusts the pump plate in
one direction and the other valve in the opposite
direction. This system alters the direction and amount
of oil flow generated by the pump, which, in turn,
changes the direction of rotation of the motor (driving
direction and speed) accordingly. In addition to the
control current of the proportional valve, the amount of
flow generated by the pump can also be changed by
adjusting the speed of the diesel engine.

The pump and motor angles are interdependent. If the


machine stands still, the pump angle is zero and the
motor angle at its maximum. When the machine starts
off, the pump angle begins to increase. When the
pump angle reaches its maximum, the motor angle
begins to decrease. If you drive at full speed, the
pump angle is at its maximum and the motor angle at
its minimum.

The motor displacement is adjusted by turning the


motor shaft while the plate stays in place.

EL62757,00001C2 1922APR021/1

9-1-2

101702

PN=185

Transmission

Control of Transmission
TMC controls electrically hydrostatic transmission:
To adjust the speed of the diesel engine and the angle
of the hydraulic pump as dictated by the signal coming
from the accelerator pedal
The electronic control system monitors the speed of the
diesel engine. If the engine speed drops as a result of
additional loading, the pump angle will be reduced by
the electronic system. In other words, the gear ratio of
the power transmission is adjusted by the electronic
system which ensures that the power needed to operate
the machine is always smaller than the power
generated by the engine
When the machine stops, the work brake is
automatically engaged by the system.
The control of transmission is part of the Total Machine
Control System. (see Instructions for use TMC enclosed).

EL62757,00001C1 1922APR021/1

9-1-3

101702

PN=186

Boom, General

T152542

UN08MAR02

A General Description of the Boom

1Base
2Tower
3Main boom
4Outer boom

5Extension boom
6Slewing cylinder
7Main boom cylinder

8Outer boom cylinder


9Extension boom cylinder
10Link

NOTE: It is important for you to familiarize yourself


with the contents of this chapter. That will

11Rotator
12Grapple
13Grapple cylinder

assist you in getting the most out of the loader


and in doing the work safely.

EL62757,00001C4 1922APR021/1

10-0-1

101702

PN=187

Boom, General

Operating Safety Precautions


IMPORTANT: Make sure that you have been provided
enough guidance in the use of the
loader since it is the operator of the
machine who is primarily responsible
for safety in loading.
Adhere strictly to all safety regulations stipulated by law
at the work site pertaining to the operation of this
equipment.
CAUTION: Before starting the engine ensure
that there is nobody within the reach of the
loader.
If you are still learning to operate the loader, adjust the
moving speed of loader functions to a low level.
Make sure that you have good visibility to the working
area.
Keep an eye on machine stability while you are
loading.
CAUTION: During operation no other people are
allowed in the cab or within the danger zone of
twenty meters.

CAUTION: It is forbidden to use the loader for


lifting people.
Observe the lifting ratings given on the loader decal, do
not overload the system.
Do not force the cylinders to their extreme positions at
full speed.
IMPORTANT: Do not use the loader for towing.
Exercise great caution particularly when operating the
loader in front of the cab.
Bear in mind the overall height of the loader and the
load.

Continued on next page

10-0-2

EL62757,00001C5 1922APR021/2
101702

PN=188

Boom, General

CAUTION: A load that is stacked too high can


cause the machine to overturn, or the topmost
logs may slide over the headboard and cause a
fatal injury to the driver.
Maintain the safety distances required between the
machine or boom and power lines.
For transport, the loader must be properly secured in
the appropriate position.
Do not leave the cab before you have securely placed
the grapple onto the ground or in transport position.
CAUTION: Approach an area where
overhanging electrical powerlines are present
with extreme caution.
Safety distances for powerlines:
Rated voltage
kV

Min. distance (m)


under

on the side

2 (6,5 ft)

2 (6,5 ft

1...45

2 (6,5 ft

3 (9,8 ft)

110

3 (9,8 ft)

5 (16 ft)

220

4 (13 ft)

5 (16 ft)

400

5 (16 ft)

5 (16 ft)

IMPORTANT: If you come into contact with a


powerline, stay in the cab.

EL62757,00001C5 1922APR022/2

10-0-3

101702

PN=189

Boom, General

General Operating Instructions


First, operate the loader smoothly without load in
order to allow the grease to warm up and a coherent
lubrication film to be formed in loader joints.
During Operation:
1. Observe the lifting ratings given on the loader decal.
The weight of the lifting equipment is included in the
load to be lifted.
2. When handling a maximum load, exercise great
caution.
3. Operate the control sticks smoothly; avoid jerky
movements
4. Exercise extra caution always when a boom or the
booms are in their extreme positions.
5. Keep an eye on machine stability.
a. Constant alertness is required particular when
operating on sloping ground.
b. If necessary, lift small loads only
c. When you notice that the machine is about to fall
over, pull all extensions in, bend the outer boom,
and lower the load smoothly onto the ground.
6. When handling a load proceed as follows
a. Lift the load up
b. Move it closer to the machine.
c. Slew it.
d. Lower the load down.
7. It is possible that you exceed the lifting capacity of the
loader (the booms will sink) if you pick up a load that is
close to the machine and move the load away from the
machine. When this happens you must bring the load
closer to the machine by pulling the outer boom or
extension inwards. This is necessary because
otherwise the power of the main boom cylinder will not
be sufficient to handle the load.
When Loading Is Over:
1. Carry out the last movements unloaded
2. Lower the booms (and also the center of gravity) onto
the load, as down as possible.
3. Close the grapple around the load or frame in order to
prevent the loader from moving sideways.

Continued on next page

10-0-4

EL62757,00001C6 1922APR021/2
101702

PN=190

Boom, General
4. Do not ever leave the loader unsupported by relying on
the hydraulic system only.
5. When you drive the machine from one place to another
make sure that the loader does not make any sudden
movements.

EL62757,00001C6 1922APR022/2

10-0-5

101702

PN=191

Boom Maintenance, General


Assembly Instructions
IMPORTANT: When removing joint pins or other
load-bearing structures bear in mind the
following:
The lifting capacity of the loader or
pulley must be adequate.
The hoisting equipment must be
reliable and in good working order.
The booms must be properly
supported in every direction

EL62757,00001C7 1922APR021/1

Bleeding the Hydraulic System


If the hydraulic system has been serviced or repaired, air
must be eliminated from the system before the machine is
put to use again (see Section 7-1)
If not eliminated from the system the presence of air will
result in the following problems:
Sudden, unintended movements
Damage to gaskets. When compressed, air heats up
quickly and burns the packing material.

EL62757,00001C8 1922APR021/1

10-1-1

101702

PN=192

Boom Maintenance, General

Maintenance Schedule
Maintenance daily or every 10 hours
Grease the grapple and link

Check boom structures


Maintenance weekly or every 50 hours

Check the boom slewing housing oil level

Check that the joint pins of the boom are secured

Check the sideways clearance of the extension booms

Check the loader extension boom chains for tightness

Grease the boom

Lubricate the extension boom chains with oil


Maintenance every 250 hours

Clean the boom


Check the extension booms for vertical clearance

Check boom structures


Check the tightness of loader screw joints
Maintenance every 1000 hours

Clean the magnetic plug of rotator

Change the loader slewing system oil


Maintenance as required

Adjusting the rotator link brakes

EL62757,00001C9 1922APR021/1

10-1-2

101702

PN=193

Boom, Maintenance every 10 hours


Grease the grapple and link.

T142860

UN13JUN01

The greasing points are shown in the illustration.

EL62757,00001B8 1921APR021/1

Check boom structures


Check hoses, joints, and cylinders for tightness.
Check the loading accessories.
Make sure that the booms are not lowered by themselves.
During the first 250 working hours check and tighten the
bolted joints of a new machine daily.
Should you locate a defective component or a
malfunctioning operation, repair it immediately. Check the
hydraulic system for potential damage visible from the
outside in order to make sure that such damage will not
result in a sudden leakage. All oil leaks must be repaired
immediately.
CAUTION: Do not ever attempt to locate or plug
an oil leak with your hand because it only takes
fluid injected at a pressure of 30 bar to
penetrate your skin and possibly cause serious
personal injury, even death.

EL62757,00001CA 1922APR021/1

10-2-1

101702

PN=194

Boom, Maintenance every 10 hours

The following service and checks are to be


made at the end of each workday
Clean the machine and check it for potential failures or
leaks. It is particularly important to clean the machine
in the winter. Remove all snow, dirt, and slash before it
freezes and gets stuck.
If it is time to change oils or lubricate, do it while the
machine is still warm.

EL62757,00001CB 1922APR021/1

10-2-2

101702

PN=195

Boom, Maintenance every 50 hours


Check the boom slewing housing oil level
The boom slew system and the lower bearing of the tower
are immersed in oil.
The oil level is checked in the measuring glass.
If the boom stands still for a long period of time, the oil
level must exceed the upper mark on the measuring
glass. This is to ensure that the slewing cylinder pipes will
not corrode.

UN02OCT02

As necessary fill in oil through the plug (1)

T160024

1Filling

Boom slewing housing

EL62757,00001B9 1921APR021/1

Check that the joint pins of the boom are


secured.

T142876

UN13JUN01

The joint pins must be well lubricated.

EL62757,00001D2 1922APR021/1

10-3-1

101702

PN=196

Boom, Maintenance every 50 hours

Check the sideways clearance of the


extension booms.

T160063

UN02OCT02

If necessary, make the adjustment by simultaneously


tightening the opposite slide piece covers (2) until there is
no clearance at all and then back them off 1/4 turn.

EL62757,00001D1 1922APR021/1

Check the boom extension boom chains for


tightness.
Operate the extension booms to their outermost position
with a load in the grapple. After this, make the extensions
return inwards and ensure that they reach their limiters at
the same time. If necessary, make the adjustment by
tightening one chain tightener (3) and loosening the other
one. If the chains are too tight the sheave bearings and
chains will be subjected to unnecessary wear.

EL62757,00001D0 1922APR021/1

10-3-2

101702

PN=197

Boom, Maintenance every 50 hours

Grease the rocker and cylinder bearings of


the boom and the slewing system bearing.
Apply a layer of grease on the sliding surface of the
extension booms (see the lubrication and maintenance
chart).
When lubricating the sliding surfaces of the extension
booms, use hydraulic oil or grease designed for open
gears. If you use ordinary grease make sure that it does
not contain molybdenum sulphite.

EL62757,00001CC 1922APR021/1

Lubricate the extension boom chains with


oil.
When lubricating, use an oilcan and engine oil, for
instance. Operate the extension booms to their outermost
positions to lubricate the upper chain.

EL62757,00001CD 1922APR021/1

Check the grapple

T142800

UN12JUL01

Rotate the grapple continuously in one direction a


minimum of 10 rotations This is to ensure that all the fluid
in the rotator and hoses is circulated back to the tank.

EL62757,00001CE 1922APR021/1

10-3-3

101702

PN=198

Boom, Maintenance every 50 hours


T160027 UN03OCT02

T160040

UN08OCT02

Lubrication and Maintenance Chart

1. Use a grease gun for greasing.


2. Grease or lubricate the extension booms and the
inner surfaces of the outer boom and the first
extension boom.
3. Lubricate the chains
4. Check the chains for tightness.
5. Check the extension boom clearances.

surfaces. The slider part of the first extension is


greased when the extensions are inside the boom.
The inner surfaces of the outer boom and extension
are easy to lubricate if the end plate of the outer boom
is first removed.

Before you grease lower the boom to the ground in


order to eliminate pressure from the cylinders. This will
also help the grease to be better spread on bearing

The lower surfaces are lubricated while the outer boom


is in its outmost position and the upper surfaces while
in the innermost position.

EL62757,00001CF 1922APR021/1

10-3-4

101702

PN=199

Boom, Maintenance every 250 hours


Clean the boom.
NOTE: When washing the machine with a pressure
washer avoid directing the stream of water at the
point where the boom main post and base meet.

EL62757,00001BA 1921APR021/1

Check boom structures

Load-bearing structures
boom bearings, pins, and links
Hydraulic system.
Loading equipment, pendant, rotator, and grapple.

You must keep an eye on these components at all times


for any failures or shortcomings related to these parts may
jeopardize operational safety. When you find a small crack
or crevice in any of the load-bearing structures, stop
loading and contact the nearest authorized repair shop for
repair instructions.

EL62757,00001D3 1922APR021/1

10-4-1

101702

PN=200

Boom, Maintenance every 250 hours

Check the extension booms for vertical


clearance.
If necessary, make the adjustment by inserting additional
adjustment plates under the slide pieces
The aggregate thickness of the fitting plates under the
slider parts must not exceed three millimeters. This is to
make sure that the slider parts will stay in place. The top
of the slider part must exceed the edges of the bearing
housing by at least two millimeters.

T152546

UN08MAR02

The condition of the rearmost slider parts can be checked


by opening the hatch at the rear end of the extension
boom.

EL62757,00001D4 1922APR021/1

Check the tightness of boom fastening bolts,


hydraulic cylinder covers, and other screw
joints
For nut and bolt torque values, see Section 6-0.
Item

Measurement

Specification

Boom bolts

Torque

1120 Nm (826 lb-ft)

EL62757,00001D5 1922APR021/1

10-4-2

101702

PN=201

Boom, Maintenance every 1000 hours


Clean the magnetic plug of rotator
Position the unit so that the magnetic plug (1) is at the
lowest point.

T142918

UN13JUN01

Place a container below the plug


Unscrew the plug, clean it and drain 2 liters of oil
Close and tighten the plug to 60 Nm

1Magnetic plug
Item

Measurement

Specification

Magnetic plug

Torque

60 Nm (44 lb-ft)
EL62757,00001BC 1921APR021/1

Change the boom slewing system oil


The oil must be changed after every 1000 running hours
or once a year.
Drain the water from the drain hose by opening the drain
plug (1).
1. The drain hose is located under the base of the boom.
Unscrew the plug (1), clean it and drain the oil into an
oil sump.
2. Fill in new oil.
9.5 l (2,5 gal)

Hypoid oil

API GL-5 eller MIL-L-2105 B eller D

Viscocity

SAE
SAE
SAE
SAE

UN02OCT02

Boom Slewing
System

90
85W/90
80W/90
75W/90

T160025

Volume

1Draining plug

EL62757,00001D6 1922APR021/1

10-5-1

101702

PN=202

Boom, Maintenance every 1000 hours

T160064

UN02OCT02

Clean the boom extension boom chains (depending on the model)

The chains and extensions can be removed by first


disconnecting the upper chain from its clamp (2).
Next, remove the sheave (3) and bearing housing.
Pull the chain through its opening and straighten it
on top of the second extension
After this, disconnect the lower chain from its clamp
(4) and tie a rope to its end. Pull the second
extension out.

NOTE: The extension booms and grapple must be


properly supported at every stage.

EL62757,000005E 6716OCT021/1

10-5-2

101702

PN=203

Boom, Maintenance as required


Adjusting the rotator link brakes

UN11MAR02

The bolted joint of the link brake pads is tightened through


screw a while securily holding flanged nut b. The
maximum tightening torque of the bolted joint is 30 Nm.
As soon as the adjustment has been made the bolt joint is
secured with locknut c.

IMPORTANT: For safety reasons the tension washers


must be in place before the bolted joint
is tightened.

T152582

When the bolted joint is opened for the replacement or


check of the brake pads, tension washers d must not be
removed before loosening the bolted joint.

aScrew
bFlanged nut
cLock nut
dWasher

EL62757,00001BB 1921APR021/1

10-6-1

101702

PN=204

Boom, Technical Data


Boom CF7
CF772

CF785

CF10

Gross lifting
moment

125,4 kNm

125,4 kNm

125,4 kNm

Net lifting
moment

90,3 kNm

86,7 kNm

77,6 kNm

Maximum
reach

7200 mm

8500 mm

10 000 mm

Stroke of
extension
boom

1390 mm

2450 mm

4200 mm

Gross slewing
moment of
booms

32,6 kNm

32,6 kNm

32,6 kNm

Slewing angle
of booms

380

380

380

Weight without
oil

1610 kg

1660 kg

1750 kg

EL62757,00001BD 1921APR021/1

Rotator and Grapple


Rotator

cv11-2

GV122

Slewing angle

Unlimited

Unlimited

Slewing moment
(21,5 MPa)

2,4 kNm (1770 lb-ft)

1,9 kNm (1400 lb-ft)

Weight

58 kg (128 lbs)

58 kg (128 lbs)

Grapple

Loglift FX25

Loglift FX35

Grip area

0,25 m2

0,35 m2

0,26 m2

0,36 m2

0,36 m2

Grapple closing
pressure (21,5 MPa)

12kN

11 kN

13 kN

16,6 kN

16,5 kN

Weight

230 kg

240 kg

235kg

432 kg

310 kg

Hultdins SG 260

Continued on next page

10-7-1

Hultdins SG 360S

Hultdins 360

EL62757,0000119 1906MAR021/2

101702

PN=205

T160023

UN08OCT02

Boom, Technical Data

EL62757,0000119 1906MAR022/2

10-7-2

101702

PN=206

Boom, Technical Data

T160022

UN02OCT02

T159871

UN08OCT02

Boom CF7

Continued on next page

10-7-3

EL62757,000009C 6705FEB021/2

101702

PN=207

T159872

UN08OCT02

Boom, Technical Data

EL62757,000009C 6705FEB022/2

10-7-4

101702

PN=208

Equipment, Air Conditioner


Introduction
IMPORTANT: The air conditioner must be serviced
and repaired by authorized personnel.
Specifications:
Type and Amount of Refrigerant and the Maximum
Pressure Allowed
CAUTION: The air conditioning system has
been charged with R-134a refrigerant. Do not
use any other type of refrigerant!
The specifications of this air conditioning system are the
following:
Refrigerant
R134a

Charging volume
1,5 kg
5,5 lbs

High pressure
8-15 bar
116-217 psi

If the air conditioning system has been modified to use


another type of refrigerant, write the new specifications
here:
Refrigerant
R____

Charging volume
____ kg
____ lbs

High pressure
______bar
_____ bar

Date of modification: _______________________

EL62757,00001D8 1922APR021/1

Main Parts of Air Conditioning System


Compressor

T152366

UN06MAR02

The compressor functions like a pump, drawing in cooled


gas under low pressure from the evaporator. After this,
the compressor compresses the gas and sends it (in a
gaseous state) to the condenser at a high pressure and
temperature.

Continued on next page

11-1-1

EL62757,00001D9 1922APR021/5
101702

PN=209

Equipment, Air Conditioner


Condenser

T152367

UN06MAR02

Upon entering the condenser, the gas is hot and under a


high pressure. The gas is cooled down by cool air flowing
through the condenser coils and, consequently, the gas is
liquefied under a high pressure. Next, the liquefied
refrigerant flows into the filter-dryer-receiver.

EL62757,00001D9 1922APR022/5

Filter-dryer-receiver
The purpose of the filter-dryer-receiver is to receive the
refrigerant coming from the condenser, and to filter out
humidity and impurities in a built-in drier. On top of the
filter-dryer-receiver there is a sightglass (1) which makes it
possible to check whether there is enough of the
refrigerant in the tank. Through the sightglass of the
moisture indicator (2) you can see weather the
filter-dryer-receiver is serviceable.

UN06MAR02

Sightglass
Moisture indicator (by color)
Service valve
Filter insert
Pressure switch

T152368

1.
2.
3.
4.
5.

Continued on next page

11-1-2

EL62757,00001D9 1922APR023/5

101702

PN=210

Equipment, Air Conditioner

The expansion valve controls the amount of refrigerant


allowed to enter the evaporator coil. The expansion valve
is mounted on the inlet pipe of the evaporator. Upon
entering the expansion valve, the refrigerant is under a
high pressure and it is injected through a nozzle into the
evaporator where the pressure drops sharply.

T152369

1From the condenser


2Into the evaporator
3Into the pipe located next after evaporator

UN06MAR02

Expansion valve

EL62757,00001D9 1922APR024/5

T152370

The evaporator cools down and dries the air before the air
is forced into the cab. A fan draws in warm air through the
evaporator, forcing the air through the lamellas and ducts
of the evaporator. The refrigerant receives the thermal
energy contained in the air that cools down while passing
through the evaporator. After this, the cooled-down air is
forced into the cab.

UN06MAR02

Evaporator

EL62757,00001D9 1922APR025/5

11-1-3

101702

PN=211

Equipment, Air Conditioner

Risks and Counter-Measures


CAUTION: The air conditioning system contains
refrigerant that is under pressure.
Do not disconnect the hoses of the system.
Refrigerant released into the air may be
harmful. Charging the air conditioning system
with a refrigerant of the wrong type will result in
serious damage to the system.
CAUTION: Risk of personal injury!
Liquid that has been released from the
system has a very low temperature, and it
quickly becomes gasified.
Warming up the filter-dryer-receiver will result
in the build-up of the gas pressure and may
cause a risk of explosion.
The gas is colorless and heavier than air, and
it spreads on the ground.
The gas begins to choke without any
premonitory symptoms.
Splashing refrigerant causes frostbite and
serious damage to eyes. When working on
the air conditioning system, always wear
good, tight-fitting safety glasses because
refrigerant under pressure may start leaking
abruptly. In addition, cover your hands as
well as all other bare spots of skin.
When refrigerant burns, it disintegrates into
noxious gases.
CAUTION: Danger of Fire and Explosion!
Do not warm up the filter-dryer-receiver beyond
50 degrees centigrade (122F), because the high
pressure of the liquid may cause an explosion.
What to Do If Fire Breaks Out ?
Cool down the filter-dryer-receiver with a jet of water.
Leak and Clean-Up

Continued on next page

11-1-4

EL62757,00001DA 1922APR021/2
101702

PN=212

Equipment, Air Conditioner


When arranging the refrigerant evacuation equipment,
make sure that no dangerous discharges of refrigerant
pass into the work area with people.

EL62757,00001DA 1922APR022/2

First Aid
Accident

First aid

Gas is inhaled

Go out to breathe fresh air

Skin contact

Frostbitten parts of body are


rinsed with lukewarm water

Splashes into eyes

Continuous rinsing with a


two-percent saline solution for 20
minutes

In gestion of refrigerant

Seek medical advice

EL62757,00001DB 1922APR021/1

11-1-5

101702

PN=213

Equipment, Air Conditioner

Air Conditioner, Using


The heating and cooling devices are controlled
automatically through temperature control. This way, the
temperature in the cabin is brought on the level set with
regulator (2).
A) In the summer, when the weather is warm and
humidity normal:

UN02OCT02

1. Close the recirculating air vent by turning the control


(3) clockwise as long as it goes.
2. Select the temperature you wish (2).
3. Direct the air flow to the vents of your choice (4)

T152201

B) In the summer, when the weather is hot and


humidity high:
IMPORTANT: The internal air circulation of the
cooling system must not be obstructed.
Make sure that the protective mesh is
not clogged.

1Speed
2Temperature
3Air circulation
4Air flow
5Defrost

1. Open the recirculating air vent by turning the control


(3) counterclockwise as long as it goes.
2. Select the temperature you wish (2).
3. Adjust the fan to the maximum speed (1).
C) In the fall and early winter, when the humidity is
high; when it is raining; when there is a lot of wet
snow; and when there is steam on the windshield:
1.
2.
3.
4.

Engage the dehumidification (max. defrost) (5).


Open the recirculating air vent (3)
Select the temperature you wish (2).
Direct the air to the windshield vents (4).

Dehumidification (5) switches the cooling device on and


the fan to the max. speed, and opens the heating valve
fully.
When the right temperature (2) has been achieved, the
fan speed switches over to the speed set with regulator
(1).
The temperature is kept on the desired level by regulating
the cooling device and the heating valve.

Continued on next page

11-1-6

EL62757,00001DC 1922APR021/3
101702

PN=214

Equipment, Air Conditioner


The cooling device must be switched off with switch (5),
when the indoor air is dry enough.
IMPORTANT: The compressor will not start if the
temperature is below 0C (14 F).

EL62757,00001DC 1922APR022/3

D) In the winter, when the weather is cold:


1. Close the recirculating air vent (3).
2. Select the temperature you wish (2)
E) In the winter, when the weather is extremely cold
and the humidity low:

NOTE: The air conditioner should be operated for a few


minutes every week by pressing the max. defrost
switch (5).
This is enough to ensure that the drive shaft seal of the
compressor, other packing, joints, and rubber hoses are
lubricated.

T152201

F) In the winter, when the weather is cold and dry;


when the system has been little used or not used at
all.

UN02OCT02

1. Open the recirculating air vent (3)


2. Select the temperature you wish (2)

EL62757,00001DC 1922APR023/3

11-1-7

101702

PN=215

Equipment, Air Conditioner

Maintenance and Inspections: Check the


refrigerant level.

UN06JUN01

1. The engine must be running at 1500 RPM.


2. Switch on the air conditioner.
3. Turn the fan speed and thermostat to the maximum
position.

T139550

When the compressor is running no bubbles should be


seen in the sightglass (1), and the refrigerant should not
appear cloudy. Bubbles and cloudiness indicate that the
charge of refrigerant is insufficient. If this is the case,
immediately contact the nearest authorized dealer to have
the problem remedied.

1Inspection sightglass

EL62757,00001DD 1922APR021/5

UN15JUN01

A. CLEARLY INSUFFICIENT AMOUNT OF


REFRIGERANT

T139551

Continuous flow of bubbles or a flow that appears


foamy
The difference in temperature between the low and high
pressure sides is small.
The pressure of the high-pressure side is unusually low.
STOP THE COMPRESSOR IMMEDIATELY and contact
an authorized mechanic to check the system.

Continued on next page

11-1-8

EL62757,00001DD 1922APR022/5

101702

PN=216

Equipment, Air Conditioner

UN15JUN01

B. INSUFFICIENT AMOUNT OF REFRIGERANT

T139552

A few bubbles seen at several second intervals


The high-pressure side is warm and the low-pressure
side cool.
Check to see that there are no leaks in the system. If
there are, repair immediately.
New refrigerant must not be added into the system by
anyone else but authorized personnel.

EL62757,00001DD 1922APR023/5

UN15JUN01

C. CORRECT AMOUNT OF REFRIGERANT

T139553

The refrigerant is clear and only a few bubbles pass by


when the engine speed is changed.
The pressure of both the high-pressure side and the
low-pressure side is normal.
The high-pressure side is hot and the low-pressure side
cold.

Continued on next page

11-1-9

EL62757,00001DD 1922APR024/5

101702

PN=217

Equipment, Air Conditioner

T139554

No bubbles at all
The high-pressure side is very hot
The pressure of both the low and high-pressure side is
unusually high

UN15JUN01

D. EXCESSIVE AMOUNT OF REFRIGERANT

If refrigerant must be removed from the pressure side of


the system, contact authorized personnel.
Control all hoses and connectors for leaks.
NOTE: New refrigerant R134a may appear slightly
cloudy during operation. This may be the case
although the system has been correctly charged.
If in doubt, please contact the nearest authorized
dealer.
IMPORTANT: Do not operate the system, if the
refrigerant charge is insufficient or if
there is a leaking in the system,
because the compressor will be
damaged. Contact your authorized
dealer.

EL62757,00001DD 1922APR025/5

11-1-10

101702

PN=218

Equipment, Air Conditioner

Check the service moisture indicator of the


dryer every 50 hours
The service indicator should be blue.
UN13JUN01

The dryer must be replaced, if the indicator area has


turned to pink.

T142872

NOTE: The filter-dryer-receiver must be replaced always


when the hoses are replaced or if the service
moisture indicator has turned to pink.
IMPORTANT: Do not operate the system, if the
refrigerant charge is insufficient or if
there is a leaking in the system,
because the compressor will be
damaged. Contact your authorized
dealer.

1Service indicator

EL62757,00001DE 1922APR021/1

Service the compressor V-belt every 250


hours

T142874

UN13JUN01

Make sure that the drive belt tension is correct and that
there are no external signs of damage.

EL62757,00001DF 1922APR021/1

Service the compressor every 1000 hours


Mounting
The compressor must be properly mounted and in
alignment, ensuring that the drive belt moves directly on
the belt pulley, without wearing the sides of the belt.
Check that the clutch plate and sprocket are clean.

Continued on next page

11-1-11

EL62757,00001E1 1922APR021/2
101702

PN=219

Equipment, Air Conditioner


Compressor plate

UN13JUN01

There must be a clearance of 0.3 ... 0.6 mm (0.012...0.02


inc) between the compressor belt pulley and plate. If there
is dirt between the pulley and plate, clean immediately.

T142890

1Compressor plate

EL62757,00001E1 1922APR022/2

Service the evaporator element every 1000


hours

Make sure that the condensation water outlet is open.

T142892

1Evaporator

UN13JUN01

The evaporation element must be clean.

EL62757,00001E2 1922APR021/1

Service the condenser element every 1000


hours

Blow through the condenser, in the opposite direction if


compared with the ordinary flow of air.
IMPORTANT: Carefully clean the ends of the
condenser element with compressed
air. Blowing direction: away from the
condenser. If the compressed air used
is too strong, the condenser fins may
be damaged.

T144037

The element must be regularly cleaned by blowing lightly


with compressed air.

UN18JUL01

Ensure that the condenser gets enough air.

EL62757,00001E3 1922APR021/1

11-1-12

101702

PN=220

Equipment, Air Conditioner

Service the hoses and connectors every


1000 hours
CAUTION: Do not open hose connections.
There is pressure in the cooling system.
Incorrect procedures may result in personal
injury.
Check the refrigerant hoses and joints regularly. Oily
connectors may result in leaks.
When connecting and fastening hoses, make sure that
nothing will abrade the hoses.
The filter-dryer-receiver must be replaced always
when the hoses are replaced or if the service
moisture indicator has turned to pink.
NOTE: Make sure that the condensation water outlet is
not restricted and that the water can freely flow
out of the system.
Ensure that the power circuit between the
thermostat and the electromagnet switch is in
order.

EL62757,00001E4 1922APR021/1

11-1-13

101702

PN=221

Equipment, Engine Preheater

T153144

UN28MAR02

Operation and maintenence

Sektionsritning
WEWater inlet
WAWater outlet
VCombustion air
BFuel
AFumes
1Combustion motor

2Flame sensor
3Combustion chamber
4Control unit
5Heater plug
6Temperature sensor
7Flame tube

8Heat exchanger
9Overheating switch
10Water pump
11Exhaust silencer
12Combustion air silencer
13Fuel feeder pump

14Fuel branch piece


15Cable tree
16Fuse bracket
17Relay for switching on the
vechicles fan
18Timer

The combustion air fan and the water pump start


to run, and the ignition plug glows (preliminary
glow).
After a preliminary glow period (about 40
seconds), and regardless of operation, the fuel
dispenser pump starts to supply fuel at rapid
impulse frequency to give full load in the
combustion chamber and the fuel ignites

The preheater heats the engine, cabin and hydraulic


system according to preselected times.
The preheater is controlled by a timer. See information
later on.
NOTE: Before starting the heater or before
pre-programming the heating sequence, set
the cabin heating control to its maximum open
position and the fan speed to position 1.

The ignition plug is switched off when the control


unit receives a signal from the flame sensor that the
fuel is burning.

1. Switching on
The control lamp on the timer will light on starting

Continued on next page

11-2-1

EL62757,00001FF 1924APR021/9
101702

PN=222

Equipment, Engine Preheater


2. Heating
Depending on the heating need the heating
power will be automatically adjusted: 5000 W /
2200 W
The settings of the control unit dictate the
temperatures at which the power level changes.
Should there be only a limited need for heat,
enabling the coolant to reach a temperature of 85
C (185 F), the heating system will switch over
to an inactive state. This is when the fan will
continue operating for another 130 seconds to
cool down the heater
The timer warning lamp will still be on and the
water pump will go on operating.
As soon as the coolant temperature drops to a
level of 7 5C (167 F), the heating system will be
automatically engaged again.

b. A renewed start will be made if the burner


should go out during operation. The malfunction
switch-off will then be actuated if it does not start
within 90 seconds or if it starts and then goes
out again within 3 minutes
c. If overheated (e.g., due to lack of water, poorly
vented cooling system), the overheating sensor
switches off and consequently the fuel supply
will be cut off, thus actuating the malfunction
switch-off. After rectifying the cause of
overheating, press in the button on the
overheating circuit breaker and also reset the
malfunction switch-off as above, so that the
heater can be started.
d. The malfunction switch-off will be activated if
voltage of the electrical system should fall below
about 20 V or rise above about 28 V.
e. The heater will not start at all if the ignition plug
is defective or if the electric circuit to the
dispenser pump is broken.
f. Functioning of the blower motor is checked on
starting and the malfunction switch-off will be
activated if it is not running.

IMPORTANT: Do not start the diesel engine while


the preheater is running. Similarly,
wait until the trailer operation (appr.
two minutes) is over before you start
the engine. Otherwise, the preheater
may be damaged.

5. Correction of malfunction
3. Switching off
The supply of fuel is cut off when the timer switches
the heater off. The indicating lamp goes out.
The combustion air fan and the water pump
continue to run for about 130 seconds and are then
switched off automatically.
4. Safety devices
The flame is monitored by the flame sensor, and
the maximum permitted temperature by the
overheating switch. Both of these affect the control
unit, which switches off the burner in the event of
malfunctioning.
a. The starting sequence will be repeated if the
heater does not ignite within 90 seconds after
the fuel supply is turned on. If the heater still
does not start within the additional 90 seconds,
the malfunction switch-off will take place. The
malfunction switch-off can be cancelled by briefly
switching the heater off and then on again

Check the following items if the heater does not start


when being switched on:
Fuses, See section 8. Also check the fuse for the
cab fan. No heated air will enter the cab if this fuse
has blown, although the heater starts and heats the
engine.
Switch the heater OFF and ON, but not more than
twice. Authorized personnel or workshop should be
contacted if the heater still does not start.
Maintenance of the engine preheater
Remember to keep the preheater and its surroundings
clean, especially near the exhaust system of the
preheater.
Check hoses, joints and other components for
overall shape and tightness.

Continued on next page

11-2-2

EL62757,00001FF 1924APR022/9
101702

PN=223

Equipment, Engine Preheater


Start the heater about once a month even during
the summer and allow it to run for a few minutes to
prevent binding of the fan and water pump.

CAUTION: Risk of fire.


Always switch off the battery main switch to protect
the control unit before any electric welding on the
machine, also see Section 8, welding.

Continued on next page

11-2-3

EL62757,00001FF 1924APR023/9

101702

PN=224

Equipment, Engine Preheater


Timer for engine and cabin preheater
The preheater is started with the timer, i.e., either directly
or at preset time.
All signals in the display will flash when electric power
supply is connected. The heater cannot be switched on in
this mode, i.e., the heater timer must first be properly set.

T153141

UN03OCT02

1. Setting the timer


Press and hold down (1) until the time flashes (basic
setting for the first time: press (1) briefly)
Set the current time using (4) and (5).
When the time display stops flashing, the time has
been stored.
The weekday begins to flash.
Set the current weekday using (4) and (5)
When the display stops flashing, the setting has been
stored. Acceptable setting can also be skipped by
pressing (1). When the ignition switch of the machine
is turned on, the current time is displayed in the timer.

1Time indication/setting
2Preselection
3Heating on
4Adjust backward
5Adjust forward
6Stored memory indication
7Day of week
8Symbol for remote control (opt. eq.)
9Current time / program time
10Temperature indication (opt. eq.)
11Operating display

When the ignition switch is turned off the display


disappears after 15 seconds. When there is no display
the current time appears by pressing (1) .
NOTE: Before starting the heater or before
pre-programming the heating sequence, set the
cabin heating control to its maximum open
position and the fan speed to position
NOTE: If a fault occurs when you switch the heater on (or
if the heater is on), the operating display shows
"F" and a fault code (two numbers) in 15 seconds.
See Malfunction codes later on this section.
2. Direct starting of heater without preselection
(ignition of the base machine is off)
Press (3), start of heating.
Heating symbol (3) and the heating duration is
displayed. The heating duration is factory-preset to 120
min.
3. Changing the heating duration
a. Temporarily:

Continued on next page

11-2-4

EL62757,00001FF 1924APR024/9
101702

PN=225

Equipment, Engine Preheater


Start heating; press (3).
To reduce heating duration: press (4).
To increase heating duration (to max. 120 min):
press (5).
b. Permanently
Do not switch heating on.
Press the (4) key and hold it down (approx. 3 s) until
the display appears and flashes.
Release the key.
Then set the heating duration (10...120 min) using
the(4) or (5) key. The new heating duration is set when
the display disappears.
4. Switching off the heater
Press (3), automatic cooling phase, about 130
seconds.
5. Heating without preselection (ignition of the base
machine is on)
Press (3) .
Heating stays in operation until ignition is switched off.
After ignition is switched off, a residual heating period
of 15 min remains.
This can be changed (1...120 min) by pressing the (4)
or (5) key. Switching off the heater: press (3).
6. Heating operation preselection

Continued on next page

11-2-5

EL62757,00001FF 1924APR025/9

101702

PN=226

Equipment, Engine Preheater


There are three preset times in the memory. Only one
can be activated at a time (the memory number is
displayed).
A) Set the program time and day
Press the key (2)(1...3 times) until the desired memory
display begins to flash.
Briefly press and then release (4) or (5) . The program
time flashes.

UN03OCT02

Then set the program time for heating using (4) or (5).

T153141

When the display stops flashing, the time has been


stored. The program day begins to flash, set the
weekday using (4) or (5).
The preselected time and weekday are stored as soon
as the display changes over to the current time.
Flashing heating on key (3) indicates an activated
preselection. The current time disappears and only the
activated memory number is displayed.
When there is no memory number displayed no
memory is activated. This is done by pressing (2)
several times. Neutral setting is after the memory
number 3.
B)Checking activated memory
Press (2) . The activated preselected time and
preselected day are displayed for approx. 5 s.
7. Advice in event of malfunctioning:
In the event of malfunctioning, switch off and then
on again (but not more than twice)
check the main fuse
ensure that the flow of air is unrestricted
contact an authorized service agent.

Continued on next page

11-2-6

EL62757,00001FF 1924APR026/9

101702

PN=227

Equipment, Engine Preheater


NOTE: If you try to switch on the heater without result
five times in a row or if the heater overheats three
times in a row, the operation will be disabled.
(Fault code F50 or F15).
Malfunction codes of the engine preheater
Example: display shows: F33 (current fault) and
heating-on symbol flashes

Continued on next page

11-2-7

EL62757,00001FF 1924APR027/9

101702

PN=228

Equipment, Engine Preheater


F00

No malfunction

F01

Warning about overvoltage

F02

Warning about undervoltage

F09

TRS 003 unplugging

F10

Overvoltage shutoff

F11

Undervoltage shutoff

F12

Overheating

F13

Possible overheating detected

F14

Too big difference between overheating- and water temperature

*F15

Operation disable because perm.number of possible overheatings exceeded

F20

Glow plug break

F21

Glow plug output overload

F33

Malfunction in combustion engine

F37

Waterpump not working

F42

Water pump short-circuit

F43

Other component short-circuit

F47

Fuel pump short-circuit

F48

Fuel pump break

*F50

Operation disable due to excessive start attempts

F51

Flame signal already at start

F52

Safety time exceeded- no start

F53

Flame cutout from POWER control stage

F54

Flame cutout, HIGH-setting

F55

Flame cutout, Medium-setting

F56

Flame cutout, LOW-setting

F59

Too quick rise in water temperature.

F60

Temperature sensor break

F61

Temperature sensor short-circuit

F64

Flame sensor break

F65

Flame sensor short-circuit

F71

Overheating sensor break

F72

Overheating sensor short-circuit

F90

Control unit defective (internal fault / reset)

F93

Control unit defective (RAM-error)

F94

Control unit defective (EPROM-error)

F97

Internal control unit fault

*) Steps to cancel the disabled operation (fault code


F15 or F50)

Continued on next page

11-2-8

EL62757,00001FF 1924APR028/9
101702

PN=229

Equipment, Engine Preheater


A How to empty the fault memory:
Switch power on.
Press(3) . Fault code appears.
Press (1) to the bottom and in 2 seconds
simultaneously press (2).
Switch power off
Press (1) and (2) simultaneously and switch the power
on. Display shows: - - : - Display flashes, heating-on symbol doesnt.
After about 3 seconds the heater will go on (the
disabled operation is canceled).
Display, when the heater has started to operate: AF : 00
BIn case of having the error F50, do the following:
Disconnect the wire coming to the fuel pump of the
preheater.
Try to start the preheater normally.
This gives the alarm F48 to the display.
After that, it is possible to deactivate the fault code as
described above.

EL62757,00001FF 1924APR029/9

11-2-9

101702

PN=230

Equipment, Fire Extinguisher System


General
Fire extinguisher system1.
This installation includes a container with extinguishing
medium, connected to a system of pipes/hoses with
nozzles in the protected areas.
Heat detectors are actuated in the event of fire and make
an electric circuit to the fire alarm.
The alarm is given by:
pulsating light and sound signals
red light on the cab roof
horn underneath the cover on the hydraulic reservoir.

in certain markets / optional equipment


EL62757,0000200 1924APR021/1

11-3-1

101702

PN=231

Equipment, Fire Extinguisher System

Fire Alarm and Actions


Fire alarm during operating the machine

UN12SEP02

NOTE: Only the fire alarm will be activated when the


main switch is ON
ACTIONS:

T152199

Operator!
1. Trigger the alarm
2. Take a hand-held extinguisher with you and check that
the fire does not spread.
The fire fighting installation can be triggered in three
ways:

UN05MAR02

1. Manually from the cab by pressing the triggering


button (3) on the control unit.

T152200A

1Warning light - machine malfunction (yellow)


2Fire alarm light (red)
3Control unit trigger button
Alarm lights

Continued on next page

11-3-2

EL62757,0000202 1924APR021/3

101702

PN=232

Equipment, Fire Extinguisher System


2. Breaking the main power supply by turning the main
switch (1) OFF
3. Triggering device, pull the triggering handle.
Fire alarm when the machine is not operated
The fire extinguisher system will be automatically triggered
in the event of fire when the machine is unmanned and
the main switch is OFF.

T152355

UN15SEP02

T152211

UN05MAR02

1Main Switch
4Triggering handle

Continued on next page

11-3-3

EL62757,0000202 1924APR022/3

101702

PN=233

T159363

UN15SEP02

Equipment, Fire Extinguisher System

Fire Extinguisher System in the machine


1.
2.
3.
4.
5.

Fire extinguisher
Signal Horn
Support
Fuse box
Connector housing

6. Junction box
a. Central Unit
b. Fuse box
c. Signal horn
d. Not in use
e. Thermal sensor
f. Tripping

EL62757,0000202 1924APR023/3

11-3-4

101702

PN=234

Equipment, Fire Extinguisher System

After a fire
The alarm ceases when the fire is put out and detectors
have cooled down. Open the ventilation covers so that
smoke and fumes can be vented.
IMPORTANT: Before opening any covers or engine
hood, wait at least 30 minutes to let the
machine cool down.
IMPORTANT: Be prepared with a hand extinguisher
while airing the machine.
CAUTION: Avoid breathing in fumes from the
fire.
Clean the machine with water as soon as possible after a
fire.
Restoring the machine after a fire: Contact service
personnel to establish the reason for the fire and to
restore the fire extinguisher system.

EL62757,0000201 1924APR021/1

11-3-5

101702

PN=235

Equipment, Fire Extinguisher System

Control unit

T152354

UN06MAR02

1. Green light emitting diode, indicating that the system is


operative.
Goes out if the power supply is broken.
2. Yellow light emitting diode, supervising the detector
circuit.
Lights up if the circuit is broken or if the end resistor is
removed.
3. Yellow light emitting diode, supervising the circuit to
the gas generator in the mechanical / electrical
triggering unit.
Lights up if the circuit is broken or when the gas
generator is triggered
4. Yellow light emitting diode.
Lights up when the system is in the manual mode =
Battery master switch is ON.
5. Triggering button for the system.
Issues a pulsating light when the fire alarm is given
and a steady light when the system is triggered
electrically.
6. Toggle switch for alarm and error testing.
a. Upper position, testing the alarm.
The alarm 5 of the installation shall be activated,
push-button (5) flashes and diode (1) and (3) will
show a steady light.
b. Middle position: Simulating break of the
detector circuit and the detonator loop.
Diodes 1, 2 and 3 should light. Diode 4 should also
light if the battery master switch is ON. The steady
light for the electrically triggered system will also be
reset when the toggle switch is moved to the middle
position.
c. Lower position, operating mode:
Diode 1 should light, and also 4 if the battery
master switch is ON.

Control unit of the fire extinguisher system


1Green
2Yellow
3Yellow
4Yellow
5Triggering button for the system
6Toggle switch for alarm and error testing

Check every day:


That diode 1 lights up, and also 4 if the battery master
switch is ON, when switch 6 is in the operation mode.

Continued on next page

11-3-6

EL62757,0000203 1924APR021/2
101702

PN=236

Equipment, Fire Extinguisher System


IMPORTANT: Before leaving the machine, remember
to turn the main switch to 0 to set the
automatic monitoring and triggering of
the fire extinguishers.
Check every week:
That diodes 1, 2 and 3 light up when switch 6 is set to
its middle position.
That diode 4 also lights up if the battery master switch
is ON
That the light and sound alarms are activated and that
push-button 5 flashes, diodes 1 and 3 light up when
switch 6 is moved to its upper position.
Ensure that the hand-held extinguishers are in place
and that the indicators show that they are full.
Annual inspection
The system is to be inspected once a year by authorized
service personnel. This inspection is a condition of the
insurance companies.
IMPORTANT: Disconnect the connector of the control
unit before carrying out any of the
following tasks;

pressure-jet washing
steam-jet washing
electric welding
battery charging

EL62757,0000203 1924APR022/2

11-3-7

101702

PN=237

Equipment, Fire Extinguisher System

Hand-held fire extinguishers

The hand-held extinguishers are intended for minor fires


and for final extinguishing after the sprinkler system has
been triggered.

T152353

The fire extinguishers must be checked, serviced and


stamped by an authorized dealer.

UN06MAR02

The machine is equipped with a hand-held fire


extinguisher.

NOTE: On certain markets fire insurance terms stipulate


that fire extinguishers must be checked after
every six months. Contact your insurance
company for all the details.

EL62757,0000204 1924APR021/1

11-3-8

101702

PN=238

Equipment, Decking Blade


Using the Decking Blade
The decking blade is operated with the push buttons (1
and 2) on the right-hand-side control panel
The decking blade can also be operated with the
right-hand-side boom control lever .
The lever control is engaged by pushing the push buttons,
(1 and 2), simultaneously for 2 seconds. When the lever
control is on the decking blade symbol will appear to TMC
display.
NOTE: Lever control can only be used when the low gear
is on and the boom is off.
When the lever control is engaged the decking blade can
be controlled even if nobody was sitting in the seat. lever
control is disengaged by switching on the boom or by
pressing the decking blade control switches
simultaneously.
IMPORTANT: Do not use the decking blade for
removing tree stumps or large rocks.
During travel, raise the decking blade
high enough to clear all obstacles

T152209

UN05MAR02

1Blade up, also with boom control lever-Y


2Blade down, also with boom control lever +Y

EL62757,0000205 1924APR021/1

11-4-1

101702

PN=239

Equipment, Decking Blade

Lowering the Decking Blade

UN12SEP02

If the machine dies and the decking blade has stayed in


upper position, the engine hood can not be opened before
the decking blade has been lowered down.

T159330

Operator can lower the decking blade with the help of


cylinders that are used through a tap (3) at the main
switch.
NOTE: After lowering, close the tap by twisting it.

EL62757,0000206 1924APR021/1

11-4-2

101702

PN=240

Equipment, Decking Blade

Decking Blades Float


Decking blades float position switch (17) is situated on
the front dashboard.
IMPORTANT: Diesel engine must be on, before you
can use the float position.
The switch has 3 positions, 0, 1, 2
Float position is ON, when you press the switch to
position 2.
After that the switch will stay in position 1.
Position 0 will stop the float position.
NOTE: Stopping the engine also stops floating.
NOTE: If you start the engine and the switch is in position
1, you cant use the float position.
Stop the engine, choose position 0 and start
again.

T152191

UN17OCT02

17Decking blade float position switch

EL62757,0000207 1924APR021/1

11-4-3

101702

PN=241

1410D Specifications

T160088

UN03OCT02

Dimensions

Continued on next page

12-0-1

EL62757,0000001 1906FEB021/2
101702

PN=242

1410D Specifications
Length

min.

9295 mm

30,5 ft

Length

max.

10495 mm

34,4 ft

Width

min.

2750 mm

9 ft

Width

max.

2930 mm

9,6 ft

Weight

6-hjulmin.

14900 kg

32849 lbs

Weight

8-hjulmin.

16500 kg

36376 lbs

Height

3900 mm

12,8 ft

Load rating

14000 kg

30864 lbs

Ground clearance

605 mm

1,98 ft

Wheelbase

6-hjul

5250 mm

17,2 ft

8-hjul

5850 mm

19,2 ft

Log length

max.

7m

23 ft

EL62757,0000001 1906FEB022/2

T160263

UN08OCT02

Decals and Signs

ASerial number
On the front frame, on the
right side of the machine
(optional)

BBehind the front frame, on


the left side

EL62757,00001E5 1922APR021/1

12-0-2

101702

PN=243

1410D Specifications

T160089

UN03OCT02

Load area

Length of load area

min.

3400 mm

max.

5000 mm

16,4 ft

11 ft

Width of load area

2740 mm

9 ft

Load area

5 m2

53,8 ft2

EL62757,0000002 1906FEB021/1

12-0-3

101702

PN=244

1410D Specifications

Engine

RG9061

UN16MAR98

RG7778

UN11NOV97

John Deere, 6068HTJ77 water-cooled and turbocharged


6-cylinder diesel engine with intercooler.

Saran Engine Serial Number Plate


ASerial Number Plate
BEngine Serial Number
CEngine Application Data
DCoefficient of Absorption (Saran Engines
Only)
Item

Measurement

Specification

Engine John Deere JD6068 HTJ77

Max. output
Torsional moment

136kW (182 hp)/ 1900 r/min


779 Nm (574,6 lbt-ft)/ 1400 r/min

EL62757,0000003 1906FEB021/1

12-0-4

101702

PN=245

1410D Specifications

Transmission
Hydrostatic-mechanical.
High/low gear, power distributed between the front and
rear axles.
Off-road driving, smooth no-surge start without
dropping engine speed.
Release of rear-wheel drive.
Item

Measurement

Specification

Transmission

Max. tractive force


Maximum driving speed

175 kN (39341 lbt)


23 km/h (14 miles/h)

EL62757,0000004 1906FEB021/1

Axles

Patented, balanced gear-driven bogie, portal type


Identical axles front and rear.
Mechanical differential lock front and rear.
Release of rear-wheel drive.

EL62757,0000005 1906FEB021/1

Steering
Articulated frame steering with two steering cylinders.
Proportional stick steering.
Item

Measurement

Specification

Frame steering

Steering angle

42

EL62757,0000006 1906FEB021/1

12-0-5

101702

PN=246

1410D Specifications

Brakes
Hydraulically actuated, oil-immersed multiple disc brakes
front and rear.
Spring actuated parking brakes and emergency brakes on
front and rear bogie.

EL62757,0000007 1906FEB021/1

Hydraulic system
Load sensing hydraulic system with power control.
Pump capacity
Hydraulics

280 l/min

74 gal/min

Power train

280 l/min

74 gal/min

Working pressure

24 MPa

3481 psi

EL62757,0000008 1906FEB021/1

Electrical System
Voltage

24 V

Batteries

2 x 140 Ah

Alternator

24 V 140 A

EL62757,0000009 1906FEB021/1

Boom
Boom CF7
Lift moment

125,4 kNm

92490 lb-ft

Reach.

7,2/8,5/10 m

23,6/27,9/32,8 ft

EL62757,000000A 1906FEB021/1

12-0-6

101702

PN=247

1410D Specifications

Cab
Sound and thermal insulated single-seater safety cab.
The cab can be raised and shifted to the side for easy
service access.
Noise level in cab
not usable at 04/02
Vibration level
not usable at 04/02

EL62757,000000B 1906FEB021/1

12-0-7

101702

PN=248

Hydraulic Diagrams, F622627


Hydraulic Diagrams, F622627
1.
2.
3.
4.
5.

Boom Hydraulics
Transmission Hydraulics
Brake Hydraulics
Extra Equipment Hydraulics
Options Hydraulics

EL62757,0000062 6717OCT021/1

Hydraulic Diagrams-1

101702

PN=249

Hydraulic Diagrams, F622627

Boom Hydraulics
Position

Meaning

100

Work pump

Pressure (MPa)

Pressure (psi)

Placement

101

Adjustment of work pumps max. pressure

24

3481

Work pump

102

Adjustment of work pumps pressure difference

2,5

362,5

Work pump

103

Return filter

0,15

22

104

Hydraulic tank

Front frame

105

Level guard

Hydraulic tank

106

Temperature sensor

Hydraulic tank

107

Bleeding

108

Bleed screw

0,02

Hydraulic tank

109

Pressure valve W84

0,13

19

Hydraulic tank

110

Quick coupler , filling of hydraulic oil

Main switch

111

Pressure measure point, work pumps pressure

Attachement valve

112

Pressure valve W41A, parking brake

290

Attachement valve

113

Adjustment screw, reduced pressure of


attachements

435

Attachement valve

114

Pressure measure point, reduced pressure of


attachements

Attachement valve

115

Attachement block

Attachement valve

116

Pressure measure point, , pressures for each


function of the boom

Attachement valve

117

Pressure measure point, work pumps signal


pressure

Attachement valve

118

Differential front

Attachement valve

119

Differential rear

Attachement valve

120

Rear wheel drive, engagement with high gear on

Attachement valve

121

High/low gear

Attachement valve

122

Pilot valve for loader valve

123

Pressure measure point, pilot pressure for loader


valve

3.5

508

Loader valve

124

Pressure reduce valve

26

3771

Loader valve

125

Orifice for a signal line

Loader valve

126

Loader valve

Under the cab

127

Pressure reduction for Boom slew

Under the cab

128

Cylinders for boom slew

Boom

129-130

Reduced pressure for boom slew

Under the cab

Front frame

Hydraulic tank

Loader valve

21.5

3118

Continued on next page

Hydraulic Diagrams-2

Loader valve

EL62757,00001E8 1922APR021/4
101702

PN=250

T160341

UN09OCT02

Hydraulic Diagrams, F622627

Continued on next page

Hydraulic Diagrams-3

EL62757,00001E8 1922APR022/4
101702

PN=251

Hydraulic Diagrams, F622627


Position
131

Meaning
Lift cylinder

Pressure (MPa)

Pressure (psi)

Placement
Boom

132

Jib cylinder

Boom

133

Rotator

Boom

134

Grapple cylinder

135

Reduced pressure for grapple, (closed)

136

Reduced Pressure for grapple, (open)

17

2466

Loader valve

137

Telescope cylinder

21.5

3118

Boom

138

Frame steering

Rear frame

139-140

Reduced pressure for frame steering

Loader valve

141

Pilot valve, frame steering

Under the cab

Boom
19

2756

Continued on next page

Hydraulic Diagrams-4

Loader valve

EL62757,00001E8 1922APR023/4

101702

PN=252

T160341

UN09OCT02

Hydraulic Diagrams, F622627

EL62757,00001E8 1922APR024/4

Hydraulic Diagrams-5

101702

PN=253

Hydraulic Diagrams, F622627

Transmission Hydraulics
Position

Meaning

200

Pulse sensor, diesel engine

Pressure (MPa)

Diesel engine

201

Transmission pump

Under the cab

202

Oil cooler

Front frame

203

Thermostat valve

Under the cab

204

Measure point for charge pressure

Transmission pump

205

Pressure sensor

206

Measure point for drive pressure; drive pressure


backwards

207

Adjustment of hydrostatic charge pressure

208

Drive pump pressure cut-off

209

Adjustment of pressure reduce valve: drive


pressure backwards

48

6961,8

Transmission pump

210

Adjustment of hydrostatic drive pressure forward


and backwards

45

6526,7

Transmission pump

211

Adjustment of pressure reduce valve: drive


pressure forward

48

6961,8

Transmission pump

212

Pressure reduce valve, transmission pump

Transmission pump

213

Charge pressure filter

Transmission pump

214

Measure point for transmission pressure; drive


pressure forward

Transmission pump

215

Direction identification valve in drive motor

Drive motor

216

Measure point, motors control pressure/ motor


pressure cut-off

Drive motor

217

Adjustment of drive motors pressure cut-off

218

Drive motors pressure cut-off

Drive motor

219

Pulse sensor, drive motor

Drive motor

220

Drive motor

Under the cab

1,0 MPa

Pressure (psi)

145

Placement

Transmission pump
Transmission pump

435

Transmission pump
Transmission pump

33

4496

Continued on next page

Hydraulic Diagrams-6

Drive motor

EL62757,00001E9 1922APR021/2

101702

PN=254

T160342

UN09OCT02

Hydraulic Diagrams, F622627

EL62757,00001E9 1922APR022/2

Hydraulic Diagrams-7

101702

PN=255

Hydraulic Diagrams, F622627

Brake Hydraulics
Position

Meaning

300

Brake valve

Pressure (MPa)

Pressure (psi)

Placement

301

Measure point, pressure accumulator

Under the cab

302

Pressure accumulator

Under the cab

303

Pressure sensor, brake light

304

Measure point for brake pressure

305

Measure point for brake pressure

Brake valve

306

Orifice

Brake valve

307

Measure point, pressure accumulator

Brake valve

308

Pressure accumulator

Under the cab

309

Pressure sensor, brakes charge pressure

310

Front brake cylinders

Front axle

311

Rear brake cylinders

Rear axle

312

Brake fluid container

Cab, front

313

Front brake pedal

Cabin

314

Rear brake pedal

Cabin

315

Shuttle valve

Under the cab

Under the cab

0,5

72,5

Brake valve
Brake valve

10

1450

Continued on next page

Hydraulic Diagrams-8

Brake valve

EL62757,00001EA 1922APR021/2

101702

PN=256

T160343

UN09OCT02

Hydraulic Diagrams, F622627

EL62757,00001EA 1922APR022/2

Hydraulic Diagrams-9

101702

PN=257

Hydraulic Diagrams, F622627

Extra Equipment Hydraulics


Position

Meaning

400

Hydraulic oil pump

Pressure (MPa)

Pressure (psi)

Under the cab

401

Hydraulic oil tank

Front frame

402

Filling pump, hydraulic oil

Under the cab

403

Quick coupler

Main switch

404

Compressed air valve

Hydraulic tank

405

Vacuum pump

Under the cab

406

Bleeding valve filter

Hydraulic tank

407

Vacuum valve

0.03

4,4

Under the cab

408

Bleeding valve

0.05

7,25

Under the cab

409

Adjustment screw, frame brake pressure

21

3046

Attachement valve

410

Solenoid Y65, frame brake

Attachement valve

411

Measure point, frame brake pressure

Middle joint

412

Frame brake cylinder

Middle joint

413

Loader valve

Under the cab

414

Lift cylinder

Boom

415

Steering valve

Rear frame

416

Manual steering valve, frame steering

Cabin

417

Steering valve, frame steering

Pilot valve

418

Shuttle valve

Front frame

419

Stairs steering valve

Front frame

420

Stairs cylinder

Front frame

421

Directional valve

Front frame

422

Quick coupler

Front frame

423

Shuttle valve

Front frame

424

Valve, hand brake (extra equipment)

Continued on next page

Hydraulic Diagrams-10

Placement

EL62757,00001EB 1922APR021/2

101702

PN=258

T160344

UN09OCT02

Hydraulic Diagrams, F622627

EL62757,00001EB 1922APR022/2

Hydraulic Diagrams-11

101702

PN=259

Hydraulic Diagrams, F622627

Options Hydraulics
Position

Meaning

500

Work pump

Pressure (MPa)

Under the cab

501

Hydraulic tank

Front frame

502

Valve for load space expansion

Boom foot

503

Cylinders for load space expansion

Boom foot

504

Cylinders for Headboard expansion (2 pc.)

Headboard

505

Headboard lift valve

Under the cab

506

Headboard lift cylinder

Headboard

507

Hand pump for cab lift

Front frame

508

Directional valve

Hand pump

509

Pressure reduce valve

Under the cab

510

Cabin, Lift cylinder, front

Under the cab

511

Cabin, Lift cylinder, rear

Under the cab

512

Loader valve

Under the cab

513

Plug

Loader valve, rear

514

Proportional valve for decking blade

Under the cab

515

Proportional pilot valve for decking blade

Under the cab

516

Adjustment for decking blade reduced pressure

517

Load reduction valve for decking blade

Under the cab

518

Decking blade cylinders

Front frame

519

On/Off -valve for decking blade

Under the cab

520

Movement valve for decking blade

Under the cab

521

Manual reduction valve of decking blade

At main switch

522

Decking blade cylinders

Front frame

523

Headboard move cylinder

Headboard

524

Headboard lift- and move valve

Under the cab

525

Headboard lift cylinder

Headboard

21

Pressure (psi)

3046

Continued on next page

Hydraulic Diagrams-12

Placement

Proportional valve for


clambunk

EL62757,00001EC 1922APR021/2

101702

PN=260

T160345

UN09OCT02

Hydraulic Diagrams, F622627

EL62757,00001EC 1922APR022/2

Hydraulic Diagrams-13

101702

PN=261

Wiring Diagrams, 1410D

T144438

UN13AUG01

General

Continued on next page

Wiring Diagrams-1

EL62757,00001EF 1924APR021/35
101702

PN=262

Wiring Diagrams, 1410D


Wiring Diagram Explanations
1. Seek column

4. Reference, seek
column 608 E

7. Connector hose X16


terminal 9

10. Single line

13. Operation symbol

2. Double lines, conductor


on circuit card

5. Earth terminal,
connector X3 terminal 3

8. Number of wire 65+

11. Magnet valve Y65

3. Relay K7

6. Fuse 25, 10A

9. S9 in the box, not


mounted in all machines

12. Machine frame

Codes for electric wire colors:


BE = blue

BL =black

BR = brown

GN = green

GR = gray

OR = orange

RD = red

YL = yellow

EL62757,00001EF 1924APR022/35

Ignition key positions


In the illustration is shown which connectors are in use in
different positions of the ignition switch.

T159290

UN15OCT02

AConnectors

Continued on next page

Wiring Diagrams-2

EL62757,00001EF 1924APR023/35

101702

PN=263

Wiring Diagrams, 1410D


F619759A 1/15
Position

Description

Scheme

Location

F15

Fuse 20A, ignition switch

107 E

PC-board

F28

Fuse 10A, fuel valve, Engine ECU

118 G

PC-board

F36

Fuse 7,5A, working pumps drop

113 L

PC-board

F41

Fuse 20A, preheater

102 M

Fuse box

F42

Fuse 15A, preheater, 24/12V voltage transformer

103 M

Fuse box

F43

Fuse 25A, air conditioner

103 M

Fuse box

F44

Fuse 7,5A, engine gridheater, signal light

104 M

Fuse box

F45

Socket 24V, hydraulic oil fill-up pump, 20A

105 M

Fuse box

F46

Fuse 20A, socket 24V, auxiliary fuel pump

106 M

Fuse box

F47

Fuse 10A, DAFO

107 M

Fuse box

F48

Fuse 10A, DAFO

108 M

Fuse box

F51

Main fuse, 60A

107 N

Fuse box

F52

Main fuse, 60A

108 N

Fuse box

G1

Alternator

106 T

Engine

G2

Batteries

102 U

Under the cabin

K1

Relay, ignition switch

115 F

PC-board

K3

Relay, starting motor

108 S

Fuse box

K14

Relay, starting prevent

111 M

PC-board

K24

Relay, engine preheater

111 R

Under the cabine

M1

Starting motor

104 T

Engine

R2

Heater resistor, grid heater

111 V

Engine

S1

Main switch

101 R

Front frame

S2

Ignition switch

108 H

Control panel

S56

Emergency STOP -button

112 D

Control panel

X21

16-pin connector

104 J

Cabin floor

X22

24-pin connector

103 J

Cabin floor

X23

7-pin connectorr

100 G

Cabin floor

X49

7-pin connector

109 X

Fuse box

X59

3-pin connector

114 N

Front frame

XB1

9-pin connector

100 D

PC-board

XB3

9-pin connector

107 F

PC-board

XB6

9-pin connector

118 I

PC-board

XB9

9-pin connector

111 I

PC-board

Y1

Fuel valve

118 T

Fuel tank

Y44

Magn. valve, working pumps drop

113 U

Front frame

Continued on next page

Wiring Diagrams-4

EL62757,00001EF 1924APR025/35
101702

PN=265

Wiring Diagrams, 1410D


F619759A 2/15
Position

Description

Scheme

Location

A2

Radio

214 R

Ceiling

A3

Radio-telephone

218 D

Ceiling

B1

Pressure switch, engine oil pressure

203 T

Engine

B3

Pressure switch, brakes charge pressure

205 T

Brake valve

B4

Pressure switch, hydraulic supply pressure

202 T

Hydrostatic pump

B5

Pressure switch, parking brake

201 T

Auxiliary valve

B11,B12

Loud speaker

214 V/215 V

Ceiling

B29

Voltage transformer

214 K

Instrument box

B40, B41

Loud speaker

216 V

Ceiling

F8

Fuse 10A, radio

216 C

PC-board

F20

Fuse 7,7A, indicator lights

201 C

PC-board

F32

Fuse 5A, voltage transformer

214 F

PC-board

H1

Warning light, charge

209 K

Gauge panel

H2

Warning light, engine gridheater

203 K

Gauge panel

H3

Indicator light, parking brake

201 K

Gauge panel

H6

Indicator light, blinker

207 K

Gauge panel

H10

Indicator light, working lights

208 K

Gauge panel

H12

Indicator light, main beam

205 K

Gauge panel

H18

Warning light, hydraulic supply pressure

202 K

Gauge panel

H19

Warning light, brakes charge pressure

204 K

Gauge panel

K9

Relay, hourmeter

212 H

PC-board

K20

Relay, radio

216 I

PC-board

P1

Hourmeter

212 P

Instrument box

R3

Resistor, charge warning light

210 J

Gauge panel

X6,X7

8-pin connectors

206 I, 200K

Indicator lights

X13

9-pin connector

214 N

Cabin

X17

2-pin connector

218 F

Cabin, rear

X21

16-pin connector

210 R

Cabin floor

X46

9-pin connector

215 N

Cabin

X50

8-pin connector

214 P

Radio

X51

3-pin connector

214 S

Radio

XB2

9-pin connector

216 D

PC-board

XB4

9-pin connector

201 E

PC-board

XB6

9-pin connector

211 J

PC-board

XB8

9-pin connector

216 K

PC-board

XB9

9-pin connector

212 J

PC-board

XB10

9-pin connector

214 G

PC-board

X172

2-pin connector

218 P

Continued on next page

Wiring Diagrams-6

EL62757,00001EF 1924APR027/35
101702

PN=267

Wiring Diagrams, 1410D


F619759A 3/15
Position

Description

Scheme

Location

A1

Control unit, air conditioner

311 M

Air conditioner

B6

Potentiometer, fan

309 E

Air conditioner

B7

Potentiometer, temperature

310 E

Air conditioner

B17

Thermostat, air conditioner

313 P

Air conditioner

B33

Pressure switch, air conditioner

314 S

Engine comp

B35

Thermostat, outside temperature

310 U

Air conditioner

B36

Thermostat, cabin

308 U

Air conditioner
Ceiling

B7C

3-pin connector

301 M

E1

Preheater, engine

302 T

Front frame

E30

Heater, seat

316 P

Seat

F18

Fuse, air conditioner, seat compressor

315 D

PC-board

F29

Fuse, air conditioner

308 E

PC-board

K15

Relay, air conditioner & preheater

306 T

Fuse box

K21

Relay, compressor

315 K

PC-board

K22

Relay, air conditioner

307 H

PC-board

M2

Heater, fan

314 S

Cabin

M6, M7

Fan, ceiling

317 T, 318 T

Ceiling

P7

Time switch, preheater

300 J

Ceiling

P7B

3-pin connector

301 G

Ceiling

S25

Switch, defroster

312 D

Heater

S83

Switch, fans

318 I

Ceiling

X13

9-pin connector

301 E

Instrument box

X16

9-pin connector

316 K

Instrument box

X21

16-pin connector

307 U

Cabin floor

X22

24-pin connector

307 S

Cabin floor

X46

318 C

X48

3-pin connector

316 N

Seat

X58

3-pin connector

302 V

Front frame

XB4

9-pin connector

315 F

Front frame

XB5

9-pin connector

308 G

Front frame

XB7

9-pin connector

306 I

Front frame

XB8

9-pin connector

305 G

Front frame

XB9

9-pin connector

306 C

Front frame

XK

9-pin connector

307 T

Air conditioner

Y23

Directional valve, air conditioner .

311 U

Engine comp

Y194

Magn.coupler, compressor

315 U

Compressor

Continued on next page

Wiring Diagrams-8

EL62757,00001EF 1924APR0210/35
101702

PN=270

Wiring Diagrams, 1410D


F619759A 4/15
Position

Description

Scheme

Location

B15

Pressure switch, brake lights

414 K

Brake valve

E8

Headlight

416 U

Front frame

E9

Headlight

418 U

Front frame

E10

Position light

406 U

Front left

E11

Position light

407 U

Front right

E12

Tail light

410 U

Rear left

E14

Tail light

412 U

Rear right

E24

Blinker

405 U

Front left

E26

Blinker

407 U

Front right

E52

Cigarette lighter

401 O

Control panel

F14

Fuse, headlights

411 B

PC-board

F16

Fuse, parking lights

410 B

PC-board

F23

Fuse, cigarette lighter

400 B

PC-board

F31

Fuse, low beam

416 K

PC-board

F33

Fuse, main beam

417 K

PC-board

F34

Fuse, parking lights left

411 K

PC-board

F35

Fuse, parking lights right

413 K

PC-board

K4

Blinker relay

402 M

Instrument box

S14

Switch, hazard lights

402 E

Control panel

S15

Switch, blinker

407 E

Control panel

S18

Switch, headlights/parking lights

413 E

Control panel

S19

Switch, low-/high beam

416 E

Control panel

X1

Socket, 7-pin connector

410 R

Cabin

X2

Socket, 7-pin connector

407 R

Cabin

X3

Socket,7-pin connector

405 R

Cabin

X22

24-pin connector

405 O

Cabin floor

X27

7-pin connector

415 R

Ceiling

XB3

9-pin connector

410 D

PC-board

XB4

9-pin connector

400 D

PC-board

XB7

9-pin connector

401 D

PC-board

XB9

9-pin connector

410 K

PC-board

XB10

9-pin connector

413 M

PC-board

Continued on next page

Wiring Diagrams-10

EL62757,00001EF 1924APR0212/35

101702

PN=272

Wiring Diagrams, 1410D


F619759A 5/15
Position

Description

Scheme

Location

B16

Horn

500 S

Front frame

F19

Fuse, horn

511 F

PC-board

F22

Fuse, windscreen wiper

503 B

PC-board

F27

Fuse, rear screen wiper

513 B

PC-board

K2

Relay, wiper,rear window

513 J

PC-board

K12

Relay, windshield

509 J

PC-board

M41

Motor, washer, rear

502 T

Engine comp

M42

Motor, washer, front

503 T

Engine comp.

M5B

Motor, rearscreen wiper

511 U

Cabin

M5F

Motor, windscreen wiper

506 U

Cabin

M5L

Motor, side screen wiper

519 U

Cabin

M5R

Motor, side screen wiper

516 U

Cabin

S13

Push button, horn

500 I

Control panel

S91

Switch, washer, rear

502 J

Control panel

S92

Switch, washer, front

504 J

Control panel

S101

Switch, rear screen wiper

508 J

Control panel

S102

Switch, windscreen wiper

506 J

Control panel

S103

Switch, side screen wiper

517 J

Control panel

S104

Switch, side screen wiper

515 J

Control panel

V11

Diode

506 Q

Wiring

V13

Diode

510 Q

Cabin

V15

Diode

515 Q

Wiring

V16

Diode

518 Q

Wiring

X12

9-pin connector

506 N

Cabin, rear

X22

24-pin connector

502 Q

Instrument box

XB4

9-pin connector

500 D

PC-board

XB5

9-pin connector

508 N

PC-board

XB6

9-pin connector

514 D

PC-board

XB7

9-pin connector

513 N

PC-board

Continued on next page

Wiring Diagrams-12

EL62757,00001EF 1924APR0214/35

101702

PN=274

Wiring Diagrams, 1410D


F619759A 6/15
Position

Description

Scheme

Location

E37

Indoor light

618 R

Ceiling

E38

Service lightn

615 R

Under the cab

E40

Work light, forward

600 T

Cabin roof

E41

Work light, forward

601 T

Cabin roof

E42

Work light, left

603 T

Cabin roof

E43

Work light, left

604 T

Cabin roof

E44

Work light, right

609 T

Cabin roof
Cabin roof

E45

Work light, right

610 T

E46

Work light, backward

612 T

Cabin roof

E47

Work light, backward

613 T

Cabin roof

E58

Work light, Boom

606 T

Boom

E59

Work light, Boom

607 T

Boom

F1

Fuse, work light

603 D

PC-board

F2

Fuse, work light

604 D

PC-board

F3

Fuse, work light

609 D

PC-board

F4

Fuse, work light

610 D

PC-board

F5

Fuse, work light

612 D

PC-board

F6

Fuse, work light

613 D

PC-board

F9

Fuse, work light

601 D

PC-board

F10

Fuse, work light

605 D

PC-board

F11

Fuse, work light

602 D

PC-board

F12

Fuse, work light

606 D

PC-board

F13

Fuse, work light

607 D

PC-board

S26

Switch, indoor light

617 K

Ceiling

S27

Switch, service light

615 K

Control panel

S64

Switch, work light forwards

606 N

Ceiling

S66

Switch, work light forwards

600 N

Ceiling

S67

Switch, work light left

603 N

Ceiling

S68

Switch, work light right

609 N

Ceiling

S69

Switch, work light backwards

612 N

Ceiling

X11

9-pin connector

602 K

Ceiling

X14

9-pin connector

602 J

Instrument box

X37

2-pin connector

615 O

Cabin

X46

9-pin connector

615 M

Cabin

XB2

9-pin connector

604 F

PC-board

XB3

9-pin connector

615 F

PC-board

XB5

9-pin connector

616 F

PC-board

Continued on next page

Wiring Diagrams-14

EL62757,00001EF 1924APR0216/35
101702

PN=276

Wiring Diagrams, 1410D


F619759A 7/15
Position

Description

Scheme

Location

A4

Hub-module, CAN-bus

704 M

Instrument box

A5

Display, TMC

710 C

Seat

B23

Gas-/drivepedal, front

708 V

Cabin, front

B24

Gas-/drivepedal, rear

709 V

Cabin, rear

F17

Fuse, switches

709 F

PC-board

F21

Fuse, TMC

703 C

PC-board

H8

Alarm light, TMC

704 U

Ceiling

J1

Splice

707 Q

Wiring

J4

Splice

708 Q

Wiring

S58

Switch, parking brake

714 D

Control panel

S59

Switch, all-wheel drive

706 F

Control panel

S60

Switch, steering on/off

717 E

Control panel

X12

9-pin connector

704 R

Instrument box

X18

3-pin connector

707 U

Instrument box

X19

3-pin connector

709 U

Instrument box

X75

4-pin connector

705 R

Instrument box

X80

6-pin connector

711 V

Instrument box

XB2

9-pin connector

704 E

PC-board

XB3

9-pin connector

703 F

PC-board

XB4

9-pin connector

703 F

PC-board

XH1

8-pin connector

709 J

Hub-module

XH2

8-pin connector

712 J

Hub-module

XH3

8-pin connector

710 P

Hub-module

XH4

23-pin connector

703 P

Hub-module

XH5

8-pin connector

712 P

Hub-module

Y41

Magn. valve, parking brake

716 S

Front frame

Continued on next page

Wiring Diagrams-16

EL62757,00001EF 1924APR0218/35

101702

PN=278

Wiring Diagrams, 1410D


F619759A 8/15
Position

Description

Scheme

Location

A6

Chair module, TMC

814 L

Seat

A9

Control panel, left

801 Z

Control panel, L

A10

Control panel, right

808

Control panel, R

B8

Buzzer, alarm

812 D

Seat

B20

Steering lever, left

805 D

Control panel, L

B21

Steering lever, right

815 D

Control panel, R

B22

Machine steering, minilever

801 D

Control panel, L

810 E

Seat

805 T

Control panel, L

F60

Fuse, 12 V, Scales sensor

S31-S35

Multifunction switches A,B,C,D

S36

Load narrowing

Control panel, R

S37

Load spreading

806 T

Control panel, L

S40

Switch, driving direction

817 D

Control panel, R

S42

Button, high/low gear

813 F

Control panel, R

S43

Button, front differential lock

814 F

Control panel, L

S44

Button, rear differential lock

815 F

Control panel, L

S45

Button, wiper

808 F

Control panel, R

S46

Button, headboard up

806 X

Control panel, L

S47

Button, headboard down

807 X

Control panel, L

S48

Button, blade down

804 X

Control panel, R

S49

Button, blade up

805 X

Control panel, R

S50

Limit switch, seat direction

817 U

Seat

S51

Limit switch, driver

819 U

Seat

S57

Push button, working rpms

804 T

Control panel, L

S76

Push button, frame brake release

803 T

Control panel, L

S78

Push button, seat

813 Z

Control panel, R

X16

6-pin connector

810 C

Instrument box

X25

9-pin connector

810 P

Control panel, R

X26

9-pin connector

802 R

Control panel, L

X35

9-pin connector

816 S

Seat

X42

9-pin connector

814 H

Control panel, R

X43

9-pin connector

803 H

Control panel, L

X44

3-pin connector

800 H

Control panel, L

X45

3-pin connector

802 H

Control panel, L

X74

2-pin connector

810 B

Instrument box

X82

2-pin connector

810 F

Seat

X90

2-pin connector

818 R

Seat

X91

2-pin connector

819 R

Seat

XC1,XC2,
XC3

23-pin connector

807 H, 813 I, 814 I

Chair module

Continued on next page

Wiring Diagrams-18

EL62757,00001EF 1924APR0220/35
101702

PN=280

Wiring Diagrams, 1410D


F619759A 9/15
Position

Description

Scheme

Location

A7

Transmission module, TMC

900 N

Front frame

B9

Fuel sensor

913 U

Fuel tank

B14

Sensor rpm, driving speed/distance

914 V

Hydraulic motor

B18

Pressure switch, return filter

905 U

Hydraulic tank

J10

Splice

901 I

Wiring

J11

Splice

910 H

Wiring

J13

Splice

905 J

Wiring

J14

Splice

914 R

Wiring

J16

Splice

914 H

Wiring

J17

Splice

917 S

Wiring

J25

Splice

910 R

Wiring

R1

Resistor

902 Z

Wiring

S81

Limit switch, low gear

905 E

Gear box

S82

Limit switch, high gear

906 E

Gear box

X24

4-pin connector

908 R

Front frame

X81

4-pin connector

904 H

Front frame

XO1

3-pin connector

902 R

Front frame

XO5

3-pin connector

902 R

Front frame

XT1

23-pin connector

900 L

Transmission module

XT2

23-pin connector

904 L

Transmission module

XT3

23-pin connector

913 P

Transmission module

XT4

8-pin connector

900 P

Transmission module

Y33B

Magn. valve, rear differential lock

913 E

Auxiliary valve

Y33F

Magn. valve, front differential lock

915 E

Auxiliary valve

Y39

Magn. valve, rear wheel drive

910 E

Auxiliary valve

Y41W

Magn. valve, work brake

907 E

Brake valve

Y45

Magn. valve, low gear

901 E

Auxiliary valve

Y46

Magn. valve, high gear

902 E

Auxiliary valve

Y48

Magn. valve, hydraulic motor

918 U

Hydraulic motor

Y65

Magn. valve, frame brake

911 E

Auxiliary valve

Y102

Magn. valve, driving forward

915 U

Hydraulic pump

Y103

Magn. valve, driving reverse

916 U

Hydraulic pump

Y103B

Magn. valve, constant pressure valve, hydrostatic motor

911 U

Hydraulic motor

Y208

Magn. valve, working pumps pressure

918 E

Auxiliary valve

Continued on next page

Wiring Diagrams-20

EL62757,00001EF 1924APR0223/35
101702

PN=283

Wiring Diagrams, 1410D


F619759A 10/15
Position

Description

Scheme

Location

A7

Transmission module, TMC

1001 N

Front frame

B19

Temp. sensor, hydraulics

1003 D

Hydraulic tank

B25

Level sensor, hydraulic oil

1002 U

Hydraulic tank

B43

Back -up alarm

1006 U

Rear frame

B52

Stairs

1003 T

Front frame

F24

Fuse, stairs

1015 C

PC-board

J15

Splice

1006 H

Wiring

J23

Splice

1001 R

Wiring

S29

Switch, stairs

1015 J

Instrum. panel

X15

3-pin connector (opt. eq.).

1017 F

Instrum. panel

X22

24-pin connector

1015 R

Instrument box

X24

4-pin connector

1008 R

Front frame

X36

2-pin connector, back-up buzzer.

1006 R

Front frame

X47

4-pin connector, decking blade.

1008 G

Front frame

X67

3-pin connector, limit switch, stairs.

1003 R

Front frame

X68

4-pin connector

1014 T

Front frame

XB4

9-pin connector

1015 F

PC-board

XT1

23-pin connector

1007 D

Transmission module

XT2

23-pin connector

1006 K

Transmission module

XT3

23-pin connector

1001 L

Transmission module

Y120D

Magn. valve, stairs down

1016 T

Front frame

Y120U

Magn. valve, stairs up

1015 T

Front frame

Y195D

Magn. valve, blade down

1006 D

Front frame

Y195U

Magn. valve, blade up

1007 D

Front frame

Continued on next page

Wiring Diagrams-22

EL62757,00001EF 1924APR0225/35

101702

PN=285

Wiring Diagrams, 1410D


F619759A 11/15
Position

Description

Scheme

Location

A8

TMC-Crane module

1103 O

Under the cabin

B53

Limit switch, damping of the steering

1103 X

Middle joint

X33

4-pin connector

1102 I

Front frame

X34

2-pin connector

1105 I

Front frame

X61

12-pin connector

1114 R

Front frame

X79

3-pin connector

1116 J

Front frame

X96

4-pin connector

1116 J

Front frame

XE1

23-pin connector

1100 M

TMC-Crane module

XE2

23-pin connector

1104 M

TMC-Crane module

XE3

23-pin connector.

1102 M

TMC-Crane module

XE4

8-pin connector

1100 Q

TMC-Crane module

Y66L

Magn. valve, steering L

1105 V

Crane valve

Y66R

Magn. valve, steering R

1106 V

Crane valve

Y100D

Magn. valve, headboard

1102 G

Front frame

Y100L

Magn. valve, headboard lock valve

1104 E

Front frame

Y100U

Magn. valve, headboard

1101 G

Front frame

Y211

Clambunk magn. valve

1114 U

Front frame

Y212

Clambunk magn. valve

1115 U

Front frame

Y221

Clambunk magn. valve

1117 U

Front frame

Y222

Clambunk magn. valve

1118 U

Front frame

Y408

Magn. valve, rotator clockwise

1110 G

Crane valve

Y409

Magn. valve, rotator counterclockwise

1108 G

Crane valve

Y416

Magn. valve, grapple open

1111 G

Crane valve

Y417

Magn. valve, grapple close

1113 G

Crane valve

Y418

Magn. valve, extension out

1114 V

Crane valve

Y419

Magn. valve, extension in

1116 V

Crane valve

Y420

Magn. valve, main boom up

1105 G

Crane valve

Y421

Magn. valve, main boom down

1107 G

Crane valve

Y422

Magn. valve, jib boom out

1111 V

Crane valve

Y423

Magn. valve, jib boom in

1112 V

Crane valve

Y424

Magn. valve, Boom counterclockwise

1108 V

Crane valve

Y425

Magn. valve, Boom clockwise

1109 V

Crane valve

Continued on next page

Wiring Diagrams-24

EL62757,00001EF 1924APR0227/35

101702

PN=287

Wiring Diagrams, 1410D


F619759A 12/15
Position

Description

Scheme

Location

A1

Engine ECU

1204 L

Front frame

050

Grounding Point

1207 M

Engine, ECU, wiring harness

B01

Oil Pressure Sensor

1214 F

Engine

B02

Manifold Air Temperature Sensor

1211 G

Engine

B03

Coolant Temperature Sensor

1212 G

Engine

B04

Fuel Temperature Sensor

1210 G

Engine

B08

Crank Sensor

1210 T

Engine
PC board

F26

Fuse 10A, Engine ECU

1206 E

R10

Resistor

1205 U

Wiring

XB4

4-pin connector

1200 G

PC-board
PC-board

XB5

9-pin connector

1200 D

X02

9-pin connector

1202 F

X06

30-pin connector

1208 I

Engine ECU

X64

6-pin connector

1204 D

Front frame

Y01

Magnitic Valve, Fuel Injectors

1216 F

Engine

Continued on next page

Wiring Diagrams-26

EL62757,00001EF 1924APR0229/35

101702

PN=289

Wiring Diagrams, 1410D


F619759A 13/15
Position

Description

Scheme

Location

E48, E49

Work light, forwards

1305 S, 1306 S

Cabin roof

E50, E51

Work light, backwards

1302 S, 1303 S

Cabin, middle

E54

Work light, backwards

1304 S

Rear frame

E55, E56

Work light, Boom

1300 S, 1301 S

Boom

F7

Fuse, work light, Boom

1301 C

PC-board

F25

Fuse, vacuum pump

1312 F

PC-board

F30

Fuse, compressor, seat

1309 B

PC-board

K6

Relay, compressor, seat

1310 H

PC-board

K38

Relay, fuel pump

1315 N

Front frame

K39

Relay, fuel pump

1317 N

Front frame

M10

Compressor, seat

1310 S

Seat

M11

Fill-up pump, hydraulic oil

1314 R

Under the cabin

M12

Vacuum pump, hydr. tank

1312 R

Under the cabin

M16

Fuel pump

1316 R

Front frame

S54

Switch, fill-up pump, hydraulic oil

1314 O

Beside main switch

S55

Switch, hydraulic vacuum pump

1312 O

Beside main switch

S61

Switch, fuel pump

1315 G

Beside main switch

S65

Switch, work light forwards

1305 J

Ceiling

S70

Switch, work light Boom

1300 J

Ceiling

S71

Switch, corner lights

1303 J

Control panel

X11

9-pin connector

1302 F

Cabin

X12

9-pin connector

1301 G

Cabin

X13

9-pin connector

1301 N

Cabin

X16

6-pin connector

1309 M

Cabin

X21

16-pin connector

1307 P

Cabin floor

X22

24-pin connector

1301 N

Cabin floor

X28, X29,
X30, X31

2-pin connector

1319 G, 1315 H, 1300


V, 1312 V

Front frame

X40

2-pin connector

1310 P

Front frame

X46

9-pin connector

1303 M

Cabin

X52

2-pin connector

1305 Q

Front frame

X60

2-pin connector

1310 N

Instrument box

X86

2-pin connector

1314 V

Front frame

X93

2-pin connector

1310 O.

Instrument box

XB2

9-pin connector

1301 E

PC-board

XB5

9 -pin connector

1312 D

PC-board

Y77

Magn. valve, vacuum pump

1301 S

Hydraulic tank

Continued on next page

Wiring Diagrams-28

EL62757,00001EF 1924APR0231/35
101702

PN=291

Wiring Diagrams, 1410D


F619759A 14/15
Position

Description

Scheme

Location

A30

Control, Dafo-fire extinguisher

1403 C

Ceiling

B30.1

Temp. sensor, Dafo.

1404 T

Engine comp

B30.6

Temp. sensor, Dafo

1407 T

Under the cabin

B31

Horn, Dafo

1408 K

Engine comp.

E60

Work lights

1414 Q

Jib boom

E61

Work lights

1415 Q

Jib boom

F40

Fuse, dozer blade flotation

1416 D

Instrument box

H30

Alarm light, Dafo

1408 D

Ceiling

K40

Relay, dozer blade flotation

1416 K

Instrument box

M17

Seat lock, servomotor

1411 T

Seat

R30

Resistor, Dafo fire extinguisher

1416 T

Temp.sensor, Dafo

S74

Switch, dozer blade flotation

1414 E

Instrument box

S78

Seat lock, switch

1410 F

Control panel, R

X16

6-pin connector

1410 F

Instrument box

X22

24-pin connector

1413 I

Instrument box

X32

9-pin connector

1402 I

Fire extinguisher

X38

2-pin connector

1416 J

Seat

X60

2-pin connector

1419 O

Instrument box

X63

2-pin connector

1407 C

Ceiling

X87

3-pin connector

1401 M

Fuse box

X95

2-pin connector

1411 K

Seat

Y195

Magnetic valve, decking blade float

1416 T

Front frame

YS9

Trigger, Dafo-extinguisher

1409 O

Front frame, rear

Continued on next page

Wiring Diagrams-30

EL62757,00001EF 1924APR0233/35

101702

PN=293

Wiring Diagrams, 1410D


F619759A 15/15
Position

Description

GND1

Grounding

Scheme

Location
Instrument box

GND2

Grounding

Under the cabin, left

GND3

Grounding

Ceiling

GND4

Grounding

Under the cabin, right

GND5

Grounding

Seat

GND6

Grounding

Engine

GND7

Grounding

Front frame

GND8

Grounding

Front frame

GND9

Grounding

Front frame

GND10

Grounding

Under cabin floor

GND11

Grounding

Under cabin floor

EL62757,00001EF 1924APR0235/35

Wiring Diagrams-32

101702

PN=295

TMC
TMC CONTROL SYSTEM ver 3G+

EL62757,0000051 5416SEP021/1

TMC-1

101702

PN=296

Index
Page

A
Air conditioner
Checking. . . . . . . . . . . . . . . . . . . . . . 6-6-6, 6-10-6
Air Conditioner
Compressor . . . . . . . . . . . . . . . . . . . . . . . .11-1-11
Compressor V-belt . . . . . . . . . . . . . . . . . . .11-1-11
Condenser element. . . . . . . . . . . . . . . . . . .11-1-12
Air conditioner
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-10
Air Conditioner
Dryer service indicator . . . . . . . . . . . . . . . .11-1-11
Evaporator element. . . . . . . . . . . . . . . . . . .11-1-12
First aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1-5
Hoses and connectors . . . . . . . . . . . . . . . .11-1-13
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 11-1-1
Main parts. . . . . . . . . . . . . . . . . . . . . . . . . . 11-1-1
Air conditioner
Maintenance every 50 hour or weekly. . . . . . 6-3-2
Air Conditioner
Refrigerant level . . . . . . . . . . . . . . . . . . . . . 11-1-8
Risks and counter-measures. . . . . . . . . . . . 11-1-4
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1-6
Air filter
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-6
Outside and inside air filter . . . . . . . . . . . . . . 6-4-7
Air filter restriction indicator
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-6
Air intake system
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-4
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-2
Alternator
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-4
Anti slips
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-7
ATF oil
Check the driving brake oil level . . . . . . . . . . 6-2-6
Atomisers
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-5
Axles
Change Bogie Axle Differential Oil . . . . . . . . 6-7-7
Change Bogie Housings Oil . . . . . . . . . . . . . 6-7-8
Change Single Axle Differential Oil . . . . . . . . 6-7-9
Change Single Axle Wheel Ends Oil . . . . . . 6-7-10
Check Bogie Housings Oil Level . . . . . . . . . . 6-4-5
Check Single Axle Wheel Ends Oil Level . . . 6-4-4
Grease Bogie Bearings . . . . . . . . . . . . . . . . . 6-4-6
Tighten bolts . . . . . . . . . . . . . . . . . . . . . . . . 6-7-11

B
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-3

Page

Bearings
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-3
Grease center hinge . . . . . . . . . . . . . . . . . . . 6-3-1
Grease steering cylinder . . . . . . . . . . . . . . . . 6-3-1
Belt
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-6
Bleeding
Brake system . . . . . . . . . . . . . . . . . . . . . . . . 7-3-5
Drive hydraulic system . . . . . . . . . . . . . . . . . 7-3-1
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . 6-10-2
Hydraulic system, Boom . . . . . . . . . . . . . . . 10-1-1
Working hydraulic system . . . . . . . . . . . . . . . 7-3-3
Bogie
Change Bogie Housings Oil . . . . . . . . . . . . . 6-7-8
Bogie axle
Change Bogie Axle Differential Oil . . . . . . . . 6-7-7
Bogie tracks
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-8
Bolts and joints
Axles and frame . . . . . . . . . . . . . . . . . . . . . 6-7-11
Boom
Assembly instructions . . . . . . . . . . . . . . . . . 10-1-1
Check structures . . . . . . . . . . . . . . . . . . . . . 10-2-1
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Control levers . . . . . . . . . . . . . . . . . . . . . . . . 4-1-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . 10-0-1
Lubrication and maintenance chart . . . . . . . 10-3-4
Maintenance schedule . . . . . . . . . . . . . . . . 10-1-2
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-2
Operating instructions . . . . . . . . . . . . . . . . . 10-0-4
Operating safety precautions. . . . . . . . . . . . 10-0-2
Structures . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-2
Boom CF7
Specifications . . . . . . . . . . . . . . . . . . . . . . . 10-7-1
Boom joint pins
Check for security . . . . . . . . . . . . . . . . . . . . 10-3-1
Boom sleving housing
Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-1
Boom sleving system
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-1
Brake fluid
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-16
Brake system
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-5
Brakes
Charging pressure . . . . . . . . . . . . . . . . . . . . 7-7-3
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7-1
Checking Drive Brake
Pedal Brake. . . . . . . . . . . . . . . . . . . . . . . . 7-7-4
Mechanical adjustment . . . . . . . . . . . . . . . . . 7-7-2
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-3

Index-1

101702

PN=1

Index

Page

Page

Work Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7-3


Breather
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-3

Diferential lock-up
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-7
Differential oil
Check the level . . . . . . . . . . . . . . . . . . . . . . . 6-4-3
Drive belt
Check belt wear . . . . . . . . . . . . . . . . . . . . . . 6-5-4
Drive motor
Hydrostatic flushing valve . . . . . . . . . . . . . . . 7-5-1
Pressure cut-off. . . . . . . . . . . . . . . . . . . . . . . 7-5-2
Drive Pump
Charge pressure . . . . . . . . . . . . . . . . . . . . . . 7-4-1
Drive pump
Cut off valve setting . . . . . . . . . . . . . . . . . . . 7-4-2
Driveshafts
Geasing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-10
Driving
Driving off-road . . . . . . . . . . . . . . . . . . . . . . . 5-6-1
Driving on road . . . . . . . . . . . . . . . . . . . . . . . 5-6-2

C
Cab lift pump oil
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-17
Cab windows
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-4
Cabine
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3-1
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3-2
Capacities
Fluids and lubricants . . . . . . . . . . . . . . . . . . 6-0-11
Control panels
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-6
Control System
TMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-1
Control unit
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-1
Coolant
Checking engine coolant level. . . . . . . . . . . . 6-2-3
Pressure test system . . . . . . . . . . . . . . . . . 6-11-3
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-14
Replenishing supplemental additives. . . . . . 6-11-1
Coolant additives
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-9
Coolant, changing. . . . . . . . . . . . . . . . . . . . . . . 6-7-4
Cooling system
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-8
Pressure control . . . . . . . . . . . . . . . . . . . . . 6-5-10
Crankcase vent tube
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-4

D
Daily maintenance
Maintenence after the workshift . . . . . . . . . . 6-2-8
Dashboard
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-2
Decking Blade
Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4-3
Decking blade
Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-2
Decking Blade
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4-2
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4-1

E
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-2
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-1
Electrical
Check Batteries Electrolyte Specific
Gravity. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-7
Emergency Stopper
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-1
Engine
A normal operation . . . . . . . . . . . . . . . . . . . . 5-5-5
Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1
Coolant level check. . . . . . . . . . . . . . . . . . . . 6-2-3
Oil level check . . . . . . . . . . . . . . . . . . . . . . . 6-2-2
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-2
Turning off . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-6
Valve clearance, check (200,000- ) . . . . . . . . 6-7-1
Engine coolant
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-9
Engine grounding
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-6
Engine Oil
Check the oil level. . . . . . . . . . . . . . . . . . . . . 6-2-2
Engine oil
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-13
Engine Preheater . . . . . . . . . . . . . . . . . . . . . . 11-2-1
Empty fault memory . . . . . . . . . . . . . . . . . . 11-2-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 11-2-2
Malfunction codes . . . . . . . . . . . . . . . . . . . . 11-2-7
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2-4

Index-2

101702

PN=2

Index

Page

Page

Engine speeds
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-6
Exhaust manifold
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-6
Extension boom
Sideway clearance . . . . . . . . . . . . . . . . . . . 10-3-2
Vertical clearance . . . . . . . . . . . . . . . . . . . . 10-4-2
Extension boom chains
Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-3
Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-2

Grease
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-17

F
Fire Extinguisher System . . . . . . . . . . . . . . . . 11-3-1
After a fire. . . . . . . . . . . . . . . . . . . . . . . . . . 11-3-5
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . 11-3-6
Fire Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3-2
Hand held fire extinguishers . . . . . . . . . . . . 11-3-8
Fire extinguisher system
Have checked . . . . . . . . . . . . . . . . . . . . . . . . 6-9-1
Fire sxtinguisher
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8-1
Fluids and lubricants
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-11
Frame Brake
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-4
Fuel
Filling the fuel tank . . . . . . . . . . . . . . . . . . . . 6-2-7
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-12
Fuel filler filter
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-5
Fuel filter
Changing fitters. . . . . . . . . . . . . . . . . . . . . . . 6-5-3
Fuel system
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-2
Fuel tank
Cleaning the filler filter . . . . . . . . . . . . . . . . 6-10-5
Remove sediment and water. . . . . . . . . . . . . 6-5-6
Fuses
Engine compartment . . . . . . . . . . . . . . . . . . . 8-1-7

H
High /low gear oil
Check the oil level. . . . . . . . . . . . . . . . . . . . . 6-4-2
High-low gear
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-6
High/low gear
Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-4
Hub gears
Check oil level . . . . . . . . . . . . . . . . . . . . . . . 6-4-4
Hydraulic oil
Changing . . . . . . . . . . . . . . . . . . . . . . 6-6-1, 7-1-2
Check oil level . . . . . . . . . . . . . . . . . . . . . . . 7-1-1
Checking oil level . . . . . . . . . . . . . . . . . . . . . 6-2-1
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-15
Hydraulic oil change
Using vacuum pump . . . . . . . . . . . . . . . . . . . 7-1-1
Hydraulic return filter
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-2
Hydraulic system
Bleeding drive hydraulic system . . . . . . . . . . 7-3-1
Hydraostatic system . . . . . . . . . . . . . . . . . . . 7-2-1
Workin hydraulic system . . . . . . . . . . . . . . . . 7-2-1
Hydraulic system, working hydraulic
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-3
Hydraulic tank
Change oil . . . . . . . . . . . . . . . . . . . . . 6-6-1, 7-1-2
Check oil level . . . . . . . . . . . . . . . . . . . . . . . 7-1-1
Replace breather . . . . . . . . . . . . . . . . . . . . . 6-6-3
Replace return filter. . . . . . . . . . . . . . . . . . . . 6-6-2

I
Inside air filter
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-7
Instrument box fuses . . . . . . . . . . . . . . . . . . . . 8-1-8

G
Gear oil
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-16
Grapple
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-3
Grapple and link
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-1

L
Lubricants and Fluids
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-10
Lubrication system
Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1

Index-3

101702

PN=3

Index

Page

Page

M
Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance
Check Bogie Housings Oil Level . . . . . . . . . .
Check Differential Oil Level . . . . . . . . . . . . . .
Check Single Axle Wheel Ends Oil Level . . .
Check Wheel Nut Torque . . . . . . . . . . . . . . .
Check Windscreen Washer Fluid Level. . . . .
General maintenance instructions . . . . . . . . .
Grease Bogie Bearings . . . . . . . . . . . . . . . . .
Servicing safety precautions . . . . . . . . . . . . .
Minilevers
During transportation. . . . . . . . . . . . . . . . . . .

S
8-1-1
6-4-5
6-4-3
6-4-4
6-4-7
6-2-4
6-0-3
6-4-6
6-0-2
5-4-1

O
Oil
Hydraulic oil level checking . . . . . . . . . . . . . .
Oil, engine
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operators station . . . . . . . . . . . . . . . . . . . . . . .
Outside air filter
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overhead panel
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2-1
6-5-1
4-1-1
6-4-7
4-1-8

Safety
Safety Features. . . . . . . . . . . . . . . . . . . . . . . 3-1-1
Safety, maintain safety cabin . . . . . . . . . . . . . . 3-2-2
Screw and bolt connections
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-5
Seat Safety Switch
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-1
Sensors
Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . 8-1-10
Hydraulic Oil Return Filter . . . . . . . . . . . . . . 8-1-10
Hydraulic Oil Temperature . . . . . . . . . . . . . 8-1-10
RPM of Drive Motor . . . . . . . . . . . . . . . . . . . 8-1-9
Service
Intervaller . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1-1
Signal lights . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5
Single axle
Change Single Axle Differential Oil . . . . . . . . 6-7-9
Single axle wheel ends
Change Single Axle Wheel Ends Oil . . . . . . 6-7-10
Start Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-3
Starter motor
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-4
Starting the Engine
After starting . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-4
Starting the engine
Before starting . . . . . . . . . . . . . . . . . . . . . . . 5-5-1
Steering
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-5
Stowing a disabled boom . . . . . . . . . . . . . . . . . 5-7-4
Supplemental coolant additives
Replenishing . . . . . . . . . . . . . . . . . . . . . . . . 6-11-1

Pressure filter
Renew filter of drive hydraulic system . . . . . . 6-5-7

T
R
Radiator grille
Check cleaness. . . . . . . . . . . . . . . . . . . . . . . 6-2-5
Rear Wheel Drive
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-6
Return filter
Replace hydraulic return filter . . . . . . . . . . . . 6-6-2
Rotator
Link brakes . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-1
Magnetic plug . . . . . . . . . . . . . . . . . . . . . . . 10-5-1
Rotator and Grapple
Specifications . . . . . . . . . . . . . . . . . . . . . . . 10-7-1

Telephone
Prepardness . . . . . . . . . . . . . . . . . . . . . . . . .
Tires
Checking air pressure . . . . . . . . . . . . . . . . . .
Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . .
TMC
Control System . . . . . . . . . . . . . . . . . . . . . . .
Towing the machine . . . . . . . . . . . . . . . . . . . . .
Transfer case
Look high/low gear . . . . . . . . . . . . . . . . . . . .
Transmission
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High(Low Gear . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic System . . . . . . . . . . . . . . . . . . . .

Index-4

4-1-9
6-2-7
6-0-5
5-1-1
5-7-1
6-6-4
9-1-3
9-1-1
9-1-2

101702

PN=4

Index

Page

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-1
Turbocharger
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-4

V
Vacuum pump
How to use . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1-1
Valve clearance,
Check - Engines (200,000- ) . . . . . . . . . . . . . 6-7-1
Vibrations damper
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7-3

W
Warning signals
Lights and buzzer . . . . . . . . . . . . . . . . . . . . . 4-1-9
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . 1-1-3, 2-1-1
Wheels
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-6
Wheels and Tires
Check Wheel Nut Torque . . . . . . . . . . . . . . . 6-4-7
Windows
Washers and wipers . . . . . . . . . . . . . . . . . . . 4-1-4
Windscreen washer
Check Windscreen Washer Fluid Level. . . . . 6-2-4
Working Hydraulic System
Auxiliary functions . . . . . . . . . . . . . . . . . . . . . 7-6-4
Boom pressures . . . . . . . . . . . . . . . . . . . . . . 7-6-2
Frame Brake . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-4
Max. pressure . . . . . . . . . . . . . . . . . . . . . . . . 7-6-1
Optional Equipment. . . . . . . . . . . . . . . . . . . . 7-6-5
Pressure Difference . . . . . . . . . . . . . . . . . . . 7-6-1
Worklamp (Xenon)
Safety instructions. . . . . . . . . . . . . . . . . . . . . 3-4-2
1710D
Specifications . . . . . . . . . . . . . . . . . . . . . . . 12-0-1

Index-5

101702

PN=5

Index

Index-6

101702

PN=6