Manual Descortezador 604

PN 71510013 - OMM015008130510 i
Table of Contents
1. Introduction..................................................................................... 1-1
Section Table of Contents................................................................................... 1-1
Machine Information ............................................................................................ 1-2
About This Manual ............................................................................................... 1-5
Identification ........................................................................................................ 1-6
Replacement Parts ............................................................................................ 1-11
CBI Authorized Service ..................................................................................... 1-12
Publication Feedback ........................................................................................ 1-13
2. Safety ............................................................................................... 2-1

Introduction .......................................................................................................... 2-2
Safety Guidelines ................................................................................................. 2-2
Danger Zones ....................................................................................................... 2-4
Hazard Decals ...................................................................................................... 2-6
Safety Procedures ............................................................................................... 2-9
3. Operation......................................................................................... 3-1
General ................................................................................................................. 3-3
Operating Procedures ......................................................................................... 3-4
Automated Features .......................................................................................... 3-18
Operator Controls .............................................................................................. 3-20
Panel Controls/Settings .................................................................................... 3-32
Optional Equipment ......................................................................................... 3-116
4. Maintenance .................................................................................... 4-1

General ................................................................................................................. 4-3
Theory ................................................................................................................... 4-4
Maintenance Schedules ...................................................................................... 4-5
Lubrication ......................................................................................................... 4-11
Maintenance Procedures .................................................................................. 4-16
CONTINENTAL BIOMASS INDUSTRIES, INC.
22 Whittier St  Newton NH 03858-3524  Main No: 603.382.0556
Website: www.cbi-inc.com  E-mail: info@cbi-inc.com
ii PN 71510013 - OMM015008130510
5. Electrical System ............................................................................ 5-1

General ................................................................................................................. 5-2
Schematics ........................................................................................................... 5-2
6. Hydraulic System ........................................................................... 6-1

General ................................................................................................................. 6-2
Filter Identification ............................................................................................... 6-2
Schematic ............................................................................................................. 6-5
7. Specifications ................................................................................. 7-1

Shipping Dimensions .......................................................................................... 7-2
Machine Specifications ....................................................................................... 7-2
Machine Adjustments .......................................................................................... 7-4
Torque Specifications ......................................................................................... 7-5
Wear Specifications ............................................................................................. 7-7
8. Replacement Parts ......................................................................... 8-1

Introduction .......................................................................................................... 8-2
Wear Parts ............................................................................................................ 8-2
Spare Parts ........................................................................................................... 8-4
Consumable Parts ............................................................................................... 8-6
9. Indeces ............................................................................................ 9-1

Alphabetical Index ............................................................................................... 9-1
Table Of Figures .................................................................................................. 9-8
10. Notes.............................................................................................. 10-1

Flail Drive Bearing Inspection Records ........................................................... 10-1
Belt Tension Test Records................................................................................ 10-7
Custom Notes .................................................................................................. 10-17

PN 71510013 - OMM015008130510 INTRODUCTION - SECTION TABLE OF CONTENTS 1-1
1. Introduction
Section Table of Contents
Machine Information ............................................................................................ 1-2
Product Overview ..................................................................................................................... 1-2
Product Intent & Disclaimer .................................................................................................... 1-2
Equipment Serial Numbers ..................................................................................................... 1-3
Supplemental Manuals............................................................................................................. 1-4
About This Manual ............................................................................................... 1-5
Manual Intent ............................................................................................................................ 1-5
How to Use This Manual .......................................................................................................... 1-5
Manual Disclaimer .................................................................................................................... 1-5
Date of Publication ................................................................................................................... 1-5
Identification ........................................................................................................ 1-6
Machine Orientation & Component Location ........................................................................ 1-6
Component Location Index ..................................................................................................... 1-7
Flail Numbering Guide ............................................................................................................. 1-9
Bottom Feed Roll Numbering Guide ...................................................................................... 1-9
Idler Roll Numbering Guide ..................................................................................................... 1-9
Top Feed Roll Numbering Guide .......................................................................................... 1-10
Machine Identification ............................................................................................................ 1-10
Replacement Parts ............................................................................................ 1-11
Genuine CBI Replacement Parts .......................................................................................... 1-11
Replacement part ordering procedure ................................................................................. 1-11
Parts department contact information ................................................................................. 1-11
CBI Authorized Service ..................................................................................... 1-12
CBI Authorized Service Assistance...................................................................................... 1-12
Service Assistance Requisition Procedure ......................................................................... 1-12
Service department contact information ............................................................................. 1-12
Publication Feedback ........................................................................................ 1-13
Publication Feedback............................................................................................................. 1-13
Publication feedback reporting procedure .......................................................................... 1-13
Technical publications department contact information ................................................... 1-13

1-2 INTRODUCTION - MACHINE INFORMATION PN 71510013 - OMM015008130510
Machine Information
Product Overview
CBI’s Magnum Force 604 Flail is engineered to be the industry’s most rugged and productive
delimber/debarker, capable of processing logs up to 24" in diameter. The development of our flail was
dictated by the needs of logging contractors, particularly those working with Eucalyptus and other
species with “stringy” bark. When coupled with our Disc Chipper 754, the Magnum Force Flail is the
ideal tool for the pulp and paper industry and others looking for high production and quality, uniform
wood chips. One operator effectively controls the complete system, reducing manpower while
drastically improving throughput.
CBI’s four-roll flail design provides optimum contact with wood to deliver maximum debarking action.
Consisting of four 60" long by 40" diameter drums, the flail is capable of running single or dual 8-link
chains and speeds of 300-800 rpm. The top flail positions are determined by the top feed roll cylinder
positioning sensors and the flail rpm is automatically adjusted based on log diameter. Flail drums are
driven by high pressure hydraulic piston motors via synchronous belt drives. The motors are driven by
high-efficiency hydrostatic hydraulic pumps.
Material is fed into and out of the flail chamber by pivoting large diameter and high-torque top feed roll
assemblies with position-sensing cylinders to achieve optimum debarking performance. All cylinders
are specially designed with heavy-duty clevises and pins for long life and durability. Infeed rolls
monitor the height of incoming material and automatically adjust height and speed of flail rolls,
improving debarking by reducing chain wear, fiber loss, and fuel consumption. Bottom feed rolls are
driven by direct-coupled Char-Lynn motors through a Brevini gearbox. Top feed rolls are internally
driven by Poclain high-torque wheel motors and are completely covered to eliminate spillage. The
completely-enclosed system prevents debris from escaping the flail chamber, drastically reducing
maintenance and fire hazards.
A heavy chain curtain wipes debris loose from logs before leaving the flail chamber. Residue is
discharged from the flail chamber by a large hydraulically-actuated push ram that is 13' wide by 12"
high with 72" stroke by 5" bore trunion-mounted cylinders to provide sufficient force to push debris far
from the machine. The support frame ensures perfect alignment of ram and the frame hydraulically
folds up for transport.
The inside of the flail chamber has replaceable wear liners for easy maintenance and overall
longevity of the machine. The Magnum Force Flail also features a closed-loop hydraulic system, 580
hp CAT C-15 (C-18 optional) electronic diesel engine with a high ambient temperature radiator,
hydraulically-actuated reversing Flexxaire fan, and a Parker IQAN™ PLC with radio remote controls.
The Tigercat T-215 self-equipped knuckle boom loader comes with a 4.4 L CAT engine and has a 27'
reach. The cab is equipped with AC/heater, high-intensity light package, adjustable comfort seat,
joystick controls, and video camera display for the wood exit area and chipper discharge chute. This
large capacity, field-proven Tigercat loader allows operators to load more wood per grapple and is the
perfect complement to the flail. For short wood processing, the Flail 604 can be supplied with a feed
conveyor instead of a loader.
Product Intent & Disclaimer

The machine described in this manual is designed and constructed solely for the purpose of
debarking and delimbing organic wood trees. In the event that it is not operated properly or willfully
misused, the machine may cause damage to the surrounding environment, other equipment or bodily
harm to persons within its operating range. Operating personnel must be fully trained and instructed
in its functions as well as required safety procedures. Abuse or misuse of the machine which results
in damage or premature failure will invalidate the warranty. Machine owner is solely liable if such
negligence results in property damage and/or personal injury.

PN 71510013 - OMM015008130510 INTRODUCTION - MACHINE INFORMATION 1-3
Equipment Serial Numbers

Your CBI machine is equipped with various components some of which have their own serial
numbers. It is imperative to record and track all individual component serial numbers. Component
serial number information may be necessary for parts ordering, product update, or warrantee
purposes. The following is a list of the serial numbers for individual components intended to assist in
the recording of serial numbers. It is the responsibility of the machine owner to ensure that all
component serial numbers are recorded and kept up to date.
- CBI 604 Flail Debarker – serial no. 015008

- Trailer VIN
- CAT Engine – serial no.
- Flexxaire Fan – serial no.
- Stiebel Gear Box – serial no.
- Top Feed Roll inlet Poclain Motor – serial no.
- Top Feed Roll outlet Poclain Motor – serial no.
- Bottom Feed Roll inlet Brevini Gearbox – serial no.
- Bottom Feed Roll mid Brevini Gearbox – serial no.
- Bottom Feed Roll outlet Brevini Gearbox – serial no.
- Hydraulic Pumps
o Upper LH:
 Pump 1 – serial no.
o Upper RH:
o Lower LH:
o Lower RH:
- Tigercat Loader – serial no.
o Cat C4.4 engine – serial no.
o Rotobec Rotator – serial no.
o Rotobec Grapple – serial no.

1-4 INTRODUCTION - MACHINE INFORMATION PN 71510013 - OMM015008130510
Supplemental Manuals
Your CBI machine is constructed of many components, some of which have their own associated
publications. Although some individual component information may be present in this publication, this
is intended as a reference and is not a full or accurate account of all individual component
information. It is imperative to always consult the OEM manuals for specific and accurate product
information. IT IS THE RESPONSIBILITY OF THE MACHINE OWNER TO ENSURE THAT ALL SUPPLEMENTAL
MANUALS ARE KEPT UP TO DATE AND ALL INDIVIDUAL OEM GUIDELINES AND PROCEDURES ARE FOLLOWED.
The following is a partial list of individual component manuals intended to assist owners in identifying
the necessary supplemental manuals for their machine.
⚠WARNING: it is the responsibility of the machine owner to ensure that all supplemental manuals are
kept up to date and all individual OEM guidelines and procedures are followed.
- Tigercat 215 Loader - Operator's Manual PN: 37622AENG

- CAT C4.4 engine - Operation and Maintenance Manual PN: SEBU8180-01
- Power Packer stabilizers - Power Gear Installation & Service Manual PN: 81-1093 Rev 18
- Flexxaire Fan – FX Fan Series Manual, PN: 01521 Rev 3
- CAT C18 engine – Operation and Maintenance Manual PN: SEBU7899-04
- Stiebel pump drive – Operating Instructions For Pump Drives, Edition 01/10
- Brevini gearbox - Installation & Maintenance Manual PN: MT-0808-0699/40
- Poclain hydraulic motors – Manual PN: DOC-REPAIR-MS02-MS18-FR-EN Rev 22/03/2005
- Dexter Axles- 22,500-27,500 lbs. Capacity Operation, Maintenance, and Service Manual
- Rotobec Grapple –Operator's Manual PN: 146-0092 Rev 1
- CAT Torque Specifications Publication - PN: SENR3130-11
INFO: Always consult the OEM manuals for specific component product information.

PN 71510013 - OMM015008130510 INTRODUCTION - ABOUT THIS MANUAL 1-5
About This Manual
Manual Intent
This manual provides information for the setup, usage, maintenance and safety of the machine.
The manual is considered to be part of the machine and as such must always accompany it. If
ownership of equipment changes the manual must be provided to the succeeding owner. All
personnel involved in operation of the machine must read and fully understand the manual content.
Personnel must also be made aware of the safety procedures when working with the machine.
How to Use This Manual

Your CBI operation and maintenance manual is designed to provide a general understanding of
the machine and its safe operation. Information is included on the machine intent, safety, operations,
and select maintenance procedures and specifications data. Throughout the manual sections are
referenced by their page number; these are formatted at the top of each page with the section
number listed first followed by the consecutive page number in the section. Page numbering is
discontinuous between sections to allow insertion of new content in future issues of the publication.
Manual Disclaimer
No part of this document may be reproduced, altered or published without prior consent of CBI.
CBI reserves the right to adjust or alter equipment it produces, as well as manual content, at its sole
discretion. CBI does not accept liability for misuse or negligence of the machine as it pertains to
manual content. Please contact CBI with any questions regarding the manual or its content (see
Technical publications department contact information, p.1-13).
⚠NOTICE: Every attempt is made to provide accurate, up to date information. By the use of this
document, you agree that Continental Biomass Industries Inc. is not responsible for errors and
Omissions.
Date of Publication
The intent of this publication is to provide the most up to date information on your CBI machine as
possible. In order to ensure accuracy and quality of content, publications are continuously updated.
It is the machine owners’ responsibility to ensure that their publications are kept current. The date of
publication is provided to assist in determining which revision is present.
Date of publication: Friday, May 10, 2013

1-6 INTRODUCTION - IDENTIFICATION PN 71510013 - OMM015008130510
Identification
Machine Orientation & Component Location

Throughout this manual the orientation of the machine will be referenced using the terms “front”
“back” “left” and “right” as defined in Figure 1. When locating individual components on the machine
use the “location code” coordinates from the component location index in conjunction with Figure 1 to
triangulate the location.
Figure 1

PN 71510013 - OMM015008130510 INTRODUCTION - IDENTIFICATION 1-7
Component Location Index

The following is an index of component location codes for key components on your CBI machine.
Cross-reference the location codes with Figure 1. Location codes are always given in order of X, Y,
and then Z coordinates. For example, a location code of X13.5 Y1.7 Z2.0 would give the approximate
location of the kingpin on the 604 flail.
Part Description Location Code Part Description Location Code
Air filer Loader X2.6 Y4.3 Z2.9 Hydraulic Filter Flail Motor #1 X12.4 Y2.6 Z0.9
Air filter Flail X12.8 Y4.1 Z1.6 Hydraulic Filter Flail Motor #2 X12.4 Y2.6 Z0.9
Batteries flail X10.5 Y2.2 Z3.3 Hydraulic Filter Flail Motor #3 X12.4 Y2.6 Z0.9
Batteries Loader X2.2 Y3.4 Z3.1 Hydraulic Filter Flail Motor #4 X12.4 Y2.6 Z0.9
Battery Disconnect Switch Flail X10.7 Y2.2 Z3.3 Hydraulic Filter Idler Roll Motors X12.4 Y2.6 Z0.9
Hydraulic Filter Infeed Bottom Roll Motor
Battery Disconnect Switch Loader X2.9 Y3.5 Z1.6 X12.4 Y2.6 Z0.9
#1
Case Drain Metal Detection Filter, Flail Hydraulic Filter Infeed Bottom Roll Motor
X4.5 Z2.3 Y0.5 X12.4 Y2.6 Z0.9
Motor #1 #2
Case Drain Metal Detection Filter, Flail
X5.4 Y3.1 Z0.5 Hydraulic Filter Infeed Top Roll Motor X12.4 Y2.6 Z0.9
Motor #2
X8.2 Y3.1 Z0.5 Hydraulic Filter Upper Flail Lift Circuit X12.4 Y2.6 Z0.9
Motor #3
X9.1 Y2.3 Z0.5 Hydraulic Filter Upper Flail Lift Circuit X12.4 Y2.6 Z0.9
Motor #4
Chain Curtain X9.9 Y2.7 Z2.0 Hydraulic Filter, Return Circuit X9.0 Y3.7 Z3.1
Control panel X12.1 Y 2.4 Z2.0 Hydraulic Oil sight glass Flail X11.0 Y3.7 Z3.0
Discharge Ram Support Frame Safety Pin X10.0 Y1.2 Z3.3 Hydraulic Oil sight glass Loader X2.2 Y4.1 Z2.2
Hydraulic Pump Exit feed Bottom Roll
Engine Access Platform X13.3 Y2.9 Z2.0 X12.1 Y3.1 Z0.8
Motor
Engine oil dipstick Flail X12.8 Y3.5 X2.2 Hydraulic Pump Exit feed Top Roll Motor X12.1 Y3.5 Z0.8
Engine oil dipstick Loader X2.5 Y3.5 Z3.1 Hydraulic Pump Flail Motor #1 X12.1 Y3.1 Z0.8
Engine oil filter Flail X12.8 Y3.5 X2.2 Hydraulic Pump Flail Motor #2 X12.5 Y3.1 Z0.8
Engine oil filter Loader X2.5 Y3.5 Z3.1 Hydraulic Pump Flail Motor #3 X12.1 Y3.5 Z0.8
Exit Feed Top Roll Safety Strut X10.5 Y2.4 Z2.8 Hydraulic Pump Flail Motor #4 X12.5 Y3.5 Z0.8
Fifth wheel Pin X13.4 Y1.7 Z2.0 Hydraulic Pump Idler Roll Motors X12.1 Y3.1 Z0.8
Hydraulic Pump Infeed Bottom Roll Motor
Flail #1 X4.5 Z2.3 Y2.0 X12.5 Y3.1 Z0.8
#1
Hydraulic Pump Infeed Bottom Roll Motor
Flail #1 drive motor X4.5 Z2.3 Y0.5 X12.5 Y3.1 Z0.8
#2
Flail #2 X5.4 Y3.1 Z2.0 Hydraulic Pump Infeed Top Roll Motor X12.1 Y3.5 Z0.8
Flail #2 drive motor X5.4 Y3.1 Z0.5 Hydraulic Pump Lift Circuit Top Feed Rolls X12.5 Y3.5 Z0.8
Hydraulic Pump push out Ram / Hydraulic
Flail #3 X8.2 Y3.1 Z2.0 X12.5 Y3.5 Z0.8
Cooler Motor
Flail #3 drive motor X8.2 Y3.1 Z0.5 Hydraulic Pump Upper Flail Lift Circuit X12.5 Y3.1 Z0.8

Part Description Location Code Part Description Location Code

Flail #4 X9.1 Y2.3 Z2.0 Hydraulic Tank Access Platform X11.2 Y2.9 Z2.0
Flail #4 drive motor X9.1 Y2.3 Z0.5 Hydraulic tank fill Flail X11.0 Y3.9 Z2.0
Flail Chamber service Hatch X7.0 Y3.5 Z2.0 Hydraulic tank fill Loader X1.8 Y4.3 Z2.6
Flail Drive Belt #1 X5.0 Y2.0 Z0.8 Infeed Top Roll Safety Strut X4.7 Y2.1 Z3.0
Flail Drive Belt #2 X6.1 Y2.5 Z0.8 Loader Access Platform X 4.0 Y2.8 Z3.2
Flail Drive Belt #3 X7.5 Y2.5 Z0.8 Loader Access Stairs X1.8 Y2.0 Z0.4
Flail Drive Belt #4 X8.6 Y2.0 Z0.8 Loader Cab X2.5 Y3.8 Z1.2
Flexxaire Fan X12.3 Y3.7 Z3.0 Lower Exit feed Roll Gearbox #1 X2.1 Y1.9 Z3.1
Fuel Fill Flail X5.2 Y4.3 Z2.9 Lower Infeed Roll Gearbox #1 X4.3 Y1.9 Z3.1
fuel fill Loader X1.6 Y4.4 Z1.2 Lower Infeed Roll Gearbox #2 X10.1 Y1.9 Z3.4
fuel gauge Flail X5.0 Y3.8 Z2.9 muffler Flail X12.1 Y4.5 Z1.2
fuel gauge Loader X1.6 Y4.0 Z0.8 Pre-cleaner Flail X12.8 Y4.1 Z1.6
Grapple Cradle Frame X11.3 Y2.2 Z0.7 Pre-cleaner Loader X2.6 Y4.3 Z2.9
hydraulic cooler Flail X8.9 Y3.6 Z2.0 primary Fuel/Water filter Flail X12.8 Y3.5 X2.2
Hydraulic Filter #1 Lift Circuit Top Feed
X12.4 Y2.6 Z0.9 primary Fuel/Water filter Loader X1.3 Y3.3 Z2.2
Rolls
Hydraulic Filter #2 Lift Circuit Top Feed
X12.4 Y2.6 Z0.9 Radiator sight glass Flail X11.8 Y4.4 Z3.6
Rolls
Hydraulic Filter Exit feed Bottom Roll Motor X12.4 Y2.6 Z0.9 Radiator sight glass Loader X2.6 Y3.9 Z3.1
Hydraulic Filter Exit feed Top Roll Motor X12.4 Y2.6 Z0.9 Upper Flail Safety Strut X4.7 Y2.5 Z3.0
Waste Discharge Ram X7.4 Y1.2 Z2.0

PN 71510013 - OMM015008130510 INTRODUCTION - IDENTIFICATION 1-9
Flail Numbering Guide

In certain instances the flails on your machine will be referred to by number. The purpose of the
following illustration (Figure 2) is to familiarize the operator with which flail corresponds with which
number.
Figure 2
Bottom Feed Roll Numbering Guide

In certain instances the bottom feed rolls on your machine will be referred to by number. The
purpose of the following illustration (Figure 3) is to familiarize the operator with which bottom feed roll
corresponds with which number.
Figure 3
Idler Roll Numbering Guide

In certain instances the idler rolls on your machine will be referred to by number. The purpose of
the following illustration (Figure 4) is to familiarize the operator with which idler roll corresponds with
which number.
Figure 4

Top Feed Roll Numbering Guide

In certain instances the top feed rolls on your machine will be referred to by number. The
purpose of the following illustration (Figure 5) is to familiarize the operator with which top feed roll
corresponds with which number.
Figure 5
Machine Identification
Your CBI machine is fitted with an identification plate located at (X13.0 Y1.9 Z1.1). An illustration
of the ID plate is shown in Figure 6. The serial number, model number, machine weight, date of
manufacture, and if applicable vehicle identification number (VIN) and gross axle weight rating for the
machine is stamped onto this ID plate. Identify and record all data present on the ID plate. This
information is necessary for part, service, and warrantee support. If the ID plate ever becomes
damaged or is missing, contact CBI immediately for replacement instructions.
Figure 6

PN 71510013 - OMM015008130510 INTRODUCTION - REPLACEMENT PARTS 1-11
Replacement Parts
Genuine CBI Replacement Parts

Occasionally your CBI machine may require replacement parts. Optimal fit and function of
components can only be assured through the use of genuine CBI replacement parts. Use of
aftermarket replacement parts may void your product warranty. Genuine CBI replacement parts are
only available through CBI authorized parts representatives.
Replacement part ordering procedure

In order to ensure accuracy of your replacement parts it is critical to have the necessary
information available when placing an order. The purpose of this procedure is to assist the operator
in ordering parts quickly and easily from your CBI authorized parts representative. It is important
that this procedure be followed every time replacement parts are ordered.
1 Identify your machine

Acquire the machine model number, serial number, and date of manufacture from the machines
identification plate. For detailed information see, Machine Identification, p. 1-10.
2 Identify parts / components

Locate the components needed in the owner’s parts manual (OPM), record their part numbers
and the diagrams corresponding page reference numbers.
3 Contact CBI
Contact your CBI authorized parts representative with your specific machine data and
corresponding part information for quick and accurate replacement parts.
Parts department contact information

The following contact information should be used when ordering replacement parts for your CBI
equipment. Genuine CBI replacement parts are only available through CBI authorized parts
representatives.
CBI Parts Department: +1 (888) 224 4647 ext. 1

1-12 INTRODUCTION - CBI AUTHORIZED SERVICE PN 71510013 - OMM015008130510
CBI Authorized Service
CBI Authorized Service Assistance

Occasionally your CBI machine may require service or maintenance not outlined in the supplied
manuals. CBI will provide upon request qualified service technicians for: service, repairs, phone
assistance, field assistance or general training of personnel. Qualified service technicians are only
available through contacting CBI authorized service representatives.
Service Assistance Requisition Procedure

In order to ensure quality service can be provided, it is critical to have the necessary information
available when initiating a request. The purpose of this procedure is to assist operators in
requesting service assistance quickly and accurately from your CBI authorized service
representatives. It is important that this procedure be followed every time service assistance is
requested.
1 Identify your machine

Acquire the machine model number, serial number, and date of manufacture from the machines
identification plate. For detailed information see, Machine Identification, p. 1-10.
2 Identify problem
Create a detailed list of problematic parts, components, symptoms, or services you need
assistance with.
3 Contact CBI
Contact your CBI authorized parts representative with your specific machine data and
corresponding part information for quick and accurate replacement parts.
Service department contact information

The following contact information should be used when requesting service assistance for your
CBI equipment. Genuine CBI service information and technicians are only available through CBI
authorized service representatives. CBI service fees, terms, and conditions may apply.
CBI Service Department: +1 (888) 224 4647 ext. 2

PN 71510013 - OMM015008130510 INTRODUCTION - PUBLICATION FEEDBACK 1-13
Publication Feedback
Publication Feedback
Occasionally it may be necessary to contact CBI regarding the content in the publication. In an
effort to produce world class documentation we encourage your feedback. For feedback to be
properly received by CBI, all comments must be submitted using the procedures and contact
information specified in this section.
Publication feedback reporting procedure

Occasionally your CBI publication may contain errors or omissions. In an effort to keep our
documents as accurate, convenient, and relevant as possible we encourage your feedback. The
purpose of this procedure is to familiarize readers with the information needed when reporting errors
and omissions in publications to CBI.
1 Record Serial Number

Record your machines serial number. For detailed information see, Machine Identification, p. 1-
10.
2 Record Publication Information
Record the publication number and revision level of the document; in print manuals this is located
on the spine.
3 Record personal information

Record your contact information so that the technical publications department may contact you if
need be.
4 Record location of content in question

List the chapter number, section number, and page number of the content that you’re contacting
CBI about.
5 Record Feedback
Give a detailed list of all errors, omissions, or comments that you would like reviewed.
6 Contact CBI
Send an e-mail to the CBI technical publications department detailing all the information recorded
in steps 1-5.
Technical publications department contact information

The following contact information should be used whenever reporting errors or omissions found in
CBI publications. Official corrections and clarifications on material contained in this publication may
only be made by the CBI technical publications department.
CBI Technical Publications Department: TechnicalPublications@CBI-inc.com

PN 71510013 - OMM015008130510 SAFETY - SECTION TABLE OF CONTENTS 2-1
2. Safety
Introduction .......................................................................................................... 2-2
Safety Basics ............................................................................................................................ 2-2
Safety Guidelines ................................................................................................. 2-2
General Safety .......................................................................................................................... 2-2
Personal Safety......................................................................................................................... 2-2
Operational Safety .................................................................................................................... 2-3
Maintenance Safety .................................................................................................................. 2-3
Fire Safety ................................................................................................................................. 2-3
Danger Zones ....................................................................................................... 2-4
Operating Zone ......................................................................................................................... 2-4
Hazard Areas............................................................................................................................. 2-4
Hazard Decals ...................................................................................................... 2-6
General ...................................................................................................................................... 2-6
Decal Locations ........................................................................................................................ 2-7
Decal Images............................................................................................................................. 2-8
Safety Procedures ............................................................................................... 2-9
Lockout Tagout......................................................................................................................... 2-9
Energy Release ......................................................................................................................... 2-9
Safety Pins / Struts ................................................................................................................. 2-10

2-2 SAFETY - INTRODUCTION PN 71510013 - OMM015008130510
Introduction
Safety Basics
Establishing and adhering to standardized safety practices minimizes your risk on the job site.
Most accidents that include product operation, maintenance, & repair are caused by failure to observe
basic safety rules and precautions. Whenever working on or around CBI equipment Keep in mind
that your safety is in your hands. At the same time the safety of your coworkers is in your hands too.
Never operate a machine until you fully understand its capabilities and limitations. Ensure to adhere
to all safety guidelines set forth in the operations and maintenance manuals as well as by local and
regional regulatory authorities. Remember that the information in the operations and maintenance
manuals is not all inclusive; CBI cannot anticipate every potential hazard.
⚠WARNING: The safety guidelines in this manual are designed to supplement your existing training
program and do not constitute a complete safety training program.
Safety Guidelines
General Safety
- Machine is to be used only for the purpose it was designed and intended for.
- Follow maintenance and service schedules as required.
- Replace safety decals or signs only with the same kind. Replace if missing or illegible.
- Inspect machine daily prior to start up. Observe that all safety features are in place.
- Operate only when all guarding is in place and secured. Do not operate if guards are missing.
- Ensure that operator is familiar and has thorough knowledge of all machine functions.
- Be aware at all times of the hazards that operating the machine may present.
- If machine is in need of repairs or service, complete before operating machine again.
- Never stand or climb on machine when it is operating. Do not allow others to stand or climb on
machine either. Machine must be at complete stop before performing maintenance or service on
it.
- Do not open any covers or doors while machine is operating.
- Do not allow metal objects to pass through machine; this may cause sparks.
- Take necessary precautions when welding on machine against fire hazard.
- Clean machine every day with pressurized water. Clean electrical components with compressed
air.
- Do not allow combustible material to buildup thereby creating a fire hazard.
- Keep flammable materials away from machine; dispose of properly.
- Always keep an approved fire extinguisher nearby machine.
Personal Safety
In its most generic sense, Personal Protective Equipment (PPE) is anything you can wear that will
protect yourself from injury. PPE should be considered a last line of defense against injury on the job.
It is an employee’s job to know and understand when PPE is necessary and how to properly use it
- Wear proper Personal Protection Equipment (PPE) during operation of machine.
- Keep sufficient distance away from rotating parts. Do not wear loose clothing, jewelry, etc.
- Do not attempt to lift heavy components alone; use more than one person or use crane.
- Be aware of uneven surfaces when working on machine.
- Avoid dangerously hot surfaces such as engine components and exhaust.
- Be aware that exhaust gasses may cause unconsciousness or illness. Never use machine in
closed or restricted air space unless adequate ventilation is in place.
- Do not allow machine controls to come in contact with grease or other lubricants. Keep hands
clean.

PN 71510013 - OMM015008130510 SAFETY - SAFETY GUIDELINES 2-3
Operational Safety
- Only authorized personnel are allowed to operate machine.
- Do not allow anyone who is fatigued or has diminished, impaired capabilities to operate machine.
- Before operating, make sure that no one is within 50 feet (15 meters) of machine.
- Do not stand next to, on or under machine when operating.
- Always make sure machine is in proper working order; that all functions are operating correctly.
- Do not feed materials other than those machine is designed for.
- Do not force more material into machine than it can normally handle.
- Avoid moving parts of machine; stay away from infeed and discharge areas.
- Do not fill fuel tank when machine is operating. Make sure fuel cap is always secure.
- Keep flammable materials away from hot areas of machine.
- Stop machine if it is leaking fluids or produces unusual noises.
- Do not remove engine radiator cap when coolant is hot.
- After machine cleaning, inspect electrical and hydraulic components for damage or leakage.
- Dispose of fuel, oil, lubricants or other fluids that impact the environment in the proper manner.
- Use only CBI authorized parts or accessories on machine. Make sure they are fastened securely.
- Machine must be properly turned off after use. Remove key, close latch and lock battery
disconnect.
- Follow all safety procedures and ensure that any personnel in area also comply accordingly.
Maintenance Safety
- Wear proper Personal Protection Equipment (PPE) during machine maintenance.
- Machine must come to a complete stop before proceeding.
- Never perform maintenance or repairs when machine is running.
- Make sure that machine is locked and tagged out. Test machine; it should not start.
- Make sure that power source to machine is also locked and tagged out.
- Replace damaged parts immediately. Use only CBI authorized parts.
- Inspect wires and hoses – replace if necessary. Do not operate until doing so.
- Take necessary precautions when welding on machine against fire hazard.
- Make sure that all fasteners have been properly secured.
- Replace all removed guarding and make sure they are secure.
- Make sure that any tools or parts have been removed from machine before starting up.
Fire Safety
- Always have fire extinguisher and/or water available when operating machine.
- Make sure all personnel working with machine are properly instructed in use of fire extinguisher.
- Routinely inspect fire extinguisher to maintain proper operation.
- Inspect hydraulic hoses for leaks or damage. Replace as necessary.
- Inspect electrical wiring for wear or damage. Replace or reroute wiring as necessary.
- Check battery cables to ensure proper connection and examine for frayed or damaged insulation.
- Do not allow moving components to contact metal surfaces. This can rapidly create friction heat.
- Make sure bearings are functioning properly, and are lubricated according to CBI lubrication
schedule. Bearings that fail can reach critical temperatures and may cause fire.
- Do not feed metal objects into machine. Metals can reach temperatures high enough to ignite
fires.
- Flammable liquids, chemicals or other combustible objects must be properly stored or disposed
of.
- Do not allow debris to collect near dangerously hot areas, such as engine.
- Clean machine daily with pressurized air and water after shutdown.
- Establish proper maintenance programs to prevent fires and to keep machine running properly.

2-4 SAFETY - DANGER ZONES PN 71510013 - OMM015008130510
Danger Zones
Operating Zone
- Operating Zone is the area surrounding the machine a distance of 75 feet (23 meters).
- Do not enter Operating Zone any time machine is in operation.
- Do not allow any personnel to enter Operating Zone any time machine is in operation.
- Operating Zone may only be entered after machine has been returned to a safe state.
Hazard Areas
There are several areas of your CBI 604 flail that pose specific hazards and need special
attention. These hazard areas are illustrated in Figure 7 (p. 2-5) with a brief description of the nature
of the hazards below. Failure to use adequate caution when dealing with hazard locations may result
in severe injury or death.
1 Infeed: Never operate the machine with personnel in range of the infeed. Broken chain links or
debris may eject out the infeed at high velocities any time the flails are spinning.
2 Log Exit: Never operate the machine with personnel in range of the log exit. Broken chain links
or debris may be ejected out of the log exit at high velocities any time the flail is operating. In
addition, logs will exit the machine from the log exit when the flail is operating.
3 Waste Discharge: Never operate the machine with personnel in range of the Waste discharge.
Debris or broken chains may be ejected at high velocities out the waste discharge any time the
flail is operating. In addition, Flail debris will be ejected from the discharge as part of an
automated cycle any time the flail is operating.
4 Plunger Support Area: Never operate the machine if personnel are in range of the plunger
support area. During normal operation the plunger will retract into the support frame as part of an
automated cycle.
5 Flexxaire Fan: Never operate the machine with personnel in range of the Flexxaire fan. During
normal operation the machine will initiate a periodic fan purge cycle. Dust and debris may be
ejected at high velocities any time the machine is operating.
6 Tigercat Loader: Never operate the machine with personnel in range of the Tigercat Loader.
During normal operation the loader may swing anywhere within its travel range. Personnel within
this area are at risk for being hit.

PN 71510013 - OMM015008130510 SAFETY - DANGER ZONES 2-5
Figure 7

2-6 SAFETY - HAZARD DECALS PN 71510013 - OMM015008130510
Hazard Decals
General
Your CBI equipment is fitted with several specific hazard warnings throughout. The purpose of
these individual warnings is to familiarize personnel with nature, severity, and proper technique for
dealing with specific hazards on the machine. Before operating equipment review and become
familiar with all specific hazard warnings.
Ensure that all specific hazard warnings are clean, legible, and present. Decals should be cleaned
with water and a light detergent, solvents or harsh chemicals may dissolve the decals or their
adhesive. If hazard decals are found illegible or missing, order replacements from CBI immediately.
⚠WARNING: Become familiar with and adhere to all hazard decals. Failure to comply may result in
severe injury to personnel!

PN 71510013 - OMM015008130510 SAFETY - HAZARD DECALS 2-7
Decal Locations
Figure 8
2-8 SAFETY - HAZARD DECALSPN 71510013 - OMM015008130510
Decal Images
Figure 9
PN 71510013 - OMM015008130510 SAFETY - SAFETY PROCEDURES 2-9
Safety Procedures
Lockout Tagout
"Lockout/Tagout (LOTO)" refers to specific practices and procedures to safeguard employees
from the unexpected energization or startup of machinery and equipment, or the release of hazardous
energy during service or maintenance activities. The following is a procedure for deactivating and
then reactivating equipment before and after service.
Deactivating Equipment:
When the servicing or maintenance is required and the machine must be deactivated the
following steps shall be taken.
- If the machine or equipment is operating, shut it down by the normal stopping procedure.
- Notify affected employees that servicing or maintenance is being performed and the machine
must be deactivated.
- De-activate the machine by isolating it from its energy source.
- Lock out energy source with a LOTO hasp and assigned individual lock(s).
- Stored or residual energy (such as that in capacitors, springs, elevated machine members,
rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be
dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding down,
etc. Be familiar with your equipment to know where stored energy may be present.
- Ensure that the equipment is disconnected from the energy source. First, check that no
personnel are exposed, and then verify the isolation of the equipment by activating the normal
operating controls. Always test to make certain the equipment will not operate.
- The machine or equipment is now locked out.
Restoring Equipment to Service

When the servicing or maintenance is completed and the machine is ready to return to normal
operating condition, perform following:
- Check the machine and the immediate area around the machine to ensure that nonessential
items have been removed and that the machine or equipment components are operationally
intact.
- Check the operational area to ensure that all employees have been safely positioned or removed
from the area.
- Verify that the controls are in neutral.
- Remove the lockout devices and reenergize the machine or equipment.
- Note: The removal of some forms of blocking may require re-energizing the machine before safe
removal.
- Notify affected employees that the servicing or maintenance is completed and the machine is
ready for use.
Energy Release
Stored or residual energy (such as that in capacitors, springs, elevated machine members,
rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be dissipated
or restrained by methods such as grounding, repositioning, blocking, bleeding down, etc. Be familiar
with your equipment to know where stored energy may be present.

2-10 SAFETY - SAFETY PROCEDURES PN 71510013 - OMM015008130510
Safety Pins / Struts

In certain instances it is necessary to have equipment in elevated positions in order to perform
service. It is imperative that precautions be made to ensure elevated equipment cannot cause injury
to personnel. Safety pins and struts are forms of blocking used to immobilize elevated equipment to
prevent their unintentional release of energy. Safety struts are installed on hydraulic cylinders as a
mechanical stop to keep them, from retracting. Safety pins are inserted into their respective pin holes
to immobilize components. A list of descriptions and locations for the safety pins and struts are is
given below:
1 Infeed top feed roll safety strut: The infeed top roll safety strut is used for securing the infeed
top roll in an elevated position. It is stored at X4.7 Y2.1 Z3.0. For more information, see Machine
Orientation & Component Location, p. 1-6 and Safety Struts p. 4-17.
2 Exit top feed roll safety strut: The exit top feed roll safety strut is used for securing the exit top
feed roller in an elevated position. It is stored at X10.5 Y2.4 Z2.8. . For more information, see
Machine Orientation & Component Location, p. 1-6 and Safety Struts p. 4-17.
3 Upper flail Safety Strut: The upper flail safety strut is used for securing either of the upper flail
drums in an elevated position. It is stored at X4.7 Y2.5 Z3.0. For more information, see Machine
Orientation & Component Location, p. 1-6 and Safety Struts p. 4-17.
4 Plunger support frame safety pin: The plunger support safety pin is used for securing the
discharge plunger support frame in either the elevated or lowered position. It is located at X9.9
Y1.3 Z3.3. For more information, see Machine Orientation & Component Location, p. 1-6 and
Safety Struts p. 4-17.

PN 71510013 - OMM015008130510 OPERATION - SECTION TABLE OF CONTENTS 3-1
3. Operation
General ................................................................................................................. 3-3
Introduction............................................................................................................................... 3-3
Operation Safety: ....................................................................................................................... 3-3
Before Operating ...................................................................................................................... 3-3
Operating Procedures ......................................................................................... 3-4
Setting the Machine Up On the Job ........................................................................................ 3-4
Transportation Tear-Down ...................................................................................................... 3-5
Fifth Wheel Adapter Plate Installation and Removal ............................................................ 3-6
Daily Inspection General ......................................................................................................... 3-6
Daily Inspection Specific ......................................................................................................... 3-6
Starting the flail ...................................................................................................................... 3-10
Starting the loader .................................................................................................................. 3-11
Operating the machine by remote ........................................................................................ 3-12
Operating the machine by the control panel ....................................................................... 3-14
Enable Link to Disc Chipper .................................................................................................. 3-15
Storing the Grapple ................................................................................................................ 3-15
Stopping the Loader............................................................................................................... 3-16
Stopping the flail .................................................................................................................... 3-16
Cleaning .................................................................................................................................. 3-17
Final Inspection ...................................................................................................................... 3-17
Automated Features .......................................................................................... 3-18
Big-Bush-Busta ...................................................................................................................... 3-18
Flail Tuning Optimization....................................................................................................... 3-18
Flail Power Optimization ........................................................................................................ 3-18
Debris Purge Control ............................................................................................................. 3-18
Feeds Reverse ........................................................................................................................ 3-18
Top Roll Rapid Lift.................................................................................................................. 3-18
Minimum Operating Temperature ......................................................................................... 3-19
Infeed Clog Sense .................................................................................................................. 3-19
Automatic Hydraulic Cooler Purge ....................................................................................... 3-19
Automatic Radiator Purge ..................................................................................................... 3-19
Operator Controls .............................................................................................. 3-20
Remote Control....................................................................................................................... 3-20
Remote Control Battery ......................................................................................................... 3-20
Function Modes ...................................................................................................................... 3-20
Standard Function Mode ....................................................................................................... 3-21
Auxiliary Function Mode ........................................................................................................ 3-22
Outrigger Function Mode....................................................................................................... 3-23
Loader Controls ...................................................................................................................... 3-23
Right Loader Joystick ............................................................................................................ 3-24
Left Loader Joystick............................................................................................................... 3-26
Valve Manual Control ............................................................................................................. 3-28
Proportional Valve Manual Control ...................................................................................... 3-29
Loader Control Panel ............................................................................................................. 3-30
Engine Platform Emergency Stop Control Box ................................................................... 3-31
Loader Access Emergency Stop Control Box ..................................................................... 3-31
Panel Controls/Settings .................................................................................... 3-32
Introduction............................................................................................................................. 3-32
Control Enclosure Layout ..................................................................................................... 3-32
Control Panel Interface .......................................................................................................... 3-32
3-2 OPERATION - SECTION TABLE OF CONTENTS PN 71510013 - OMM015008130510
Control Modes ........................................................................................................................ 3-33

Startup Menu ........................................................................................................................... 3-34
Basic Operation Menu............................................................................................................ 3-35
Flail Transport Menu .............................................................................................................. 3-37
Outriggers Menu ..................................................................................................................... 3-38
Plunger Menu .......................................................................................................................... 3-40
Information Menu ................................................................................................................... 3-42
Advanced Operation Menu .................................................................................................... 3-44
Automatic Operation Menu ................................................................................................... 3-46
Run Settings Menu ................................................................................................................. 3-48
Run Mode Settings Adjust Menu .......................................................................................... 3-50
Flail Lift Tuning Adjust Menu ................................................................................................ 3-54
Flail #1 Manual Operation Menu ........................................................................................... 3-58
Top Roll #1 Manual Operation Menu .................................................................................... 3-66
Top Roll #2 Manual Operation Menu .................................................................................... 3-68
Bottom Roll #1 Manual Operation Menu .............................................................................. 3-70
Idler Roll #1 Manual Operation Menu ................................................................................... 3-76
Push Out Ram Manual Operation Menu ............................................................................... 3-84
Out Riggers Loader Manual Operation Menu ...................................................................... 3-86
Out Riggers King Pin Manual Operation Menu ................................................................... 3-88
Flail Box Door Manual Operation Menu ............................................................................... 3-90
Engine Manual Operation Menu ............................................................................................ 3-92
Engine Menu ........................................................................................................................... 3-94
Cooling System Menu ............................................................................................................ 3-96
Cooling System Adjust Menu ................................................................................................ 3-98
Flail Power Menu .................................................................................................................. 3-100
Link Mode Menu ................................................................................................................... 3-102
Fuel Consumption Menu...................................................................................................... 3-104
Main System Menu ............................................................................................................... 3-106
Adjust System Menu ............................................................................................................ 3-107
Measure System Menu ......................................................................................................... 3-108
Preferences System Menu ................................................................................................... 3-109
Info System Menu ................................................................................................................. 3-110
Feed Offset Adjust Menu ..................................................................................................... 3-111
Idler Output Adjust Menu .................................................................................................... 3-113
Optional Equipment ......................................................................................... 3-116
Introduction........................................................................................................................... 3-116
Gas Powered Air Compressor ............................................................................................ 3-116

PN 71510013 - OMM015008130510 OPERATION - GENERAL 3-3
General
Introduction
The following section is arranged to guide the operator through the steps taken to operate the
machine. Read this section through and understand it from beginning to end. Proper machine operation
is an art form that cannot be learned simply by reading a manual. Procedures given in this section are
basic and will be expanded on as the operator becomes more knowledgeable in this machine and its
capabilities. The purpose of this section is to act as a starting point of which to base your operators
training program and it does not constitute a complete operators training program in its self. Never
operate a machine until you fully understand its capabilities and limitations.
Operation Safety:
Whenever operating equipment, there are several basic safety precautions that you should always
adhere to. The following is a partial list of these guidelines. Always adhere to all safety guidelines set
forth by local and regional regulatory authorities. For more information, refer to Safety Guidelines, p.2-2
- Only authorized personnel are allowed to operate machine.
- Do not allow anyone who is fatigued or has diminished, impaired capabilities to operate
machine.
- Before operating, make sure that no one is within 50 feet (15 meters) of machine.
- Do not stand next to, on or under machine when operating.
- Always make sure machine is in proper working order; that all functions are operating correctly.
- Do not feed materials other than those machine is designed for.
- Do not force more material into machine than it can normally handle.
- Avoid moving parts of machine; stay away from infeed and discharge areas.
- Do not fill fuel tank when machine is operating. Make sure fuel cap is always secure.
- Keep flammable materials away from hot areas of machine.
- Stop machine if it is leaking fluids or produces unusual noises.
- Do not remove engine radiator cap when coolant is hot.
- After machine cleaning, inspect electrical and hydraulic components for damage or leakage.
- Dispose of fuel, oil, lubricants or other fluids that impact the environment in the proper manner.
- Machine must be properly turned off after use. Remove key, close latch and lock battery
disconnect.
- Follow all safety procedures and ensure that any personnel in area also comply accordingly.
Before Operating
Before operating any machine it is important to perform a walk around inspection (see Daily
Inspection, p.3-6). Inspect the entire machine for items such as loose hardware, trash buildup, oil leak,
fuel leaks, coolant leaks, frayed or chaffed parts, worn parts, crack propagation, or broken components.
Always perform all necessary repairs / maintenance prior to operating the machine.
Always review and fully understand all pertinent manuals and regulations. Never operate a machine
until you fully understand its capabilities and limitations.
⚠WARNING: Always review and fully understand all pertinent publications and regulations before
operating a machine
⚠WARNING: Never operate a machine until you fully understand its capabilities and limitations.

3-4 OPERATION - OPERATING PROCEDURES PN 71510013 - OMM015008130510
Operating Procedures
Setting the Machine Up On the Job

When a machine is first delivered, it must be “set up” to be in an operable state. The purpose of this
procedure is to help familiarize personnel with how to unhook, position, and prepare a CBI 604 flail
debarker at start up.
1 Disconnect Truck
With the truck stopped and the flail in position, signal truck driver that you are approaching.
Disconnect the trailer air supplies and electrical connections.
2 Start the 604 flail

Using all pertinent safety precautions, start the machine. See Starting the flail, p. 3-10
3 Navigate to Outriggers Menu

From the Startup Menu (p. 3-34) at the control panel, press the “F5” button to go to the Flail
Transport Menu (p. 3-37). From there, press the “F2” button to navigate to the Outriggers Menu (p.
3-38). For more information see Outriggers Menu, p. 3-38.
4 Lower Outriggers
Use the “jog/shuttle button” to select the “king pin” end, and lower the right and left outriggers until
the weight of the flail is taken off the truck. Select “loader end” with the “jog / shuttle button and do
the same with the loader-end out riggers until the weight is taken off the trailer tires. For more
information see Outriggers Menu, p. 3-38.
5 Unhitch truck
With the stabilizers lowered & the weight off the fifth wheel, signal the truck to unhitch and pull away
6 Lower access ladders

Remove the pins securing the engine and hydraulic tank access ladders and lower them. Refit the
pin when complete.
7 Remove Safety Pin

Walk over and remove the discharge plunger support frame safety pin. For more information see
Safety Pins, p. 4-17.
8 Lower plunger support frame

Return to the Flail Transport Menu (p. 3-37) by pressing the “escape” button on the control panel.
Enter the Plunger Menu by pressing the “F4” button. Press the “C” button t enter “service mode” and
press the “F2” button to fold down the plunger support frame. For more information see Plunger
Menu, p. 3-40.
9 Shut off engine

Shut down the machine. For detailed information see stopping the machine, p. 3-2
10 Refit safety devices

Refit the discharge plunger support frame safety pin. Raise the two discharge support frame safety
rope stanchions and install the safety rope.
11 Remove Trailer Lights

Disconnect the trailer light wiring from the back of the flail. Undo the two bolts securing the light bar
to the infeed and store the light bar in a secure location.

PN 71510013 - OMM015008130510 OPERATION - OPERATING PROCEDURES 3-5
Transportation Tear-Down
When a machine is going to be transported, it must be “torn down” from its operable state. The
purpose of this procedure is to help familiarize personnel with how to prepare a CBI 604 flail debarker for
transportation.
1 Refit Trailer Lights

Obtain trailer light bar from stored location, fasten two bolts securing light bar to infeed. Connect
trailer wiring to receptacle on back right of flail.
2 Break down safety devices

Disconnect safety rope from flail frame. Hook the loose
rope ends to each other between stanchions (see
Figure 10). Lower the two discharge support frame
safety rope stanchions and disengage the discharge
plunger support frame safety pin. For more information
see Safety Pins, p. 4-17.
Figure 10
3 Start the 604 flail
Using all pertinent safety precautions, start the machine. See Starting the flail, p. 3-10
4 Retract the plunger

From the Startup Menu (p. 3-34) at the control panel, press the “F5” button to go to the Flail
Transport Menu (p. 3-37). From there, press the “F4” button to navigate to the Plunger Menu (p. 3-
40). Press the “C” button t enter “service mode” and press the “F3” button to retract the plunger into
the machine. For more information see Plunger Menu, p. 3-40.
5 Raise plunger support frame

In the Plunger Menu, fold up the plunger support frame by pressing the “’F1” button. For more
information see Plunger Menu, p. 3-40..
6 Raise access ladders

Remove the pins for the engine and hydraulic tank access ladders and raise them. Refit the pins,
securing the ladders when complete.
7 Refit Safety Pin

Reengage the discharge plunger support frame safety pin, locking the frame in the upright position.
For more information see Safety Pins, p. 4-17.
8 Connect truck
Signal the truck driver to back up and hitch onto the kingpin.
9 Navigate to Outriggers Menu

Return to the Flail Transport Menu (p. 3-37) by pressing the “escape” button on the control panel.
Enter the Outriggers Menu by pressing the “F2” button. For more information see Outriggers Menu,
p. 3-38.
.
10 Raise the Outriggers

Use the “jog/shuttle button” to select the “king pin” end, and raise the right and left outriggers until
the flail is on the truck and the outriggers are fully retracted. Select “loader end” with the “jog /
shuttle” button and do the same with the loader-end out riggers until the the laoder end outriggers
are fully retracted. For more information see Outriggers Menu, p. 3-38.
11 Shut off engine

Shut down the machine. For detailed information see Stopping the flail, p. 3-16.
12 Reconnect Truck
Reconnect the trailer air supplies and electrical connections to the truck.

Fifth Wheel Adapter Plate Installation and Removal

The CBI 754 disc chipper has provisions for attaching a fifth wheel plate for towing other
equipment off-road. This feature is especially important when being operated in tandem with the
604 flail debarker. The purpose of this procedure is to familiarize operators with installation and
removal of the fifth wheel adapter plate onto the 604 flail.
1 Retrieve Plate
Retrieve the fifth wheel adapter plate from its stowed location.
2 Install Plate
Install the fifth wheel plate by sliding the trailer
kingpin into the receiving hole in the fifth wheel plate
(Figure 11 / A).
3 Secure Plate
Secure the fifth wheel plate to the machine being
towed with binders or ratchet straps attached to the
adapter plate’s tie down holes (Figure 11 / B).
Figure 11
⚠NOTICE: The procedure for removal is the opposite of installation.
Daily Inspection General

Starting the workday with the proper machine inspection ensures that your CBI machine is ready to
perform. Regular visual inspections and maintenance minimize downtime, increasing productivity.
When performing a routine walk around inspection there are several items that you must look for in all
areas of the machine.
- Inspect structures and welds for cracks and signs of wear.
- Inspect machine for worn, missing or loose hardware and pins.
- Inspect electrical wires and connections for corrosion and signs of damage.
- Inspect hydraulic hoses and fittings for leaks and signs of damage.
- Inspect all sealed components for signs of leaks.
- Inspect all safety equipment to ensure it is both present and operational.
- When performing maintenance, carefully inventory all tools and hardware to ensure no foreign
object damage (FOD).
Daily Inspection Specific

Your CBI 604 flail is a complex machine and as such requires considerable attention be paid on a
regular basis to ensure all components are operating properly.
The following checklist is presented in the order in which it should be performed so as to minimize
unnecessary backtracking; it is broken down into three phases: 1) machine off, 2) machine running,
and 3) components elevated. You will start at control box and work your way around the machine.

Performing the same inspection every day helps operators to develop a routine and results in
intimate knowledge of the equipment.
INFO: Always consult the OEM manuals for specific daily inspection needs (see Supplemental
Manuals p. 1-4).
With the Machine off
- Start at the control box; inspect the wiring for signs of damage.
- Inspect the trailer wiring and air (glad-hands) connections for signs of damage.
- Inspect the Engine Access ladder & Platform for damage and to ensure it is securely fastened.
- Inspect the engine air cleaner service indicator
- Inspect the engine air filter
- Inspect the engine oil level, adjust as necessary
- Inspect the fuel system primary filter / water filter. Drain as necessary
- Clean the air cleaner unloading valve
- Inspect the exhaust system flap for proper operation
- Perform a visual inspection of the air filter side of the engine.
- Inspect the trailer kingpin for signs of damage or wear.
- Inspect the hydraulic pumps and filter bank for signs of damage or leaks
- Inspect the grapple mount for signs of damage
- Inspect the front left trailer jack for signs of damage
- inspect the following on all the left side trailer wheels:
- Inspect the hub oil for proper levels,
- Inspect the tire side walls for signs of damage
- Inspect the tire pressure for flats
- Inspect the back left trailer jack for signs of damage
- Inspect the loader access steps for damage or cracks.
- Inspect the fuel level on the loader.
- Inspect the loaders primary filter / water filter. Drain as necessary.
- Inspect the infeed feed rolls for signs of debris entanglement.
- Inspect all the trailer axles and brakes for signs of damage
- Inspect the first feed roll gear drive oil level.
- Inspect the right rear trailer jack for signs of damage or leaks
- Begin the right side wheel inspection. You will need to inspect the following on all the wheels:
- Inspect the hub oil for proper levels,
- Inspect the tire side walls for signs of damage
- Inspect the tire pressure for flats
- Inspect the oil levels in the second infeed roll gear drive
- Inspect the loader access ladder & platform for damage and to ensure it is securely fastened.
- inspect the loader engine, This include:
- Inspect the loader’s batteries
- Inspect the loader engine oil levels.
- Inspect the v-belts for signs of wear and proper adjustment
- Inspect the alternator belt for signs of wear and proper adjustment
- Inspect the loaders coolant level at the sight glass, adjust as necessary
- Empty the loader engine air cleaner un-loader valve
- Inspect the air filter pre-cleaner (if applicable)
- Inspect the oil cooler, charge air cooler, radiator & AC condenser for cleanliness, damage or
leaks.
- Lubricate the joints for the loader boom & cylinders (6pts. See Lubrication, p. 4-11).
- Inspect the Hydraulic cooler and screen for damage, leaks, or trapped debris
- Inspect the flail fuel tank fuel levels.
- Inspect the waste discharge plunger safety rope to ensure it is present and free of damage.
- Inspect the third lower feed roll gear box for proper oil levels.
- Inspect the front right trailer jack for signs of damage or leaks
- Inspect the batteries and cables for signs of damage, leaks, or corrosion.
- Inspect the hydraulic tank access ladder & platform for damage and ensure it is securely
fastened.
- Inspect the hydraulic tank levels. adjust as necessary
- Inspect the Alternator belt for wear and proper tension. Adjust or replace as needed
- Perform a visual inspection of the air filter side of the engine.
- Inspect the radiator and screen for trapped debris, damage, or leaks
- Inspect radiator for proper fluid levels.
With the Machine running

- Start the flail.
- Verify proper fan purge operation (see Verifying Proper Fan Purge, p. 4-36).
- Verify proper pre-cleaner operation (see Verifying Pre-cleaner Operation, p. 4-36).
- From the cab of the loader, Look out the window and inspect
- Inspect the air filter service indicator, service air filter if necessary
- Inspect for proper hydraulic oil levels in hydraulic tank sight gauge
- Inspect for proper swing gearbox oil levels in swing gear box oil reservoir.
- Start the loader
- Inspect the hydraulic return filter restriction indicator (done at high idle and oil flow).
- Lubricate the swing bearings and pinion (2pts. see Lubrication, p. 4-11).
- Place the grapple down on the ground in the open position next to the cradle.
- Shut down the loader (see Stopping the Loader, p. 3-16)
- Perform a lockout tag-out on the loader (see. Lockout Tagout, p. 2-9).
- Raise the feed rolls (see Top Roll #1 Manual Operation Menu, p. 3-66 and Top Roll #2 Manual
Operation Menu, p. 3-68).
- Shut off the engine (see Stopping the flail, p. 3-16)

With components elevated

- This section will begin working clockwise around the machine.
- Perform a lockout-tagout procedure on the flail (see. Lockout Tagout, p. 2-9).
- Retrieve and Fit the exit feed roll safety strut (see Safety Pins / Struts, p. 2-10).
- Grease the non-drive side top exit feed roll end plate bearing (1 pts. See Lubrication, p. 4-11).
- Grease the right side idler roll, flail, and feed roll bearings (11pts. See Lubrication, p. 4-11).
- Inspect the upper flail outer seals (4X) for wear or signs of damage.
- Retrieve and install the top infeed roll safety strut (see Safety Pins / Struts, p. 2-10).
- Grease the non-drive side top infeed roll end plate bearing (1 pts. See Lubrication, p. 4-11).
- Grease the left side idler roll, flail, and feed roll bearings (11pts. See Lubrication, p. 4-11).
- Inspect the upper flail left side outer seals (4X) for wear or signs of damage.
- Inspect and lubricate the grapple and the loader’s dipper (see Lubrication, p. 4-11).
- Inspect the grapple, rotator, connecting link, and dipper for crack formation or damage
- Grease the grapple (10 pts.) connecting link (2 pts.), and remote lines on the dipper (2 pts.).
- Enter and Inspect the Flail Chamber
- Inspect the exit feed rolls and infeed rolls for damage or debris entanglement.
- Inspect the exit chain curtain chains for signs of damage or excessive wear
- Inspect the inner side flail wear liners (8X per side) for signs of damage or excessive wear.
- Inspect the plunger top seal wear liner for signs of damage or excessive wear
- Inspect the plunger bottom seal wear liner for signs of damage or excessive wear
- Inspect the 4 flail rotors for excessive wear, signs of damage, or crack formation.
- Inspect the 4 flail chain sets for wear, replace if necessary.
- Remove the lockout tag-out from the loader
- Remove the infeed top roll safety strut and return to its proper stowage location
- Inspect discharge plunger side (2X) and bottom (6X) wear liners for excessive wear or damage.
- Remove the exit feed roll safety strut and return to its proper stowage location.
- Remove the lockout-tagout device from the flail
- Enable control panel and press “system reset” button to lower feed rollers.

Starting the flail

Every time a CBI machine is started there is a set procedure to follow. The purpose of this procedure
is to help familiarize personnel with how to properly start a CBI 604 flail debarker.
1 Turn on Battery Switch

Open the cover clasp (Figure 12 / A), Insert
the key (Figure 12 / B) and turn the main
battery switch on enabling the machine.
2 Turn on the control panel

Open the main control panel and insert the
ignition key, turn it to “run”. For more
information see Control Enclosure Layout,
p, 3-32. Figure 12
3 Reset system
Once the controller boots up, hit the
“system reset” button (Figure 13/C).
4 Give Warning
CBI advises always giving a clear auditory
warning before starting a machine. Allow
sufficient time for anyone in a danger zone
to respond before starting.
5 Start The Machine

Hold the ignition key (Figure 13/B) in then
“start” position until the engine starts.
Figure 13
⚠ NOTICE: Allow the engine to warm up for 15 minutes or until the engine temperature is over 145°F
(62°C) before loading.

Starting the loader

Every time a Tigercat loader is started there is a set procedure to follow. The purpose of this
procedure is to help familiarize personnel with how to properly start the loader on the 604 flail debarker.
INFO: Always consult the OEM manual for detailed product information, see Supplemental Manuals
p.1-4
1 Enter loader cab

Enter the loader cab and sit in the operator’s seat
2 Close the door

Close the loader door. There is a safety disconnect to keep machine from functioning if the door is
not closed.
3 Lower the armrest

Lower the left armrest. There is a safety disconnect to keep machine from functioning if the armrest
is in the upright position.
4 Turn on Battery Switch

Turn the main battery switch on enabling the loader.
5 Start loader
Insert the ignition key and, turn it to “run”. Hold for three seconds while the system starts up and
then turn the key to the “start” position until the engine starts.
6 Reset pilot system

Reset the “pilot reset” switch to enable the loaders functions.
⚠ NOTICE: Allow the engine to warm up for 15 minutes or until the engine temperature is over 145°F
(62°C) before loading.

Operating the machine by remote

Your CBI machine can be operated entirely using the remote control unit. The purpose of this
section is to familiarize operators with a technique for operating the machine using the remote
controller.
1 Start machine
Start the machine and allow its engine coolant
and hydraulic systems to reach operating
temperature. For more information see Starting
the flail, p. 3-10.
2 Enter “Radio Mode”

At the control panel, toggle “radio mode” on, for
more information see Basic Operation Menu, p.
3-35.
INFO: Machine should be in “Radio” and “auto”

modes, for more information see Control Modes, p.
3-33.
3 Turn on the remote control

Hold down the on/off button (Figure 14/A) for
three seconds to turn on the remote control, for
more information see Standard Function Mode,
p. 3-21.
4 Start the Loader

Start the Loader and allow its engine coolant
and hydraulic systems to reach operating
temperature. For more information see Starting
the loader, p. 3-11.
5 Connect Remote to Loader Figure 14

Connect the radio controller’s battery charge
port (Figure 15/A) to the link cable marked
“flail” in the cab of the loader (Figure 15/B).
This will enable select functions on the flail to
be controlled from the loaders joysticks. For
more information see Loader Controls, p. 3-23.
6 Throttle the engine up

Hold down the “Eng. Fast” button (Figure 14/E)
to throttle the engine up to operating speed.
For more information see Standard Function
Mode, p. 3-21. Figure 15
7 Turn on Flails
Hold down the “function” button (Figure 14/B) and press the “feed FWD” button (Figure 14/G) to
turn on the flails. For more information see Auxiliary Function Mode, p. 3-22.
8 Turn on feed system

Hold down the “Feed FWD” (Figure 14/G) button to turn on the feed system. For more information
see Standard Function Mode, p. 3-21.
9 Feed material
Your machine is now prepared to operate, feed material into the infeed.

10 Adjust run modes as needed

You can use the remote controller to cycle through preset “run modes”. To do this hold down the
“function” button (Figure 14/B) and press the “feed Rev” button (Figure 14/H); for more information
see Auxiliary Function Mode, p. 3-22.

Operating the machine by the control panel

Your CBI machine can be operated entirely from the control panel. The purpose of this section is
to familiarize operators with a technique for operating the machine using the control panel.
1 Start machine
Start the machine and allow its engine coolant and hydraulic systems to reach operating
temperature. For more information see Starting the flail, p. 3-10.
INFO: Machine should be in “local control” and “auto” modes, for more information see Control
Modes, p. 3-33.
2 Navigate to the “Basic Operation Menu” Menu

Navigate to the Basic Operation Menu. For more information see Basic Operation Menu, p. 3-35.
3 Throttle the engine up

From the Basic Operation Menu, hold down the “F2” button to throttle the engine up to operating
speed. For more information see Basic Operation Menu, p. 3-35.
4 Turn on Flails
From the Basic Operation Menu hold down the “F1” button to turn on the flails. For more
information see Basic Operation Menu, p. 3-35.

From the Basic Operation Menu hold down the “F4” button to engage the feed system. For more
information see Basic Operation Menu, p. 3-35.
6 Feed material
Your machine is now prepared to operate, feed material into the infeed.
7 Adjust run modes as needed

You can use the Remote Control to cycle through preset “run modes”; these vary feed rates, flail
speeds, and flail positions to suit different operating conditions. For more information on run mode
adjustments, see Run Mode Settings Adjust Menu, p. 3-50.

Enable Link to Disc Chipper

Your CBI machine can communicate wirelessly with other CBI machines allowing certain functions
to sync when the two are run in tandem; for more information see Link Mode, p. 3-33. The purpose of
this section is to familiarize operators with a technique for linking this machine to others.
1 Move flail in range

Position the flail so that it is within wireless range of this machine and prepared to feed it material.
2 Start disc chipper

Start the 754 disc chipper; it will act as the “master”. For more information consult its operation and
maintenance manual.
3 Start the flail

Start the flail; it will act as the “slave”. For more information see Starting the flail, p. 3-10.
4 Confirm Link Request

Once the flail is running, a prompt notifies you that the disc chipper is within range and available to
link; press “Confirm” to enable “link mode”. For more information see Link Mode, p. 3-33.
5 Operate combination unit

Your machine is now linked to the disc chipper and ready to operate in tandem. Both machines
may be controlled wirelessly from the cab of the flail. For more information see Operating the
machine by remote, p. 3-12.
6 Disable link when complete

When operation of the combo unit is complete, disable “link mode”. Navigate to the Link Mode
Menu and press the “Cancel Flail Link” button. For more information see Link Mode Menu, p. 3-
102.
Storing the Grapple

It is important to always return the loader into its cradle before shutting down the loader.
CBI’s frame cradle is specifically designed to secure the boom and grapple when not in use.
This ensures the machine does not accidentally drift when off.
1 Extend dipper
Fully extend the loaders dipper, for detailed
instructions see Loader Controls, p. 3-23.
2 Position grapple
With the grapple on the side of the machine by the
cradle, position it closed and rotated to be in line
with the flail.
3 Rotate loader
The cradle is not visible from the loader cab. As a
visual queue, there is an alignment post (Figure
16/A) on the side of the hydraulic tank. Using
extreme caution, swing the loader until the grapple
is next to the alignment post.
4 Lower main boom

Lower the loader’s main boom. When you
encounter resistance the grapple is firmly seated Figure 16
in the cradle.

Stopping the Loader

The following procedure should be followed every time the Tigercat loader is shut down.
 INFO: Always consult the OEM manual for detailed product information, see Supplemental Manuals
p.1-4
1 Return grapple to cradle

It is important to always return the loader grapple into its cradle before shutting down the loader to
ensure it does not drift. For more information, see Storing the Grapple, p. 3-15.
2 Shut off the loader

Turn the key to the “off” position, remove it from the ignition and store it in your pocket.
3 Turn off battery switch

Turn off the main battery switch on the loader control panel.
4 Exit the loader

Raise the left armrest, open the door and exit the loader
Stopping the flail

Every time a CBI machine is shut down there is a set procedure to follow. The purpose of this
procedure is to help familiarize personnel with that process.
1 Prepare machine
Lower all elevated components, stop all rotating components, and idle the engine down. For more
information see Operator Controls, p. 3-20.
2 Shut off the machine

Turn the ignition key to the “off” position, remove
it from the ignition and store it in your pocket.
3 Turn off battery switch

Turn off the main battery switch, remove the key
(Figure 17/B) and store it in your pocket. Close
the cover claps (Figure 17/A).
Figure 17

Cleaning
It is important to keep your machine clean in order to maintain optimal performance and reduce the
risk of fire. The following is basic instruction for cleaning equipment and should not be considered
complete. a minmum on which to build your own house cleaning procedures.equipment should be
cleaned on a daily basis following operation.
1 Shovel heavy debris

Shovel all heavy debris off of the machine. The purpose is to get the bulk of the material off.
2 Blow off machine

Adhering to all pertinent safety precautions, use compressed air to blow residual debris off of the
machine
3 Wash machine
Using water with a mild detergent, wash off all debris that remains after you blew the machine off.
Washing can create additional mess; by washing the machine last you minimize the “mud”
generated.
⚠WARNING: Always Use extreme caution when using pressurized water around sensitive electronic or
mechanical components, Failure to comply may result in severe equipment damage!
4 Scrape machine
Any persistent dirt can be scraped off using a putty knife. Excess grease can be removed using a
clean rag.
⚠NOTICE: never aim a water hose at electrical components. Re-lubricate any components that the
lubrication may have been washed off of.
Final Inspection
At the end of the day a final inspection should be performed on the machine. The purpose of this
inspection is to ensure the safety of the machine.
- Check that the entire machine is switched off and secured against unintentional activation.
- Store the remote control in the control unit and connect it to the charger.
- Switch off the battery switch and remove the key. Store this key in the control unit.
- Close the bracket of the battery switch and lock it using a padlock. Store this key in the control
unit.
- Lock the large and small hatches of the control unit.

3-18 OPERATION - AUTOMATED FEATURES PN 71510013 - OMM015008130510
Automated Features
Automated features are built in to the machines electronic control system. These features control
how various components interact with each other during normal operation. Their primary function is to
increase machine safety and efficiency while minimalizing the need for operator input. Some automated
features can be individually toggled on and off through the control panel but the majority are only
disabled by entering “service mode”. The purpose of the following section is to familiarize operators with
what the automated features are on their machine and the basics of how the features function.
Big-Bush-Busta
“Big-Bush-Busta” is an optional feature used for processing material with excessive branches or
foliage. This feature works by stopping the feed system and bursting the flail speeds up to their
maximum. Material is then shuttled forward for an adjustable amount of time and the feeds are paused
for an additional burst from the flails. The amount, duration of, and interval between bursts can all be
adjusted. This feature is useful for ensuring that nonconforming material with extra branches or foliage
is fully processed without modifying your run settings. This feature is enabled using the Remote Control
(p.3-20).
Flail Tuning Optimization

“Flail Tuning Optimization” is a feature used for optimizing the flail tuning characteristics for the
material being fed through the machine. This feature works by gauging the amount and size of material
being fed by measureing the hight of the top feed roll. Flail heights and speeds are then automatically
adjusted dependant on the amount and size of material being fed into the machine. The heights adjust
to match an adjustable percentage of top feed roll height and the speeds adjust linearly on an adjustable
scale based on flail hight. Each movable flail can be tuned individually. This feature is useful for
maximizing production and ensuring consistency of product regarless of how much or little is fed into the
machine. This feature can only be disabled by entering "Service Mode" (p.3-33).
Flail Power Optimization

“Flail Power Optimization” is a feature used to optimize and distribute power to specific flails
depending on their varying needs. This feature works by measureing the power required for each flail
and varying the command output to the flail pumps to increase power where needed and decrease it
where not. This feature is useful for limiting fuel consumption and maximizing machine performance.
This feature cannot be disabled.
Debris Purge Control

“Debris Purge Control” is the default feature for clearing the flail chamber of flail debris. This feature
works by cycling the discharge plunger in and out of the machine at preset adjustable intervals. Once
the interval has passed, the plunger will discharge flail debris again. This feature is necessary for
ensuring excess debris does not build up in the flail chamber with out requiring operator input. This
feature can only be disabled by entering "Service Mode" (p.3-33).
Feeds Reverse
“Feeds Reverse” is the default feature for protecting the flail drive motors from overloading. This
feature works by automatically reversing the feed system if the control system detects that the flail drive
motor pressures have exceed a preset adjustable limit. The feed system will reverse for a preset
amount of time and then automatically resume feeding when that time has passed. This feature is useful
because it protects the flail drives from overfeeding and against material being wedged against a flail
drum. This feature can only be disabled by entering "Service Mode" (p.3-33).
Top Roll Rapid Lift

“Top Roll Rapid Lift” is a feature where the top feed roll lift cylinders have enough hydraulic
pressure applied to them to effectively lighten the load to the point there is very little down pressure.
This feature is automatically disabled when the engine RPM falls below a certain set point or the top
feed roll is opened above a certain height. The feature will automatically resume when the engine RPM
recovers or the top feed roll returns below a certain height. This feature is useful for aiding the top feed
roll in climbing on top of and grabbing material when it’s first fed in. This is particularly helpful when
large material is fed into the machine that the feed roll may have difficulty climbing on top of. This
feature can be disabled by entering"Service Mode" (p.3-33).

PN 71510013 - OMM015008130510 OPERATION - AUTOMATED FEATURES 3-19
Minimum Operating Temperature

“Minimum Operating Temperature” is a feature used to ensure the machine is up to temperature
before it is operated. When this feature is enabled, the feed system is automatically disabled from
moving forwards until the engine has reached a programmable minimum operating temperature. This
feature is useful for prolonging the life of the engine. This feature can only be disabled by entering
"Service Mode" (p.3-33).
Infeed Clog Sense

“Infeed Clog Sense” is a feature that keeps the machines infeed from clogging. The loads on the
feed systems drive motors are monitored and when a preset limit is reached, it considers the infeed
“clogged” and automatically reverses the feed system for an adjustable preset amount of time. This
feature is useful for unjamming a stuck feed roll or feed conveyor. This feature can only be disabled by
entering "Service Mode" (p.3-33).
Automatic Hydraulic Cooler Purge

“Automatic Hydraulic Cooler Purge” is a feature which purges built up debris from the hydraulic
cooler. This feature reverses the direction of the hydraulic cooler fan (from pulling to pushing) for an
adjustable amount of time at regular adjustable intervals. When the fan reverses any material that was
trapped in the cooler is blown out. A purge also occurs if an adjustable temperature limit is reached in
case there is sudden debris buildup between timed purge cycles. This feature is useful for keeping the
hydraulic system from overheating. This feature cannot be disabled.
Automatic Radiator Purge

“Automatic Radiator Purge” is a feature which purges built up debris from the engines radiator. This
feature reverses the pitch of the engine radiator fan (from pulling to pushing) for an adjustable amount of
time at regular adjustable intervals. When the fan pitch reverses any material that was trapped in the
radiator is blown out. A purge also occurs if an adjustable temperature limit is reached in case there is
sudden debris buildup between timed purge cycles. This feature is useful for keeping the engines
cooling system from overheating. This feature cannot be disabled.

3-20 OPERATION - OPERATOR CONTROLS PN 71510013 - OMM015008130510
Operator Controls
Remote Control
The remote control (Figure 18) is used to operate the
machine from a distance to keep personnel out of the
danger zone (see Danger Zones, p. 2-4). The remote also
relays important operational data from the machine back
to the operator through its LCD screen. The remote is
usually placed inside the cabin of the vehicle that is
loading your CBI machine.
The remote has a four line LCD screen (Figure 18 /
K). The top line displays the machine name. The second
line of the screen scrolls through machine data such as:
engine rpm, engine temperature, oil pressure, fuel
consumption, fuel pressure, feed power, feed rate, and
clutch pressure. The third line of the screen displays
information related to remote operation such as alternate
control schemes that are enabled or buttons which are
pressed. The bottom line of the screen displays remote
control parameters. These include battery strength (BT),
message strength (MS, strength of signal going from
machine to remote), signal strength (SS; strength of
signal going from remote to machine), and a spinning
charge indicator
There are 10 buttons (Figure 18 / A through J) on the
remote that are used for operating the machine. By
utilizing combinations of multiple buttons in conjunction
with alternate control schemes (called “function modes”)
the ten buttons on the controller may be used to control
many more than ten machine functions. For detailed
information see Function Modes, p. 3-20.
The following sections are provided to familiarize the
Figure 18
operator with remote control operation.
Remote Control Battery

The remote control is powered by a battery, the
charging port for the battery is located on the back of the
remote (Figure 19 / A).
During operation the remote can be charged using
the supplied 12 – 24 VDC charger placed in the cigarette
lighter socket in the cab of the vehicle that feeds material
into this machine. An additional charging port (Figure 19 /
B) is located in the control panel of your CBI machine.
Connect the remote controller to this port when the
machine is not being operated to keep the battery
charged.
Failure to maintain the remote control’s battery
charge may result in loss of radio communications. Figure 19
Function Modes
Function modes are used because there are more machine functions that need to be controlled than
there are buttons on the remote. Function modes enable a single button on the remote to control multiple
functions depending which mode is enabled. The following sections detail what the various function
modes are on your CBI machine are, how they’re enabled, and what the specific remote control button
functions are for them.

PN 71510013 - OMM015008130510 OPERATION - OPERATOR CONTROLS 3-21
Standard Function Mode

Standard Mode is the default control scheme on the remote controller (Figure 20). The
following is a list of functions controlled by the remote under normal conditions.
REF. NAME PICTOGRAPH BUTTON FUNCTION

On/Off Switch
Holding this button for three
A ON/OFF
seconds will turn on the remote;
do this again to turn it off.
Auxiliary Function
Holding this button down and
B FUNCTION
pressing another button enables
the buttons auxiliary function
Emergency Stop Switch
This button stops the machine in
C E-STOP
emergency situations; a radio link
must be established for it to work.
Big-Bush-Busta
Press this button to initiate the
D PUSHOUT
“Big-Bush-Busta” feature; see
Big-Bush-Busta, p. 3-18.
Idle Engine Up
E ENG FAST Hold this button to increase the
engines speed
Idle Engine Down

F ENG SLOW Hold this button to decrease the
engines speed
Engage Feed Wheels

Press this button to engage the
G FEED FWD feed system. Feed can only be
engaged when flails are spinning Figure 20
or machine is in “Service mode”
Stop / Reverse Feed Wheels

H FEED REV Press this button with the feed on to stop the feed wheels. Hold the button
down to reverse the feed direction.
Raise Infeed Top Roll

I ROLL UP
Hold this button to raise the top infeed roll wheel
Lower Infeed Top Roll

J ROLL DWN
Hold this button to lower or apply down pressure with the top infeed roll wheel

Auxiliary Function Mode

Auxiliary function mode is an alternate control scheme for the remote controller. To enable auxiliary
function mode hold down the function button (Figure 21 / B), this will enable the auxiliary functions for the
other controller buttons. Buttons without assigned auxiliary functions will still work the same as when is
standard mode. To exit auxiliary function mode, release the “function” button.
The following is a list of special functions controlled by the remote only when auxiliary function mode
is enabled.

On/Off Switch
Holding this button for three
B+A ON/OFF
seconds will turn on the remote;
Hold down this button
combination to stop the machine
B+C E-STOP
in emergency situations; a radio
link must be established for it to
work.
Enter Outrigger Function Mode
By holding down this button
B+D OUTRIG combination for three seconds
you will enter “outrigger mode”.
Repeat to exit outrigger mode..
Idle Engine Up
B+E ENG FAST Hold this button to increase the
engines speed
Idle Engine Down

B + F ENG SLOW Hold this button to decrease the
engines speed
Turn Flails On/Off

By holding down this button
B+G FLAILS combination for three seconds
you will turn the flails on. Repeat
to turn flails off.
Cycle Through Run Modes
Pressing this button combination Figure 21
B+H RUNMOD
will cycle through the four
available “run modes”.
Raise Exit Top Roll

B+I ETRUP
Holding this button combination will raise the exit feed top roll wheel
Lower Exit Top Roll

B+J ETRDN Holding this button combination will lower or apply down pressure with the exit
feed top roll wheel

Outrigger Function Mode

Outrigger Function mode is an alternate control scheme used for controlling the outriggers. To
enable outrigger mode hold down the function button (Figure 22 / B) and the “push out” button (Figure 22
/ D) for three seconds. Use outrigger mode to select which outrigger needs to be adjusted and then
either raise or lower it. To exit “outrigger mode” hold down the “function” button and the “push out”
button for three seconds. The following is a list of functions controlled by the remote only when outrigger
function mode is enabled.

On/Off Switch
Outrigger
Mode Holding this button for three
ON/OFF
+A seconds will turn on the remote;
Auxiliary Function
Outrigger
Mode Holding this button down and
FUNCTION
+B pressing another button enables
the buttons auxiliary function
Outrigger
Mode This button stops the machine in
E-STOP
+C emergency situations; a radio link
must be established for it to work.
Big-Bush-Busta
Outrigger
Mode Press this button to initiate the
PUSHOUT
+D “Big-Bush-Busta” feature; see
Big-Bush-Busta, p. 3-18.
Select Back Left Outrigger
Outrigger
Mode By holding down this button it will
IN LFT
+E select the back left outrigger to be
moved.
Select Back Right Outrigger
Outrigger
IN RHT
+F select the back right outrigger to
be moved.
Select Front Left Outrigger
Outrigger
EXTLFT
+G select the front left outrigger to be
moved. Figure 22
Outrigger
Mode Select Front Right Outrigger
EXTRHT
+H By holding down this button it will select the front right outrigger to be moved..
Outrigger Raise Selected Outrigger

Mode RIGUP Holding this button in combination with selecting one of the outriggers will raise
+I the selected outrigger.
Outrigger Lower Selected Outrigger

Mode RIGDN Holding this button in combination with selecting one of the outriggers will lower
+J the selected outrigger.
Loader Controls
The joystick controls are used for controlling the Tigercat loader and are located inside its cab. The
joysticks also have some limited ability for controlling functions on the flail. There are two joysticks in the
cab of the loader, a right (Figure 23, p.3-24) and a left (Figure 24, p.3-26). Both joysticks have two-axis
functionality with trigger buttons for controlling the loader functions. There also six auxiliary buttons on
each joystick that will control functions on the flail or disk chipper. These auxiliary buttons only function
when their associated remote controller is plugged into its respective link cable in the cab of the loader
and radio communication between the machines is established
INFO: For detailed information on Tigercat controls, please consult the OEM manuals (see
Supplemental Manuals, p. 1-4).
Right Loader Joystick

The right joystick (Figure 23) has two-axis functionality with a trigger button (Figure 23 / E).
There are six auxiliary buttons (Figure 23 / F-K) that can control functions on the flail. These
auxiliary buttons only function when the remote controller for the flail is plugged into its
respective link cable in the loader cab and radio communication with the flail is established.

Lower Boom
A RJS FWD By pushing the right joystick forward it will
lower the loader’s boom.
Open Grapple
B RJS RHT By holding the right joystick to the right it
will open the loader’s grapple
Raise Boom
C RJS BCK By pulling the right joystick backward it
will raise the loader’s boom.
Close Grapple
D RJS LFT By holding the right joystick to the left it
will close the loader’s grapple.
Rotate Grapple Clockwise

E RJS TRIG Holding the right joystick trigger button
will rotate the loader’s grapple clockwise.
Engage Feed Wheels

By pressing the right joystick auxiliary
button #1, you will engage the feed
system. Repeat to turn feed off. .
F RJS AUX1
⚠NOTE: This button will only work if the
flail remote is linked in the loader cab and
radio communications with the flail are
established. Figure 23
Stop / Reverse Feed Wheels
By pressing the right joystick auxiliary button #2 with the feed system engaged
G RJS AUX2 you will stop it. Holding this button down will reverse the feed system.
⚠NOTE: This button will only work if the flail remote is linked in the loader cab
and radio communications with the flail are established.
No Current Function Assigned
H RJS AUX3 none
This button currently has no assigned function.


I RJS AUX4 none
Raise Infeed Top Roll

By holding down the right joystick auxiliary button #5, you will raise the infeed
J RJS AUX5 top roll wheel.
Lower Infeed Top Roll

By holding down the right joystick auxiliary button #6, you will lower or apply
K RJS AUX6 down pressure with the infeed top roll wheel.

Left Loader Joystick

The left joystick (Figure 24) has two-axis functionality with a trigger button (Figure 24 / P).
There are six auxiliary buttons (Figure 24 / Q-V) that can control functions on the disc chipper if
connected. These auxiliary buttons only function when the remote controller for the disc chipper
is plugged into its respective link cable in the loader cab and radio communication with the disc
chipper is established.

Extend Dipper
L LJS FWD By pushing the left joystick forward it will
extend the loader’s dipper.
Swing Loader Right

M LJS RHT By holding the left joystick to the right it
will swing the loader to the right.
Retract Dipper
N LJS BCK By pulling the left joystick backward it will
pull the loader’s dipper in.
Swing Loader Left

O LJS LFT By holding the left joystick to the left it will
swing the loader to the left.
Rotate Grapple Counter Clockwise

Holding the left joystick trigger button will
P LJS TRIG
rotate the loader’s grapple counter
clockwise.
Rotate Chute Left

By holding down the left joystick auxiliary
button #1 you will rotate the chipper’s
chute to the left. .
Q LJS AUX1
⚠NOTE: This button will only work if the
disc chipper remote is linked in the loader
cab and radio communications with the
chipper are established
Figure 24
Rotate Chute Right
By holding down the left joystick auxiliary button #2 you will rotate the chipper’s
R LJS AUX2 chute to the right.
⚠NOTE: This button will only work if the disc chipper remote is linked in the
loader cab and radio communications with the chipper are established

S LJS AUX3 none

T LJS AUX4 none

Move Chip Deflector Out

By holding down the left joystick auxiliary button #5 you will move the chipper
U LJS AUX5 chute’s chip deflector out.
Move Chip Deflector In

By holding down the left joystick auxiliary button #6 you will move the chipper
V LJS AUX6 chute’s chip deflector in.

Valve Manual Control

Certain components on your CBI machine can be operated manually from the control valves (Figure
25). Manual operation is used for functions that are not commonly used and therefore do not need to be
included on the remote controller. Manual operation can also be used as a backup for certain functions
in case the remote controller battery dies. The purpose of this section is to familiarize the operator with
the manual controls on this equipment.
⚠WARNING: Electronic Safety switches may be bypassed when using manual controls; always use
extreme caution and ensure components are safe to position before using manual controls. Failure to
comply may result in severe equipment damage!
⚠WARNING: Always use extreme caution when using manual controls. Ensure personnel are a
sufficient distance away from components prior to positioning them. Failure to comply may result in
Lower Left Rear Outrigger

A VLV1 IN Pushing this lever forward will
lower the left rear outrigger.
Raise Left Rear Outrigger

A VLV1 OUT Pulling this lever backward will
raise the left rear outrigger.
Lower Right Rear Outrigger

B VLV2 IN Pushing this lever forward will
lower the right rear outrigger.
Raise Right Rear Outrigger

B VLV2 OUT Pulling this lever backward will Figure 25
raise the right rear outrigger.
Lower Left Front Outrigger

C VLV3 IN
Pushing this lever forward will lower the left front outrigger.
Raise Left Front Outrigger

C VLV3 OUT
Pulling this lever backward will raise the left front outrigger.
Lower Right Front Outrigger

D VLV4 IN
Pushing this lever forward will lower the right front outrigger.
Raise Right Front Outrigger

D VLV4 OUT
Pulling this lever backward will raise the right front outrigger.
Close Flail Chamber Access Hatch

E VLV5 IN
Pushing this lever forward will close the flail chamber access hatch.

Open Flail Chamber Access Hatch

Pulling this lever backward will open the flail chamber access hatch.
E VLV5 OUT
⚠WARNING: Never operate this valve if the flails are running; failure to comply
may result in severe injury or equipment damage!
Proportional Valve Manual Control

Certain components on your CBI machine can be operated manually from proportional control
valves (Figure 26). Manual proportional operation can be used for servicing the machine and is also
used as a backup for certain functions in case the remote controller battery dies. The purpose of this
section is to familiarize the operator with the proportional valve manual controls on this equipment.
⚠WARNING: Electronic Safety switches may be bypassed when using manual controls; always use
extreme caution and ensure components are safe to position before using manual controls. Failure to
comply may result in severe equipment damage!
⚠WARNING: Always use extreme caution when using manual controls. Ensure personnel are a
sufficient distance away from components prior to positioning them. Failure to comply may result in

Idler Roll #1 Speed Control
Pulling this lever will
A PVLV1
proportionally control the speed
of the first idler roll.
B PVLV2
of the second idler roll.
C PVLV3
of the third idler roll. Figure 26

D PVLV4
Pulling this lever will proportionally control the speed of the fourth idler roll.

Loader Control Panel

The Loader control panel is located on the right hand side of the cab. It is used for controlling
certain machine functions that are not covered by the joysticks. These controls include:
1 Battery Disconnect switch
2 Optional accessory switched
3 Horn switch
4 Pilot reset switch
5 Emergency stop switch
6 Engine sped switch
7 Ignition key switch
8 24V auxiliary power outlet
9 12V auxiliary power outlet
10 Rear work lights switch
11 Service lights switch
12 Front work lights switch
INFO: For a complete list of loader control panel switches and controls please refer to the OEM
manual (see Supplemental Manuals p. 1-4).

Engine Platform Emergency Stop Control Box

The machine has a standalone emergency stop control box (Figure 27) located on the engine
access platform. The purpose of this section is to familiarize the operator with the buttons at the
emergency stop control box.

Emergency Stop
Press this button to immediately
A ESCB1 SW1 stop the machine in emergency
situations. Pull this button out to
reset the system.
Figure 27
Loader Access Emergency Stop Control Box

The machine has a standalone emergency stop control box (Figure 28) located next the loader
access ladder on the back left side of the flail. The purpose of this section is to familiarize the operator
with the buttons at this emergency stop control box.

Emergency Stop
Press this button to immediately
A ESCB2 SW1 stop the machine in emergency
situations. Pull this button out to
reset the system.
Figure 28

3-32 OPERATION - PANEL CONTROLS/SETTINGS PN 71510013 - OMM015008130510
Panel Controls/Settings
Introduction
Your machine comes standard with an MDL control unit. The MDL provides a simple user interface
for operators to interact with the machine. Machine settings, controls, and information can all be
accessed from the MDL. The MDL features increased I/O capacity that can be utilized for the addition of
customized machine functions. The purpose of this section is to familiarize the operator with the proper
techniques for navigation, machine control, and setting modification in the MDL controller.
Control Enclosure Layout

The control enclosure (Figure 29) is situated on
the side of the machine.
Behind the smaller enclosure door (Figure 29 / A)
is the ignition switch (Figure 29 / B) for starting and
stopping the machine, a “system reset” button (Figure
29 / C), and a control panel (Figure 29 / D) for
machine controls, settings, and data.
There is an emergency stop button (Figure 29 / E)
located on the face of the larger enclosure (Figure 29 /
F). The remote control and its charger are stored
inside the larger enclosure.
Both enclosures (Figure 29 / A & F) should remain Figure 29
closed during operation and may be locked for
security.
Control Panel Interface

The control panel on your machine may feature an optional MDL control unit (Figure 30). It is
important to understand the controller’s user interface in order to operate the controller. The following
is a list of buttons available on your MDL controller.
Function Key 1
Function Key 2
Function Key 3
Function Key 4
Function Key 5
Escape Button: close current screen
A Button: next screen
B Button: previous screen
C Button: Selector button

Figure 30
D Button: Set button
System Menu Button: MDL sub-menu
Jog / Shuttle button: Select items on the screen by turning the button; Confirm selection by
pressing the button.

PN 71510013 - OMM015008130510 OPERATION - PANEL CONTROLS/SETTINGS 3-33
Control Modes
Control modes are used because in certain instances it is necessary for the machine to operate
differently. This allows certain features to be enabled or disabled depending on your needs. Which
control modes are currently enabled is changed in the control panel and displayed in the upper corners
of its display. The following section details what the various control modes on your CBI machine are,
and under what conditions they should be used.
Local Mode
Local mode is used when all the machine functions are going to be controlled from the control panel.
When the machine is first turned on it will be in “local mode” by default. This mode is useful for
controlling the machine while adjusting settings or running diagnostics.
Radio Mode
Radio mode is used when all the machine functions are going to be controlled from the remote
control (see Remote Control, p. 3-20). To enter radio mode you must enable it from the control panel
using the “local / radio toggle”. This mode is useful for regular operation of the machine or performing
service when the operator is away from the control panel.
Auto Mode
Auto mode enables all the automated safety functions of the machine. When the machine is first
turned on it will be in “Auto mode” by default. This mode is used for all regular operation of the
machine.
Service Mode
Service mode disables all the automated features on the machine and allows components to be
controlled independently of each other. To enter service mode you must enable it from the control panel
using the “Service / auto toggle”. This mode should only be used for performing service on the machine
that requires automated features be disabled.
⚠WARNING: Never operate the machine in “service” mode. Automated safety features will be disabled,
ensure conditions are safe prior to controlling any machine function. Failure to comply may result in
severe machine damage or injury to personnel!
Link Mode
Link mode enables two CBI machines to communicate with each other wirelessly so that certain
functions can sync. One machine becomes the "master" and one becomes the slave. The slave
machines feed rates will automatically sync to match the masters. Certain functions such as emergency
stops, feed direction and engagement status are linked so that if it is engaged on one machine it is
automatically engaged on the other. This mode is used to allow a single operator to control multiple
machines running in tandem.

Startup Menu
Button Functions
The Startup Menu (Figure 20) is used for navigating between the basic and advanced operations
menus. This is the first menu displayed when the machine is turned on. The purpose of this section is to
familiarize operators with navigation of the startup menu.
Button Image Function
Basic Operation
Press this button to navigate to the
basic operation menu.
Advanced Operation
advanced operation menu.
Transportation Menu
Transportation menu.
Figure 31
Information Menu
information menu.
Display Parameters
The Startup Menu (Figure 32) has various machine parameters displayed on it. In order to
successfully use this menu it is critical that you fully understand the parameters displayed. The following
is a list of all the parameters in the Startup Menu along with a brief explanation of what they are.
Image Parameter
Local Auto Mode
This Image displays that the machine is
currently in local / auto mode.
Local Service Mode

This displays that the machine is currently
in local / service mode.
Radio Auto Mode

in radio / auto mode.
Figure 32
Radio Service Mode

This displays that the machine is currently in radio / service mode.
Link Mode enabled

This displays that link mode is enabled.
Link mode disabled

This displays that link mode is disabled

Basic Operation Menu

Button Functions
The basic operation menu (Figure 33) is used for basic operation of the machine; it is a simplified
interface that is sufficient for the day to day activities of the majority of users. This menu can be accessed
by pressing the “F2” button in the Startup Menu (p. 3-34). The purpose of this section is to familiarize
operators with the information displayed in and navigation of the “basic operation menu”.

Flail Toggle
Hold this button for three seconds to
engage or disengage the Flails.
Engine Fast
Press this button to throttle the engine
up.
Engine Slow
Press this button to idle the engine
down.
Feed Forward
Press this button to engage the feed
system. System can only be engaged
when the flails are spinning or the Figure 33
machine is in "service mode".
Local / Radio toggle
Press this button to toggle the machine between radio and local mode.
Return
Press this button once to go the last menu you were at; press it repeatedly to navigate to
the “main menu”.

Display Parameters
The Basic Operations Menu (Figure 34) has various machine parameters displayed on it. In order to
is a list of all the parameters in the basic operations menu along with a brief explanation of what they are.
Image Parameter
Local Auto Mode
Local Service Mode

This displays that the machine is currently in
local / service mode.
Radio Auto Mode

radio / auto mode.
Figure 34
Radio Service Mode

Run Mode
This image displays which one of the four programmable run modes is currently selected.
Feed Rate
This displays the current feed rate of the machine.
Engine Diagnostic Lamps

This displays the CAT engine diagnostic lamps. For detailed information consult your CAT
engine manual.
Fuel Pressure
This displays the fuel pressure.
Engine Hours
This displays the total cumulative hours the engine has run.
Engine RPM
This displays the engines speed in RPM.
Engine Coolant Temperature

This displays the engine coolant temperature.
Link Mode enabled

Link mode disabled


Flail Transport Menu

Button Functions
The Flail Transport Menu (Figure 35) is used for preparing the machine for transport; it is a simplified
interface that is sufficient for the day to day activities of the majority of users. This menu can be accessed
by pressing the “F5” button in the Startup Menu (p. 3-34). The purpose of this section is to familiarize
operators with the information displayed in and navigation of the Flail Transport Menu.

Outriggers Menu
outriggers menu.
Plunger Menu
plunger menu.
Return
Press this button once to go the last
menu you were at; press it repeatedly
to navigate to the “main menu”. Figure 35
Display Parameters
The Flail Transport Menu (Figure 36) has various machine parameters displayed on it. In order to
successfully use this menu it is critical that you fully understand the parameters displayed. The following is
a list of all the parameters in the Flail Transport Menu along with a brief explanation of what they are.
Image Parameter
Local Auto Mode
Local Service Mode

Radio Auto Mode

radio / auto mode.
Figure 36
Radio Service Mode

Link Mode enabled

Link mode disabled


Outriggers Menu
Button Functions
The Outriggers Menu (Figure 37) is used for controlling the outriggers on the machine. This Menu
can be accessed from the Startup Menu (p. 3-34) by pressing the “F5” button and then pressing the “F2”
button. It can be accessed from the Advanced Operation Menu (p. 3-44) by pressing the “D” button. Use
the “jog / shuttle” button to select which end of the machine you’re controlling the outriggers on. The
purpose of this section is to familiarize operators with button functions in the Outriggers Menu.
Left Outrigger Up
Press this button to raise the left
outrigger.
Left Outrigger Down

Press this button to lower the left
outrigger.
Right Outrigger Up
Press this button to raise the right
outrigger.
Right Outrigger Down

Press this button to lower the right Figure 37
outrigger.
Next Menu
Press this button to display the next menu in the sequence.
Previous Menu
Press this button to display the Previous menu in the sequence.
Service / Auto Toggle

Press this button to toggle between service and auto mode.
⚠NOTICE: Confirmation of mode selection is highlighted in the top left corner of the
screen.
Local / Radio Toggle
screen.
Jog / Shuttle Button
Turn this knob to scroll through different items on the screen. Press this button to
confirm that the highlighted item is the desired selection.
No Image
⚠NOTICE: If the “jog/shuttle” button is turned, all other control panel buttons are
deactivated as a safety feature until a selection is confirmed by pressing the
“jog/shuttle” button.
Escape Button
Press this button once to return to the previous menu you were at; press it repeatedly
to navigate to the “Startup Menu”.
System menu
Press this button to display the “sub-menu”. Here users can adjust application
No Image
specific parameters, measure electrical inputs and outputs, change preferences and
view module information.

Display Parameters
The Outriggers Menu (Figure 38) has various machine parameters displayed on it. In order to
is a list of all the parameters in the Outriggers Menu along with a brief explanation of what they are.
Image Parameter
Local Auto Mode
Local Service Mode

Radio Auto Mode

Figure 38
Radio Service Mode

Loader End Outriggers Selected

This displays that outriggers on the loader end of the machine are selected for manual
control.
Kingpin End Outriggers Selected
This displays that outriggers on the kingpin end of the machine are selected for manual
control.
Link Mode enabled

Link mode disabled


Plunger Menu
Button Functions
The Plunger Menu (Figure 39) is used for controlling the plunger on the machine. This Menu can be
accessed from the Startup Menu (p. 3-34) by pressing the “F5” button and then pressing the “F4” button.
It can be accessed from the Advanced Operation Menu (p. 3-44) by pressing the “C” button. The purpose
of this section is to familiarize operators with button functions in the Plunger Menu.
Fold Up
This button folds the plunger
support frame up.
⚠WARNING: Ensure all safety pins
are removed before operating
components; Failure to comply may
result in severe equipment damage!
⚠WARNING: Ensure plunger is fully
retracted into the flail chamber for
moving the support frame. Failure
to comply may result in severe
equipment damage! Figure 39
Fold Down
This button folds the plunger support frame down.
⚠WARNING: Ensure all safety pins are removed before operating components; Failure
to comply may result in severe equipment damage!
Plunger Into Machine

This button retracts the waste discharge plunger into the flail chamber.
Plunger Out Of Machine

This button extends the waste discharge plunger into the support frame.
Next Menu
Previous Menu

screen.
screen.
Escape Button
System menu
No Image

Display Parameters
The Plunger Menu (Figure 40) has various machine parameters displayed on it. In order to
is a list of all the parameters in the Plunger Menu along with a brief explanation of what they are.
Image Parameter
Local Auto Mode
Local Service Mode

Radio Auto Mode

Figure 40
Radio Service Mode

Hydraulic Cylinder Pressure

This displays the hydraulic pressure in the cylinder.
Frame Up / Down
This image displays the control status of the plunger frame, whether it is currently moving up
or down.
Proximity Switch
This image displays whether or not the proximity switch shows contact or not.
Plunger Out / In
This image displays the control status of the plunger, whether it is currently moving Out or In.
Link Mode enabled

Link mode disabled


Information Menu
Button Functions
The Information Menu (Figure 41) is used for displaying machine specific information such as the
build date, and serial number. It also lists the contact information for CBI. This Menu can be accessed
from the Startup Menu (p. 3-34) by pressing the “B” button. The purpose of this section is to familiarize
operators with button functions in the Information Menu.
Return
No Image Press this button to return to the
startup menu.
Return
startup menu.
Return
startup menu.
Return
No Image Press this button to return to the Figure 41
startup menu.
Return
No Image
Press this button to return to the startup menu.
Return
No Image
Return
No Image
Return
No Image
Return
No Image
Return
No Image
Return
No Image

Display Parameters
The Information Menu (Figure 42) has various machine parameters displayed on it. In order to
is a list of all the parameters in the Information Menu along with a brief explanation of what they are.
Image Parameter
Local Auto Mode
Local Service Mode

Radio Auto Mode

in radio / auto mode. Figure 42
Radio Service Mode

Link Mode enabled

Link mode disabled


Advanced Operation Menu

Button Functions
The Advanced Operation Menu (Figure 43) is used for accessing advanced features intended only for
qualified personnel. It is password protected to deter unauthorized use. This Menu can be accessed
from the Startup Menu (p. 3-34) by pressing the “F3” button and then entering the password. The purpose
of this section is to familiarize operators with button functions in the Advanced Operation Menu.
Automatic Operation Menu

Press this button to navigate
to the “Automatic operation
menu”.
Run Settings Menu

to the “Run Settings menu”.
Manual Operation Menu

to the “manual operation
menu”.
Engine Menu Figure 43
to the “engine menu”.
Cooling Menu
Press this button to navigate to the “cooling menu”.
Plunger Menu
Press this button to navigate to the “Plunger Menu”.
Outrigger Menu
Press this button to navigate to the “outrigger menu”.
Escape Button
Press this button once to return to the previous menu you were at; press it
repeatedly to navigate to the “Startup Menu”.
System menu
No Image
specific parameters, measure electrical inputs and outputs, change preferences
and view module information.

Display Parameters
The Advanced Operation Menu (Figure 44) has various machine parameters displayed on it. In order
to successfully use this menu it is critical that you fully understand the parameters displayed. The
following is a list of all the parameters in the Advanced Operation Menu along with a brief explanation of
what they are.
Image Parameter
Local Auto Mode
Local Service Mode

Radio Auto Mode

Figure 44
Radio Service Mode

Link Mode enabled

Link mode disabled


Automatic Operation Menu

Button Functions
The automatic operation menu (Figure 45) is used for basic operation of the machine; it is a simplified
interface that is sufficient for the day to day activities of the majority of users. This menu can be
accessed by pressing the “F1” button in the Advanced Operation Menu (p. 3-44). The purpose of this
section is to familiarize operators with the information displayed in and navigation of the “automatic
operation menu”.

Flail Toggle
Hold this button for three seconds to
engage or disengage the Flails.
Feed Forward
Press this button to engage the feed
system. System can only be
engaged when the flails are spinning
or the machine is in "service mode".
Engine Fast
Press this button to throttle the
engine up. Figure 45
Engine Slow
Press this button to idle the engine down.
Next Menu
Previous Menu
screen.
screen.
Return
Press this button once to go the last menu you were at; press it repeatedly to navigate
to the “main menu”.
System menu
Press this button to display the “sub-menu”. Here users can adjust application specific
No Image
parameters, measure electrical inputs and outputs, change preferences and view
module information.

Display Parameters
The automatic Operations Menu (Figure 46) has various machine parameters displayed on it. In
order to successfully use this menu it is critical that you fully understand the parameters displayed. The
following is a list of all the parameters in the automatic operations menu along with a brief explanation of
what they are.
Image Parameter
Local Auto Mode
Local Service Mode

Radio Auto Mode

radio / auto mode.
Radio Service Mode
Figure 46
radio / service mode.
Feed Rate
This displays the current feed rate of the machine.
Run Mode
This image displays which one of the four programmable run modes is currently selected.

This displays the CAT engine diagnostic lamps. For detailed information consult your CAT
engine manual.
Engine RPM

This displays the engine coolant temperature.
Hydraulic Oil Temperature

This displays the hydraulic oil temperature.
Engine Hours
Discharge Plunger Cylinder Pressure

This image displays the hydraulic pressure in the discharge plunger’s hydraulic cylinders.
Fuel Pressure
This displays the fuel pressure.
Link Mode enabled

Link mode disabled


Run Settings Menu

Button Functions
The Run Settings Menu (Figure 47) is used for viewing and modifying the run settings on your
machine. This Menu can be accessed from the Advanced Operation Menu (p. 3-44) by pressing the “F2”
button. The purpose of this section is to familiarize operators with button functions in the Run Settings
Menu.
Run Mode Settings Adjust Menu

“run mode settings adjust menu”.
Run Mode Toggle

Press this button to toggle between
the four selectable programmable
run modes.
Flail Lift Tuning Adjust Menu

“flail lift tuning adjust menu”
Next Menu Figure 47

Press this button to display the next
menu in the sequence.
Previous Menu

screen.
screen.
Escape Button
System menu
No Image

Display Parameters
Image Parameter
Feed Rate
This displays the current feed rate of the
machine.
Run Mode
This image displays which one of the four
programmable run modes is currently
selected.
Flail #1
This Image displays that Flail #1 is selected.
Flail #2
This Image displays that Flail #2 is selected. Figure 48
Flail #3
Flail #4
Top Roll #1 Float Pressure
This Image displays the float pressure in the lift cylinders for top roll #1.
Top Roll #2 Float Pressure
This Image displays the float pressure in the lift cylinders for top roll #2.
Flail Speed When Raised
This image displays the speed of specified flail when the associated upper flail is raised.
Flail Speed When Lowered
This image displays the speed of specified flail when the associated upper flail is lowered.
Flail Lift Percentage
This image displays the percentage of the height the top feed roll is lifted to which the upper
flail will lift to.
Local Auto Mode
This Image displays that the machine is currently in local / auto mode.
Local Service Mode

This displays that the machine is currently in local / service mode.
Radio Auto Mode

This displays that the machine is currently in radio / auto mode.
Radio Service Mode

Link Mode enabled

Link mode disabled


Run Mode Settings Adjust Menu

The Run Mode Settings Adjust Menu (Figure 49) can be accessed from the Run Settings Menu (p. 3-
48) or the Adjust System Menu (p. 3-107). Turn the “jog / shuttle” button to scroll through the available
settings and press the “jog / shuttle” button to select the highlighted setting for adjustment. Once a
setting is selected for adjustment use the “jog / shuttle” button to adjust the setting. Return to the Run
Mode Settings Adjust Menu by pressing the “escape button”. The following is a list of all the machine
settings that can be adjusted from the Run Mode Settings Adjust Menu along with a brief explanation of
what effect adjusting the settings will have.
⚠WARNING: Before adjusting any machine settings it is

critical that you fully understand how they will affect
machine performance. Failure to comply may result in
INFO: For detailed information on machine setup and

settings contact CBI; see CBI Authorized Service
Assistance, p. 1-12.
Figure 49
1 Run Mode Feed Speed
This is the feed rate of all the feed rolls and idler rolls. A different value may be specified for each
of the four run modes.
Units of Measure Adjustment Size Minimum Value Maximum Value Default Value
Feet / Min. 1 50 175 N/A
2 Flail #1 Down RPM

This set point is the rotational speed of flail #1 when flail #2 is lowered all the way. The speed of
flail #1 varies between this value and the “Flail #1 Up RPM” depending on the height of flail #2. A
different value may be specified for each of the four run modes.
RPM 1 200 700 N/A
3 Flail #1 Up RPM
This set point is the rotational speed of flail #1 when flail #2 is raised all the way. The speed of
flail #1 varies between this value and the “Flail #1 Down RPM” depending on the height of flail #2.
A different value may be specified for each of the four run modes. For more information see Flail
Tuning Optimization, p. 3-18.
RPM 1 200 700 N/A
4 Flail #2 Down RPM

This set point is the rotational speed of flail #2 when it is lowered all the way. The speed of flail
#2 varies between this value and the “Flail #2 Up RPM” depending on its height. A different value
may be specified for each of the four run modes. For more information see Flail Tuning
Optimization, p. 3-18.
RPM 1 200 700 N/A

5 Flail #2 Up RPM
This set point is the rotational speed of flail #2 when it is raised all the way. The speed of flail #2
varies between this value and the “Flail #2 Down RPM” depending on its height. A different value
RPM 1 200 700 N/A
6 Flail #3 Down RPM

This set point is the rotational speed of flail #3 when it is lowered all the way. The speed of flail
#3 varies between this value and the “Flail #3 Up RPM” depending on its height. A different value
RPM 1 200 700 N/A
7 Flail #3 Up RPM
This set point is the rotational speed of flail #3 when it is raised all the way. The speed of flail #3
varies between this value and the “Flail #3 Down RPM” depending on its height. A different value
RPM 1 200 700 N/A
8 Flail #4 Down RPM

This set point is the rotational speed of flail #4 when flail #3 is lowered all the way. The speed of
flail #4 varies between this value and the “Flail #4 Up RPM” depending on the height of flail #3. A
different value may be specified for each of the four run modes. For more information see Flail
RPM 1 200 700 N/A
9 Flail #4 Up RPM
This set point is the rotational speed of flail #4 when flail #3 is raised all the way. The speed of
flail #4 varies between this value and the “Flail #4 Down RPM” depending on the height of flail #3.
A different value may be specified for each of the four run modes. For more information see Flail
RPM 1 200 700 N/A
10 Flail #1 Direction
This set point is the rotational direction of flail #1 as observed when looking at the right side of the
machine when the specified run mode is selected. A different value may be specified for each of
the four run modes.
Clockwise /
N/A N/A N/A N/A
Counterclockwise

the four run modes.
Clockwise /
N/A N/A N/A N/A
Counterclockwise
the four run modes.
Clockwise /
N/A N/A N/A N/A
Counterclockwise
the four run modes.
Clockwise /
N/A N/A N/A N/A
Counterclockwise
14 Top Roll #1 Float Pressure

This set point is the amount of pressure applied to the lift cylinders for top roll #1 which allows the
feed roll to rise with less effort (float) when being fed. A different value may be specified for each
of the four run modes. For more information see Top Roll Rapid Lift, p. 3-18.
PSI / BAR /1 /0 / 35 N/A
15 Top Roll #2 Float Pressure

This set point is the amount of pressure applied to the lift cylinders for top roll #2 which allows the
feed roll to rise with less effort (float) when being fed. A different value may be specified for each
of the four run modes. For more information see Top Roll Rapid Lift, p. 3-18.
PSI / BAR /1 /0 / 35 N/A
16 Flail #2 Movement Limit

This set point is the the relative lift height of flail #2 in relation to the top feed roll; flail #2 will be
lifted to this percentage of the current top feed roll height. A different value may be specified for
each of the four run modes. For more information see Flail Tuning Optimization, p. 3-18.
% 1 0 100 N/A
17 Flail #3 Movement Limit

This set point is the the relative lift height of flail #3 in relation to the top feed roll; flail #3 will be
lifted to this percentage of the current top feed roll height. A different value may be specified for
each of the four run modes. For more information see Flail Tuning Optimization, p. 3-18.
% 1 0 100 N/A

18 Push-out Ram Interval Set-point

This set point is the amount of time between automated waste discharge cycles. A different
value may be specified for each of the four run modes. For more information see Debris Purge
Control, p. 3-18.
Sec. 1 0 30 N/A
19 Big Bush Busting Dwell

This set point is the amount of time (duration) that the busts last where the feeds will stop and the
flails will rotate at their maximum speed when big bush busting mode is enabled.. A different
value may be specified for each of the four run modes. For more information see Big-Bush-
Busta, p. 3-18.
Sec. 1 1 60 N/A
20 Big Bush Busting Count Run

This set point is the amount of bursts where the feeds will stop and the flails will rotate at their
maximum speed when big bush busting mode is enabled. A different value may be specified for
each of the four run modes. For more information see Big-Bush-Busta, p. 3-18.
# 1 1 10 N/A
21 Big Bush Busting Pause Run

This set point is the amount of time in between bursts when big bush busting mode is enabled
and the “big bush busting count run” is set to greater than 1. A different value may be specified
for each of the four run modes. For more information see Big-Bush-Busta, p. 3-18.
Sec. 1 1 20 N/A

Flail Lift Tuning Adjust Menu

The Flail Lift Tuning Adjust Menu (Figure 50) can be accessed from the Run Settings Menu (p. 3-48)
or the Adjust System Menu (p. 3-107). Turn the “jog / shuttle” button to scroll through the available
setting is selected for adjustment use the “jog / shuttle” button to adjust the setting. Return to the “Flail
Lift Tuning Adjust Menu” by pressing the “escape button”. The following is a list of all the machine
settings that can be adjusted from the Flail Lift Tuning Adjust Menu along with a brief explanation of what
effect adjusting the settings will have.


Figure 50
1 Flail #2 Lift Start
This controls the rate at which flail #2 initially begins to rise from a static lowered position when it
starts rising to meet the material being fed into the machine. It is given in Percent command
supplied to the proportional electronic relief valve controlling the lift cylinders. The greater the
command, the higher the pressure, the quicker they lift. This set-point is meant as an initial burst
of pressure to get the flails from static to lifting. This value must always be greater than the “flail
#2 keep moving” setting. A different value may be specified for each of the four run modes. For
more information see Flail Tuning Optimization, p. 3-18.
% 1 0 100 N/A
2 Flail #2 Keep Moving

This controls the rate at which flail #2 rises when it is rising to meet the material being fed into the
machine. It is given in Percent command supplied to the proportional electronic relief valve
controlling the lift cylinders. The greater the command, the higher the pressure, the quicker they
lift. This set-point is meant as a controlled pressure that makes the flails rise at a constant rate
which is fast enough but not too fast. This value must always be greater than the “flail #2 hold”
setting but less than the “flail #2 lift start” setting. A different value may be specified for each of
the four run modes. For more information see Flail Tuning Optimization, p. 3-18.
% 1 0 100 N/A
3 Flail #2 Hold
This controls flail #2 as it holds in place when it has already rises to meet the material being fed
into the machine. It is given in Percent command supplied to the proportional electronic relief
valve controlling the lift cylinders. This set-point is meant as a neutral pressure that makes the
flails hold in place. The greater the command, the higher the pressure, too high will cause the
flails to unintentionally rise, too low will cause them to unintentionally fall. This value must always
be greater than the “flail #2 lower” setting but less than the “flail #2 keep moving” setting. A
% 1 0 100 N/A

4 Flail #2 Lower
This controls the rate at which flail #2 falls when it is lowering after material is done feeding
through the machine. It is given in Percent command supplied to the proportional electronic relief
valve controlling the lift cylinders. The lower the command, the lower the pressure, the quicker
they fall. This set-point is meant as a controlled pressure that makes the flails fall at a constant
rate which is fast enough but not too fast. This value must always be less than the “flail #2 hold”
setting. A different value may be specified for each of the four run modes. For more information
see Flail Tuning Optimization, p. 3-18.
% 1 0 100 N/A
5 Flail #3 Lift Start

This controls the rate at which flail #3 initially begins to rise from a static lowered position when it
starts rising to meet the material being fed into the machine. It is given in Percent command
supplied to the proportional electronic relief valve controlling the lift cylinders. The greater the
command, the higher the pressure, the quicker they lift. This set-point is meant as an initial burst
of pressure to get the flails from static to lifting. This value must always be greater than the “flail
#3 keep moving” setting. A different value may be specified for each of the four run modes. For
% 1 0 100 N/A
6 Flail #3 Keep Moving

This controls the rate at which flail #3 rises when it is rising to meet the material being fed into the
machine. It is given in Percent command supplied to the proportional electronic relief valve
controlling the lift cylinders. The greater the command, the higher the pressure, the quicker they
lift. This set-point is meant as a controlled pressure that makes the flails rise at a constant rate
which is fast enough but not too fast. This value must always be greater than the “flail #3 hold”
setting but less than the “flail #3 lift start” setting. A different value may be specified for each of
% 1 0 100 N/A
7 Flail #3 Hold
This controls flail #3 as it holds in place when it has already rises to meet the material being fed
into the machine. It is given in Percent command supplied to the proportional electronic relief
valve controlling the lift cylinders. This set-point is meant as a neutral pressure that makes the
flails hold in place. The greater the command, the higher the pressure, too high will cause the
flails to unintentionally rise, too low will cause them to unintentionally fall. This value must always
be greater than the “flail #3 lower” setting but less than the “flail #3 keep moving” setting. A
% 1 0 100 N/A

8 Flail #3 Lower
This controls the rate at which flail #3 falls when it is lowering after material is done feeding
through the machine. It is given in Percent command supplied to the proportional electronic relief
valve controlling the lift cylinders. The lower the command, the lower the pressure, and the
quicker the flails fall. This set-point is meant as a controlled pressure that makes the flails fall at
a constant rate which is fast enough but not too fast. This value must always be less than the
“flail #3 hold” setting. A different value may be specified for each of the four run modes. For
% 1 0 100 N/A
9 Flail #2 Max Hold Up CMD

This Controls the way that flail #2 is held in position when in standby mode. When material is not
being fed into the machine the flails are maintained at specified heights by pulsing the
proportional electronic relief valve controlling the lift cylinders on and off. This is the percent
command supplied to the valve when they are pulsed on. Having this value too high or low will
cause erratic flail movement when not being fed. A different value may be specified for each of
% 0.1 0 100 44.40
10 Flail #2 Down Limit Start Hold

This Controls the height that flail #2 is held in position at when in standby mode. When material
is not being fed into the machine the flails are maintained at specified heights by pulsing the
proportional electronic relief valve controlling the lift cylinders on and off. This is the minimum flail
height that the controller will keep the flails above by pulsing the valve on. A different value may
be specified for each of the four run modes. For more information see Flail Tuning Optimization,
p. 3-18.
inch 0.25 0.00 7.00 N/A
11 Flail #2 Down Limit Stop Hold

proportional electronic relief valve controlling the lift cylinders on and off. This is the maximum
flail height that the controller will keep the flails below by pulsing the valve off. A different value
inch 0.25 0.00 7.00 N/A
12 Flail #3 Max Hold Up CMD

This Controls the way that flail #3 is held in position when in standby mode. When material is not
being fed into the machine the flails are maintained at specified heights by pulsing the
proportional electronic relief valve controlling the lift cylinders on and off. This is the percent
command supplied to the valve when they are pulsed on. Having this value too high or low will
cause erratic flail movement when not being fed. A different value may be specified for each of
% 0.1 0 100 45.10

13 Flail #3 Down Limit Start Hold

proportional electronic relief valve controlling the lift cylinders on and off. This is the minimum flail
height that the controller will keep the flails above by pulsing the valve on. A different value may
be specified for each of the four run modes. For more information see Flail Tuning Optimization,
p. 3-18.
inch 0.25 0.00 7.00 N/A
14 Flail #3 Down Limit Stop Hold

proportional electronic relief valve controlling the lift cylinders on and off. This is the maximum
flail height that the controller will keep the flails below by pulsing the valve off. A different value
inch 0.25 0.00 7.00 N/A

Flail #1 Manual Operation Menu

Button Functions
The Flail #1 Manual Operation Menu (Figure 51) is used for manual control and displaying
parameters of flail #1. This Menu can be accessed from the Advanced Operation Menu (p. 3-44) by
pressing the “F3” button and then using the “jog shuttle button” to select “flail #1”. The purpose of this
section is to familiarize operators with button functions in the Flail #1 Manual Operation Menu.
Flail #1 Toggle
Press this button to toggle flail #1 on
and off.
Flails Toggle
Press this button to toggle the flails
on and off.
Next Menu
Figure 51
Previous Menu

screen.
screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
Image Parameter
Engine RPM
Page Number
This Image displays which sequentially
numbered page in the menu is being
manually controlled.
Flail #1
This Image displays that flail #1 is selected.
Figure 52
Output Command (mA)

This Image displays the output command in milliamps from the controller.
Hydraulic Motor Pressure

This Image displays the hydraulic pressure going to the motor.
Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled



Button Functions
Flail #2 Toggle
and off.
Flail #2 Up
Press and hold this button to raise
flail #2.
Flails Toggle
on and off.
Figure 53
Next Menu
Previous Menu

screen.
screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
The Flail #2 Manual Operation Menu (Figure 54) has various machine parameters displayed on it. In
following is a list of all the parameters in the Flail #2 Manual Operation Menu along with a brief
explanation of what they are.
Image Parameter
Engine RPM
Page Number
Flail #2
Figure 54
Output Command (mA)


Flail #2 Height
This Image displays the height of flail #2.
Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled



Button Functions
Flail #3 Toggle
and off.
Flail #3 Up
Press and hold this button to raise
flail #3.
Flails Toggle
on and off.
Figure 55
Next Menu
Previous Menu

screen.
screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
Image Parameter
Engine RPM
Page Number
Flail #3
Figure 56
Output Command (mA)


Flail #3 Height
This Image displays the height of flail #3.
Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled



Button Functions
Flail #4 Toggle
and off.
Flails Toggle
on and off.
Next Menu
Figure 57
Previous Menu

screen.
screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
Image Parameter
Engine RPM
Page Number
Flail #4
Figure 58
Output Command (mA)


Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Top Roll #1 Manual Operation Menu

Button Functions
The Top Roll #1 Manual Operation Menu (Figure 59) is used for manual control and displaying
parameters of the #1 Top Feed Roll. This Menu can be accessed from the Advanced Operation Menu (p.
3-44) by pressing the “F3” button and then using the “jog shuttle button” to select “top roll #1”. The
purpose of this section is to familiarize operators with button functions in the Top Roll #1 Manual
Operation Menu.
Top Roll #1 Forward
Press this button to toggle the #1
top feed roll on moving forward.
Top Roll #1 Reverse
Press this button to stop the #1 top
feed roll if it is moving. Hold this
button down to reverse the #1 top
feed roll.
Top Roll #1 Up
Press this button to raise the #1 top
feed roll. Figure 59
Top Roll #1 Down

Press this button to apply down pressure to the #1 top feed roll.
Feed Rolls Forward

Press this button to toggle all feed rolls on moving forward.
Next Menu
Previous Menu

screen.

screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
The Top Roll #1 Manual Operation Menu (Figure 60) has various machine parameters displayed on it.
In order to successfully use this menu it is critical that you fully understand the parameters displayed. The
following is a list of all the parameters in the Top Roll #1 Manual Operation Menu along with a brief
Image Parameter
Engine RPM
System Number
numbered system is being manually
controlled.
Top Feed Roll #1

This Image displays that the #1 top feed roll
is selected.
Figure 60
Output Command (mA)


This Image displays the pressure going to the hydraulic motor.
Top Feed Roll Position

This Image displays the height of the top feed roll.
Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Top Roll #2 Manual Operation Menu

Button Functions
The Top Roll #2 Manual Operation Menu (Figure 61) is used for manual control and displaying
parameters of the #2 Top Feed Roll. This Menu can be accessed from the Advanced Operation Menu (p.
3-44) by pressing the “F3” button and then using the “jog shuttle button” to select “top roll #2”. The
purpose of this section is to familiarize operators with button functions in the Top Roll #2 Manual
Operation Menu.
Top Roll #2 Forward

top feed roll on moving forward.
Top Roll #2 Reverse
Press this button to stop the #2 top
feed roll if it is moving. Hold this
button down to reverse the #2 top
feed roll.
Top Roll #2 Up
Press this button to raise the #1 top
feed roll. Figure 61
Top Roll #2 Down

Press this button to apply down pressure to the #1 top feed roll.
Feed Rolls Forward

Press this button to toggle all feed rolls on moving forward.
Next Menu
Previous Menu

screen.
screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
The Top Roll #2 Manual Operation Menu (Figure 62) has various machine parameters displayed on it.
In order to successfully use this menu it is critical that you fully understand the parameters displayed. The
following is a list of all the parameters in the Top Roll #2 Manual Operation Menu along with a brief
Image Parameter
Engine RPM
System Number
controlled.
Top Feed Roll #2

This Image displays that the #2 top feed roll
is selected.
Figure 62
Output Command (mA)

Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Bottom Roll #1 Manual Operation Menu

Button Functions
The Bottom Roll #1 Manual Operation Menu (Figure 63) is used for manual control and displaying
parameters of the #1 Bottom Feed Roll. This Menu can be accessed from the Advanced Operation Menu
(p. 3-44) by pressing the “F3” button and then using the “jog shuttle button” to select “bottom roll #1”. The
purpose of this section is to familiarize operators with button functions in the Bottom Roll #1 Manual
Operation Menu.
Bottom Roll #1 Forward

bottom feed roll on moving forward.
Bottom Roll #1 Reverse
Press this button to stop the #1
bottom feed roll if it is moving. Hold
this button down to reverse the #1
bottom feed roll.
Feed Rolls Forward
Press this button to toggle all feed
rolls on moving forward. Figure 63
Feed Rolls Reverse

Press this button to stop all feed rolls if they are moving. Hold this button down to
reverse all feed rolls.
Next Menu
Previous Menu

screen.

screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
The Bottom Roll #1 Manual Operation Menu (Figure 64) has various machine parameters displayed
on it. In order to successfully use this menu it is critical that you fully understand the parameters
displayed. The following is a list of all the parameters in the Bottom Roll #1 Manual Operation Menu
along with a brief explanation of what they are.
Image Parameter
Engine RPM
System Number
controlled.
Bottom Feed Roll #1

This Image displays that the #1 bottom feed
roll is selected.
Figure 64
Output Command (mA)

Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled



Button Functions
Operation Menu.

bottom feed roll.
Feed Rolls Forward
Feed Rolls Reverse

Next Menu
Previous Menu

screen.

screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
Image Parameter
Engine RPM
System Number
controlled.
Bottom Feed Roll #2

roll is selected.
Figure 66
Output Command (mA)


Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled



Button Functions
Operation Menu.

bottom feed roll.
Feed Rolls Forward
Feed Rolls Reverse

Next Menu
Previous Menu

screen.

screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
Image Parameter
Engine RPM
System Number
controlled.
Bottom Feed Roll #3

roll is selected.
Figure 68
Output Command (mA)


Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Idler Roll #1 Manual Operation Menu

Button Functions
The Idler Roll #1 Manual Operation Menu (Figure 69) is used for manual control and displaying
parameters of the #1 Idler Roll. This Menu can be accessed from the Advanced Operation Menu (p. 3-
44) by pressing the “F3” button and then using the “jog shuttle button” to select “Idler roll #1”. The purpose
of this section is to familiarize operators with button functions in the Idler Roll #1 Manual Operation Menu.
Idler Roll #1 Forward

idler roll on moving forward.
Idler Roll #1 Reverse

Press this button to stop the #1 idler
roll if it is moving. Hold this button
down to reverse the #1 idler roll.
Idler Rolls Forward

Press this button to toggle all idler
Idler Rolls Reverse

Press this button to stop all idler rolls if they are moving. Hold this button down to
reverse all idler rolls.
Next Menu
Previous Menu

screen.

screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
The Idler Roll #1 Manual Operation Menu (Figure 70) has various machine parameters displayed on
it. In order to successfully use this menu it is critical that you fully understand the parameters displayed.
The following is a list of all the parameters in the Idler Roll #1 Manual Operation Menu along with a brief
Image Parameter
Engine RPM
System Number
controlled.
Idler Roll #1
This Image displays that the #1 idler roll is
selected.
Figure 70
Output Command (mA)

Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled



Button Functions


Idler Rolls Forward

Idler Rolls Reverse

Next Menu
Previous Menu

screen.

screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
Image Parameter
Engine RPM
System Number
controlled.
Idler Roll #2
selected.
Figure 72
Output Command (mA)

Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled



Button Functions


Idler Rolls Forward

Idler Rolls Reverse

Next Menu
Previous Menu

screen.

screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
Image Parameter
Engine RPM
System Number
controlled.
Idler Roll #3
selected.
Figure 74
Output Command (mA)

Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled



Button Functions


Idler Rolls Forward

Idler Rolls Reverse

Next Menu
Previous Menu

screen.

screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
Image Parameter
Engine RPM
System Number
controlled.
Idler Roll #4
selected.
Figure 76
Output Command (mA)

Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Push Out Ram Manual Operation Menu

Button Functions
The Push Out Ram Manual Operation Menu (Figure 77) is used for manual control and displaying
parameters of the push out ram. This Menu can be accessed from the Advanced Operation Menu (p. 3-
44) by pressing the “F3” button and then using the “jog shuttle button” to select “Push Out Ram”. The
purpose of this section is to familiarize operators with button functions in the Push Out Ram Manual
Operation Menu.
Plunger Out Of Machine
This button extends the waste
discharge plunger into the support
frame.
Plunger Into Machine

This button retracts the waste
discharge plunger into the flail
chamber.
Fold Up
This button folds the plunger support
frame up. Figure 77
⚠WARNING: Ensure plunger is fully retracted into the flail chamber for moving the
support frame. Failure to comply may result in severe equipment damage!
Fold Down
This button folds the plunger support frame down.
Next Menu
Previous Menu

screen.
screen.
No Image

Escape Button
System menu
No Image
module information.
Display Parameters
The Push Out Ram Manual Operation Menu (Figure 78) has various machine parameters displayed
displayed. The following is a list of all the parameters in the Push Out Ram Manual Operation Menu
Image Parameter
Engine RPM
System Number
controlled.
Push Out Ram

This Image displays that the push out ram is
selected.
Figure 78
Output Command (mA)

Hydraulic Cylinder Pressure

This Image displays the pressure in the hydraulic cylinder.
Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Out Riggers Loader Manual Operation Menu

Button Functions
The Out Riggers Loader Manual Operation Menu (Figure 79) is used for manual control and
displaying parameters of the Loader end outriggers. This Menu can be accessed from the Advanced
Operation Menu (p. 3-44) by pressing the “F3” button and then using the “jog shuttle button” to select “Out
Riggers Loader”. The purpose of this section is to familiarize operators with button functions in the Out
Riggers Loader Manual Operation Menu.
Raise Left Rear Outrigger
rear outrigger.
Lower Left Rear Outrigger

rear outrigger.
Raise Right Rear Outrigger

rear outrigger.
Figure 79
Lower Right Rear Outrigger

Press this button to lower the right rear outrigger.
Next Menu
Previous Menu
screen.
screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
The Out Riggers Loader Manual Operation Menu (Figure 80) has various machine parameters
displayed on it. In order to successfully use this menu it is critical that you fully understand the
parameters displayed. The following is a list of all the parameters in the Out Riggers Loader Manual
Operation Menu along with a brief explanation of what they are.
Image Parameter
Engine RPM
System Number
controlled.
Loader End Outriggers

This Image displays that the loader end
outriggers are selected.
Figure 80
Output Command (O/I)

This Image displays the output command (on: “I” / off: “O”) from the controller.
Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Out Riggers King Pin Manual Operation Menu

Button Functions
The Out Riggers King Pin Manual Operation Menu (Figure 81) is used for manual control and
displaying parameters of the king pin end outriggers. This Menu can be accessed from the Advanced
Operation Menu (p. 3-44) by pressing the “F3” button and then using the “jog shuttle button” to select “Out
Riggers King Pin”. The purpose of this section is to familiarize operators with button functions in the Out
Riggers King Pin Manual Operation Menu.
Raise Left Front Outrigger
front outrigger.
Lower Left Front Outrigger

front outrigger.
Raise Right Front Outrigger

front outrigger.
Figure 81
Lower Right Front Outrigger

Press this button to lower the right front outrigger.
Next Menu
Previous Menu
screen.
screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
The Out Riggers King Pin Manual Operation Menu (Figure 82) has various machine parameters
displayed on it. In order to successfully use this menu it is critical that you fully understand the
parameters displayed. The following is a list of all the parameters in the Out Riggers King Pin Manual
Operation Menu along with a brief explanation of what they are.
Image Parameter
Engine RPM
System Number
controlled.
King Pin End Outriggers

This Image displays that the king pin end
outriggers are selected.
Figure 82

Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Flail Box Door Manual Operation Menu

Button Functions
The Flail Box Door Manual Operation Menu (Figure 83) is used for manual control and displaying
parameters of the flail chamber access hatch. This Menu can be accessed from the Advanced Operation
Menu (p. 3-44) by pressing the “F3” button and then using the “jog shuttle button” to select “Flail Box
Door”. The purpose of this section is to familiarize operators with button functions in the Flail Box Door
Manual Operation Menu.
Open Flail Chamber Access Hatch
Press this button to open the flail
chamber access hatch.
⚠WARNING: Never operate this
valve if the flails are running; failure
to comply may result in severe injury
or equipment damage!
Close Flail Chamber Access Hatch
Press this button to close the flail
chamber access hatch.
Next Menu
Press this button to display the next Figure 83
Previous Menu
screen.
screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
The Flail Box Door Manual Operation Menu (Figure 84) has various machine parameters displayed
displayed. The following is a list of all the parameters in the Flail Box Door Manual Operation Menu along
with a brief explanation of what they are.
Image Parameter
Engine RPM
System Number
controlled.
Flail Access Hatch

This Image displays that the flail access
hatch is selected.
Figure 84

Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Engine Manual Operation Menu

Button Functions
The Engine Manual Operation Menu (Figure 85) is used for manual control and displaying parameters
of the engine. This Menu can be accessed from the Advanced Operation Menu (p. 3-44) by pressing the
“F3” button and then using the “jog shuttle button” to select “Engine”. The purpose of this section is to
familiarize operators with button functions in the Engine Manual Operation Menu.
Engine Fast
engine up.
Engine Slow
down.
Next Menu
menu in the sequence. Figure 85
Previous Menu

screen.
screen.
No Image
Escape Button
System menu
No Image
module information.

Display Parameters
The Engine Manual Operation Menu (Figure 86) has various machine parameters displayed on it. In
following is a list of all the parameters in the Engine Manual Operation Menu along with a brief
Image Parameter
Engine RPM
System Number
controlled.
Engine
This Image displays that the engine is
selected.
Figure 86
Output Command (N/A)

This Image displays the output command which is not available, disregard this.
Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Engine Menu
Button Functions
The Engine Menu (Figure 87) is used for controlling the engine and displaying engine operating data.
This Menu can be accessed from the Advanced Operation Menu (p. 3-44) by pressing the”F4” button. The
purpose of this section is to familiarize operators with button functions in the Engine Menu.
Engine Fast
engine up.
Engine Slow
down.
Fuel Consumption Menu
fuel consumption menu.
Next Menu
Press this button to display the next Figure 87
Previous Menu

screen.
screen.
Escape Button
System menu
No Image
module information.

Display Parameters
The Engine Menu (Figure 88) has various machine parameters displayed on it. In order to
is a list of all the parameters in the Engine Menu along with a brief explanation of what they are.
Image Parameter
This displays the engine coolant
temperature.
Engine Oil Pressure
This image displays the engine oil pressure.
Turbo Boost Pressure

This Image displays turbo boost pressure.
This displays the CAT engine diagnostic
lamps. For detailed information consult
your CAT engine manual. Figure 88
Engine RPM
Engine Percent Load
This Image displays percent of maximum load the engine is currently under.
Battery Voltage
This Image displays the battery voltage.
Engine Hours
Fuel Temperature
This Image displays the fuel temperature.
Fuel Consumption
This Image displays the instantaneous fuel consumption rate.
Fuel Pressure
This Image displays the current fuel pressure.
Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Cooling System Menu

Button Functions
The Cooling System Menu (Figure 89) is used for controlling the cooling system functions on your
machine. This Menu can be accessed from the Advanced Operation Menu (p. 3-44) by pressing the “F5”
button. The purpose of this section is to familiarize operators with button functions in the Cooling System
Menu.
Hydraulic Cooling System Purge

Press this button to initiate a
momentary hydraulic cooling system
fan purge.
Cooling system adjust menu
cooling system adjust menu.
Engine Cooling System Purge
Press this button to initiate a
momentary engine cooling system
fan purge.
Next Menu
Figure 89
Previous Menu

screen.
screen.
Escape Button
System menu
No Image
module information.

Display Parameters
Image Parameter
Hydraulic Oil Temperature
This Image displays the hydraulic oil
temperature.
Hydraulic cooling enable temperature
This Image displays the minimum hydraulic
oil temperature for hydraulic cooling
functions to be enabled.
Hydraulic fan purge Time
This Image displays the amount of time an
automated hydraulic cooling fan purge cycle
lasts. Figure 90
Hydraulic Fan Cooling time
This Image displays the amount of time between automated purge cycles of the hydraulic
cooling fan.

This Image displays the engine coolant temperature.
Engine Cooling Enable Temperature

This Image displays the minimum engine coolant temperature for engine fan cooling functions
to be enabled.
Engine fan purge Time

This Image displays the amount of time an automated engine cooling fan purge cycle lasts.
Engine Fan Cooling time

This Image displays the amount of time between automated purge cycles of the engine
cooling fan.
Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Cooling System Adjust Menu

The Cooling System Adjust Menu (Figure 91) can be accessed from the Cooling System Menu (p. 3-
96) or the Adjust System Menu (p. 3-107). Turn the “jog / shuttle” button to scroll through the available
setting is selected for adjustment use the “jog / shuttle” button to adjust the setting. Return to the Cooling
System Adjust Menu by pressing the “escape button”. The following is a list of all the machine settings
that can be adjusted from the Cooling System Adjust Menu along with a brief explanation of what effect
adjusting the settings will have.


Figure 91
1 Hydraulic Cooling Purge Time
The time interval (in seconds) that the automated hydraulic cooler fan purge cycle lasts. During
this time the fan pushes air (reverse) to purge debris out of the hydraulic cooler. For more
information see Automatic Hydraulic Cooler Purge, p. 3-19.
Seconds 1 0 20 15
2 Hydraulic Cooling Interval

The time interval (in minutes) in between automated hydraulic cooling system fan purge cycles.
During this time the fan pulls air (forward) to cool down the hydraulics. For more information see
Automatic Hydraulic Cooler Purge, p. 3-19.
Minutes 1 0 20 15
3 Hydraulic Cooling Enable Temperature

This temperature is the minimum temperature that the hydraulic oil must be at for the cooling fan
functions to be engaged. This set point can be used to get the hydraulic system up to operating
temperature quicker. For more information see Automatic Hydraulic Cooler Purge, p. 3-19.
°F / °C 1 32 / 0 150 / 65 120 / 35
4 Radiator purge time

The time interval (in seconds) that an engine cooling system fan purge cycle lasts. During this
time the fan pushes air (backward) to purge any debris from the radiator. For more information
see Automatic Radiator Purge, p. 3-19.
Seconds 1 0 30 10

5 Radiator Interval time

The time interval (in minutes) in between automated engine cooling system fan purge cycles.
During this time the fan pulls air (forward) to cool down the engine. For more information see
Automatic Radiator Purge, p. 3-19.
Minutes 1 5 30 17
6 Cooling Enable Temperature

This temperature is the minimum temperature that the engine must be at for the cooling fan
functions to be engaged. This set point can be used to get the engine up to operating
temperature quicker. For more information see Automatic Radiator Purge, p. 3-19.
°F / °C 1/1 0/0 225 / 107 120 / 83

Flail Power Menu

Button Functions
The Flail Power Menu (Figure 92) is used for displaying flail operating and performance data. This
Menu can be accessed from the Advanced Operation Menu (p. 3-44) by pressing the ”C” button and then
the “A” button. The purpose of this section is to familiarize operators with button functions in the Flail
Power Menu.
Next Menu
Previous Menu
Press this button to display the
Previous menu in the sequence.
Press this button to toggle between
service and auto mode.
⚠NOTICE: Confirmation of mode
selection is highlighted in the top left Figure 92
corner of the screen.
screen.
Escape Button
System menu
No Image

Display Parameters
The Flail Power Menu (Figure 93) has various machine parameters displayed on it. In order to
is a list of all the parameters in the Flail Power Menu along with a brief explanation of what they are.
Image Parameter
Flail #1
This Image displays that Flail
#1 is selected.
Flail #2
#2 is selected.
Flail #3
#3 is selected.
Flail #4
This Image displays that Flail Figure 93
#4 is selected.
Flail Hydraulic Pressure
This displays the hydraulic pressure in the associated flail.
Flail Power
This Image displays the current power output of the associated flail.
Flail Power Limit

This Image displays the maximum power limit of the associated flail.
Total Power
This displays the total cumulative power output of all the flails combined.
Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Link Mode Menu

Button Functions
The Link Mode Menu (Figure 94) is used for controlling and displaying the status of the link between
the two machines. This Menu can be accessed from the Advanced Operation Menu (p. 3-44) by pressing
the “F4” button, then hitting the “F3” button, and then hitting the “B” button. The purpose of this section is
to familiarize operators with button functions in the Link Mode Menu.
Link Mode Reset

Press this button to reset the link
between the two machines.
Link Mode Cancel

Press this button to cancel the link
between the two machines.
Next Menu
Previous Menu Figure 94

Press this button to display the
Previous menu in the sequence.
screen.
screen.
Escape Button
System menu
No Image

Display Parameters
The Link Mode Menu (Figure 95) has various machine parameters displayed on it. In order to
is a list of all the parameters in the Link Mode Menu along with a brief explanation of what they are.
Image Parameter
Link Mode Reception Quality
This Image displays the quality of the signal
being received from the other machine.
Link Mode Signal Strength
This Image displays the strength of the
signal being received from the other
machine.
Flail Link Mode Status
This Image displays the status of the flail in
link mode. Green is enabled and red is
canceled. Figure 95
Chipper Link mode Status
This Image displays the status of the disc chipper in link mode. Green is enabled and red is
canceled.
Local Auto Mode

Local Service Mode

Radio Auto Mode

Radio Service Mode

Link Mode enabled

Link mode disabled


Fuel Consumption Menu

Button Functions
The Fuel Consumption Menu (Figure 96) is used for displaying information about the machines fuel
consumption. This Menu can be accessed from the Advanced Operation Menu (p. 3-44) by pressing the
“F4” button and then pressing the “F3” button. The purpose of this section is to familiarize operators with
button functions in the Fuel Consumption Menu.
Reset Fuel Consumption Average

Press this button to reset the fuel
consumption running, hourly, and
daily average.
Start Fuel Consumption Average
Press this button to start recording
the fuel consumption running,
hourly, and daily average.
Stop Fuel Consumption Average

Press this button to stop recording
the fuel consumption running,
hourly, and daily average. Figure 96
Record Daily Fuel Consumption Averages

Press this button to record the current fuel consumption information to the system log.
View Daily Fuel Consumption Log

Press this button to navigate to the fuel consumption system log.
Next Menu
Previous Menu

screen.
screen.
Escape Button
System menu
No Image
module information.

Display Parameters
The Fuel Consumption Menu (Figure 97) has various machine parameters displayed on it. In order to
is a list of all the parameters in the Fuel Consumption Menu along with a brief explanation of what they
are.
Image Parameter
Local Auto Mode
Local Service Mode

Radio Auto Mode

Figure 97
Radio Service Mode

Link Mode enabled

Link mode disabled

Fuel Consumption Rate

This Image displays the instantaneous fuel consumption rate.
Fuel Consumption Running Average

This Image displays the current running average fuel consumption.
Fuel Consumption Hourly Average
This Image displays a consecutive list of hourly fuel consumptions for the previous 12 hours
they were recorded.
Fuel Consumption Daily Average
This Image displays the average fuel consumption rate for an 8 hour interval.

Main System Menu

Button Functions
The Main System Menu (Figure 98) is used for accessing the other system menus which are used for
adjusting settings, measuring inputs/outputs, changing preferences, or viewing system information. This
Menu can be accessed from the Advanced Operation Menu (p. 3-44) by pressing the “system menu”
button. The purpose of this section is to familiarize operators with button functions in the Main System
Menu.
Adjust System Menu

adjust system menu.
Measure System Menu
measure system menu.
Preferences System Menu
preferences system menu.
Info System Menu
Press this button to navigate to the Figure 98
info system menu.
Return Button
None Press this button once to return to the previous menu you were at; press it repeatedly
system menu button

None Press this button to return to the previous user menu you were at when the system
menu was accessed.

Adjust System Menu

Button Functions
The Adjust System Menu (Figure 99) is used for accessing and adjusting machine program settings.
This Menu can be accessed from the Advanced Operation Menu (p. 3-44) by pressing the “system menu”
button, and then pressing the “F1” button. The purpose of this section is to familiarize operators with
button functions in the Adjust System Menu.

Main System Menu
main system menu.
Turn this knob to scroll through
different items on the screen. Press
this button to confirm that the
highlighted item is the desired
selection.
⚠NOTICE: If the “jog/shuttle” button
is turned, all other control panel
buttons are deactivated as a safety
feature until a selection is confirmed Figure 99
by pressing the “jog/shuttle” button.
Return Button
system menu button
Press this button to return to the previous user menu you were at when the system
menu was accessed.

Measure System Menu

Button Functions
The Measure System Menu (Figure 100) is used for viewing control panel inputs and outputs, and
displaying machine performance logs. This Menu can be accessed from the Advanced Operation Menu
(p. 3-44) by pressing the “system menu” button, and then pressing the “F2” button. The purpose of this
section is to familiarize operators with button functions in the Measure System Menu.

Main System Menu
main system menu.
Turn this knob to scroll through
different items on the screen. Press
this button to confirm that the
highlighted item is the desired
selection.
⚠NOTICE: If the “jog/shuttle” button
is turned, all other control panel
buttons are deactivated as a safety
feature until a selection is confirmed Figure 100
by pressing the “jog/shuttle” button.
Return Button
system menu button
Press this button to return to the previous user menu you were at when the system
menu was accessed.

Preferences System Menu

Button Functions
The Preferences System Menu (Figure 101) is used for viewing and changing controller setup
preferences such as language and backlighting. This Menu can be accessed from the Advanced
Operation Menu (p. 3-44) by pressing the “system menu” button, and then pressing the “F3” button. The
purpose of this section is to familiarize operators with button functions in the Preferences System Menu.

Main System Menu
main system menu.
Date / Time
Press this button to edit the time
and date settings in the controller.
Display
Press this button to edit the display
settings in the controller.
Figure 101
Language
Press this button to edit the language settings in the controller.
Return Button
system menu button
menu was accessed.

Info System Menu

Button Functions
The Info System Menu (Figure 102) is used for viewing machine and component specific information
as well as performance logs. This Menu can be accessed from the Advanced Operation Menu (p. 3-44)
by pressing the “system menu” button, and then pressing the “F3” button. The purpose of this section is to
familiarize operators with button functions in the Info System Menu.

Main System Menu
main system menu.
Modules
Press this button view module
specific information.
Modem
Press this button to view information
on the machines modem (if fitted).
Figure 102
Logs
Press this button to view logs of select machine performance data.

Return Button
system menu button
menu was accessed.

Feed Offset Adjust Menu

The Feed Offset Adjust Menu (Figure 103) can be selected in the Adjust System Menu (p. 3-107).
This menu is used for adjusting the controller’s output commands for individual feed components and to
calibrate feed rates. Turn the “jog / shuttle” button to scroll through the available settings and press the
“jog / shuttle” button to select the highlighted setting for adjustment. Once a setting is selected for
adjustment use the “jog / shuttle” button to adjust the setting. Return to the Feed Offset Adjust Menu by
pressing the “escape button”. The following is a list of all the machine settings that can be adjusted from
the Feed Offset Adjust Menu along with a brief explanation of what effect adjusting the settings will have.


Figure 103
1 Idler Roll Rate Offset
The Idler roll rate offset is the correction factor the controller uses to calculate the speed of all
four idler rolls as a function of current supplied to the variable displacement pump that drives
them.
No Units 0.01 0 2 1.00
2 #1 Top Roll Rate Offset

The Top roll rate offset is the correction factor the controller uses to calculate the speed of the top
feed rolls as a function of current supplied to the variable displacement pumps that drives them.
No Units 0.01 0 2 0.65
3 Bottom Roll #1 Rate Offset

The bottom roll #1 rate offset is the correction factor the controller uses to calculate the speed of
the #1 bottom feed roll as a function of current supplied to the variable displacement pump that
drives it.
No Units 0.01 0 2 0.34
4 Bottom Roll #2 & #3 Rate Offset

The bottom roll #2 & #3 rate offset is the correction factor the controller uses to calculate the
speed of the #2 & #3 bottom feed rolls as a function of current supplied to the variable
displacement pumps that drives them.
No Units 0.01 0 2 0.37

5 #1 Top CMD Limit

The Infeed top CMD limit is the maximum percent command that will be supplied to the pump for
the infeed top feed roll when the machine feed rates are set to run at maximum speed.
% 1 0 100 100
6 #3 Bottom CMD Limit

The Exit Bottom CMD limit is the maximum percent command that will be supplied to the pump
for the Exit Bottom feed roll when the machine feed rates are set to run at maximum speed.
% 1 0 100 86
7 #2 Top CMD Limit

The Exit top CMD limit is the maximum percent command that will be supplied to the pump for
the Exit top feed roll when the machine feed rates are set to run at maximum speed.
% 1 0 100 100

The Infeed bottom CMD limit is the maximum percent command that will be supplied to the pump
for the infeed bottom feed roll when the machine feed rates are set to run at maximum speed.
% 1 0 100 86

The Middle Bottom CMD limit is the maximum percent command that will be supplied to the pump
for the Middle Bottom feed roll when the machine feed rates are set to run at maximum speed.
% 1 0 100 100
10 Idler Max CMD

The Idler Max CMD limit is the maximum percent command that will be supplied to the pump for
the idler rolls when the machine feed rates are set to run at maximum speed.
% 1 0 100 100
11 Idler Min CMD

The Idler Min CMD limit is the minimum percent command that will be supplied to the pump for
the idler rolls when the machine feed rates are set to run at their minimum speed.
% 1 0 100 0

Idler Output Adjust Menu

The Idler Output Adjust Menu (Figure 104) can be selected in the Adjust System Menu (p. 3-107).
This menu is used for adjusting the controller’s output commands for individual idler rolls. Turn the “jog /
shuttle” button to scroll through the available settings and press the “jog / shuttle” button to select the
highlighted setting for adjustment. Once a setting is selected for adjustment use the “jog / shuttle” button
to adjust the setting. Return to the Idler Output Adjust Menu by pressing the “escape button”. The
following is a list of all the machine settings that can be adjusted from the Idler Output Adjust Menu along
with a brief explanation of what effect adjusting the settings will have.


Figure 104
1 Idler Roll #4 Min
The “Idler roll #4 Min” adjustment is the minimum current (in milliamps) that will be supplied to the
valve for idler roll #4 when the machine is supplying 0% command.
mA 1 0 440 360
2 Idler Roll #4 Max

The “Idler roll #4 Max” adjustment is the maximum current (in milliamps) that will be supplied to
the valve for idler roll #4 when the machine is supplying 100% command.
mA 1 360 1500 440
3 Idler Roll #4 Start

The “Idler roll #4 Start” adjustment is the amount of time (in milliseconds) that is takes the
controller to give the valve full command when idler roll #4 is started.
mS 1 0 1000 0
4 Idler Roll #4 Stop

The “Idler roll #4 Stop” adjustment is the amount of time (in milliseconds) that is takes the
controller to give the valve zero command when idler roll #4 is stopped.
mS 1 0 1000 0
5 Idler Roll #1 Min

mA 1 0 440 360

6 Idler Roll #1 Max

mA 1 360 1500 440

mS 1 0 1000 0

mS 1 0 1000 0
9 Idler Roll #2 Min

mA 1 0 440 360
10 Idler Roll #2 Max

mA 1 360 1500 440
mS 1 0 1000 0

mS 1 0 1000 0
13 Idler Roll #3 Min

mA 1 0 440 360

14 Idler Roll #3 Max

mA 1 360 1500 440

mS 1 0 1000 0

mS 1 0 1000 0

3-116 OPERATION - OPTIONAL EQUIPMENT PN 71510013 - OMM015008130510
Optional Equipment
Introduction
Your CBI equipment may be outfitted with optional equipment. The purpose of this section is to
familiarize the operator with basic operations of the optional equipment.
INFO: Always consult the OEM manuals for detailed product information; see Supplemental Manuals,
p. 1-4.
Gas Powered Air Compressor

The machine may be equipped with an optional air compressor. The compressor can be used for
cleaning debris off the machine or driving air powered service tools. The compressor is powered by its
own gas engine. The purpose of this section is to familiarize operators with the most basic operation of
the air compressor, for more detailed product information see Supplemental Manuals, p. 1-4.
INFO: Always consult the OEM manuals for detailed product information; see Supplemental Manuals,
p. 1-4.
⚠WARNING: Flying debris propelled by compressed air can be hazardous. Ensure sufficient precautions
are taken to protect personnel.
⚠WARNING: The exhaust gases contain carbon monoxide, which may cause unconsciousness or death.
Never start the machine in an enclosed space and always ensure sufficient ventilation.
⚠NOTICE: Never operate the engine with its storage enclosure sealed. Always provide sufficient venting
for heat and combustion gasses.
Starting (electric):
The following steps are for starting the air compressor engine using the electric starter motor.
1 Open the Fuel Valve
Open the fuel valve (Figure 105 / E).
2 Turn Choke On
Turn the choke lever (Figure 105 / A).to the open
position.
3 Turn ignition to “start”
Insert the key into the ignition (Figure 105 / C) and
hold it in the “START” position. Release the key as
soon as the engine is running.
4 Turn Choke off

Once the engine is running, switch the choke lever
(Figure 105 / A) to the closed position. Colder
temperatures require more time running with the
choke open and warmer temperatures requires less.
Figure 105
5 Throttle Engine Up
Once the engine has warmed up, move the throttle lever (Figure 105/ B) to the fully open position.
Starting (manual):
The following steps are for starting the air compressor engine manually using the pull starter. This
system serves as a backup in case the electric starting system fails.
1 Open the Fuel Valve
Open the fuel valve (Figure 105 / E).
2 Turn Choke On
Turn the choke lever (Figure 105 / A).to the open position.
3 Turn ignition to “Run”
Insert the key into the ignition (Figure 105 / C) and turn it to the “RUN” position.

PN 71510013 - OMM015008130510 OPERATION - OPTIONAL EQUIPMENT 3-117
4 Pull the Starter Cord

Pull the starter cord (Figure 105 / D) until you feel resistance, allow the cord to retract and then pull
quickly. Repeat until the engine starts and then return the starter cord to retracted position. If the
engine will not start, please refer to Trouble Shooting, p. 3-36
5 Turn Choke off
Once the engine has started switch the choke lever (Figure 105 / A) to the closed position. Colder
temperatures require more time running with the choke open and warmer temperatures requires less.
6 Throttle Engine Up
Once the engine has warmed up, move the throttle lever (Figure 105 / B) to the fully open position.
Shutting Down:
The following steps are for shutting down the water pump.
1 Idle Engine down
Move the throttle lever (Figure 105 / B) to the fully closed (idle) position.
2 Turn ignition off
Turn The Ignition switch (Figure 105 / C) to the “OFF” position; the engine will stop. Remove the key
and store it properly.
3 Close the Fuel valve
Move the fuel valve (Figure 105 / E).to the closed position.
4 Bleed the tank
Loosen the drain valve on the bottom of the air tank to relieve residual pressure and drain
condensation built up from use.
Compressor Quick Connect Couplings:

The following steps are using the quick connect airline fittings used on the compressor
1 Inspect Couplings
Before use, check both quick-connect couplings
(Figure 106 / A & B) for debris or damage.
Clean or replace as needed.
2 Connect Coupling
Insert the male quick-connect coupler for the air
hose (Figure 106 / B) into the female quick-
connect coupling for the compressor (Figure 106
/ A).
Figure 106

3-118 OPERATION - OPTIONAL EQUIPMENT PN 71510013 - OMM015008130510
Work Light Control Box

The work lights have their own control box (Figure 107) located near the main control panel. This
control box is used for turning the work lights on and off. The purpose of this section is to familiarize
operators with the switches at the work light control box.
Figure 107
REF. NAME PICTOGRAPH SWITCH FUNCTION
Work lights Off

A WLCB SW1L
Turn this switch to the left to turn off the machines work lights.
Work Lights On
A WLCB SW1R
Turn this switch to the right to turn on the machines work lights.

PN 71510013 - OMM015008130510 MAINTENANCE - SECTION TABLE OF CONTENTS 4-1
4. Maintenance
General ................................................................................................................. 4-3
Introduction............................................................................................................................... 4-3
Safety ......................................................................................................................................... 4-3
Service Tools ............................................................................................................................ 4-3
Theory ................................................................................................................... 4-4
General ...................................................................................................................................... 4-4
Chain Rotation .......................................................................................................................... 4-4
Maintenance Schedules ...................................................................................... 4-5
Introduction............................................................................................................................... 4-5
How to Use ................................................................................................................................ 4-5
Tigercat 215 loader maintenance schedule ........................................................................... 4-6
Rotobec grapple maintenance schedule ............................................................................... 4-6
CAT C4.4 loader engine maintenance schedule ................................................................... 4-7
Flexxaire Fan maintenance schedule on Loader .................................................................. 4-7
CAT C18 Shallow Sump Flail Engine Maintenance Schedule.............................................. 4-8
Brevini gear box maintenance schedule ............................................................................... 4-9
Dexter trailer axle Maintenance schedule .............................................................................. 4-9
Power Packer outrigger Maintenance schedule ................................................................... 4-9
Flexxaire Fan maintenance schedule ..................................................................................... 4-9
Stiebel Pump Drive Maintenance Schedule ......................................................................... 4-10
General Flail Maintenance Schedule .................................................................................... 4-10
Lubrication ......................................................................................................... 4-11
General .................................................................................................................................... 4-11
Safety ....................................................................................................................................... 4-11
Lubrication Schedule and Specifications ............................................................................ 4-11
Oil analysis policy .................................................................................................................. 4-15
Maintenance Procedures .................................................................................. 4-16
Service Preparation ................................................................................................................ 4-16
Safety Pins .............................................................................................................................. 4-17
Safety Struts ........................................................................................................................... 4-17
Chain Rotation and Replacement ......................................................................................... 4-18
Chain Rod Rotation and Replacement ................................................................................. 4-20
Flail Drive Bearing Inspection ............................................................................................... 4-22
Checking Belt Tension ........................................................................................................... 4-23
Adjusting Belt Tension .......................................................................................................... 4-25
Jack Shaft Spring Preload Inspection .................................................................................. 4-26
Jack Shaft Spring Preload Adjustment ................................................................................ 4-27
Feed Rate Calibration............................................................................................................. 4-28
Bolt-In Style Kingpin Inspection ........................................................................................... 4-30
Bolt-In Style Kingpin Assembly ............................................................................................ 4-31
Axle Oil Level Inspection ....................................................................................................... 4-32
Engine Coolant level inspection ........................................................................................... 4-33
Adding Engine Coolant .......................................................................................................... 4-34
Changing Engine Coolant ..................................................................................................... 4-35
Verifying Proper Fan Purge ................................................................................................... 4-36
Verifying Pre-cleaner Operation ........................................................................................... 4-36
Air filter service indicator inspection ................................................................................... 4-37
Air Filter Unloader Valve Inspection..................................................................................... 4-37
Welding On the Machine ........................................................................................................ 4-38
Hydraulic oil level inspection ................................................................................................ 4-39
4-2 MAINTENANCE - SECTION TABLE OF CONTENTS PN 71510013 - OMM015008130510
Adding Hydraulic Fluid .......................................................................................................... 4-40

Changing Hydraulic Oil .......................................................................................................... 4-41
Hydraulic Tank Breather Inspection ..................................................................................... 4-42
Hydraulic Tank Breather Replacement ................................................................................ 4-43
Pressure Line Filter Inspection ............................................................................................. 4-44
Pressure Line Filter Replacement ........................................................................................ 4-45
Charge Circuit Filter Inspection ............................................................................................ 4-47
Charge Circuit Filter Replacement ....................................................................................... 4-48
Return Circuit Filter Inspection ............................................................................................. 4-50
Return Circuit Filter Replacement ........................................................................................ 4-51
Magnetic Hydraulic Filter Core Cleaning ............................................................................. 4-53
Oil Analysis ............................................................................................................................. 4-56

PN 71510013 - OMM015008130510 MAINTENANCE - GENERAL 4-3
General
Introduction
Careful maintenance preserves the operational reliability and increases the useful life of the
important parts. Inspections and maintenance work, such as lubrication, must be carried out by
trained and certified personnel. Other maintenance and repair work can be carried out by CBI OR CBI
authorized service representatives. Spare parts used must meet the specifications of the
manufacturer. When genuine parts are used, this is guaranteed. Parts that do not meet the
specifications of the manufacturer may risk the proper functioning of the machine and endanger the
safety of people.
Safety
Maintenance Safety:
When performing maintenance work, make sure to observe all applicable safety instructions and
guidelines. Make sure that a lock out tag out procedure is used to ensure the machine is secured
against unintentional energy release any time personnel are in danger from unintended machine
actions. Make sure that the hydraulics system cannot be switched on and release the pressure off
the system before performing any maintenance or repairs to it. Ensure that the power supply has
been switched off, and cannot be switched on, during maintenance or repair to the electrical system,
unless power is needed to locate and remedy faults. Note: all parts weighing over 55lb (25kg) must
be lifted by two or more persons or by means of hoisting equipment.
Chemical Safety:
Used oil must be collected and disposed of in an environmentally-friendly manner. Products that
are used during the work have to be processed in such a way as to burden the environment as little
as possible. Remove any excess grease and any oil spills with a cleaning cloth.
Service Tools
Certain maintenance procedures for your CBI equipment will benefit from specialized tools. CBI
offers specialized tooling to customers for improved ease of maintenance. For detailed ordering
information see Replacement Parts, 1-11 in this manual. The following is a list of descriptions and
CBI part numbers for the available customized tooling.
Tool Description CBI Part Number
Flail Drive Sprocket Removal tool 31510127
Flail Drive Sprocket Removal bolt 31510128
Flail Chain Keep Slide Hammer 81510006
Sonic flail drive Belt tension meter 81510009
Fluid sampling kit 71011887
Safety Breaker 81010086
Surge Suppressor 80013138

4-4 MAINTENANCE - THEORY PN 71510013 - OMM015008130510
Theory
General
Certain aspects of the maintenance requirements for your CBI machine will vary greatly
depending on operating conditions. In such instances CBI encourages operators to establish
maintenance schedules adequate for their operating environment. The purpose of this section is to
introduce the theory behind the maintenance to assist operators in determining schedules to meet
their specific requirements.
Chain Rotation
The flail chains on your 604 flail debarker may not wear evenly. Chain wear can account for up to
20% of flail operating costs. Replacing chains before they break increases profits by decreasing risk
of product contamination or crash damage to your chipper. Replacing chains too soon will lead to
inflated operating costs. It is important to develop a chain rotation schedule; this will maximize part
life and increase machine profitability. Variations in operating conditions can greatly affect wear life.
The purpose of this section is to familiarize the operator with established wear patterns in order to
assist them in developing their own rotation schedule.
Chain Failure
Contrary to popular belief, the leading cause of chain failure is not abrasion or impacts with the
trees but rather impacts with links from other chains and impact in between mating links of a
chain. Repeated impacts over the life of the chain cause peening at the surface of the links. The
peening “uses up” the ductility of the steel and surface cracks begin to form. The surface cracks
grow until link failure occurs. Link failure is not caused by chain wear, however wear can
sometimes be used to gauge the amount of life left in a chain. A general rule of thumb for .656”
flail chain is that failure is a concern once links are thinner than ≈0.43”.
Individual chain wear

Individual chains wear in a predictable manner. The greatest wear is typically in the 2nd or 3rd
outer links of the chain; this is because it experiences the most impacts. Once one end of the
chain is worn, it can be flipped so that wear is concentrated on the other end. A general rule of
thumb is that a .656” flail chain will still have enough structural integrity to be flipped when its
outer links are worn at their thinnest point to ≈0.46”, link failure is a concern once links are thinner
than ≈0.43”.
Row Chain Wear

Rows of chains on the flail drum wear in a predictable manner. The greatest wear is typically in
the center of the flail roll and the least is on the sides; this is because the center experiences the
most contact with wood. Center chains wear out approximately 5 times faster than end chains.
Once chains in the center of the drum are worn, they can be rotated with chains taken from the
ends of the drum to increase effective life. A general rule of thumb for a .656” flail chain is that
there is enough structural integrity remaining for the chain to be flipped when its outer links are
worn at their thinnest point to ≈0.46”, link failure is a concern once links are thinner than ≈0.43”.
Double Chains
Chain life can be extended by running two chains per slot in the flail rotor. In practice, the two
chains in the slot inhibit each other from flopping around and impacting other chains achieving
approximately double chain life. However, because twice as many chains are required, hard
goods costs remain the same while service intervals increase. The greatest determining factor in
the use of double chains is its effect on fiber loss which varies depending on specific operating
conditions.

PN 71510013 - OMM015008130510 MAINTENANCE - MAINTENANCE SCHEDULES 4-5
Maintenance Schedules
Introduction
Your CBI machine is a complex machine that requires regularly scheduled maintenance in order
to perform. The purpose of the following section is to assist operators in determining what
maintenance needs to be performed at regular intervals. Service intervals may need to be shortened
depending on the severity of conditions.
INFO: Always consult the OEM manuals for specific maintenance procedures and intervals; see
Supplemental Manuals, p. 1-4.
How to Use
The regularly scheduled maintenance for your machine is listed in service intervals. If a service
activity is required to be a performed at a specific interval. It should be performed every time that
interval is reached. For example, if a service is listed at the 50 hour interval, it should be performed
every 50 machine hours. If a service needs to be performed at an interval different from those listed it
is noted in the note section under the maintenance schedule. Always check the notes at the bottom of
the maintenance schedules for any special noted regarding when a service needs to be performed. If
you need assistance in determining your machines service needs, please contact CBI, see

Tigercat 215 loader maintenance schedule
4-6
Component Description Service Description 10 HR 50 HR 100 HR 250 HR 500 HR 1000 HR 1500 HR 3000 HR 4500 HR 5000 HR 6000 HR 7500 HR 8000 HR 9000 HR 10000 HR 10500 HR 12000 HR For More Information See:
coolant system level inspect & adjust as needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
engine oil level inspect & adjust as needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
fuel system primary filter / water filter inspect & drain as needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
swing gearbox oil level inspect & adjust as needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
air cleaner unloader valve inspect X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
engine air cleaner service indicator inspect X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
hydraulic oil level inspect & adjust as needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
swing bearings grease X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
swing pinion grease X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
boom joint grease X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
stick joint grease X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
cylinder pins grease X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
coolers & condensers clean X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
sticks & debris clean X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
engine air intake components inspect X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
hydraulic components inspect X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
hardware & fasteners inspect & adjust as needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
condition and tension of fan belts inspect & replace as needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
exhaust system inspect for leaks & cracks X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
MAINTENANCE - MAINTENANCE SCHEDULES

entire machine perform visual inspection X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
return filter restriction indicator inspect X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
battery electrolyte level inspect & adjust as needed X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Engine RPM inspect & adjust as needed X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
All Hydraulic Pressure inspect & adjust as needed X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Hydraulic pump and motor fasteners inspect & torque as needed X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
air conditioning recirculation filter clean & replace as needed X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
cab fresh air filter clean & replace as needed X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
fire extinguisher rotation clean & replace as needed X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
swing gearbox oil level drain & replace X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
door and cover hinges grease X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
hydraulic oil return filters replace X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
swing pump charge filter replace X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
hydraulic oil pilot pressure filter replace X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
swing bearing and swing gearbox fasteners inspect & torque as needed X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
air cleaner unloader valve replace X X X X X X X X X X X X Supplemental Manuals, p. 1-4
In-tank fuel strainer inspect, service as needed X X X X X X X X X X X X Supplemental Manuals, p. 1-4
hydraulic oil drain & refill X X X X X X X X X X X Supplemental Manuals, p. 1-4
air intake rubber components replace X X X X X X X X X X X Supplemental Manuals, p. 1-4
Maintenance schedule taken from Tigercat Operator's Manual PN: 37622AENG

X Note: Service Performed at specified interval
Rotobec grapple maintenance schedule

PN 71510013 - OMM015008130510
inspect rotator inspect X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
inspect grapple inspect X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
lubricate grapple grease X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
lubricate connecting yoke grease X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
lubricate rotator grease X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Maintenance schedule taken from Rotobec Medium & Heavy-Duty Bunching Grapples Operator's Manual PN: 146-0092 Rev 1
X Note: Service performed at specified interval
PN 71510013 - OMM015008130510
CAT C4.4 loader engine maintenance schedule
alternator belt inspect & adjust as needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
coolant system level inspect & adjust as needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
driven equipment check inspect & adjust as needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
engine air cleaner service indicator inspect X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
engine air pre-cleaner inspect & clean as needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
engine oil level inspect & adjust as needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
fuel system primary filter / water filter inspect & drain as needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
v-belts Inspect & service As Needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Hoses and Clamps Inspect & Replace As Needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
walk around inspection visual inspection X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
cooling system sample (level 1) obtain X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Engine Oil Sample Obtain X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Engine Oil And Filter Change X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
engine valve lash inspect & adjust as needed X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
fan clearance check X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
crank case breather (canister) replace □ □ □ □ □ □ □ □ □ □ □ □ □ Supplemental Manuals, p. 1-4
battery electrolyte level inspect & adjust as needed ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Supplemental Manuals, p. 1-4
cooling system supplemental coolant additive test & add as needed ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Supplemental Manuals, p. 1-4
engine air cleaner main element Clean & Replace As Needed ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Supplemental Manuals, p. 1-4

fuel system primary filter / water filter replace ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Supplemental Manuals, p. 1-4
Fuel System Secondary Filter Replace ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Supplemental Manuals, p. 1-4
After cooler core Inspect X X X X X X X X Supplemental Manuals, p. 1-4

exhaust manifold Inspect X X X X X X X X Supplemental Manuals, p. 1-4
Starting Motor Inspect X X X X X X X X Supplemental Manuals, p. 1-4
Turbo Charger Inspect X X X X X X X X Supplemental Manuals, p. 1-4
Water Pump Inspect X X X X X X X X Supplemental Manuals, p. 1-4
alternator belt Inspect ○ ○ ○ ○ ○ ○ ○ ○ Supplemental Manuals, p. 1-4
engine mounts Inspect ○ ○ ○ ○ ○ ○ ○ ○ Supplemental Manuals, p. 1-4
cooling system sample (level 2) Obtain ○ ○ ○ ○ ○ ○ ○ ○ Supplemental Manuals, p. 1-4
Cooling System Coolant (DEAC) Change ∆ ∆ ∆ ∆ Supplemental Manuals, p. 1-4
Cooling System Water temperature regulator Replace ∆ ∆ ∆ ∆ Supplemental Manuals, p. 1-4
Cooling System Coolant Extender (ELC) Add ◊ ◊ Supplemental Manuals, p. 1-4
Cooling System Coolant (ELC) change ⌂ Supplemental Manuals, p. 1-4
Maintenance schedule taken from Caterpillar Operation and Maintenance Manual PN: SEBU8180-01
† Note: service performed only when service hour interval is initially reached
□ Note: service performed at specified hour interval or every 2 months
○ Note: service performed at specified hour interval or every 1 year
∆ Note: service performed at specified hour interval or every 2 years
◊ Note: service performed at specified hour interval or every 3 years
⌂ Note: : service performed at specified hour interval or every 6 years
Flexxaire Fan maintenance schedule on Loader

Purge Function Inspect X X X X X X X X X X X X X X X X X Verifying Proper Fan Purge, p. 4-36
Fan Blades Inspect X X X X X X X X Supplemental Manuals, p. 1-4
Rear Seal Inspect X X X X X X X X Supplemental Manuals, p. 1-4
Hub Oil Level Inspect X X X X X X X X Supplemental Manuals, p. 1-4
Hub Oil Change X Supplemental Manuals, p. 1-4
Maintenance schedule taken from Flexxaire Fan FX Fan Series Manual, PN: 01523 Rev 12
4-7
CAT C18 Shallow Sump Flail Engine Maintenance Schedule
4-8
Battery Replace ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Supplemental Manuals, p. 1-4
Battery Or Battery Cable Disconnect ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Supplemental Manuals, p. 1-4
Coolant Change ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Changing Engine Coolant, p. 4-35
Coolant Extender (ELC) Add ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Adding Engine Coolant, p. 4-34
Engine Air Cleaner Element (Dual Element) Inspect / Clean / Replace ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Supplemental Manuals, p. 1-4
Engine Oil And Filter Change ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Supplemental Manuals, p. 1-4
Engine Storage Procedure Check ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Supplemental Manuals, p. 1-4
Fuel System Prime ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Supplemental Manuals, p. 1-4
Coolant System Level Inspect & Adjust As Needed X X X X X X X X X X X X X X X X X Engine Coolant level inspection, p. 4-33
Engine Air Cleaner Service Indicator Inspect X X X X X X X X X X X X X X X X X Air filter service indicator inspection, p. 4-37
Engine Air Pre-Cleaner Inspect & Clean As Needed X X X X X X X X X X X X X X X X X Verifying Pre-cleaner Operation, p. 4-36
Engine Oil Level Inspect & Adjust As Needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Fuel System Primary Filter / Water Filter Inspect & Drain As Needed X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Fuel Tank Water And Sediment Drain X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Walk Around Inspection Visual Inspection X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Jacket Water Heater Inspect X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Battery Electrolyte Level Inspect & Adjust As Needed X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Coolant Sample (Level 1) Obtain X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Cooling System Supplemental Coolant Additive Test & Add As Needed X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4

Engine Crankcase Breather Clean X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Engine Oil And Filter Change X X X X X X X X X X X X X X
Engine Oil Sample Obtain X X X X X X X X X X X X X X

Electronics Grounding Stud Inspect/Clean/Tighten X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Hoses And Clamps Inspect/Replace X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Radiator Clean X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Fuel System Primary Filter (Water Separator) Replace X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Fuel System Secondary Filter Replace X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Starting Motor Inspect X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Belt Inspection Inspect & Service As Needed † X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Turbo-Charger Inspect X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Water Pump Inspect X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
Coolant Sample (Level 2) Obtain † ○ ○ ○ ○ ○ ○ ○ ○ Supplemental Manuals, p. 1-4
Alternator Inspect ○ ○ ○ ○ ○ ○ ○ ○ Supplemental Manuals, p. 1-4
Electronic Unit Injector Inspect & Replace As Needed ◊ ◊ ◊ ◊ Supplemental Manuals, p. 1-4
Engine Valve Lash Check † ◊ ◊ ◊ ◊ Supplemental Manuals, p. 1-4
Engine Valve Rotators Inspect † ◊ ◊ ◊ ◊ Supplemental Manuals, p. 1-4
Fan Drive Bearing Lubricate ◊ ◊ ◊ ◊ Supplemental Manuals, p. 1-4
Driven Equipment Check Inspect & Adjust As Needed ◊ ◊ ◊ ◊ Supplemental Manuals, p. 1-4
After Cooler Core Clean / Test ◊ ◊ ◊ ◊ Supplemental Manuals, p. 1-4
Cooling System Temperature Regulator Replace ◊ ◊ ◊ ◊ Supplemental Manuals, p. 1-4
Crankshaft Vibration Damper Inspect ◊ ◊ ◊ ◊ Supplemental Manuals, p. 1-4
Engine Clean ◊ ◊ ◊ ◊ Supplemental Manuals, p. 1-4
Engine Mounts Inspect ◊ ◊ ◊ ◊ Supplemental Manuals, p. 1-4
Engine Speed/ Timing Sensors Clean / Inspect ◊ ◊ ◊ ◊ Supplemental Manuals, p. 1-4
Engine Protective Devices Check ◊ ◊ ◊ ◊ Supplemental Manuals, p. 1-4
Overhaul Considerations Perform □ Supplemental Manuals, p. 1-4
PN 71510013 - OMM015008130510
Fan Drive Bearing Replace □ Supplemental Manuals, p. 1-4
Maintenance schedule taken from Caterpillar C18 engine Operation and Maintenance Manual PN: SEBU7899-04
⁕ Note: service performed whenever Required
◊ Note: service performed at specified hour interval or every 3 years
□ Note: service performed at specified hour interval or every 760,000 L (200,770 US gal) of fuel consumed.
PN 71510013 - OMM015008130510
Brevini gear box maintenance schedule
gear case oil inspect & adjust as necessary X X X X X X X X X X X X X X X X X Supplemental Manuals, p. 1-4
gear case oil change † ○ ○ ○ ○ Supplemental Manuals, p. 1-4
gear case interior flush ○ ○ ○ ○ Supplemental Manuals, p. 1-4
Maintenance schedule taken from Brevini Standard Series & "S" Series Installation & Maintenance Manual PN: MT-0808-0699/40
Dexter trailer axle Maintenance schedule

wheel hub oil level inspect & adjust as necessary ⟲1 ⟲1 ⟲1 ⟲1 ⟲1 ⟲1 ⟲1 ⟲1 ⟲1 ⟲1 ⟲1 ⟲1 ⟲1 ⟲1 ⟲1 ⟲1 ⟲1 Axle Oil Level Inspection, p. 4-32
brake adjustment inspect & adjust as necessary ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 Supplemental Manuals, p. 1-4
⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12 ⟲12

wheel bearings repack Supplemental Manuals, p. 1-4
brake components inspect for damage & wear ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 Supplemental Manuals, p. 1-4
brake actuation components lubricate ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 ⟲25 Supplemental Manuals, p. 1-4
wheel bearing oil replace ⟲100 ⟲100 ⟲100 ⟲100 ⟲100 ⟲100 ⟲100 ⟲100 Supplemental Manuals, p. 1-4
Maintenance schedule taken from Dexter Axle 22,500-27,500 lbs. Capacity Operation, Maintenance, and Service Manual
⟲1 Note: service Performed at specified hour interval or every 1,000 miles.
Power Packer outrigger Maintenance schedule

Lubricate Outriggers Grease □ □ □ □ □ □ □ □ □ □ □ □ □ Supplemental Manuals, p. 1-4
Maintenance schedule taken from Power Packer Power Gear Installation & Service Manual PN: 81-1093 Rev 18
□ Note: service performed at specified hour interval or every 6 months
Flexxaire Fan maintenance schedule

Purge Function Inspect X X X X X X X X X X X X X X X X X Verifying Proper Fan Purge, p. 4-36
Fan Blades Inspect X X X X X X X X Supplemental Manuals, p. 1-4
Rear Seal Inspect X X X X X X X X Supplemental Manuals, p. 1-4
Hub Oil Level Inspect X X X X X X X X Supplemental Manuals, p. 1-4
Hub Oil Change X Supplemental Manuals, p. 1-4
Maintenance schedule taken from Flexxaire Fan FX Fan Series Manual, PN: 01523 Rev 12
4-9
Stiebel Pump Drive Maintenance Schedule
4-10
Gear Oil Change □ □ □ □ □ □ □ □ □ □ □ □ □ Supplemental Manuals, p. 1-4
Maintenance schedule taken from Stiebel Operating Instructions For Pump Drives, Edition 01/10
General Flail Maintenance Schedule

Entire Machine Visual Inspection X X X X X X X X X X X X X X X X X Daily Inspection Specific, p. 3-6
Entire Machine Clean Debris Build Up X X X X X X X X X X X X X X X X X Cleaning, p. 3-17
Hydraulic Oil Level Inspect X X X X X X X X X X X X X X X X X Hydraulic oil level inspection, p. 4-39
Hydraulic Charge Filters Inspect Indicator X X X X X X X X X X X X X X X X X Charge Circuit Filter Inspection, p. 4-47
Hydraulic Pressure Filters Inspect Indicator X X X X X X X X X X X X X X X X X Pressure Line Filter Inspection, p. 4-44
Hydraulic Return Filters Inspect Indicator X X X X X X X X X X X X X X X X X Return Circuit Filter Inspection, p. 4-50
Hydraulic Tank Breather Element Inspect Hydraulic Tank Breather Inspection, p. 4-42

X X X X X X X X X X X X X X X X X
upper and Lower Flail Bearings Grease X X X X X X X X X X X X X X X X X Lubrication Schedule and Specifications, p. 4-11
top feed toll end plate bearings Grease
X X X X X X X X X X X X X X X X X Lubrication Schedule and Specifications, p. 4-11

bottom feed roll bearings Grease X X X X X X X X X X X X X X X X X Lubrication Schedule and Specifications, p. 4-11
idler roll bearings Grease X X X X X X X X X X X X X X X X X Lubrication Schedule and Specifications, p. 4-11
Flail Chains Rotate ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Chain Rotation and Replacement, p. 4-18
Flail Drive Bearings Inspect X X X X X X X X X X X X X X X X X Flail Drive Bearing Inspection, p. 4-22
Axle Oil Inspect Level X X X X X X X X X X X X X X X X X Axle Oil Level Inspection, p. 4-32
Engine Coolant Inspect Level X X X X X X X X X X X X X X X X X Engine Coolant level inspection, p. 4-33
Engine Fan Purge Inspect X X X X X X X X X X X X X X X X X Verifying Proper Fan Purge, p. 4-36
Engine Air Pre-cleaner Inspect X X X X X X X X X X X X X X X X X Verifying Pre-cleaner Operation, p. 4-36
Engine Air Filter Service Indicator Inspect X X X X X X X X X X X X X X X X X Air filter service indicator inspection, p. 4-37
Engine Air Filter Unloader Valve Inspect X X X X X X X X X X X X X X X X X Air Filter Unloader Valve Inspection, p. 4-37
plunger slide cylinder pins Grease X X X X X X X X X X X X X X X X Lubrication Schedule and Specifications, p. 4-11
general hydraulic cylinder hinge pins Grease X X X X X X X X X X X X X X X X Lubrication Schedule and Specifications, p. 4-11
Flail Chains Replace ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Chain Rotation and Replacement, p. 4-18
Hydraulic Oil Test † X X X X X X X X X X X X X X Oil Analysis, p. 4-56
Flail Drive Belt Tension Check X X X X X X X X X X X X X X X X Checking Belt Tension, p. 4-23
Flail Chain Rods Rotate X X X X X X X X X X X X X X X Chain Rod Rotation and Replacement, p. 4-20
Hydraulic Tank Breather Element Replace X X X X X X X X X X X X X X Hydraulic Tank Breather Replacement, p. 4-43
Jack Shaft Spring Preload Inspect X X X X X X X X X X X X X X Jack Shaft Spring Preload Inspection, p. 4-26
Hydraulic Charge Filters Replace †† † ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Charge Circuit Filter Replacement, p. 4-48
Hydraulic Pressure Filters Replace †† † ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Pressure Line Filter Replacement, p. 4-45
Hydraulic Return Filters Replace †† † ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Return Circuit Filter Replacement, p. 4-51
Magnetic Hydraulic Filters Clean †† † ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Magnetic Hydraulic Filter Core Cleaning, p. 4-53
PN 71510013 - OMM015008130510
Kingpin Inspect X X X X X X X X Bolt-In Style Kingpin Inspection, p. 4-30
Hydraulic Oil Replace X X X X X X X X Changing Hydraulic Oil, p. 4-41
Flail Chain Rods Replace ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ ⁕ Chain Rod Rotation and Replacement, p. 4-20
Feed System Calibrate X X X X X X X X Feed Rate Calibration, p. 4-28

⁕ Note: service performed at specified interval or whenever Required
†† Note: service performed only the first two times the service hour interval is reached
PN 71510013 - OMM015008130510 MAINTENANCE - LUBRICATION 4-11
Lubrication
General
Your CBI equipment is a complex machine that requires precise lubrication to function properly.
CBI lubrication specifications and schedules are developed to maintain the highest level of
performance over the life of the machine. Failure to follow recommended lubrication practices will
result in premature wear and unsatisfactory performance. Consult CBI for recommendations on
severe duty applications.
Safety
Used oil must be collected and disposed of in an environmentally-friendly manner. Products that
are used during the work have to be processed in such a way as to burden the environment as little
as possible. Remove any excess grease and any oil spills with a cleaning cloth. Always utilize the
appropriate PPE when dealing with used oil or chemicals.
Lubrication Schedule and Specifications

Lubrication of your CBI equipment must be performed at set intervals. The purpose of this
section is to help operators identify the lubrication requirements of your CBI machine. Locations of
lubrication points can be identified in Figure 108 (p. 4-12), followed by a table summarizing the
frequency and specifications for lubrication shown in Figure 109 (p. 4-13) and Figure 110 (p. 4-14).
INFO: For Tigercat loader lubrication, please consult the OEM manual (see Supplemental Manuals,
P. 1-4).

4-12 MAINTENANCE - LUBRICATION PN 71510013 - OMM015008130510
Figure 108
Figure 109
4-14 MAINTENANCE - LUBRICATION PN 71510013 - OMM015008130510
Figure 110
Oil analysis policy

CBI warranty policy for its equipment stipulates that a hydraulic and engine oil analysis be
performed by a certified testing laboratory (Mobil Oil test lab, Parker Par-test, or equivalent), a
minimum of 1 (one) time per month or every 250 operating hours (whichever comes first). CBI part
number for the fluid test kit is 71011887.
Test report results indicating any problems must be submitted to CBI via fax or overnight delivery
within 24 (twenty four) hours of receiving such report. Any corrective action(s) recommended within
report must be performed immediately.
To further enable analysis of system performance and machine longevity, copies of all test
reports conducted during the previous 12 (twelve) months must be kept on file by customer, and be
made available to CBI upon request. Failure to adhere to policy requirements may void warranty of
machine.

4-16 MAINTENANCE - MAINTENANCE PROCEDURES PN 71510013 - OMM015008130510
Maintenance Procedures
Service Preparation
Before performing any maintenance on your CBI equipment, it is imperative to prepare the
machine for service. Proper preparation minimizes personnel’s exposure to potential hazards. This
procedure must be followed every time unexpected energy release or machine movement poses a
hazard to personnel.
⚠WARNING: Failure to properly prepare the machine for service may result in severe injury or death!
INFO: For Tigercat service preparation procedures and lockout information please consult the
OEM manual. See Supplemental Manuals, P. 1-4.
1 Shut down machine

At the control panel turn the ignition key to off (if
running), remove key and place it in your pocket.
Perform this procedure for both the flail and the
loader if applicable.
2 Disable the machine

Turn the flail’s battery disconnect switch off (Figure
111), remove the key (B), place it in your pocket, Figure 111
and close the cover plate (A). For the loader, just
turn the switch off, there is no key.
3 Perform LOTO
Install a lockout hasp (Figure 112, B) into the battery
disconnect switch cover plate. Install your personal
lock out device (C) in the hasp, ensuring no one else
can enable equipment. Perform the same for the
loader. For more detailed information, see Safety
Procedures, p. 2-8.
4 Isolate Energy
Ensure that all elevated components have safety
pins or struts installed; relieve all residual or stored
electrical, mechanical, or hydraulic energy. It is the
operator’s responsibility to recognize when residual
energy must be safely neutralized. For detailed
inquiries please see Service Assistance, 1-5.
Figure 112

PN 71510013 - OMM015008130510 MAINTENANCE - MAINTENANCE PROCEDURES 4-17
Safety Pins
Certain components on your CBI equipment are required to be locked into position for safe
maintenance or operation. One of the techniques used to immobilize components is the use of safety
pins. The purpose of this procedure is to familiarize the operator with general technique used for
installing safety pins.
1 Position machine component(s)

Position the machine components so that
the safety pin holes are aligned.
2 Insert safety pin

Unlock the safety pin from its detached
position (Figure 113 / A), insert it into the
component being constrained (Figure 113 /
B), and relock the safety pin in the installed
position (Figure 113 / C).
Figure 113
⚠NOTICE: the procedure for removal is the opposite of installation.
Safety Struts
Certain components on your CBI equipment are required to be locked into position while elevated
for safe maintenance. One of the techniques used to immobilize components is the use of safety
struts. The purpose of this procedure is to familiarize the operator with general technique used for
installing safety struts.
1 Raise machine component(s)

Raise the machine component into position.
2 Retrieve safety strut

retrieve the safety strut (see Figure 114 / A)
from its stowed location.
3 Install the safety strut

Place the safety strut (Figure 114 / A) over
the extended cylinder rod. Install the lock
pin (Figure 114 / B) and secure it with the Figure 114
supplied clip (Figure 114 / C).
⚠NOTICE: the procedure for removal is the opposite of installation.

Chain Rotation and Replacement

The flail chains on your 604 flail debarker will need regular replacement. Replacing chains
before they break increases profits by decreasing risk of product contamination or crash damage
to your chipper. Chain life can be extended by developing a chain rotation schedule (see Chain
Rotation, p. 4-4). The purpose of this procedure is to familiarize the operator with flail chain
replacement technique. Please note that this procedure requires two people, they are referred to
as person “X” and person “Y”.
⚠NOTICE: This procedure is intended to be performed with the Discharge plunger retracted from
the flail chamber. For detailed instructions see Plunger Menu, p. 3-40.
INFO: This procedure may be performed in conjunction with chain changing / rotation. For more
information see Chain Rotation and Replacement, p. 4-18.
1 Prepare the machine for service

It is imperative to prepare the machine for service to safeguard employees from the
unexpected release of hazardous energy during service or maintenance. Both personnel must
perform their own LOTO procedure on the flail and the loader.
2 Begin Service
Person “X” will open the 4 ball valves on the flail motors (Figure 115) and enter the flail
chamber. The valves bypass the motors allowing the flails to be easily rotated. Person “Y” will
set up tools on the discharge plunger and open the flail chamber service panels (Figure 116).
Figure 115 Figure 116
3 Position Flail
Person “X” will rotate the flail until person
“Y” instructs them to stop. Person “Y” will
instruct person “X” to stop rotating the flail
when flail chain rod pipe plug (Figure 117 /
A) is aligned with the service port (Figure
117 / B).
4 Remove plug
Person “X” will keep the flail from rotating
while person “Y” Removes flail chain rod
pipe plugs (Figure 117 / A)
Figure 117

5 Remove Chain Rod

Person “X” will collect the old chains off of
drum as the rod is retracted. Person “Y” will
loosen if stuck and slowly remove the chain
rod using the CBI chain keep slide hammer
(Figure 118 / A) (CBI PN: 81510006).
6 Exchange chains
Person “X” will Pass the old chains to
person “Y” through the service panel
(Figure 116). Person “Y” will pass the new
chains (CBI PN 41510011P8) to person “X”
back through flail chamber service panel.
Figure 118
7 Install New Chains
Person “X” will align the new chain sections
in the chain pockets on the drum and
instruct person “Y” when to insert the rod
further (see Figure 119). Continue until
entire row is installed. The chain rod may
need to be “wiggled” to help locate the end
of the chain rod into its mating hole on the
far side of the drum. Person “Y” will
reinsert the chain rod into the new chain
sections when instructed to by person “X”
until the rod is fully reinserted in the drum.
8 Replace Plug
Person “X” will hold the flail steady for
person “Y”. Person “Y” will reinstall chain Figure 119
rod pipe plug in accordance with Torque
Specifications: 7-5.
9 Reposition Flail
Person “X” will rotate flail until person “Y”
instructs them that the next chain section is
aligned. Person “Y” will Instruct person “X”
to stop rotating the flail when the next flail
chain rod pipe plug (Figure 120 / A) is
aligned with the service port (Figure 120 /
B).
10 Service all chain rows on drum

Both person “X” and “Y” will Repeat steps
3-9 until all rows on the flail have been
serviced (6 total).
Figure 120
11 Service all drums on machine
Both person “X” and “Y” will Repeat steps 3-10 until all flail drums on the machine have been
serviced (4 total).
12 Reset Machine for operation

Person “X” will ensure all tools and parts are removed from the flail chamber and close the 4
ball valves (Figure 115). Person “Y” will close and secure the service panels (Figure 116) and
ensure that all tools and parts are removed from the discharge plunger.

Chain Rod Rotation and Replacement

The flail chain rods on your 604 flail need regular replacement / rotation. Waiting too long to
perform this service will cause product contamination and/or machine damage. There are three
chain offsets per flail; rods can be rotated through each offset position and then must be replaced.
The purpose of this procedure is to familiarize the operator with a flail chain rod replacement /
rotation technique. This procedure requires two people, referred to as person “X” and person “Y”.
⚠NOTICE: This procedure is intended to be performed with the Discharge plunger retracted from
the flail chamber. For detailed instructions see Plunger Menu, p. 3-40.
INFO: This procedure may be performed in conjunction with chain changing / rotation. For more
information see Chain Rotation and Replacement, p. 4-18.

It is imperative to prepare the machine for service to safeguard employees from the
unexpected release of hazardous energy during service or maintenance. Both personnel must
perform their own LOTO procedure on the flail and the loader.
2 Begin Service
Person “X” will open the 4 ball valves on the flail motors (Figure 115) and enter the flail
chamber. These valves bypass the hydraulic motors allowing the flails to be rotated by hand.
Person “Y” will set up tools on the discharge plunger and open the flail chamber service panels
(Figure 116).
3 Position Flail
Person “X” will rotate the flail until person “Y”
instructs them to stop. Person “Y” will
instruct person “X” to stop rotating the flail
when flail chain rod pipe plug (Figure 117 / A)
is aligned with the service port (Figure 117 /
B).
4 Remove First plug

while person “Y” Removes flail chain rod pipe
plugs (Figure 117 / A)
Figure 123

5 Remove First Chain Rod

Person “X” will collect the old chains off of
drum as the rod is retracted. Person “Y” will
loosen if stuck and slowly remove the chain
rod using the CBI chain keep slide hammer
(Figure 118 / A) (CBI PN: 81510006).
6 Reposition Flail
Person “X” will rotate flail until person “Y”
instructs them that the next chain section is
aligned. Person “Y” will Instruct person “X” to
stop rotating the flail when the next flail chain
rod pipe plug (Figure 117 / A) is aligned with Figure 124
the service port (Figure 117 / B).
7 Remove Second plug

while person “Y” Removes flail chain rod pipe
plugs (Figure 117 / A).
8 Remove Second Chain Rod

Person “X” will grab the second set of chains.
Person “Y” will remove the second chain rod.
Use the same techniques used in step 0.
9 Install Previous Rod Into Current Row

Person “X” will align the chain sections in the
chain pockets on the drum and instruct
person “Y” when to insert the rod further (see Figure 125
Figure 119). Person “Y” will insert the rod
removed from the previous section into the
current section when instructed. For more
information on chain installation please refer
to Chain Rotation and Replacement, p. 4-18.
10 Replace Second Plug

Person “X” will hold the flail drum steady for
person “Y”. Person “Y” will reinstall the chain
rod pipe plug into the current row. Tighten
the plug in accordance with Torque
Specifications: 7-5.
Figure 126
11 Rotate all chain rods on drum
Both person “X” and “Y” will Repeat steps 3-10 until all rods on the flail have been serviced.
There are three different row offsets on the flails (Figure 126 / A, B, & C). Rods from A can be
rotated to B, B to C, and C to A. Fully warn (at all offsets) rods should be replaced.
12 Service all drums on machine

Both person “X” and “Y” will Repeat steps 3-11 until all flail drums on the machine have been
serviced (4 total).
13 Reset Machine for operation

Person “X” will ensure all tools and parts are removed from the flail chamber and close the 4
ball valves (Figure 115). Person “Y” will close and secure the service panels (Figure 116) and
ensure that all tools and parts are removed from the discharge plunger.

Flail Drive Bearing Inspection

The flail drive bearings are critical components on the machine that will generate excess heat if
they begin to fail. As a safeguard against unscheduled downtime their temperature should be
inspected regularly to ensure they haven’t degraded. Failure to identify and remedy bearing
degradation may lead to severe equipment damage. The purpose of this bulletin is to familiarize
operators with a technique for inspecting the flail drive bearings on their CBI machine.
1 Get bearings up to temp.

This inspection should be performed at the end of the
day immediately after shut down when the flail
bearings have reached their maximum operating
temperature.

Before performing maintenance on your machine, it is
imperative to safeguard employees from the
unexpected release of hazardous energy. For more
information see Service Preparation, p. 4-16.
3 Inspect NDS rotor bearings Figure 127

Use an infrared thermometer (CBI PN: 71510206) to
measure the temperature of the bearing housings of
the non-drive side flail rotor bearings (Figure 127).
Record the values in your maintenance log.
4 Inspect DS rotor bearings

Remove the access plugs (Figure 128) and point the
infrared thermometer at the housings of the drive side
flail rotor bearings. Record the values in your
maintenance log.
5 Inspect Jack-shaft bearings

Remove the access plugs (Figure 129) and point the
infrared thermometer at the housings of the jack shaft
bearings. Record the values in your maintenance log.
Figure 128
6 Compare Values
Compare the values measured to previous recorded
values. Sudden and isolated increases in
temperature may be indicative of degradation in that
bearing. For detailed information contact CBI, see
CBI Authorized Service, p. 1-12.
⚠NOTICE: Typical operating temperature should not

exceed 212F° (100C°). Higher ambient temperatures or
operation in direct sunlight may skew results. For
detailed information contact CBI, see CBI Authorized
Service, p. 1-12.
Figure 129

Checking Belt Tension

The four drive belts for the flails require their tension to be checked periodically (see General
maintenance schedule, page 4-10). The purpose of this procedure is to familiarize the operator with
this technique.
⚠WARNING: Operating the flail with improper belt

tensions can cause severe damage to the drive
motors and belts. Never operate the equipment with
improperly tensioned belts.

Before performing maintenance on your machine,
it is imperative to prepare the machine for service
to safeguard employees from the unexpected
release of hazardous energy during service or
maintenance activities.
2 Remove Belt Cover

Remove the bolts (Figure 130 / A) securing the
cover plates for belt drives; see Figure 130.
Figure 130
3 Open The Ball Valve
Open the ball valve on the flail drive motor. This
valve bypasses the hydraulic motor allowing it to
be rotated by hand.
4 Align the Driven Pulley

The driven pulley for each flail has a “tight spot”
mark stamped by the factory on its outer rim
(Figure 132 / A). This mark denotes the alignment
where run-out in the pulleys results in the highest
belt tension. Align the driven pulley so that this
mark is facing up (the 12 o’clock position).
⚠NOTICE: If the Flail belt sprockets are ever

removed, they will need to be recalibrated to find the
“tight spot”. For more information contact CBI, see
Figure 131
CBI Authorized Service, p. 1-12
5 Configure sonic tensioner

Input CBI’s belt data into your sonic tension tester
(CBI Part # 81510009).
- Belt weight: 7.9 g/m
- Belt Width: 68mm
- Belt span: 746mm
Figure 132

6 Measure upper belt tension

Hold the sonic tensioner probe next to the upper
belt section in the middle of the span (Figure 133
/ A). Press “measure” on the tester and strum the
belt (Figure 133 / B). Repeat procedure until
three consecutive values are recorded within 3
Hz of each other. Average the measured results.
⚠NOTICE: It is important to measure tension in a

quiet environment. Background noise/music will be
picked up by the sonic tester and will skew results.
7 Measure Lower belt tension

Hold the sonic tensioner probe next to the lower
belt section in the middle of the span (Figure 134
/ A). Press “measure” on the tester and strum the Figure 133
belt (Figure 134 / B). Repeat procedure until
three consecutive values are recorded within 3
Hz of each other. Average the measured results
⚠NOTICE: It is important to measure tension in a

quiet environment. Background noise/music will be
picked up by the sonic tester and will skew results.
8 Review and Record Results

Review the averaged upper and lower tension
results compared to a desired value of 64-66 Hz;
both readings should fall within the “desirable
range. Record the results (see Belt Tension Test
Records, p. 10-7)
Figure 134
9 Adjust Belt Tension
Adjust Belt Tension If necessary (see Adjusting Belt Tension, page 4-25)
10 Close The Ball Valve

Close the ball valve on the flail drive motor. The flail will not operate properly with this ball valve
open.
11 Refit Belt Cover

Refit the belt cover and tighten the fasteners (Figure 130 / A) in accordance with Torque
Specifications, page 7-5
⚠NOTICE: The procedure is similar for checking the belt tension on all four flail drives.

Adjusting Belt Tension

Periodically, the drive belts for the flails will need tension adjustment (see Checking Belt Tension,
page 4-20). The purpose of this procedure is to familiarize the operator with the technique for
adjusting it.
Before performing maintenance on your machine, it is
imperative to prepare the machine for service to safeguard
employees from the unexpected release of hazardous
energy during service or maintenance activities.
2 Loosen the drive motor mounting bolts

Loosen the four drive motor mounting bolts (Figure 135 /
A). Only loosen bolts enough to allow motor to slide freely.
Any additional loosening will cause tilting of the motor
assembly.
3 Loosen tension adjustment nut

Loosen the nut (Figure 136 / A) that is securing tension
adjustment screw (Figure 136 / B).
Figure 135
4 Adjust tension adjustment nut
Adjust the tension adjustment nut (item C, Figure 136) to
set the proper belt tension. If the measured belt frequency
is too low, the belt must be tightened and if it is too high
the belt must be loosened. A good rule of thumb is ¼ turn
in the adjustment bolt will change the belt frequency
approximately 10 Hz.
5 Retighten adjustment nut

Retighten the tension adjustment screw lock nut (Figure
136 / A) in accordance with Torque Specifications, p. 7-5.
6 Retighten drive motor mounting bolts

Retighten the drive motor mounting bolts using the
tightening order shown in Figure 137 and the torque
values in Torque Specifications, p. 7-5. Figure 136
⚠NOTICE: Improper tightening of the motor mounting bolts
may result in inaccurate tension measurements!
7 Retest Belt Tension

Retest the belt tension frequency in accordance with
Checking Belt Tension: 4-20. Repeat steps 2 through 7
until the belt tension frequency measurements are in the
desired range.
8 Inspect Jack Shaft Spring Preload (if fitted)

Inspect the upper and lower jack shaft spring’s preload;
see Jack Shaft Spring Preload Inspection, p. 4-26.
9 Refit Components
Replace all covers and Retighten all bolts in accordance
with Torque Specifications: 7-5. Figure 137
⚠NOTICE: The procedure is similar to perform on all four flail drives.

Jack Shaft Spring Preload Inspection

The flails on your machine are fitted with spring loaded jack shafts that reduce the side loading
on the flail drives. It is important to verify that the jack shaft springs have the proper tension applied.
Failure to run proper preload may result in severe damage to drive components. The purpose of this
procedure is to familiarize operators with the proper technique for inspecting the preload in the jack
shaft tension springs.

Before performing maintenance on your machine, it
is imperative to prepare the machine for service to
safeguard employees from the unexpected release
of hazardous energy during service or maintenance
activities.
2 Remove Belt Cover

Remove the bolts (Figure 138 / A) securing the
cover plates for flail belt drive housing; see Figure
138.
3 Inspect Preload
Measure the compressed length of the upper (Figure
139 / A) and lower (Figure 139 / B) jack shaft
springs. The springs should be compressed to a
length of 4¾ inches (120.65mm)
Figure 138
⚠NOTICE: The jack shaft springs are seated against
washers at both ends. Ensure you are measuring to the
inside of the washers when measuring spring preload!
4 Adjust as Necessary
If the jack shaft springs are not tensioned properly,
adjust their preload. For more information, see Jack
Shaft Spring Preload Adjustment, p. 4-27.
5 Refit Components
Once complete, replace all covers and Retighten all
bolts in accordance with Torque Specifications, p.7-
5. Figure 139

Jack Shaft Spring Preload Adjustment

The flails on your machine are fitted with spring loaded jack shafts that reduce the side loading on
the flail drives. Failure to run proper tension in the jackshaft springs may result in severe damage to
drive components. The purpose of this procedure is to familiarize operators with the proper technique
for adjusting the preload in the jack shaft tension springs.

Before performing maintenance on your machine, it is imperative to prepare the machine for
service to safeguard employees from the unexpected release of hazardous energy during service
or maintenance activities.
2 Remove Belt Cover

Remove the bolts (Figure 140 / A) securing the cover plates for belt drives; see Figure 140.
3 Loosen Tensioning Springs

Loosen the upper and lower jack shaft spring
adjustment jam nuts (Figure 141 / A). Turn the spring
tension adjustment nuts (Figure 141 / B) until all the
tension is removed from the springs (Figure 141/ C)
but no further (the spring free length is approximately 6
inches).
4 Adjust the Drive Belt Tension
With the tension removed from the jackshaft springs
adjust the flail drive belt tension to 56-58 Hz. Use the
same technique described in Adjusting Belt Tension,
p.4-25.
⚠NOTICE: The tension frequencies given in step 4 are
generic. Specific machines may require this value be set
higher or lower in order to achieve the proper belt tension
when the jackshaft springs are compressed (step 5).
Figure 140
5 Tension Jackshaft Springs
Tighten the upper and lower jack shaft spring
adjustment nuts (Figure 141/ B) until both springs
(Figure 141/ C) are compressed to a length of 4¾
inches. When the springs are compressed to the
proper length tighten the jam nuts (Figure 141/ A)
against the adjustment nuts in accordance with
Torque Specifications, p. 7-5.
⚠NOTICE: The jack shaft springs are seated against
washers at both ends. Ensure you are measuring to the
inside of the washers when measuring spring preload!
Figure 141
6 Retest Belt Tension
Retest the belt tension in accordance with Checking Belt Tension, p. 4-23.
⚠WARNING: If the belt tension cannot be adjusted to within the specified frequency range while
maintaining the proper jack shaft spring preload, repeat steps 4 through 6 of this procedure using
different frequency values in step 4 to compensate.
7 Refit Components
Replace all covers and Retighten all bolts in accordance with Torque Specifications, p.7-5.
⚠NOTICE: The procedure is similar to perform on all flail drives with a jackshaft.

Feed Rate Calibration

The feed rates on the machine are calibrated in order to match up with the disc chipper when
operating as a “combo unit”; they must be recalibrated any time critical parts are changed or as the
machine wears. Using feed speeds that are too high will force material into the rotor causing extreme
wear and fuel consumption. Using feed rates that are too low will result in inconsistent chip length
and decreased production. The purpose of this procedure is to familiarize operators with a technique
for calibrating the feed rates on their machine.
⚠WARNING: This procedure requires personnel perform service while the machine is running. Ensure
all applicable safety precautions are followed to safeguard personnel from injury; If you are not
qualified to do so please contact CBI to perform the service, see CBI Authorized Service, p. 1-12.
⚠WARNING: Before adjusting any machine settings it is critical that you fully understand how they will
affect machine performance. Failure to comply may result in severe machine damage or injury to
personnel!
1 Start The Machine

The machine must be running for the feed rates to be calibrated. For detailed information see
Starting the flail, p. 3-10.
2 Lower The Speed Of Feed Rolls

Lower the speed of all the top and bottom
feed rolls from the control panel by adjusting
their “Rate Offset” to the minimum value. For
detailed instructions see Feed Offset Adjust
Menu, p. 3-111.
3 Throttle The Engine Up

The engine must be running at the operating
RPM for the feed rates to be calibrated. For Figure 142
detailed information see Basic Operation
Menu, p. 3-35.

Turn on the machine’s feed system.
5 Adjust Feed Roll Speed

From the control panel make a small Increase
in the “Rate offset” to the feed roll being
adjusted. For detailed instructions see Feed
Offset Adjust Menu, p. 3-111.
Figure 143
6 Measure Feed Roll Speed
Use a hand held digital tachometer to measure
the RPM of the feed roll you’re adjusting the
speed of. You may have to use center line
contact (Figure 142), non-contact (Figure 143),
or radial contact (Figure 144) techniques
depending on the configuration of the roll.
Compare this to the desired values listed in
Feed Rate Settings, p. 7-4. Figure 144

7 Calibrate Feed Roll

Repeat steps 5 through 6 until the measured speed matches the desired values displayed in the
Feed Rate Settings, p. 7-4.
⚠NOTICE: It is very important to make small adjustments. Due to hysteresis the calibration will only
be accurate if you’re “climbing” towards the desired value. If you adjust the components speed past
the desired value you must start the process over again (for just that component) by lowering its
“percent command” significantly.
8 Adjust All Feed Rolls

Repeat steps 5 through 0 until all the feed rolls have been calibrated.
9 Measure Idler Roll Speed

Use a hand held digital tachometer to measure the RPM of the idler roll you’re adjusting the
speed of. You may have to use center line contact (Figure 142), non-contact (Figure 143), or
radial contact (Figure 144) techniques depending on the configuration of the roll. Compare this
to the desired values listed in Feed Rate Settings, p. 7-4.
10 Adjust Idler Roll Speed

From the control panel, adjust the “Idler Roll Max” setting for the idler roll you’re measuring the
speed of until its speed matches the desired value listed in Feed Rate Settings, p. 7-4. For
more information see Idler Output Adjust Menu, p. 3-113.
11 Cycle feed system off and on

Turn the feed system off, let it sit for 10 seconds, and then turn the feed system on again.
12 Calibrate Idler roll

Repeat steps 9 through 11 until the measured speed matches the desired speed. 3-4
repetitions are usually required to obtain the desired RPM values.
⚠NOTICE: It is very important to turn the feed system off and on again. Due to the especially high
hysteresis in these components the calibration will only be accurate if it is checked after being reset.
If you adjust the components without resetting them the calibration will be inaccurate.
13 Calibrate all Idler Rolls

Repeat steps 9 through 12 until all four idler rolls have been calibrated.
14 Record Settings
Record the “Rate Offset” settings in your maintenance log. These may be useful in the future if
the settings ever need to be reset.

Bolt-In Style Kingpin Inspection

Certain CBI portable machines are fitted with a bolt-on style kingpin. In order to ensure the
kingpin functions as intended it must be inspected periodically. Failure to identify and remedy unsafe
conditions may lead to severe equipment damage. The purpose of this bulletin is to familiarize
customers with how to inspect their bolt-in style kingpin.
⚠ WARNING: Inspection should only be performed by trained and qualified personnel!

Before performing maintenance on your
machine, it is imperative to safeguard
employees from the unexpected release of
hazardous energy. For more information see
Service Preparation, p. 4-16.
2 Perform Visual Inspection

Inspect the entire kingpin assembly (Figure
145) for signs of corrosion, damage, or
cracks. Make appropriate repairs if
necessary. Figure 145
3 Check Lubrication
Check the lubrication on the kingpin. It
should be thoroughly lubricated with a high
pressure (EP) grease with MoS2 or graphite
additive. Apply new grease if necessary.
4 Inspect for Wear

Measure the kingpin for wear. Measure the
kingpin’s major diameter (Figure 146 / A),
minor diameter (Figure 146 / B), and height
(Figure 146 / C). Compare the measured
values to the wear limits specified in Wear
Specifications, p. 7-7. Figure 146
⚠ NOTICE: the kingpin wear will be most noticeable in the direction of travel.
5 Replace Kingpin if necessary
Replace the kingpin if necessary, for installation instructions see Bolt-In Style Kingpin Assembly,
p. 4-31.
6 Inspect Fastener torque

Inspect all the kingpin mounting bolts (Figure 145 / A) to ensure they are tightened to 140 ft·lbs
(189.8 N·m). If any fasteners are loose, replace all of them. For more information see Bolt-In
Style Kingpin Assembly, p. 4-31.

Bolt-In Style Kingpin Assembly

Certain CBI portable machines are fitted with a bolt-on style kingpin. In order for the kingpin to
function properly it must be installed using the appropriate technique. Failure to install the kingpin
properly may result in component failure and sever equipment damage or injury to personnel. The
purpose of this procedure is to familiarize personnel with a technique for assembling a bolt-in style
kingpin.
⚠WARNING: Always replace any fasteners that have sustained wear or damage; failure to comply may
result in component failure, equipment damage, or injury to personnel!

Before performing maintenance on your machine, it
is imperative to safeguard employees from the
unexpected release of hazardous energy. For more
2 Remove the mounting bolts

Remove and dispose of the old mounting bolts
(Figure 147 / A) that secure the kingpin to the trailer
frame. Ensure the kingpin is properly supported
before removing the last bolt.
Figure 147
3 Apply thread locking compound
Apply removable “blue” style thread locking
compound to the first four threads on each new
mounting bolt.
4 Reinstall Kingpin
Reinstall the kingpin into the trailer frame using new
fasteners. Only tighten the mounting bolts hand-
tight.
5 Torque the mounting bolts

Torque all the mounting bolts to 140 ft·lbs (189.8
N·m). Apply the torque in 70ft·lbs (95.9 N·m)
increments using a “star pattern” as shown in Figure
148.
Figure 148

Axle Oil Level Inspection

CBI portable machine are fitted with oil filled axle assemblies. It is important to inspect the oil level
on a regular basis. Operating with levels too high can lead to seal damage and operating with levels
too low can lead to severe damage and/or component failure. The purpose of this section is to
familiarize operators with the technique for inspecting the axle oil levels.
⚠WARNING: Follow all applicable safety precautions when dealing with used oil or any chemicals.
Take care that chemicals are handled in an environmentally friendly manner. Always acquire and read
the MSDS for any chemical prior to working with it.
⚠NOTICE: The oil level should be checked with the machine level and prior to operating the machine
when the oil is at ambient temperature.
1. Prepare the machine for service

Perform a lock out / tag out procedure on the machine
to ensure no unintentional machine movement or
hazardous releases of energy. For more information
see Service Preparation, p. 4-16.
2. Inspect oil level

Inspect the oil level at the site gauge on the end of
each hub. The oil should be level with the inner “full”
ring marked on the outside of the hub as shown in
Figure 149.
⚠NOTICE: Make note of any adjustments in your

maintenance log, fluctuations in levels may be indicative of
larger systemic problems.
Figure 149
3. Adjust level as necessary
Adjust the oil level as necessary, using the plug on the hub cap. for more information see:
⚠WARNING: Failure to use CBI approved fluids may result in severe damage, for more information see
Lubrication Schedule and Specifications, p. 4-11.

Engine Coolant level inspection

It is important to inspect the engine coolant levels for your CBI machine on a regular basis.
Operating with levels too high can lead to fluid loss and operating with levels too low can lead to
severe damage and/or component failure. Sudden fluctuations in coolant levels may be indicative of
larger systemic problems. The purpose of this section is to familiarize operators with the technique for
inspecting the engine coolant level.
⚠NOTICE: The coolant level should be checked with the machine level and prior to operating the
machine when the coolant is at ambient temperature.

5. Inspect coolant level

Inspect the coolant level at the site gauge on the top of
the expansion tank. The coolant should be visible ¾ of
the way to the top of the sight glass (Figure 150). The
level should never be above the sight glass or lower
than ½ way up the sight glass. Excessively low coolant
levels may trip the low coolant level fault in the engine
computer and disable the engine.
⚠NOTICE: Make note of any adjustments in your

maintenance log, fluctuations in levels may be indicative of
larger systemic problems. Figure 150
6. Adjust level as necessary

Adjust the coolant level as necessary, for more information see: Adding Engine Coolant, p. 4-34.

Adding Engine Coolant

Occasionally the engines cooling system may need coolant added to it. Operating with levels too
low may compromise the systems effectiveness. The purpose of this section is to familiarize operators
with a technique for adding engine coolant.

2. Remove fill cap

Slowly remove the engine coolant fill cap from the top
of the radiator (Figure 151). Ensure no contaminants
enter the cooling system once the cap is removed.
⚠WARNING: At operating temperature the engine coolant is

hot and under pressure. Never remove the fill cap until it
has cooled enough to touch with a bare hand! Figure 151
3. Add coolant
Use a filtered funnel to add coolant through though the filler neck until the levels are in the
desirable range. For more information see Engine Coolant level inspection, p. 4-33.
4. Replace Cap
Reinstall the fill cap on the radiator, ensure the cap seals properly or it may compromise the
effectiveness of the cooling system.

Changing Engine Coolant

The engines cooling system requires its coolant be changed periodically, failure to change it as
required may compromise the systems effectiveness and lead to premature component failure. The
purpose of this section is to familiarize operators with a technique for changing engine coolant.

2 Remove fill cap

Slowly remove the engine coolant fill cap from the top
of the radiator (Figure 152). This allows the coolant to
flow freely once the drain is opened. Ensure no
contaminants enter the cooling system.
⚠WARNING: At operating temperature the engine coolant is

hot and under pressure. Never remove the fill cap until it Figure 152
has cooled enough to touch with a bare hand!
3 Remove drain valve plug

Remove the plug from the drain valve (Figure 153 / A)
4 Drain Coolant
Slowly open the drain by turning the valve handle
(Figure 153 / B) and allow the coolant to drain into a
suitable container.
5 Flush System
Flush the cooling system with clean water until the
water coming out the drain is transparent. Figure 153
6 Close the drain

Close the coolant drain valve by turning the valve handle until it is fully shut (Figure 153 / B).
Reinstall the plug into the end of the drain valve (Figure 153 / A).
7 Refill the system

Refill the coolant system with the appropriate coolant. For detailed information see Adding Engine
Coolant, p. 4-34.
8 Purge the system

Run the engine with the radiator cap loosened to the point it does not seal but not fully removed
until the water temperature regulator opens and the coolant level stabilizes.
9 Check the coolant level

Check the coolant level, for more information see Engine Coolant level inspection, p. 4-32.
10 Reset Components
Stop the engine and reinstall the fill cap on the radiator, ensure the cap seals properly or it may
compromise the effectiveness of the cooling system.

Verifying Proper Fan Purge

Your CBI equipment is fitted with a Flexxaire automatic hydraulically controlled reversing fan. It
is important to verify that this fan functions properly or severe damage to the machine could result.
The following procedure will familiarize the operator with how to verify proper fan purge operation.
1 Start the machine

Start the machine, for more information see
Starting the flail, p. 3-10.
2 Enter “Cooling System Menu”

From the main menu at the control panel, enter the
Cooling System Menu. For detailed information
see Cooling System Menu, p. 3-96.
3 Initiate a momentary “purge override”

At the control panel, from the Cooling System
Menu, initiate a momentary “purge override”. For
detailed information see Cooling System Menu, p.
3-96.
4 Verify Proper fan purge operation

Quickly head over to the radiator, using a rag or
piece of paper held to the face of the fan (Figure
154), verify that the fan direction changes when the
purge cycle ends (typically 10 seconds from when it
was initiated) Figure 154
⚠WARNING: Use extreme caution around the fan; rotating blades and flying debris pose a severe
hazard. Always adhere to the pertinent safety procedures when working on CBI equipment.
Verifying Pre-cleaner Operation

Your CBI equipment is fitted with an engine air pre-cleaner. It is important to verify that this pre-
cleaner functions properly. The following procedure will familiarize the operator with how to verify their
pre-cleaner is functioning properly.
1 Start the machine

In order to inspect the pre-cleaner, the engine must
be running. For more information see Starting the
flail, p. 3-10.
2 Inspect the pre-cleaner
Using a portable work light, look underneath the pre-
cleaner; you should be able to see the turbine blades
(Figure 155 / A) rotating freely in the pre-cleaner
housing.
⚠WARNING: Never stick insert anything into the pre-

cleaner housing, injury to personnel or damage to the
rotating fan blades may result. Use extreme caution
when working around running equipment. Always
adhere to the pertinent safety procedures when working
on CBI equipment. Figure 155

Air filter service indicator inspection

Your CBI equipment is fitted with a service Indicator on the outlet side of the air filter housing(s).
This indicator warns operators when there is an excessive restriction in the air filter, it should be
inspected on a regular basis. The purpose of the following procedure is to familiarize operators with a
technique for inspecting the air filter service indicator(s) on their machine.
1 Turn off the machine

In order to inspect the air filter service indicator the engine should not be running.
2 Inspect the Indicator

Inspect the indicator (Figure 156) for signs of
damage, cracks, or potential leaks; replace
immediately if any are noted.
3 Read the Indicator

Observe the yellow plunger inside the barrel of the
filter indicator (Figure 156 / A). If the plunger is in
the green zone (< 25” of H2O) than the filter is fine, if
the plunger is in the red zone (> 25” of H2O) then the
filter needs to be replaced.
4 Service air filter if required

Service the air cleaner if required, for detailed
information consult Supplemental Manuals, p. 1-4.
Figure 156
5 Reset indicator
Depress the yellow button on the end of the indicator (Figure 156 / B) to reset the plunger
Air Filter Unloader Valve Inspection

Your CBI equipment is fitted with an unloader valve on the bottom of the engines air filter cover(s).
This valve is used for releasing larger contaminants that make it through the pre-filter and should be
inspected on a regular basis. The purpose of the following procedure is to familiarize operators with a
technique for inspecting the air filter unloader valve(s) on their machine.
1. Turn off the machine

In order to inspect the air filter unloader valve the engine
must be turned off.
2. Clean the valve

Squeeze the two sides of the valve together to release
any of the larger contaminants that have been
separated out of (Figure 157).
3. Inspect the valve

Inspect the valve for signs of damage, cracks, or
potential leaks.
4. Replace if necessary
If the unloader valve shows signs of any conditions that
may adversely affect its performance, replace it
immediately.
Figure 157

Welding On the Machine

Certain maintenance on your machine may require welding. There are sensitive electronic and
precision mechanical components that may be damaged if proper precautions are not taken. The
purpose of this section is to familiarize operators with the basic procedure for welding on CBI
machines.
INFO: For complete welding precautions for all components consult the OEM manuals; see
⚠WARNING: Always follow all applicable safety precautions and have sufficient fire suppression
equipment present when welding! For more information see Safety, p. 2-1.

Perform a lock out / tag out procedure on the
machine to ensure no unintentional releases of
energy. For more information see Service
Preparation, p. 4-16.
2 Clean The Work Area

Thoroughly clean the work area. Any built up
trash, debris, or residue generates a serious fire
hazard. For more information see
Cleaning, p. 3-17.
3 Disconnect the ECM

Disconnect the J1/P1 and J2/P2 connectors
from the ECM. Move the harness to a position
that will not allow the harness to accidentally Figure 158
move back and make contact with any ECM
pins. For more information consult the engine
manual; see Supplemental Manuals, p. 1-4.
4 Disconnect link CAN antenna (if applicable)

If your machine is configured to wirelessly link
with another CBI machine (a “combo unit”),
disconnect the wireless CAN antenna (Figure
158) that they use for communication.
Figure 159
5 Mount the Safety Breaker
Mount the CBI safety breaker (PN: 80013138)
across the terminals on the back of the battery
disconnect switch (Figure 159 / A). Mounting
the breaker ensures the entire electrical system
is protected by the suppressor while still
ensuring the machine cannot be started.
6 Mount Surge Suppressor

Mount the CBI surge protector (PN: 81010086)
across the battery terminals for both batteries
(Figure 160 / A). If the surge protector is hooked
up properly, the status LED will glow green.
Figure 160
7 Mount Grounding Cable
Mount the Welding Ground Cable in a secure fashion to ensure sufficient contact for the entire
welding process.

⚠WARNING: Never mount the welding ground cable with a bearing or precision component in between
the ground and electrode. Severe damage to the component will result. Always mount the welding
ground as close to the area being welded as possible. This ensures components are not exposed to
unnecessary high electrical currents. Never mount the grounding cable to electronic components or
with electronic components in the current path between the electrode and ground. Always ensure
electronic components are isolated from direct or induced current from welding.
8 Perform Welding
The machine is now successfully prepared for safe welding using standard welding practices.
9 Ensure work area is safe from fire

When welding is complete, CBI advises to always wet down the entire work area with sufficient
water to ensure no hot spots and to observe the machine for a minimum of 30 (thirty) minutes to
ensure no fires start.
10 Reset machine
Remove all electronic safety components fitted for weld preparation and refasten the ECM
connectors.
⚠NOTICE: Use extreme caution when reconnecting the ECM to not strip the delicate fasteners on the
ECM connectors. For more information consult the engine OEM manuals.
Hydraulic oil level inspection

It is important to inspect the hydraulic oil level of your CBI machine on a regular basis. Operating
with levels too high can lead to fluid loss and operating with levels too low can lead to severe damage
and/or component failure. The purpose of this section is to familiarize operators with the technique for
inspecting the hydraulic oil level.
⚠NOTICE: Hydraulic oil level should be checked before operating the machine when the oil is cool.
The machine must be level and components should be in their lowered state where applicable.

2 Inspect Oil Level

Inspect the hydraulic oil level at the site gauge on the
tank. The hydraulic oil should be visible ¾ of the way
to the top of the sight glass (Figure 161). For the sight
glass location see Machine Orientation & Component
Location, p. 1-6.
3 Adjust level as necessary

Adjust the hydraulic oil level as necessary. Failure to
use CBI approved fluids may result in severe damage,
for more information see Lubrication Schedule and
Specifications, p. 4-11.
Figure 161

Adding Hydraulic Fluid

The hydraulic oil level on your machine may need to be adjusted periodically. Fluid loss due to
system leaks can lead to dangerously low operating levels. The purpose of this procedure is to
familiarize operators with the technique for adding hydraulic oil to the machine.
1 Park Machine on Level Ground

Oil levels should always be checked with the machine parked on level ground to ensure an
accurate reading.

Before performing maintenance on your machine, it is imperative to safeguard employees from the
unexpected release of hazardous energy; see Service Preparation, p. 4-16.
3 Clean the tank

Clean the area above and around the fill plug to
ensure no contaminants are knocked into the tank
when the cap is removed.
4 Remove fill plug

Unscrew the fill plug from the top of the hydraulic tank
(Figure 162).
5 Add new oil

Add new oil to the tank through the filler neck where
the plug was installed.
⚠WARNING: Use extreme caution to ensure no

contaminants are knocked into the tank when filling it! Figure 162
⚠WARNING: Failure to use CBI approved fluids may result in severe damage, for more information
see Lubrication Schedule and Specifications, p. 4-11.
6 Check oil level

Check the oil height to confirm appropriate oil level, for more information see Hydraulic oil level
inspection, p. 4-39.

Changing Hydraulic Oil

The hydraulic fluid on your machine needs to be changed periodically. If not replaced when
required, contamination and break down of the oil can lead to premature component failure. The
purpose of the following procedure is to familiarize operators with a technique for changing the
hydraulic oil on their CBI machine.
Take care that chemicals are handles in an environmentally friendly manner. Always acquire and read
1 Park Machine on Level Ground

Oil levels should always be checked with the machine parked on level ground to ensure an
accurate reading.

Before performing maintenance on your machine, it is imperative to safeguard employees from the
unexpected release of hazardous energy; see Service Preparation, p. 4-16.
3 Clean the tank

Clean the area above and around the filler neck to ensure no contaminants are knocked into the
tank when the plug is removed
4 Remove ORB plug

Remove the ORB plug from the filler neck on top of the
hydraulic oil tank (Figure 163).
5 Drain the Oil

Use a vacuum based fluid extraction device or transfer
pump to suction the oil out from the filler neck. This
technique is preferable because it allows more control
over the used oil as its draining. If no tool is available
the oil can be drained by removing one of the drain
fittings at the bottom of the tank.
⚠WARNING: Use extreme caution to ensure no
contaminants enter the tank when draining it!
Figure 163
6 Refill the oil
Refill the tank through the filler neck with the new hydraulic oil; for detailed information see: Adding
Hydraulic Fluid, p. 4-40.
⚠WARNING: Use extreme caution to ensure no contaminants enter the tank when filling it!
7 Check oil level

Check the oil height to confirm appropriate oil level, for more information see Hydraulic oil level
inspection, p. 4-39.
8 Replace ORB plug

Thread the ORB plug back into the filler neck in accordance with Torque Specifications, p. 7-5.

Hydraulic Tank Breather Inspection

The hydraulic tank on your machine is fitted with a replaceable breather element. This element
allows the system to “breathe” as it expands and contracts with temperature changes without
allowing contaminants into the system. Regular inspections of the hydraulic tank breather must be
performed to ensure that it is able to function as intended. The purpose of this procedure is to
familiarize operators with how to inspect a hydraulic tank breather on a CBI machine.
1 Prepare the Machine for service

to ensure no hazardous release of energy. For more
2 Clean the tank

Clean the area above and around the breather
element on top of the hydraulic tank (Figure 164) to
ensure no debris interferes with its functioning
properly.
3 Inspect for blockage

Inspect the bottom of the element to ensure that no
contaminants are blocking the breather’s intake
(Figure 165). If the element shows signs of
blockage it must be replaced.
4 Inspect breather for damage

Inspect the body of the breather for damage (Figure
Figure 164
164). If the element shows signs of damage, it must
be replaced.
5 Replace Breather as Necessary

Replace the filter element immediately If the
inspection shows it’s needed. For more information
see Hydraulic Tank Breather Replacement, p. 4-43.
⚠NOTICE: Any time a filter requires replacement prior to

its regularly scheduled maintenance; make a record of it
in your maintenance log.
Figure 165

Hydraulic Tank Breather Replacement

The hydraulic tank on your machine is fitted with a breather element that requires periodic
replacement. This is done to prevent contaminants from working their way into the hydraulic system.
Failure to maintain the breather may result in severe system damage. The purpose of this procedure
is to familiarize operators with how to replace a hydraulic tank breather on a CBI machine.
1 Prepare the Machine for service

2 Clean area
Clean any debris off the filter element on top of the
hydraulic tank (Figure 166). Clean the area above and
around the breather also to ensure no debris enters
the system during service.
3 Remove old element

Unscrew the old breather element and inspect it for
abnormal debris or damage. Contact CBI if any
abnormalities are noted. For more information see
⚠WARNING: Use extreme caution to ensure that no

contamination enters the tank when the cap is removed!
Figure 166
4 Install new element
Thread the new element onto the mounting neck. The breather should only be tightened
“hand-tight”.

Pressure Line Filter Inspection

The hydraulic filters on your machine are fitted with indicators to alert operators if the filters
require replacement before their scheduled intervals. It is important to inspect the filters on a regular
basis as increased filter consumption can be indicative of larger systemic problems. The purpose of
this procedure is to familiarize operators with how to inspect a pressure line filter on a CBI machine.
1 Start the machine

For the filter indicator to read properly hydraulic oil
must be flowing through the filter. For detailed
information see Starting the flail, p. 3-10.
⚠NOTICE: Cold oil temperatures may cause false

restriction readings. In such cases allow oil to reach
operating temperature before inspecting indicator.

Inspect the indicator on the top of the filter housing
(Figure 167). If the indicator is green the filter is
fine, if the indicator is red than the filter needs to be
replaced. Figure 167
3 Replace Filter if Necessary

Replace the filter element immediately if the indicator shows it’s needed. For more information
see Pressure Line Filter Replacement, p. 4-45.
⚠NOTICE: Any time a filter requires replacement prior to its regularly scheduled maintenance, make
a record of it in your maintenance log; it may be indicative of larger systemic problems.

Pressure Line Filter Replacement

The hydraulic filters on your machine act as a barrier for protecting expensive components such
as pumps, valves and motors from contaminants. It is important to replace the filters on a regular
basis to protect the hydraulic system. The purpose of this procedure is to familiarize operators with
how to replace a pressure line filter element on a CBI machine.
⚠WARNING: Follow all applicable safety precautions when

dealing with used oil or any chemicals. Take care that
chemicals are handled in an environmentally friendly
manner. Always acquire and read the MSDS for any
chemical prior to working with it.

2 Release residual hydraulic pressure

Release all residual pressure from the hydraulic
system. For detailed information see CBI Authorized
Service, p. 1-12.
⚠WARNING: Pressurized fluid can penetrate the skin Figure 168

causing severe injury or death! Always release residual
pressure before disconnecting any hydraulic or fluid
system components.
3 Clean filter housing

Thoroughly clean the outside of the filter housing to
ensure no contaminants enter the system when
performing service (Figure 168).
4 Remove bowl
Unscrew the bowl and remove it from the filter housing
(Figure 169).

Remove the old element from the housing and inspect
for abnormal debris or damage. Contact CBI if any
Figure 169
Install the new filter element onto the housing. Make
sure to lubricate the filters seal (Figure 170 / A) with
hydraulic oil prior to installing it.
7 Clean the bowl

Thoroughly clean the inside of the filter bowl of any
debris or residue. Use caution around the seal if using
solvent.
Figure 170

8 Inspect bowl seal

Inspect the bowl seal (Figure 171 / A) for cracks, nicks,
compression set, or signs of damage. Replace if
necessary.
9 Reinstall bowl
Lubricate the threads and seal on the bowl with
hydraulic oil and reinstall it.
⚠NOTICE: Do not torque component only hand tighten.

10 Inspect for leaks
Start the machine and inspect the assembly for signs
of leaks. Use caution to protect yourself from
exposure to high pressure fluids. Figure 171

Charge Circuit Filter Inspection

The hydraulic filters on your machine are fitted with indicators to alert operators if the filters
require replacement before their scheduled intervals. It is important to inspect the filters on a regular
basis as increased filter consumption can be indicative of larger systemic problems. The purpose of
this procedure is to familiarize operators with how to inspect a charge circuit filter on a CBI machine.
1 Start the machine

For the filter indicator to read properly hydraulic oil must be flowing through the filter. For detailed
⚠NOTICE: Cold oil temperatures may cause false restriction readings. In such cases allow oil to
reach operating temperature before inspecting indicator.
2 Reset dial
Occasionally the inrush of hydraulic pressure at
startup will cause a false restriction reading in the dial
on the top of the filter housing (Figure 172 / A). Reset
the dial by rotating it as far as it will easily go towards
the green side of the scale.

Inspect the dial on the top of the filter housing (Figure
172 / A). If the dial is pointing to the green side of the
scale the filter is fine, if the dial is in the red than the
filter needs to be replaced.
Figure 172
Replace the filter element immediately If the indicator shows it’s needed. For more information
see Charge Circuit Filter Replacement, p.4-48.

Charge Circuit Filter Replacement

as pumps, valves, and motors from contaminants. It is important to replace the filters on a regular
how to replace a charge circuit filter element on a CBI machine.
⚠WARNING: Follow all applicable safety precautions when

dealing with used oil or any chemicals. Take care that
chemicals are handled in an environmentally friendly
manner. Always acquire and read the MSDS for any
chemical prior to working with it.


Service, p. 1-12.
Figure 173
⚠WARNING: Pressurized fluid can penetrate the skin
system components.

4 Remove bowl
Unscrew the bowl and remove it from the filter housing
(Figure 174).

Remove the old element from the housing and inspect
for abnormal debris or damage. Contact CBI if any
Figure 174
sure to lubricate the filters seal (Figure 175 / A) with
hydraulic oil prior to installing it.
7 Clean the bowl

debris or residue. Use caution around the seal if using
solvent.
Figure 175

8 Inspect bowl seal

Inspect the bowl seal (Figure 176 / A) for cracks, nicks,
compression set, or signs of damage. Replace if
necessary.
9 Reinstall bowl
Lubricate the threads and seal on the bowl with
hydraulic oil and install it. Torque the bowl to 45 ft/lbs
(61Nm)

Start the machine and inspect the assembly for signs
of leaks. Use caution to protect yourself from
exposure to high pressure fluids.
Figure 176

Return Circuit Filter Inspection

The return circuit hydraulic filters on your machine are fitted with indicators to alert operators if
the filters require replacement before their scheduled intervals. It is important to inspect the filters on
a regular basis as increased filter consumption can be indicative of larger systemic problems. The
purpose of this procedure is to familiarize operators with how to inspect a return circuit filter on a CBI
machine.
1 Start the machine

For the filter indicator to read properly hydraulic oil
must be flowing through the filter. For detailed
⚠NOTICE: Cold oil temperatures may cause false

restriction readings. In such cases allow oil to reach
operating temps before inspecting indicator.
2 Reset dial
Occasionally the inrush of hydraulic pressure at
startup will cause a false restriction reading in the dial
on the top of the filter housing (Figure 177 / A). Reset
the dial by rotating it as far as it will easily go towards
the green side of the scale.

Inspect the dial on the top of the filter housing (Figure
177 / A). If the dial is pointing to the green side of the
scale the filter is fine, if the dial is in the red, the filter Figure 177
needs to be replaced.

Replace the filter element immediately If the indicator shows it’s needed. For more information
see Return Circuit Filter Replacement, p.4-51.

Return Circuit Filter Replacement

as pumps, valves, and motors from contaminants. It is important to replace the filters on a regular
how to replace a return circuit filter element on a CBI machine.
Take care that chemicals are handled in an environmentally friendly manner. Always acquire and
read the MSDS for any chemical prior to working with it.


Service, p. 1-12.

system components.

performing service (Figure 178). Figure 178
4 Remove bowl
Loosen the fasteners on the top of the filter housing (Figure 179 / A) that secure the bowl and
remove the bowl from the housing (Figure 180). Use caution to ensure the spring on the bottom
of the filter element is not knocked loose when removing the bowl.

⚠NOTICE: On certain machines oil may siphon out of the hydraulic tank when the return filter bowl
is removed. In such instances, crack the return line at the tank to stop the siphoning. Ensure the
fitting is retightened after service is complete.

5 Remove spring and plate

Remove the compression spring and its mounting
plate from the bottom of the old filter element (Figure
181).

Remove the old element from the housing and
inspect for abnormal debris or damage. Contact CBI
if any abnormalities are noted. For more information
see CBI Authorized Service, p. 1-12.

sure to lubricate the filters seals at both ends of the
filter (Figure 182 / A) with hydraulic oil prior to
installing it.
8 Reinstall the spring and plate

Thoroughly clean the compression spring and its Figure 181
mounting plate of any debris or residue, reinstall
them in the bottom of the filter element.
9 Clean the bowl

debris or residue. Use caution around the seal if
using solvent.
10 Inspect bowl seal

Inspect the bowl seal (Figure 183 / A) for cracks,
nicks, compression set, or signs of damage.
Replace if necessary. Figure 182
11 Reinstall bowl
Lubricate the bowl seal with hydraulic oil and
reinstall the bowl. Torque the mounting bolts (Figure
179 / A) to 45 ft/lbs (61Nm).

Start the machine and inspect the assembly for
signs of leaks. Use caution to protect yourself from
exposure to high pressure fluids.
⚠NOTICE: On certain filter assemblies multiple filter

elements are connected in series using an intermediate
union. On these assemblies, remove, clean, and reuse
the union to connect the new filter elements. Figure 183

Magnetic Hydraulic Filter Core Cleaning

The Magnetic Hydraulic filters on your machine remove ferrous contaminants from the hydraulic
system. It is important to clean the filters on a regular basis to protect the machine from premature
wear. The purpose of this procedure is to familiarize operators with how to clean the filter core inside
a magnetic hydraulic filter on a CBI machine.
⚠WARNING: Follow all applicable safety precautions

when dealing with used oil or any chemicals. Take care
that chemicals are handled in an environmentally
friendly manner. Always acquire and read the MSDS for
any chemical prior to working with it.

Perform a lock out / tag out procedure on the
machine to ensure no hazardous release of energy.
For more information see Service Preparation, p. 4-
16.

system. For detailed information contact CBI; see Figure 184

system components.

4 Detach Connections
Disconnect the lower hydraulic hose (Figure 185 / A)
and the contaminant sensor connector (Figure 185 /
B) from the filter housing.
Figure 185
5 Separate Filter Housing
Use a wrench to loosen the lower half of the filter
housing and then remove it from the machine.
6 Remove lower Filter Housing

Remove the lower filter housing from the machine,
see Figure 187.
7 Remove Magnetic Core

Remove the magnetic core from the lower filter
housing, it should slide out easily. See Figure 188.
Figure 186

8 Clean the magnetic core

Use a solvent to remove as much oil residue as
possible from the core. Use a blow gun directed
away from the core’s center to blow away
contaminants, see Figure 189.
⚠WARNING: Flying debris propelled by compressed

air can be hazardous. Ensure sufficient precautions
are taken to protect personnel.
Figure 189
9 Remove Contamination sensor
Remove the contamination sensor from the lower
filter housing by unscrewing it; see Figure 190.
10 Clean Contamination sensor

Thoroughly clean the contamination sensor.
Ensure no ferrous material is trapped between the
outer and inner magnetic contacts (Figure 191 / A
& B respectively). Use caution around the seal
contacts (Figure 191 / C) if using solvent.

Thoroughly clean the inside of the filter housing of Figure 190
any debris or residue. Use caution around the
seal if using solvent.
12 Reinstall Contamination sensor

Reinstall the contamination sensor in to the lower
filter housing. The sensor should be torqued no
tighter than 44 ft/lbs (60Nm).
13 Reinstall Magnetic core

Reinstall the magnetic core into the lower filter
housing.
14 Inspect housing seal

Inspect the housing seal (Figure 192 / A) for
cracks, nicks, compression set, or signs of
damage. Replace if necessary. Figure 191

15 Reinstall Housing
Lubricate the housing seal (Figure 192 / A) with
hydraulic oil and reinstall the lower housing.
⚠NOTICE: Do not torque component, hand tighten only.
16 Reattach Connections
Reconnect the lower hydraulic hose (Figure 185 / A)
and the contaminant sensor connector (Figure 185 /
B) to the filter housing. Tighten components in
accordance with Torque Specifications, p. 7-5.

Start the machine and inspect the assembly for
signs of leaks. Use sufficient caution to protect
yourself from exposure to high pressure fluids. Figure 192

Oil Analysis
CBI warranty policy for its equipment may stipulate that a hydraulic and/or engine oil analysis be
performed by a certified testing laboratory (Mobil Oil test lab, Parker Par-test, or equivalent), a
minimum of 1 (one) time per month or every 250 operating hours (whichever comes first). If
competent local testing services are not available, the CBI part number for 10 parker fluid test kits
with prepaid laboratory analysis is 71011887. The following is a generic procedure for obtaining in-
tank samples.
1 Warm up oil
Operate the system for at least ½ hour to warm the oil and distribute any contaminants for
accurate sampling.
2 Sample Oil
Using a small hand held vacuum pump bottle thief or “basting syringe” sample fluid from the
center portion of the tank. Do not let the sampling device come in contact with the sides of the
tank.
3 Put oil in approved sampling container

Insert oil sample into the pre-cleaned CBI approved sampling container (PN 71011887). Do not
fill bottle more than on inch (25mm) from the top
4 Seal sample
Cap sample bottle immediately to avoid contamination
5 Tag the Sample

Tag the sample bottle with pertinent data (i.e. machine serial number, machine hours, fluid type,
fluid supplier, fluid part number, and elapsed time since last sample).
6 Submit Sample for testing

Keep records of all pertinent data and submit oil sample to an approved test lab for testing.
Ensure proper techniques are used for transportation of hazardous materials if applicable.
⚠WARNING: If a sample-test report indicates that an oil change is required, it is imperative that a
complete fluid change including replacement of all filter elements is performed. For detailed
information contact CBI, see Service department contact information, p. 1-12.
⚠NOTICE: Observe common sense rules, any equipment used in the fluid sampling procedure must
be washed and rinsed with filtered solvent. This includes vacuum pumps, syringes, and tubing. Your
goal is to count only the particles in the system fluid. Non representative samples will lead to
erroneous conclusions.

PN 71510013 - OMM015008130510 ELECTRICAL SYSTEM - SECTION TABLE OF CONTENTS 5-1
5. Electrical System
General ................................................................................................................. 5-2
Description ................................................................................................................................ 5-2
Schematics ........................................................................................................... 5-2
Power and CAT Starter Connections ..................................................................................... 5-3
Main System Input Signals ...................................................................................................... 5-4
MDL Wiring ................................................................................................................................ 5-5
XA2 Wiring ................................................................................................................................ 5-6
Position Sensors ...................................................................................................................... 5-9
RTD / PT100 Converters ........................................................................................................ 5-10
Radio Receiver Speed Signal Converter .............................................................................. 5-11
Remote Diagnostic Package ................................................................................................. 5-12
Panel Layout ........................................................................................................................... 5-13
Field Connection Upper Rail ................................................................................................. 5-15
Field Connections, Lower Rail, Left Center ......................................................................... 5-16
Field Connections, Lower Rail, Center Right ...................................................................... 5-17
Connector Layout ................................................................................................................... 5-18
Tigercat 215 Loader Joysticks .............................................................................................. 5-19
Wiring Schematic & Numbering Legend .............................................................................. 5-20

5-2 ELECTRICAL SYSTEM - GENERAL PN 71510013 - OMM015008130510
General
Description
Your CBI machine is equipped with a parker IQAN control system. The IQAN system is a unique,
totally electronic approach that replaces mechanical and electromechanical systems for controlling
and monitoring hydraulics in mobile machines. IQAN hardware is tested for robust operation and
compatibility with mobile hydraulic equipment. In addition, it meets industry and government
standards for operation in severe conditions that include extremely high or low temperatures,
vibrations, mechanical impact and electromagnetic interference.
The IQAN-MDL is the central Display unit that works with a variety of expansion modules in an
IQAN control system. The MDL works as a master, displays information, provides a data gateway and
has a variety of flexible I/O channels. In most applications the display will replace all mechanical dial
type instruments. The MDL has a 6.5” transflective TFT color display that has very high optical
performance across a wide range of operating conditions. The MDL can control proportional valves
using current mode (current closed-loop) or PWM mode (voltage open-loop) signals. The analog
inputs accept 0-5V signals from input devices or sensors. These inputs can also be set up to accept
one frequency or directional frequency (quadrature) input. Many outputs may alternatively be used as
digital inputs for switches. The unit also has 4 CAN interfaces, all of which are user configurable. The
MDL is connected to other units by a CAN bus.
The IQAN-XA2 can control proportional valves using current mode (current closed-loop) or PWM
mode (voltage open-loop) signals. The aluminum housing is designed to be rugged, but light and has
a sealed, automotive AMP/Tyco power timer connector. The XA2 has a membrane to prevent
condensation inside the housing. This controller is designed for the outdoor environment. The unit
executes a self-test during start up and cyclic operation. An internal watch dog checks for software
errors and will interrupt outputs if errors are detected. The IQAN-XA2 is made using selected
components and conforms to strict international requirements. Diagnostics: If an error is detected an
LED on the top of the controller flashes a sequence to indicate the nature of the error.
Schematics
The following are schematics for the electrical system of your CBI machine. Their purpose is to
familiarize operators with the functions of their electrical system. For specific requests or detailed
information please contact CBI, see Service Assistance, 1-11.

PN 71510013 - OMM015008130510 ELECTRICAL SYSTEM - SCHEMATICS 5-3
Power and CAT Starter Connections
Figure 193
5-4 ELECTRICAL SYSTEM - SCHEMATICS PN 71510013 - OMM015008130510
Main System Input Signals
Figure 194
MDL Wiring
Figure 195
XA2 Wiring
Figure 196
Figure 197
Figure 198
Position Sensors
Figure 199
RTD / PT100 Converters
Figure 200
Radio Receiver Speed Signal Converter
Figure 201
Remote Diagnostic Package
Figure 202
Panel Layout
Figure 203
Figure 204
Field Connection Upper Rail
Figure 205
Field Connections, Lower Rail, Left Center
Figure 206
Field Connections, Lower Rail, Center Right
Figure 207
Connector Layout
Figure 208
Tigercat 215 Loader Joysticks
Figure 209
Wiring Schematic & Numbering Legend
Figure 210
PN 71510013 - OMM015008130510 HYDRAULIC SYSTEM - SECTION TABLE OF CONTENTS 6-1
6. Hydraulic System
General ................................................................................................................. 6-2
Description ................................................................................................................................ 6-2
Filter Identification ............................................................................................... 6-2
Charge Filters ........................................................................................................................... 6-2
Pressure Filters ........................................................................................................................ 6-3
Return Filters ............................................................................................................................ 6-3
Magnetic Filters ........................................................................................................................ 6-4
Schematic ............................................................................................................. 6-5
System Schematic .................................................................................................................... 6-5

6-2 HYDRAULIC SYSTEM - GENERAL PN 71510013 - OMM015008130510
General
Description
Your CBI machine is equipped with a state of the art hydraulic system featuring 15 unique
circuits. Flow to the flails drives and feed drives is supplied by nine hydrostatic closed loop pumps
featuring electronic proportional speed control. Flow to the idler roll circuit is supplied by a single load
sense piston pump. Flow to the flail lift circuit is provided by one pressure compensated piston pump.
Flow to for the discharge rams, cooler motor, and feed roller lift circuits is provided by four open loop gear
pumps. Hydraulic circuits incorporate specific filtration systems as well as a common filtration circuit in
line with the flow return to the tank. System cooling is managed by a common fluid cooler featuring a
hydraulically powered reversing fan motor.
Filter Identification
Charge Filters
The charge filters are located in the filter bank on the front left side of your machine (Figure 211).
These filter the charge oil before it reaches the closed loop part of the circuit. The purpose of this
section is to help operators identify where the charge filters are located and which circuit they belong to.
REF. CIRCUIT
A Flail #2 drive charge circuit
B Flail #3 drive charge circuit
C Flail #1 drive charge circuit
D Flail #4 drive charge circuit
E Inlet bottom roll charge circuit
F Exit top feed roll charge circuit
G Middle bottom roll charge circuit
H Exit Bottom roll charge circuit
I Infeed top feed roll charge circuit
Figure 211

PN 71510013 - OMM015008130510 HYDRAULIC SYSTEM - FILTER IDENTIFICATION 6-3
Pressure Filters
The pressure filters are located in the filter bank on the front left side of your machine (Figure 212).
These filter the pressurized oil after it leaves the pump but before it reaches components. The purpose
of this section is to help operators identify where the pressure filters are located and which circuit they
belong to.
REF. CIRCUIT
J Exit top roll lift pressure circuit
K Infeed top roll lift pressure circuit
L Flail #2 and #3 lift pressure circuit
M Idler rolls pressure circuit
Figure 212
Return Filters
The Return filters are located in the filter bank on the side of the hydraulic cooler (Figure 213).
These filter the oil after it leaves the pressurized components and before it returns to the tank. The
purpose of this section is to help operators identify where the return filters are located and which circuit
they belong to.
REF. CIRCUIT
N Return filter Canister #1
O Return filter Canister #2
Figure 213

6-4 HYDRAULIC SYSTEM - FILTER IDENTIFICATION PN 71510013 - OMM015008130510
Magnetic Filters
The magnetic filters are located in the filter bank above the flail drives (Figure 214). These filter
ferrous particles out of the oil leaving the flail drive case drains. They act as an advanced warning in
case of component failure in one of the flail drives. An electronic sensor monitors fluid upstream from
the filter and will automatically shut the machine down if contamination is detected. The purpose of this
section is to help operators identify where the magnetic filters are located and which circuit they belong
to.
REF. CIRCUIT
P Flail #1 Drive Motor Magnetic Filter
Q Flail #2 Drive Motor Magnetic Filter
R Flail #3 Drive Motor Magnetic Filter
S Flail #4 Drive Motor Magnetic Filter
Figure 214

PN 71510013 - OMM015008130510 HYDRAULIC SYSTEM - SCHEMATIC 6-5
Schematic
System Schematic
The system schematic for the hydraulic system of your CBI machine is shown on the following
page. Its purpose is to familiarize operators with the functions of their hydraulic system and serve as
a quick reference source. An additional large format copy for service use is available separately as a
supplement. For detailed information on your hydraulic circuits, please contact CBI (see Service
Assistance, 1-11)

PN 71510013 - OMM015008130510 HYDRAULIC SYSTEM - SCHEMATIC 6-7
Figure 215
6-8 HYDRAULIC SYSTEM - SCHEMATIC PN 71510013 - OMM015008130510
Figure 216
PN 71510013 - OMM015008130510 SPECIFICATIONS - SECTION TABLE OF CONTENTS 7-1
7. Specifications
Shipping Dimensions .......................................................................................... 7-2
Overall Dimensions .................................................................................................................. 7-2
Machine Specifications ....................................................................................... 7-2
Overall Dimensions .................................................................................................................. 7-2
Flail Drum .................................................................................................................................. 7-2
Flail Drive .................................................................................................................................. 7-2
Top Feed Roll ............................................................................................................................ 7-2
Bottom Feed Roll ...................................................................................................................... 7-2
Throughput ............................................................................................................................... 7-2
Power ......................................................................................................................................... 7-3
Fuel Tank ................................................................................................................................... 7-3
Electrical .................................................................................................................................... 7-3
Loader/Cab ................................................................................................................................ 7-3
Machine Adjustments .......................................................................................... 7-4
Feed Rate Settings ................................................................................................................... 7-4
Torque Specifications ......................................................................................... 7-5
Flail Drum Torque Specifications ........................................................................................... 7-5
General Torque Specifications ............................................................................................... 7-6
Wear Specifications ............................................................................................. 7-7
Kingpin 90 (3.5”) Wear Specifications.................................................................................... 7-7

7-2 SPECIFICATIONS - SHIPPING DIMENSIONS PN 71510013 - OMM015008130510
Shipping Dimensions
Overall Dimensions
Figure 217
Machine Specifications
Overall Dimensions
Length 44' 11"
Width 11'
Height 13' 6"
Weight Approx. 98,000 lb
Flail Drum
Width 60"
Diameter 40"
Chain Single or dual 8-link chains (50-96/roll) Speed 300-800 rpm
Flail Drive
Rexroth Hydrostatic Pumps, Rexroth motors, synchronous drives
Top Feed Roll

Width 60"
Diameter 21"
Motor Built-in high-torque Poclain
Bottom Feed Roll

High-torque Brevini planetary with Char-Lynn hydraulic motor
Throughput
Up to 175 tons/hour (dependent on operating conditions)
PN 71510013 - OMM015008130510 SPECIFICATIONS - MACHINE SPECIFICATIONS 7-3
Power
Engine CAT C18; 600 hp
Flexxaire® Fan Reversing pitch radiator fan that reverses airflow every 5-15 minutes
automatically (adjustable)
Fuel Tank
Capacity 275 gallons
Electrical
Parker IQANTM system with full radio remote control Remote wireless camera at
discharge end.
Loader/Cab
Tigercat T-215 Knuckle Boom with 4.4 L CAT engine and 27’reach

7-4 SPECIFICATIONS - MACHINE ADJUSTMENTS PN 71510013 - OMM015008130510
Machine Adjustments
Feed Rate Settings

The components of the feed system on your machine are calibrated to give known feed rates.
Occasionally the control system must be recalibrated for the feed system to perform as expected.
The following graph is provided to assist personnel in determining what speed the various
components should be spinning at for a given feed rate.
Figure 218

PN 71510013 - OMM015008130510 SPECIFICATIONS - TORQUE SPECIFICATIONS 7-5
Torque Specifications
Flail Drum Torque Specifications

The following torque values should be used when servicing the flail drum on your CBI 604 flail
debarker. CBI advices always using a high grade nickel based anti-seize compound on flail rod
retaining plugs.
Item Part Thread Torque

Wrench Size
# Description Size Specification
Flail Rod 37 ± 4 N·m

33 1” NPT ½” square drive
Retaining Plug (27 ± 3 FT·LB)

7-6 SPECIFICATIONS - TORQUE SPECIFICATIONS PN 71510013 - OMM015008130510
General Torque Specifications

The purpose of this section is to familiarize the operator with standard torque settings for typical
fasteners. Exceptions to these torque values may be given in the manual. For detailed information
please consult the Caterpillar publication number SENR3130.
SAE (English) Fasteners

The following torque settings are typical for grade 8 SAE thread machine screws, nuts, and bolts.
English (SAE) Nuts and Bolts English (SAE) Machine Screws

Thread Size Thread Size
Torque Torque
(Inch) (No.)
1/4 12 ± 3 N·m (105 ± 27 lb in) 0-80 0.10 ± 0.01 N·m (0.9 ± 0.1 lb in)
5/16 25 ± 6 N·m (18 ± 4 lb ft) 1-64 0.15 ± 0.01 N·m (1.3 ± 0.1 lb in)
3/8 47 ± 9 N·m (35 ± 7 lb ft) 2-56 0.25 ± 0.02 N·m (2.2 ± 0.2 lb in)
7/16 70 ± 15 N·m (50 ± 11 lb ft) 3-48 0.35 ± 0.05 N·m (3.1 ± 0.4 lb in)
1/2 105 ± 20 N·m (75 ± 15 lb ft) 4-40 0.50 ± 0.05 N·m (4.4 ± 0.4 lb in)
9/16 160 ± 30 N·m (120 ± 22 lb ft) 5-40 0.70 ± 0.10 N·m (6.2 ± 0.9 lb in)
5/8 215 ± 40 N·m (160 ± 30 lb ft) 6-32 0.90 ± 0.10 N·m (8.0 ± 0.9 lb in)
3/4 370 ± 50 N·m (275 ± 37 lb ft) 8-32 1.70 ± 0.25 N·m (15.0 ± 2.2 lb in)
7/8 620 ± 80 N·m (460 ± 60 lb ft) 10-24 2.25 ± 0.25 N·m (19.9 ± 2.2 lb in)
1 900 ± 100 N·m (660 ± 75 lb ft) 12-24 3.40 ± 0.60 N·m (30.1 ± 5.3 lb in)
1 1/8 1300 ± 150 N·m (960 ± 110 lb ft)
1 1/4 1800 ± 200 N·m (1320 ± 150 lb ft)
1 3/8 2400 ± 300 N·m (1780 ± 220 lb ft)
1 1/2 3100 ± 350 N·m (2280 ± 260 lb ft)
ISO (Metric) Fasteners

The following torque settings are typical for grade 10.9 ISO thread machine screws, nuts, and bolts.
Metric (ISO) Nuts and Bolts Metric (ISO) Machine Screws

Thread Size Thread Size
Torque Torque
(mm) (mm)
M6 12 ± 3 N·m (9 ± 2 lb ft) M1.6 0.10 ± 0.01 N·m (0.9 ± 0.1 lb in)
M8 28 ± 7 N·m (21 ± 5 lb ft) M2 0.15 ± 0.01 N·m (1.3 ± 0.1 lb in)
M10 55 ± 10 N·m (41 ± 7 lb ft) M2.5 0.35 ± 0.05 N·m (3.1 ± 0.4 lb in)
M12 100 ± 20 N·m (75 ± 15 lb ft) M3 0.50 ± 0.05 N·m (4.4 ± 0.4 lb in)
M14 160 ± 30 N·m (120 ± 22 lb ft) M4 1.70 ± 0.25 N·m (15.0 ± 2.2 lb in)
M16 240 ± 40 N·m (175 ± 30 lb ft) M5 2.25 ± 0.25 N·m (19.9 ± 2.2 lb in)
M20 460 ± 60 N·m (340 ± 44 lb ft)
M24 800 ± 100 N·m (590 ± 75 lb ft)
M30 1600 ± 200 N·m (1180 ± 150 lb ft)
M36 2700 ± 300 N·m (2000 ± 220 lb ft)

PN 71510013 - OMM015008130510 SPECIFICATIONS - WEAR SPECIFICATIONS 7-7
Wear Specifications
Kingpin 90 (3.5”) Wear Specifications

The Kingpin on your machine is subject to wear. Allowing components to become excessively
worn may lead to component failure and severe equipment damage. The purpose of this section is to
familiarize operators with the acceptable wear limits for a size 90 (3.5”) bolt-on style kingpin.
Dimension Maximum Minimum

Ref
Description Value Value
Kingpin Major 4.488 in 4.409 in

A
Diameter (114.0 mm) (112.0 mm)
Kingpin Minor 3.504 in 3.386 in

B
Diameter (89.0 mm) (86.0 mm)
2.913 in 2.835 in
C Kingpin Height
(74.0 mm) (72.0 mm)
Figure 219

PN 71510013 - OMM015008130510 REPLACEMENT PARTS - SECTION TABLE OF CONTENTS 8-1
8. Replacement Parts
Introduction .......................................................................................................... 8-2
Wear Parts ............................................................................................................ 8-2
Flail #1 – Bottom Flail Assembly – Inlet ................................................................................. 8-2
Flail #2 – Top Flail Assembly – Inlet ....................................................................................... 8-2
Flail #3 – Top Flail Assembly – Outlet .................................................................................... 8-3
Flail #4 – Bottom Flail Assembly – Outlet .............................................................................. 8-3
Plunger Assembly .................................................................................................................... 8-3
Misc. Wear Parts ....................................................................................................................... 8-3
Spare Parts ........................................................................................................... 8-4
Spare Electrical Parts............................................................................................................... 8-4
Spare Hydraulic Components ................................................................................................. 8-4
Spare Tigercat Loader misc. components ............................................................................. 8-4
Tigercat Loader service tools ................................................................................................. 8-5
Spare Misc. Components ........................................................................................................ 8-5
Consumable Parts ............................................................................................... 8-6
Engine Filters C15 .................................................................................................................... 8-6
Hydraulic Filters ....................................................................................................................... 8-6

8-2 REPLACEMENT PARTS - INTRODUCTION PN 71510013 - OMM015008130510
Introduction
The following are parts lists for commonly replaced components on your CBI machine. This list is
intended to assist in identifying common wear parts and does not constitute a complete list.
Operating conditions and techniques will determine how parts wear. For detailed ordering
instructions, please see Genuine CBI Replacement Parts, p. 1-11
Wear Parts
Wear parts are parts subjected to wear during normal operation that will need regular
replacement. The following is a list of common components that are subjected to regular wear on
your CBI machine.
Flail #1 – Bottom Flail Assembly – Inlet

QTY COMMON DESCRIPTION CBI PART NO.
1 SIDE WEAR LINER D.S. - UPPER 41510127
1 SIDE WEAR LINER N.D.S. - UPPER 41510128
1 SIDE WEAR LINER D.S. - LOWER 41510129
1 SIDE WEAR LINER N.D.S. - LOWER 41510130
1 DRIVE BELT 71510075
6 CHAIN KEEPER ROD 41510148-A
50 FLAIL CHAIN 41510011P8
6 END PLUG 71510071
Flail #2 – Top Flail Assembly – Inlet

1 SIDE WEAR LINER D.S. - LOWER 41510133-C
1 SIDE WEAR LINER N.D.S. - LOWER 41510134-B
2 OUTSIDE SEAL 41510141P1
2 OUTSIDE SEAL 41510141P2
6 END PLUG 71510071

PN 71510013 - OMM015008130510 REPLACEMENT PARTS - WEAR PARTS 8-3
Flail #3 – Top Flail Assembly – Outlet

1 SIDE WEAR LINER D.S. - UPPER 41510135-B
1 SIDE WEAR LINER N.D.S. - UPPER 41510136-B
2 OUTSIDE SEAL 41510141P1-A
2 OUTSIDE SEAL 41510141P2-A
6 END PLUG 71510071
Flail #4 – Bottom Flail Assembly – Outlet

6 END PLUG 71510071
Plunger Assembly
6 WEAR PLASCTIC - BOTTOM MID 41510116
1 WEAR PLASCTIC - BOTTOM FRONT 41510117
2 WEAR PLASTIC - PLUNGER 41510114
4 SPLIT BUSHING 71510020
2 PLUNGER BAR 41510113
1 PLUNGER TOP SEAL - PLASCTIC 41510118-A
1 PROXIMITY SENSOR 60011714
Misc. Wear Parts

QTY COMMON DESCRIPTION PART NO.
8 SPLIT BUSHING 71510025
2 SPRING 71510054

8-4 REPLACEMENT PARTS - SPARE PARTS PN 71510013 - OMM015008130510
Spare Parts
Spare parts are parts that have been identified as useful to keep on hand. These parts are
inexpensive to keep in stock relative to the expense of machine downtime. Maintaining a full
inventory of spare parts helps to ensure your machine can return to production even when facing
unforeseen mechanical failures or operator induced damage.
Spare Electrical Parts

2 CONTACT BLOCK N/C 60010062
2 CONTACT BLOCK N/O 60010171
5 FUSE 5 AMP 60011439
5 FUSE 10 AMP 60011438
5 FUSE 15 AMP 60011437
2 6 POLE RELAY 60011695
4 CANFIELD CONNECTOR - ILLUMINATED 60010492
1 CABLE ASSEMBLY - J1939 60010964
1 E STOP BOX ASSEMBLY 80010117
1 XA2 MODULE 60010875
Spare Hydraulic Components

1 VALVE 71015495
1 COIL 71015496
1 MANIFOLD VALVE 71015497
2 SHUTTLE VALVE 71015204
2 RELIEF VALVE 71015215
1 RELIEF VALVE 71015125
1 REDUCING VALVE 71015128
1 PROPORTIONAL VALVE 71015127
1 PILOT VALVE 71011289
1 HYD. PUMP 71015669
Spare Tigercat Loader misc. components

QTY COMMON DESCRIPTION TIGERCAT PART NO.
1 BELT, A/C COMPRESSOR BH469
1 BELT, FAN CAT PN: 4N8771
1 CABIN AIR FILTER 90019
1 AC / HEATER AIR FILTER 91287

PN 71510013 - OMM015008130510 REPLACEMENT PARTS - SPARE PARTS 8-5
Tigercat Loader service tools

1 O-RING KIT 1855D
1 DIGITAL PRESSURE KIT BE005
1 10000 PSI TRANSDUCER BE007
2 5000 PSI TRANSDUCER BE006
5 COUPLER, 04 NPT(F) 2656A002
5 EXTRACTOR, DEUTSCH 16 DG002
5 EXTRACTOR, DEUTSCH 20 DG007
Spare Misc. Components

QTY COMMON DESCRIPTION PART NO.
20 lb. WELDING HARDFACE CRONAWEAR 80010032
40 GREASE - LUBRICATION (4 CASES) 80014000

8-6 REPLACEMENT PARTS - CONSUMABLE PARTS PN 71510013 - OMM015008130510
Consumable Parts
Consumable parts are parts that will need regular scheduled replacement during normal
operation. The following is a list of common components that are required for performing routine
maintenance on your CBI machine.
Engine Filters C15

(FILTER CHANGE QTY SHOWN IS FOR ONE CHANGE)
1 FUEL FILTER 70010178
1 WATER SEPARATOR IR-0770 60010958
2 OIL FILTER 70010352
1 AIR FILTER- INNER 70015146
1 AIR FILTER- OUTER 70015147
1 COOLING SYSTEM WATER TEMP. REGULATOR
Hydraulic Filters
4 FILTER ELEMENT, RETURN LINE 70011192
9 FILTER ELEMENT, CHARGE PUMP 70011472
1 REPLACEMENT ELEMENT, TANK BREATHER 71011268
4 FILTER ELEMENT, PRESSURE FILTERS 71015070
Tigercat Loader engine filters

1 PRIMARY FUEL FILTER /WATER SEPARATOR CAT PN: ZV043
1 SECONDARY FUEL FILTER CAT PN: V0101
1 OIL FILTER CAT PN: 7W2326
1 AIR FILTER- INNER 203305
1 AIR FILTER- OUTER 203304
Tigercat loader hydraulic filter

1 FILTER ELEMENT, RETURN LINE AY063
2 FILTER ELEMENT, MAIN FILTER AY003
1 REPLACEMENT STRAINER. SPIN ON AY059

PN 71510013 - OMM015008130510 INDECES - ALPHABETICAL INDEX 9-1
9. Indeces
Alphabetical Index
Bottom Roll #2 & #3 Rate Offset ................................. 3-111
Bottom Roll #2 Forward ................................................ 3-72
# Bottom Roll #2 Manual Operation Menu ...................... 3-72
#1 Bottom CMD Limit.................................................. 3-112 Bottom Roll #2 Reverse ................................................. 3-72
#1 Top CMD Limit........................................................ 3-112 Bottom Roll #3 Forward ................................................ 3-74
#1 Top Roll Rate Offset ............................................... 3-111 Bottom Roll #3 Manual Operation Menu ...................... 3-74
#2 Bottom CMD Limit.................................................. 3-112 Bottom Roll #3 Reverse ................................................. 3-74
#2 Top CMD Limit........................................................ 3-112 Brevini gear box maintenance schedule ......................... 4-9
#3 Bottom CMD Limit.................................................. 3-112 build date ...................................................................... 3-42
A C
Adding Engine Coolant.................................................. 4-34 C18 Maintenance Schedule ............................................. 4-8
Adding Engine Coolant procedure ................................ 4-34 C4.4 maintenance schedule ............................................ 4-7
Adjust System Menu ........................................ 3-106, 3-107 CABLE ASSEMBLY - J1939 ................................................ 8-4
Adjusting Belt Tension .................................................. 4-25 CANFIELD CONNECTOR - ILLUMINATED .......................... 8-4
Advanced Operation Menu........................................... 3-44 Case Drain Metal Detection Filter ......................................... 1-7
Air Compressor ........................................................... 3-116 CAT C18 Flail Engine Maintenance Schedule................... 4-8
Air filer Loader .................................................................... 1-7 CAT C4.4 loader engine maintenance schedule .............. 4-7
Air filter Flail ....................................................................... 1-7 Chain Curtain ..................................................................... 1-7
AIR FILTER- INNER ........................................................... 8-6 Chain Failure theory ........................................................ 4-4
AIR FILTER- OUTER .......................................................... 8-6 Chain Keep Slide Hammer ............................................... 4-3
Air filter service indicator inspection procedure .......... 4-37 CHAIN KEEPER ROD ................................................. 8-2, 8-3
Air Filter Unloader Valve Inspection procedure............ 4-37 Chain Replacement procedure ...................................... 4-18
Auto Mode .................................................................... 3-33 Chain Rotation Theory..................................................... 4-4
Automated Features ..................................................... 3-18 Changing Engine Coolant procedure ............................. 4-35
Automatic hydraulic cooler purge, automated feature 3-19 Charge Circuit Filter Inspection procedure.................... 4-47
Automatic Operation Menu .......................................... 3-46 Charge Circuit Filter Replacement procedure ............... 4-48
Automatic radiator purge, automated feature ............. 3-19 charge filter identification ............................................... 6-2
Auxiliary Function ................................................ 3-21, 3-23 Checking Belt Tension ................................................... 4-23
Auxiliary Function Mode ............................................... 3-22 Chipper Link mode Status ............................................ 3-103
Axle Oil Level Inspection ............................................... 4-32 Cleaning procedure ....................................................... 3-17
close current screen button .......................................... 3-32
Close Flail Chamber Access Hatch ........................ 3-28, 3-90
B Close Grapple ................................................................ 3-24
Basic Operation Menu .................................................. 3-35 COIL ................................................................................. 8-4
Batteries flail ...................................................................... 1-7 Component Location Index ............................................. 1-7
Batteries Loader ................................................................. 1-7 consumable parts, Engine Filters C15 ............................ 8-6
Battery Disconnect Switch Flail............................................. 1-7 consumable parts, Hydraulic Filters................................ 8-6
Battery Disconnect Switch Loader ........................................ 1-7 CONTACT BLOCK N/C ...................................................... 8-4
Battery Voltage ............................................................. 3-95 Control Enclosure Layout .............................................. 3-32
Before Operation ............................................................ 3-3 Control Modes............................................................... 3-33
Belt tension meter........................................................... 4-3 Control panel ..................................................................... 1-7
Belt Tension Test Records ............................................. 10-7 Control Panel Interface ................................................. 3-32
BELT, A/C COMPRESSOR, TIGERCAT ............................... 8-4 control panel introduction ............................................ 3-32
BELT, FAN, TIGERCAT ...................................................... 8-4 control panel location ................................................... 3-32
Big Bush Busting Count Run .......................................... 3-53 Cooling Enable Temperature ......................................... 3-99
Big Bush Busting Dwell ................................................. 3-53 Cooling System Menu.................................................... 3-96
Big Bush Busting Pause Run .......................................... 3-53 COUPLER, 04 NPT(F) ........................................................ 8-5
Big-bush-Busta ..................................................... 3-21, 3-23 Cycle Through Run Modes ............................................. 3-22
Bolt-In Style Kingpin Assembly...................................... 4-31
Bolt-In Style Kingpin Inspection .................................... 4-30 D
Bottom Feed Roll dimensions ....................................... 7-2
Bottom Feed Roll Numbering Guide ............................... 1-9 Daily Inspection ............................................................... 3-3
Bottom Roll #1 Forward ................................................ 3-70 daily inspection general procedure ................................. 3-6
Bottom Roll #1 Manual Operation Menu ..................... 3-70 daily inspection specific procedure ................................. 3-6
Bottom Roll #1 Rate Offset ......................................... 3-111 Date / Time.................................................................. 3-109
Bottom Roll #1 Reverse ................................................. 3-70 Date of Publication .......................................................... 1-5

9-2 INDECES - ALPHABETICAL INDEX PN 71510013 - OMM015008130510
Decal descriptions & locations ........................................ 2-7 EXTRACTOR, DEUTSCH ................................................... 8-5
Decals.............................................................................. 2-6 EXTRACTOR, DEUTSCH 20............................................... 8-5
Dexter trailer axle Maintenance schedule ...................... 4-9 EXTRHT .......................................................................... 3-23
DIGITAL PRESSURE KIT .................................................... 8-5
Discharge Plunger Cylinder Pressure............................. 3-47 F
Discharge Ram Support Frame Safety Pin ............................ 1-7
Display Settings ........................................................... 3-109 Feed Forward ....................................................... 3-35, 3-46
Double Chain theory ....................................................... 4-4 FEED FWD....................................................................... 3-21
DRIVE BELT ............................................................... 8-2, 8-3 Feed Offset Adjust Menu ............................................ 3-111
Drive Sprocket Removal bolt ........................................... 4-3 Feed Rate.............................................................. 3-36, 3-47
Drive Sprocket Removal tool ........................................... 4-3 Feed Rate Calibration Procedure .................................. 4-28
feed rates .................................................................... 3-111
FEED REV ....................................................................... 3-21
E Feeds reverse, automated feature ................................ 3-18
E STOP BOX ASSEMBLY ................................................... 8-4 Field connections upper rail wiring schematic .............. 5-15
Electrical Connector layout schematic .......................... 5-18 Field Connections, Lower Rail, Center Right wiring
electrical system description .......................................... 5-2 schematics ................................................................ 5-17
electrical system schematics........................................... 5-2 Field connections, lower rail, left center wiring schematic5-
Emergency Stop Switch ................................................ 3-31 16
emergency stop button on control enclosure .............. 3-32 Fifth Wheel Adapter Plate Installation and Removal ...... 3-6
Emergency Stop Control Box by loader access ladder .. 3-31 Fifth wheel Pin ................................................................... 1-7
Emergency Stop Control Box on engine platform ......... 3-31 FILTER , AC / HEATER, TIGERCAT .................................... 8-4
emergency stop reset .................................................... 3-31 FILTER ELEMENT, CHARGE PUMP ................................... 8-6
Emergency Stop Switch ............................... 3-21, 3-22, 3-23 FILTER ELEMENT, MAIN FILTER ....................................... 8-6
enable link to flail ......................................................... 3-15 FILTER ELEMENT, pressure filters ...................................... 8-6
FILTER ELEMENT, RETURN LINE ...................................... 8-6
enclosure door .............................................................. 3-32
FILTER, CABIN AIR, TIGERCAT ......................................... 8-4
END PLUG ................................................................. 8-2, 8-3
Final Inspection procedure ............................................ 3-17
Energy Release ................................................................ 2-9
Fire Safety ....................................................................... 2-3
ENG FAST .............................................................. 3-21, 3-22
Flail #1 ............................................................................. 1-7
ENG SLOW ............................................................ 3-21, 3-22 Flail #1 drive motor ............................................................ 1-7
Engage Feed Wheels ............................................. 3-21, 3-24 Flail #2 ............................................................................. 1-7
Engine Access Platform....................................................... 1-7 Flail #2 drive motor ............................................................ 1-7
Engine Coolant level inspection procedure .................. 4-33 Flail #3 ............................................................................. 1-7
Engine Coolant Temperature ............. 3-36, 3-47, 3-95, 3-97 Flail #3 drive motor ............................................................ 1-7
engine cooling enable temperature .............................. 3-97 Flail #4 ............................................................................. 1-8
Engine Cooling System Purge ........................................ 3-96 Flail #4 drive motor ............................................................ 1-8
Engine Diagnostic Lamps ............................ 3-36, 3-47, 3-95 Flail #1 Direction............................................................ 3-51
Engine Fan Cooling time ............................................... 3-97 Flail #1 Down RPM ........................................................ 3-50
Engine fan purge Time .................................................. 3-97 Flail #1 Manual Operation Menu .................................. 3-58
Engine Fast......................................... 3-35, 3-46, 3-92, 3-94 Flail #1 Toggle ............................................................... 3-58
Engine Hours ............................................... 3-36, 3-47, 3-95 Flail #1 Up RPM ............................................................. 3-50
Engine Manual Operation Menu .................................. 3-92 Flail #2 Direction............................................................ 3-52
Engine Menu ................................................................. 3-94 Flail #2 Down Limit Start Hold ....................................... 3-56
Engine oil dipstick Flail ........................................................ 1-7 Flail #2 Down Limit Stop Hold ........................................ 3-56
Engine oil filter Flail ............................................................. 1-7 Flail #2 Down RPM ........................................................ 3-50
Engine oil filter Loader ......................................................... 1-7 Flail #2 Hold ................................................................... 3-54
Engine Oil Pressure ....................................................... 3-95 Flail #2 Keep Moving ..................................................... 3-54
Engine Percent Load ..................................................... 3-95 Flail #2 Lift Start ............................................................ 3-54
Engine Platform Emergency Stop Control Box .............. 3-31 Flail #2 Lower ................................................................ 3-55
Engine RPM ................................................. 3-36, 3-47, 3-95 Flail #2 Manual Operation Menu .................................. 3-60
Engine Slow ........................................ 3-35, 3-46, 3-92, 3-94 Flail #2 Max Hold Up CMD ............................................ 3-56
Enter Outrigger Function Mode .................................... 3-22 Flail #2 Movement Limit ................................................ 3-52
Equipment Serial Numbers ............................................. 1-3 Flail #2 Toggle ............................................................... 3-60
ESCB1 SW1 .................................................................... 3-31 Flail #2 Up...................................................................... 3-60
ESCB2 SW1 .................................................................... 3-31 Flail #2 Up RPM ............................................................. 3-51
E-STOP ......................................................... 3-21, 3-22, 3-23 Flail #3 Direction............................................................ 3-52
ETRDN ............................................................................ 3-22 Flail #3 Down Limit Start Hold ....................................... 3-57
ETRUP ............................................................................ 3-22
Flail #3 Down Limit Stop Hold ........................................ 3-57
Exit Feed Top Roll Safety Strut ............................................ 1-7
Flail #3 Down RPM ........................................................ 3-51
Exit Bottom CMD Limit ................................................ 3-112
Flail #3 Hold ................................................................... 3-55
Exit Top CMD Limit ...................................................... 3-112
Flail #3 Keep Moving ..................................................... 3-55
Extend Dipper................................................................ 3-26
Flail #3 Lift Start ............................................................ 3-55
EXTLFT ........................................................................... 3-23
Flail #3 Lower ................................................................ 3-56
Flail #3 Manual Operation Menu .................................. 3-62 G

Flail #3 Max Hold Up CMD ............................................ 3-56
Flail #3 Movement Limit ............................................... 3-52 General Flail Maintenance Schedule ............................. 4-10
Flail #3 Toggle ............................................................... 3-62 General Safety ................................................................. 2-2
Flail #3 Up ..................................................................... 3-62 General theory ................................................................ 4-4
Flail #3 Up RPM ............................................................. 3-51 General torque specifications ......................................... 7-6
Flail #4 Direction ........................................................... 3-52 Grapple Cradle Frame ........................................................ 1-8
Flail #4 Down RPM ........................................................ 3-51 grapple storage procedure ............................................ 3-15
Flail #4 Manual Operation Menu .................................. 3-64 GREASE - LUBRICATION (4 CASES).................................. 8-5
Flail #4 Toggle ............................................................... 3-64
Flail #4 Up RPM ............................................................. 3-51 H
Flail Access Hatch.......................................................... 3-91
Flail bearing Inspection ................................................. 4-22 Hazard Areas ................................................................... 2-4
Flail Box Door Manual Operation Menu ....................... 3-90 hub Oil Level .................................................................. 4-32
FLAIL CHAIN .............................................................. 8-2, 8-3 HYD. PUMP ...................................................................... 8-4
Flail Chamber service Hatch .............................................. 1-8 hydraulic cooler Flail ........................................................... 1-8
Flail Drive Bearing Inspection Records .......................... 10-1 Hydraulic cooling enable temperature .......................... 3-97
Flail Drive Belt #1................................................................ 1-8 Hydraulic Cooling Enable Temperature ......................... 3-98
Flail Drive Belt #2................................................................ 1-8 Hydraulic Cooling Interval ............................................. 3-98
Flail Drive Belt #3................................................................ 1-8 Hydraulic Cooling Purge Time ....................................... 3-98
Flail Drive Belt #4................................................................ 1-8 Hydraulic Cooling System Purge .................................... 3-96
Flail Drive specifications................................................ 7-2 Hydraulic Fan Cooling time............................................ 3-97
Flail Drum dimensions .................................................... 7-2 Hydraulic fan purge Time .............................................. 3-97
Flail Drum Torque Specifications .................................... 7-5 Hydraulic Filter #1 Lift Circuit Top Feed Rolls ........................ 1-8
Flail Hydraulic Pressure ............................................... 3-101 Hydraulic Filter #2 Lift Circuit Top Feed Rolls ........................ 1-8
Flail Lift Tuning Adjust Menu ........................................ 3-54 Hydraulic Filter Exit feed Bottom Roll Motor........................... 1-8
flail link.......................................................................... 3-15 Hydraulic Filter Exit feed Top Roll Motor ............................... 1-8
Flail Link Mode Status ................................................. 3-103 Hydraulic Filter Flail Motor #1 .............................................. 1-7
Flail Numbering Guide .................................................... 1-9 Hydraulic Filter Flail Motor #2 .............................................. 1-7
Flail Power .................................................................. 3-101 Hydraulic Filter Flail Motor #3 .............................................. 1-7
Flail Power Limit.......................................................... 3-101 Hydraulic Filter Flail Motor #4 .............................................. 1-7
Hydraulic Filter Idler Roll Motors .......................................... 1-7
Flail Power Menu ........................................................ 3-100
Hydraulic Filter Infeed Bottom Roll Motor #1 .......................... 1-7
Flail Toggle ........................................................... 3-35, 3-46
Hydraulic Filter Infeed Bottom Roll Motor #2 .......................... 1-7
Flail Transport Menu..................................................... 3-37 Hydraulic Filter Infeed Top Roll Motor ................................... 1-7
FLAILS ............................................................................ 3-22 Hydraulic Filter Upper Flail Lift Circuit ................................... 1-7
Flexxaire Fan ............................................................. 1-8, 2-4 Hydraulic Filter, Return Circuit ............................................. 1-7
Flexxaire Fan maintenance schedule ....................... 4-7, 4-9 Hydraulic Fluid, procedure for adding ........................... 4-40
Fold Down ............................................................ 3-40, 3-84 Hydraulic Oil sight glass Flail ............................................... 1-7
Fold Up ................................................................. 3-40, 3-84 Hydraulic Oil sight glass Loader ........................................... 1-7
Fuel Consumption ......................................................... 3-95 Hydraulic Oil Temperature ................................... 3-47, 3-97
Fuel Consumption Daily Average ................................ 3-105 Hydraulic Pump Exit feed Bottom Roll Motor ......................... 1-7
Fuel Consumption Hourly Average .............................. 3-105 Hydraulic Pump Exit feed Top Roll Motor .............................. 1-7
Fuel Consumption Menu ............................................ 3-104 Hydraulic Pump Flail Motor #1 ............................................. 1-7
Fuel Consumption Rate ............................................... 3-105 Hydraulic Pump Flail Motor #2 ............................................. 1-7
Fuel Consumption Running Average ........................... 3-105 Hydraulic Pump Flail Motor #3 ............................................. 1-7
Fuel Fill Flail ....................................................................... 1-8 Hydraulic Pump Flail Motor #4 ............................................. 1-7
fuel fill Loader ..................................................................... 1-8 Hydraulic Pump Idler Roll Motors ......................................... 1-7
FUEL FILTER ..................................................................... 8-6 Hydraulic Pump Infeed Bottom Roll Motor #1 ........................ 1-7
fuel gauge Flail ................................................................... 1-8 Hydraulic Pump Infeed Bottom Roll Motor #2 ........................ 1-7
fuel gauge Loader ............................................................... 1-8 Hydraulic Pump Infeed Top Roll Motor.................................. 1-7
Fuel Pressure ............................................... 3-36, 3-47, 3-95 Hydraulic Pump Lift Circuit Top Feed Rolls ........................... 1-7
Fuel Tank capacity........................................................... 7-3 Hydraulic Pump push out Ram / Hydraulic Cooler Motor ......... 1-7
Fuel Temperature.......................................................... 3-95 Hydraulic Pump Upper Flail Lift Circuit .................................. 1-7
FUNCTION ............................................................. 3-21, 3-23 hydraulic system description........................................... 6-2
Function Key 1 .............................................................. 3-32 hydraulic system schematic ............................................ 6-5
Hydraulic Tank Access Platform........................................... 1-8
Function Key 2 .............................................................. 3-32
Hydraulic Tank Breather Inspection procedure............. 4-42
Function Key 3 .............................................................. 3-32
Hydraulic Tank Breather Replacement procedure ........ 4-43
Function Key 4 .............................................................. 3-32
Hydraulic tank fill Flail ......................................................... 1-8
Function Key 5 .............................................................. 3-32
Hydraulic tank fill Loader ..................................................... 1-8
Function modes, description of .................................... 3-20
FUSE 10 AMP .................................................................... 8-4
FUSE 15 AMP .................................................................... 8-4 I
FUSE 5 AMP ...................................................................... 8-4
Idle Engine Down .................................................. 3-21, 3-22
Idle Engine Up ...................................................... 3-21, 3-22 L

Idler Max CMD ............................................................ 3-112
Idler Min CMD ............................................................. 3-112 Language Settings ....................................................... 3-109
Idler Output Adjust Menu ........................................... 3-113 Left Loader Joystick ....................................................... 3-26
Idler Roll #1 Forward ..................................................... 3-76 Link Mode...................................................................... 3-33
Idler Roll #1 Manual Operation Menu .......................... 3-76 Link Mode Cancel ........................................................ 3-102
Idler Roll #1 Max ......................................................... 3-114 Link mode disabled ...................................................... 3-103
Idler Roll #1 Min .......................................................... 3-113 Link Mode enabled ...................................................... 3-103
Idler Roll #1 Reverse ...................................................... 3-76 Link Mode Menu ......................................................... 3-102
Idler Roll #1 Speed Control ............................................ 3-29 link mode procedure ..................................................... 3-15
Idler Roll #1 Start ........................................................ 3-114 Link Mode Reception Quality....................................... 3-103
Idler Roll #1 Stop ......................................................... 3-114 Link Mode Reset .......................................................... 3-102
Idler Roll #2 Forward ..................................................... 3-78 Link Mode Signal Strength........................................... 3-103
Idler Roll #2 Manual Operation Menu .......................... 3-78 Link Mode Status ......................................................... 3-103
Idler Roll #2 Max ......................................................... 3-114 link to flail ...................................................................... 3-15
Idler Roll #2 Min .......................................................... 3-114 LJS AUX1 ........................................................................ 3-26
Idler Roll #2 Reverse ...................................................... 3-78 LJS AUX2 ........................................................................ 3-26
Idler Roll #2 Speed Control ............................................ 3-29 LJS AUX3 ........................................................................ 3-26
Idler Roll #2 Start ........................................................ 3-114 LJS AUX4 ........................................................................ 3-26
Idler Roll #2 Stop ......................................................... 3-114 LJS AUX5 ........................................................................ 3-27
Idler Roll #3 Forward ..................................................... 3-80 LJS AUX6 ........................................................................ 3-27
Idler Roll #3 Manual Operation Menu .......................... 3-80 LJS BCK .......................................................................... 3-26
LJS FWD.......................................................................... 3-26
Idler Roll #3 Max ......................................................... 3-115
LJS LFT ........................................................................... 3-26
Idler Roll #3 Min .......................................................... 3-114
LJS RHT .......................................................................... 3-26
Idler Roll #3 Reverse ...................................................... 3-80 LJS TRIG ......................................................................... 3-26
Idler Roll #3 Speed Control ............................................ 3-29 Loader access Emergency Stop Control Box .................. 3-31
Idler Roll #3 Start ........................................................ 3-115 Loader Access Platform ...................................................... 1-8
Idler Roll #3 Stop ......................................................... 3-115 Loader Access Stairs .......................................................... 1-8
Idler Roll #4 Forward ..................................................... 3-82 Loader Cab ....................................................................... 1-8
Idler Roll #4 Manual Operation Menu .......................... 3-82 Loader Control Panel ..................................................... 3-30
Idler Roll #4 Max ......................................................... 3-113 Loader Controls ............................................................. 3-23
Idler Roll #4 Min .......................................................... 3-113 Loader End Outriggers................................................... 3-87
Idler Roll #4 Reverse ...................................................... 3-82 Loader End Outriggers Selected .................................... 3-39
Idler Roll #4 Speed Control ............................................ 3-29 loader engine maintenance schedule ............................. 4-7
Idler Roll #4 Start ........................................................ 3-113 Loader/Cab specifications ............................................. 7-3
Idler Roll #4 Stop ......................................................... 3-113 Local Mode .................................................................... 3-33
Idler Roll Numbering Guide ............................................ 1-9 Lockout Tagout ................................................................ 2-9
Idler Roll Rate Offset ................................................... 3-111 Log Exit ........................................................................... 2-4
ignition switch............................................................... 3-32 Logs ............................................................................. 3-110
IN LFT ............................................................................. 3-23 Lower Boom .................................................................. 3-24
IN RHT ............................................................................ 3-23 Lower Exit feed Roll Gearbox #1 .......................................... 1-8
Individual chain wear theory........................................... 4-4 Lower Exit Top Roll ........................................................ 3-22
Infeed ............................................................................. 2-4 Lower Infeed Roll Gearbox #1 ............................................. 1-8
Infeed Bottom CMD Limit ........................................... 3-112 Lower Infeed Roll Gearbox #2 ............................................. 1-8
Infeed Clog sense, automated feature ......................... 3-19 Lower Infeed Top Roll ............................................3-21, 3-25
Infeed Top CMD Limit ................................................. 3-112 Lower Left Front Outrigger ................................... 3-28, 3-88
Infeed Top Roll Safety Strut ................................................. 1-8 Lower Left Rear Outrigger .................................... 3-28, 3-86
Info System Menu ............................................ 3-106, 3-110 Lower Right Front Outrigger................................. 3-28, 3-88
Information Menu ........................................................ 3-42 Lower Right Rear Outrigger .................................. 3-28, 3-86
ISO (Metric) torque specifications .................................. 7-6 Lower Selected Outrigger .............................................. 3-23
Lubrication .................................................................... 4-11
J lubrication General........................................................ 4-11
lubrication Safety .......................................................... 4-11
Jack Shaft Spring Preload Adjustment procedure ......... 4-27 Lubrication Schedule ..................................................... 4-16
Jack Shaft Spring Preload Inspection procedure ........... 4-26
Jog / Shuttle button ...................................................... 3-32
M
K Machine Identification .................................................. 1-10
Magnetic Filter Core Cleaning ....................................... 4-53
king pin Adapter Plate Installation and Removal ............ 3-6 main system input signals ............................................... 5-4
King Pin End Outriggers ................................................ 3-89 Main System Menu ..................................................... 3-106
Kingpin 90 (3.5”) Wear Specifications ............................. 7-7 maintenance Introduction ....................................... 3-3, 4-3
Kingpin End Outriggers Selected ................................... 3-39 Maintenance Safety ................................................. 2-3, 4-3
Maintenance Schedules .................................................. 4-5 Power specifications ....................................................... 7-3

MANIFOLD VALVE ............................................................. 8-4 Pre-cleaner Flail ................................................................. 1-8
Manual Disclaimer .......................................................... 1-5 Pre-cleaner Loader ............................................................. 1-8
Manual Intent ................................................................. 1-5 Pre-cleaner verification procedure ............................... 4-36
Manual Use ..................................................................... 1-5 Preferences System Menu ................................ 3-106, 3-109
MDL location ................................................................. 3-32 Pressure Filters ................................................................ 6-3
MDL Submenu .... 3-38, 3-44, 3-46, 3-48, 3-58, 3-60, 3-62, 3- Pressure Line Filter Inspection procedure ..................... 4-44
64, 3-66, 3-68, 3-70, 3-72, 3-74, 3-76, 3-78, 3-80, 3-82, Pressure Line Filter Replacement procedure ................ 4-45
3-85, 3-86, 3-88, 3-90, 3-92, 3-94, 3-96, 3-100, 3-102, 3- previous screen button ................................................. 3-32
104 PRIMARY FUEL FILTER /WATER SEPARATOR .................. 8-6
MDL sub-menu button.................................................. 3-32 primary Fuel/Water filter Flail ............................................... 1-8
MDL wiring schematic..................................................... 5-5 primary Fuel/Water filter Loader ........................................... 1-8
Measure System Menu .................................... 3-106, 3-108 Product Intent & Disclaimer ............................................ 1-2
Middle Bottom CMD Limit .......................................... 3-112 Product Overview ............................................................ 1-2
Minimum operating temperature, automated feature 3-19 PROPORTIONAL VALVE ................................................... 8-4
Modem ....................................................................... 3-110 Proportional Valve Manual Control............................... 3-29
Modules ...................................................................... 3-110 PROXIMITY SENSOR ........................................................ 8-3
Move Chip Deflector In.................................................. 3-27 Publication Feedback .................................................... 1-13
Move Chip Deflector Out ............................................... 3-27 Publication Feedback reporting procedure ................... 1-13
muffler Flail ........................................................................ 1-8 purge cycle verification procedure ................................ 4-36
Push Out Ram Manual Operation Menu ....................... 3-84
PUSHOUT...............................................................3-21, 3-23
N Push-out Ram Interval Set-point ................................... 3-53
PVLV1 ............................................................................. 3-29
next screen button........................................................ 3-32
PVLV2 ............................................................................. 3-29
PVLV3 ............................................................................. 3-29
O PVLV4 ............................................................................. 3-29
Oil analysis Policy .......................................................... 4-15

Oil Analysis procedure .................................................. 4-56 R
OIL FILTER ........................................................................ 8-6 Radiator Interval time ................................................... 3-99
ON/OFF ......................................................... 3-21, 3-22, 3-23
Radiator purge time ...................................................... 3-98
On/Off Switch ............................................. 3-21, 3-22, 3-23 Radiator sight glass Flail ..................................................... 1-8
Open Flail Chamber Access Hatch ........................ 3-29, 3-90 Radiator sight glass Loader ................................................. 1-8
Open Grapple ................................................................ 3-24 Radio Mode ................................................................... 3-33
Operating the machine by remote ............................... 3-12 Radio receiver speed signal converter wiring schematics 5-
Operating the machine by the control panel ................ 3-14 11
Operating Zone ............................................................... 2-4 Raise Boom .................................................................... 3-24
Operational Safety .......................................................... 2-3 Raise Exit Top Roll ......................................................... 3-22
optional equipment introduction ............................... 3-116 Raise Infeed Top Roll .............................................3-21, 3-25
Orientation & Component Location ............................... 1-6 Raise Left Front Outrigger .................................... 3-28, 3-88
O-RING KIT ....................................................................... 8-5 Raise Left Rear Outrigger ..................................... 3-28, 3-86
Out Riggers King Pin Manual Operation Menu ............. 3-88 Raise Right Front Outrigger .................................. 3-28, 3-88
Out Riggers Loader Manual Operation Menu ............... 3-86 Raise Right Rear Outrigger ................................... 3-28, 3-86
OUTRIG .......................................................................... 3-22 Raise Selected Outrigger ............................................... 3-23
Outrigger Function Mode ............................................. 3-23
Reception Quality ........................................................ 3-103
Outriggers Menu ........................................................... 3-38
Record Daily Fuel Consumption Averages ................... 3-104
Overall dimensions ......................................................... 7-2 REDUCING VALVE ............................................................ 8-4
Relay, 6 POLE................................................................... 8-4
P RELIEF VALVE .................................................................. 8-4
Remote control battery ................................................. 3-20
Panel Layout Schematic ................................................ 5-13 remote control charger ................................................. 3-32
Parts department contact information ......................... 1-11 Remote control introduction......................................... 3-20
Personal Safety ............................................................... 2-2 remote control location ................................................ 3-32
PILOT VALVE .................................................................... 8-4 replacement chain part number .......................... 4-19, 4-21
PLUNGER BAR .................................................................. 8-3 REPLACEMENT ELEMENT, TANK BREATHER ................... 8-6
Plunger Into Machine ........................................... 3-40, 3-84 Replacement part ordering procedure.......................... 1-11
Plunger Menu ............................................................... 3-40 Replacement Parts ................................................. 1-11, 8-1
Plunger Out Of Machine ...................................... 3-40, 3-84 REPLACEMENT STRAINER, SPIN ON ................................ 8-6
Plunger Support Area..................................................... 2-4 Reset Fuel Consumption Average ................................ 3-104
PLUNGER TOP SEAL - PLACTIC ........................................ 8-3 Retract Dipper ............................................................... 3-26
Position Sensors Wiring Schematic ................................. 5-9 Return Circuit Filter Inspection procedure .................... 4-50
power and CAT starter connections ............................... 5-3 Return Circuit Filter Replacement procedure ............... 4-51
Power Packer outrigger Maintenance schedule ............. 4-9 Return Filters ................................................................... 6-3
RIGDN............................................................................. 3-23 SIDE WEAR LINER N.D.S. - UPPER ............................ 8-2, 8-3
Right Loader Joystick .................................................... 3-24 Signal Strength ............................................................ 3-103
RIGUP ............................................................................. 3-23 Spare parts, Electrical Parts............................................ 8-4
RJS AUX1 ....................................................................... 3-24 Spare parts, Hydraulic Components................................ 8-4
RJS AUX2 ....................................................................... 3-24 Spare parts, Misc. Component ........................................ 8-5
RJS AUX3 ....................................................................... 3-24 Spare Tigercat Loader misc. components ....................... 8-4
RJS AUX4 ....................................................................... 3-25 SPLIT BUSHING ................................................................ 8-3
RJS AUX5 ....................................................................... 3-25 SPRING ............................................................................ 8-3
RJS AUX6 ....................................................................... 3-25 Standard Function Mode............................................... 3-21
RJS BCK ......................................................................... 3-24 Start Fuel Consumption Average ................................. 3-104
RJS FWD......................................................................... 3-24
Starting procedure for flail ............................................ 3-10
RJS LFT .......................................................................... 3-24
Starting procedure for loader........................................ 3-11
RJS RHT ......................................................................... 3-24
RJS TRIG ........................................................................ 3-24 Startup Menu ................................................................ 3-34
Rod Replacement procedure ........................................ 4-20 Stiebel Pump Drive Maintenance Schedule .................. 4-10
Rod rotation procedure ................................................ 4-20 stinger Adapter Plate Installation and Removal .............. 3-6
ROLL DWN ...................................................................... 3-21 Stop / Reverse Feed Wheels ..................................3-21, 3-24
ROLL UP ......................................................................... 3-21 Stop Fuel Consumption Average.................................. 3-104
Rotate Chute Left .......................................................... 3-26 Stopping the flail ........................................................... 3-16
Rotate Chute Right ........................................................ 3-26 Supplemental Manuals...... 1-4, 3-7, 3-11, 3-16, 3-30, 3-116
Rotate Grapple Clockwise ............................................. 3-24 Swing Loader Left .......................................................... 3-26
Rotate Grapple Counter Clockwise................................ 3-26 Swing Loader Right ........................................................ 3-26
Rotobec grapple maintenance schedule......................... 4-6 system reset button ...................................................... 3-32
Row Chain Wear theory .................................................. 4-4
RTD / PT100 Converter wiring schematics .................... 5-10 T
Run Mode............................................................. 3-36, 3-47
Run Mode Feed Speed................................................... 3-50 Table of Contents ................................................................ i
Run Mode Toggle .......................................................... 3-48 Technical publications department contact information .. 1-
Run Settings Menu........................................................ 3-48 13
RUNMOD ........................................................................ 3-22 Throughput ..................................................................... 7-2
Tigercat 215 loader maintenance schedule .................... 4-6
Tigercat Loader............................................................... 2-4
S Tigercat Loader engine filters......................................... 8-6
SAE (English) torque specifications ................................. 7-6 Tigercat loader hydraulic filter ....................................... 8-6
Safety Basics ................................................................... 2-2 Tigercat Loader service tools ........................................... 8-5
Safety pin procedures ................................................... 4-17 Time / Date.................................................................. 3-109
safety pin, plunger support frame ............................... 2-10 Top Feed Roll dimensions ............................................... 7-2
Safety Pins / Struts ........................................................ 2-10 Top Feed Roll Numbering Guide ................................... 1-10
Safety Procedures ........................................................... 2-9 Top Roll #1 Down........................................................... 3-66
Safety strut procedures ................................................ 4-17 Top Roll #1 Float Pressure ............................................. 3-52
safety strut, exit top feed roll ...................................... 2-10 Top Roll #1 Forward ...................................................... 3-66
safety strut, infeed top feed roll .................................. 2-10 Top Roll #1 Manual Operation Menu ............................ 3-66
safety strut, upper flail................................................. 2-10 Top Roll #1 Reverse ....................................................... 3-66
SECONDARY FUEL FILTER ............................................... 8-6 Top Roll #1 Up ............................................................... 3-66
Select Back Left Outrigger ............................................. 3-23 Top Roll #2 Down........................................................... 3-68
Select Back Right Outrigger .......................................... 3-23 Top Roll #2 Float Pressure ............................................. 3-52
Select Front Left Outrigger ............................................ 3-23 Top Roll #2 Forward ...................................................... 3-68
Select Front Right Outrigger ......................................... 3-23 Top Roll #2 Manual Operation Menu ............................ 3-68
Selector button ............................................................. 3-32 Top Roll #2 Reverse ....................................................... 3-68
serial number ................................................................ 3-42 Top Roll #2 Up ............................................................... 3-68
Service Assistance ......................................................... 1-12 Top roll rapid lift, automated feature ........................... 3-18
Service Assistance Requisition procedure .................... 1-12 Top Roll Rate Offset ..................................................... 3-111
Service Department Contact Information..................... 1-12 Torque Specifications ...................................................... 7-5
Service Mode ................................................................ 3-33 Total Power ................................................................. 3-101
Service Preparation procedure ..................................... 4-16 TRANSDUCER, 10000 PSI.................................................. 8-5
Service Tools ................................................................... 4-3 TRANSDUCER, 5000 PSI ................................................... 8-5
Set button ..................................................................... 3-32 transportation tear-down procedure .............................. 3-5
Shipping Dimensions....................................................... 7-2 Turbo Boost Pressure..................................................... 3-95
shutdown procedure for loader.................................... 3-16 Turn Flails On/Off .......................................................... 3-22
SHUTTLE VALVE ............................................................... 8-4
SIDE WEAR LINER D.S. - LOWER ............................... 8-2, 8-3 U
SIDE WEAR LINER D.S. - UPPER ................................ 8-2, 8-3
SIDE WEAR LINER N.D.S. - LOWER ............................ 8-2, 8-3 Upper Flail Safety Strut ....................................................... 1-8

V wear parts, Flail #1 – Bottom Flail Assembly – Inlet ........ 8-2

wear parts, Flail #2 – Top Flail Assembly – Inlet .............. 8-2
VALVE .............................................................................. 8-4 wear parts, Flail #3 – Top Flail Assembly – Outlet ........... 8-3
Valve Manual Control ................................................... 3-28 wear parts, Flail #4 – Bottom Flail Assembly – Outlet .... 8-3
View Daily Fuel Consumption Log ............................... 3-104 Wear Parts, misc ............................................................. 8-3
VLV1 IN ........................................................................... 3-28 wear parts, Plunger Assembly ........................................ 8-3
VLV1 OUT ....................................................................... 3-28 WEAR PLACTIC - BOTTOM FRONT ................................... 8-3
VLV2 IN ........................................................................... 3-28 WEAR PLACTIC - BOTTOM MID......................................... 8-3
VLV2 OUT ....................................................................... 3-28 WEAR PLASTIC - PLUNGER .............................................. 8-3
VLV3 IN ........................................................................... 3-28 WELDING HARDFACE CRONAWEAR ................................ 8-5
VLV3 OUT ....................................................................... 3-28 WLCB SW1L .................................................................. 3-118
VLV4 IN ........................................................................... 3-28 WLCB SW1R .................................................................. 3-118
VLV4 OUT ....................................................................... 3-28 Work Light Control Box ............................................... 3-118
VLV5 IN ........................................................................... 3-28 Work lights Off ............................................................ 3-118
VLV5 OUT ....................................................................... 3-29 Work Lights On ............................................................ 3-118
W X
Waste Discharge ............................................................ 2-4 XA2 MODULE.................................................................... 8-4
Waste Discharge Ram......................................................... 1-8 XA2 wiring schematic ...................................................... 5-6
WATER SEPARATOR IR-0770 ........................................... 8-6

9-8 INDECES - TABLE OF FIGURES PN 71510013 - OMM015008130510
Table Of Figures
FIGURE 1 .................................................................. 1-6 FIGURE 56 .............................................................. 3-63
FIGURE 2 .................................................................. 1-9 FIGURE 57 .............................................................. 3-64
FIGURE 3 .................................................................. 1-9 FIGURE 58 .............................................................. 3-65
FIGURE 4 .................................................................. 1-9 FIGURE 59 .............................................................. 3-66
FIGURE 5 ................................................................ 1-10 FIGURE 60 .............................................................. 3-67
FIGURE 6 ................................................................ 1-10 FIGURE 61 .............................................................. 3-68
FIGURE 7 .................................................................. 2-5 FIGURE 62 .............................................................. 3-69
FIGURE 8 .................................................................. 2-7 FIGURE 63 .............................................................. 3-70
FIGURE 9 .................................................................. 2-8 FIGURE 64 .............................................................. 3-71
FIGURE 10 ................................................................ 3-5 FIGURE 65 .............................................................. 3-72
FIGURE 11 ................................................................ 3-6 FIGURE 66 .............................................................. 3-73
FIGURE 12 .............................................................. 3-10 FIGURE 67 .............................................................. 3-74
FIGURE 13 .............................................................. 3-10 FIGURE 68 .............................................................. 3-75
FIGURE 14 .............................................................. 3-12 FIGURE 69 .............................................................. 3-76
FIGURE 15 .............................................................. 3-12 FIGURE 70 .............................................................. 3-77
FIGURE 16 .............................................................. 3-15 FIGURE 71 .............................................................. 3-78
FIGURE 17 .............................................................. 3-16 FIGURE 72 .............................................................. 3-79
FIGURE 18 .............................................................. 3-20 FIGURE 73 .............................................................. 3-80
FIGURE 19 .............................................................. 3-20 FIGURE 74 .............................................................. 3-81
FIGURE 20 .............................................................. 3-21 FIGURE 75 .............................................................. 3-82
FIGURE 21 .............................................................. 3-22 FIGURE 76 .............................................................. 3-83
FIGURE 22 .............................................................. 3-23 FIGURE 77 .............................................................. 3-84
FIGURE 23 .............................................................. 3-24 FIGURE 78 .............................................................. 3-85
FIGURE 24 .............................................................. 3-26 FIGURE 79 .............................................................. 3-86
FIGURE 25 .............................................................. 3-28 FIGURE 80 .............................................................. 3-87
FIGURE 26 .............................................................. 3-29 FIGURE 81 .............................................................. 3-88
FIGURE 27 .............................................................. 3-31 FIGURE 82 .............................................................. 3-89
FIGURE 28 .............................................................. 3-31 FIGURE 83 .............................................................. 3-90
FIGURE 29 .............................................................. 3-32 FIGURE 84 .............................................................. 3-91
FIGURE 30 .............................................................. 3-32 FIGURE 85 .............................................................. 3-92
FIGURE 31 .............................................................. 3-34 FIGURE 86 .............................................................. 3-93
FIGURE 32 .............................................................. 3-34 FIGURE 87 .............................................................. 3-94
FIGURE 33 .............................................................. 3-35 FIGURE 88 .............................................................. 3-95
FIGURE 34 .............................................................. 3-36 FIGURE 89 .............................................................. 3-96
FIGURE 35 .............................................................. 3-37 FIGURE 90 .............................................................. 3-97
FIGURE 36 .............................................................. 3-37 FIGURE 91 .............................................................. 3-98
FIGURE 37 .............................................................. 3-38 FIGURE 92 ............................................................ 3-100
FIGURE 38 .............................................................. 3-39 FIGURE 93 ............................................................ 3-101
FIGURE 39 .............................................................. 3-40 FIGURE 94 ............................................................ 3-102
FIGURE 40 .............................................................. 3-41 FIGURE 95 ............................................................ 3-103
FIGURE 41 .............................................................. 3-42 FIGURE 96 ............................................................ 3-104
FIGURE 42 .............................................................. 3-43 FIGURE 97 ............................................................ 3-105
FIGURE 43 .............................................................. 3-44 FIGURE 98 ............................................................ 3-106
FIGURE 44 .............................................................. 3-45 FIGURE 99 ............................................................ 3-107
FIGURE 45 .............................................................. 3-46 FIGURE 100 .......................................................... 3-108
FIGURE 46 .............................................................. 3-47 FIGURE 101 .......................................................... 3-109
FIGURE 47 .............................................................. 3-48 FIGURE 102 .......................................................... 3-110
FIGURE 48 .............................................................. 3-49 FIGURE 103 .......................................................... 3-111
FIGURE 49 .............................................................. 3-50 FIGURE 104 .......................................................... 3-113
FIGURE 50 .............................................................. 3-54 FIGURE 105 .......................................................... 3-116
FIGURE 51 .............................................................. 3-58 FIGURE 106 .......................................................... 3-117
FIGURE 52 .............................................................. 3-59 FIGURE 107 .......................................................... 3-118
FIGURE 53 .............................................................. 3-60 FIGURE 108 ............................................................ 4-12
FIGURE 54 .............................................................. 3-61 FIGURE 109 ............................................................ 4-13
FIGURE 55 .............................................................. 3-62 FIGURE 110 ............................................................ 4-14

PN 71510013 - OMM015008130510 INDECES - TABLE OF FIGURES 9-9
FIGURE 111 ............................................................ 4-16 FIGURE 167 ............................................................ 4-44

FIGURE 112 ............................................................ 4-16 FIGURE 168 ............................................................ 4-45
FIGURE 113 ............................................................ 4-17 FIGURE 169 ............................................................ 4-45
FIGURE 114 ............................................................ 4-17 FIGURE 170 ............................................................ 4-45
FIGURE 115 ............................................................ 4-18 FIGURE 171 ............................................................ 4-46
FIGURE 116 ............................................................ 4-18 FIGURE 172 ............................................................ 4-47
FIGURE 117 ............................................................ 4-18 FIGURE 173 ............................................................ 4-48
FIGURE 118 ............................................................ 4-19 FIGURE 174 ............................................................ 4-48
FIGURE 119 ............................................................ 4-19 FIGURE 175 ............................................................ 4-48
FIGURE 120 ............................................................ 4-19 FIGURE 176 ............................................................ 4-49
FIGURE 121 ............................................................ 4-20 FIGURE 177 ............................................................ 4-50
FIGURE 122 ............................................................ 4-20 FIGURE 178 ............................................................ 4-51
FIGURE 123 ............................................................ 4-20 FIGURE 179 ............................................................ 4-51
FIGURE 124 ............................................................ 4-21 FIGURE 180 ............................................................ 4-51
FIGURE 125 ............................................................ 4-21 FIGURE 181 ............................................................ 4-52
FIGURE 126 ............................................................ 4-21 FIGURE 182 ............................................................ 4-52
FIGURE 127 ............................................................ 4-22 FIGURE 183 ............................................................ 4-52
FIGURE 128 ............................................................ 4-22 FIGURE 184 ............................................................ 4-53
FIGURE 129 ............................................................ 4-22 FIGURE 185 ............................................................ 4-53
FIGURE 130 ............................................................ 4-23 FIGURE 186 ............................................................ 4-53
FIGURE 131 ............................................................ 4-23 FIGURE 187 ............................................................ 4-54
FIGURE 132 ............................................................ 4-23 FIGURE 188 ............................................................ 4-54
FIGURE 133 ............................................................ 4-24 FIGURE 189 ............................................................ 4-54
FIGURE 134 ............................................................ 4-24 FIGURE 190 ............................................................ 4-54
FIGURE 135 ............................................................ 4-25 FIGURE 191 ............................................................ 4-54
FIGURE 136 ............................................................ 4-25 FIGURE 192 ............................................................ 4-55
FIGURE 137 ............................................................ 4-25 FIGURE 193 .............................................................. 5-3
FIGURE 138 ............................................................ 4-26 FIGURE 194 .............................................................. 5-4
FIGURE 139 ............................................................ 4-26 FIGURE 195 .............................................................. 5-5
FIGURE 140 ............................................................ 4-27 FIGURE 196 .............................................................. 5-6
FIGURE 141 ............................................................ 4-27 FIGURE 197 .............................................................. 5-7
FIGURE 142 ............................................................ 4-28 FIGURE 198 .............................................................. 5-8
FIGURE 143 ............................................................ 4-28 FIGURE 199 .............................................................. 5-9
FIGURE 144 ............................................................ 4-28 FIGURE 200 ............................................................ 5-10
FIGURE 145 ............................................................ 4-30 FIGURE 201 ............................................................ 5-11
FIGURE 146 ............................................................ 4-30 FIGURE 202 ............................................................ 5-12
FIGURE 147 ............................................................ 4-31 FIGURE 203 ............................................................ 5-13
FIGURE 148 ............................................................ 4-31 FIGURE 204 ............................................................ 5-14
FIGURE 149 ............................................................ 4-32 FIGURE 205 ............................................................ 5-15
FIGURE 150 ............................................................ 4-33 FIGURE 206 ............................................................ 5-16
FIGURE 151 ............................................................ 4-34 FIGURE 207 ............................................................ 5-17
FIGURE 152 ............................................................ 4-35 FIGURE 208 ............................................................ 5-18
FIGURE 153 ............................................................ 4-35 FIGURE 209 ............................................................ 5-19
FIGURE 154 ............................................................ 4-36 FIGURE 210 ............................................................ 5-20
FIGURE 155 ............................................................ 4-36 FIGURE 211 .............................................................. 6-2
FIGURE 156 ............................................................ 4-37 FIGURE 212 .............................................................. 6-3
FIGURE 157 ............................................................ 4-37 FIGURE 213 .............................................................. 6-3
FIGURE 158 ............................................................ 4-38 FIGURE 214 .............................................................. 6-4
FIGURE 159 ............................................................ 4-38 FIGURE 215 .............................................................. 6-7
FIGURE 160 ............................................................ 4-38 FIGURE 216 .............................................................. 6-8
FIGURE 161 ............................................................ 4-39 FIGURE 217 .............................................................. 7-2
FIGURE 162 ............................................................ 4-40 FIGURE 218 .............................................................. 7-4
FIGURE 163 ............................................................ 4-41 FIGURE 219 .............................................................. 7-7
FIGURE 164 ............................................................ 4-42
FIGURE 165 ............................................................ 4-42
FIGURE 166 ............................................................ 4-43

PN 71510013 - OMM015008130510 NOTES - FLAIL DRIVE BEARING INSPECTION RECORDS 10-1
10. Notes
Flail Drive Bearing Inspection Records
The following section is provided to assist in recording the drive bearing temperatures as
measured on your CBI 604 flail. For flail locations listed by flail number please see Machine
Orientation & Component Location, p. 1-6.
Performed By:
Machine Hours: Date:
Flail # N.D.S. Rotor Bearing Temp. D.S. Rotor Bearing Temp. Jackshaft Bearing Temp.
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

10-2 NOTES - FLAIL DRIVE BEARING INSPECTION RECORDS PN 71510013 - OMM015008130510
Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

PN 71510013 - OMM015008130510 NOTES - BELT TENSION TEST RECORDS 10-7
Belt Tension Test Records

The following section is provided to assist in recording the drive belt tensions as measured on
your CBI 604 flail. For flail locations listed by flail number please see Machine Orientation &
Component Location, p. 1-6.
Performed By:
Flail # Average Belt Tension – Top (HZ) Average Belt Tension – Bottom (HZ)
1
2
3
4
Performed By:
1
2
3
4

10-8 NOTES - BELT TENSION TEST RECORDS PN 71510013 - OMM015008130510
Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

Performed By:
1
2
3
4
Performed By:
1
2
3
4
Performed By:
1
2
3
4

PN 71510013 - OMM015008130510 NOTES - CUSTOM NOTES 10-17
Custom Notes
The following section is provided for operators to record notes about this CBI machine.
Consulting this section can be valuable for learning what other operators have learned before you.

10-18 NOTES - CUSTOM NOTES PN 71510013 - OMM015008130510

PN 71510013 - OMM015008130510 NOTES - CUSTOM NOTES 10-19

10-20 NOTES - CUSTOM NOTES PN 71510013 - OMM015008130510


Manual Descortezador 604

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PN 71510013 - OMM015008130510 i

2. Safety ............................................................................................... 2-1

4. Maintenance .................................................................................... 4-1

5. Electrical System ............................................................................ 5-1

6. Hydraulic System ........................................................................... 6-1

7. Specifications ................................................................................. 7-1

8. Replacement Parts ......................................................................... 8-1

9. Indeces ............................................................................................ 9-1

10. Notes.............................................................................................. 10-1

CONTINENTAL BIOMASS INDUSTRIES, INC.

CONTINENTAL BIOMASS INDUSTRIES, INC.

Product Intent & Disclaimer

CONTINENTAL BIOMASS INDUSTRIES, INC.

Equipment Serial Numbers

- CBI 604 Flail Debarker – serial no. 015008

CONTINENTAL BIOMASS INDUSTRIES, INC.

- Tigercat 215 Loader - Operator's Manual PN: 37622AENG

CONTINENTAL BIOMASS INDUSTRIES, INC.

About This Manual

How to Use This Manual

Date of publication: Friday, May 10, 2013

CONTINENTAL BIOMASS INDUSTRIES, INC.

Machine Orientation & Component Location

CONTINENTAL BIOMASS INDUSTRIES, INC.

Component Location Index

Part Description Location Code Part Description Location Code

CONTINENTAL BIOMASS INDUSTRIES, INC.

Part Description Location Code Part Description Location Code

Waste Discharge Ram X7.4 Y1.2 Z2.0

CONTINENTAL BIOMASS INDUSTRIES, INC.

Flail Numbering Guide

Bottom Feed Roll Numbering Guide

Idler Roll Numbering Guide

CONTINENTAL BIOMASS INDUSTRIES, INC.

Top Feed Roll Numbering Guide

CONTINENTAL BIOMASS INDUSTRIES, INC.

Genuine CBI Replacement Parts

Replacement part ordering procedure

1 Identify your machine

2 Identify parts / components

Parts department contact information

CBI Parts Department: +1 (888) 224 4647 ext. 1

CONTINENTAL BIOMASS INDUSTRIES, INC.

CBI Authorized Service

CBI Authorized Service Assistance

Service Assistance Requisition Procedure

1 Identify your machine

Service department contact information

CBI Service Department: +1 (888) 224 4647 ext. 2

CONTINENTAL BIOMASS INDUSTRIES, INC.

Publication feedback reporting procedure

1 Record Serial Number

3 Record personal information

4 Record location of content in question

Technical publications department contact information

CBI Technical Publications Department: TechnicalPublications@CBI-inc.com

CONTINENTAL BIOMASS INDUSTRIES, INC.

CONTINENTAL BIOMASS INDUSTRIES, INC.

CONTINENTAL BIOMASS INDUSTRIES, INC.

CONTINENTAL BIOMASS INDUSTRIES, INC.

CONTINENTAL BIOMASS INDUSTRIES, INC.

CONTINENTAL BIOMASS INDUSTRIES, INC.

CONTINENTAL BIOMASS INDUSTRIES, INC.

Restoring Equipment to Service