Caterpillar Forest 2410, 2410 PH OPERATOR’S MANUAL

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Page 1

OPERATOR’S MANUAL

Knuckleboom Loader

2410 - 2410 PH

Part No. 30015166

March 2012

Rev. A

Page 2

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TO THE OPERATOR

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TO THE OPERATOR

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TO THE OPERATOR

INTRODUCTION

DO NOT USE THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTOOD THIS MANUAL AND HAVE THE NECESSARY TRAINING AND AUTHORIZATION TO OPERATE AND MAINTAIN YOUR MACHINE PROPERLY.

REMEMBER THAT YOU ARE THE KEY TO SAFETY. GOOD SAFETY PRACTICES PROTECT YOU AND THE PEOPLE AROUND YOU. MAKE THIS MANUAL A WORKING PART OF YOUR SAFETY PROGRAM.

2410 Loader

This operator's manual describes how to safely operate the Prentice Loaders. The Prentice loader is a truck trailer–mounted loader used for handling random–length logs and tree–length stems.

Minimum trailer is a 40-foot (12.2 m) tandem-axle trailer (45-foot (13.7 m) for delimbers) with 40,000 pounds (18,144 kg) GVW (gross vehicle weight) rating, and a mounting surface height of about 39 inches (99 cm). Minimum truck is a 6 x 4 live tandem truck of not less than 50,000 pounds (22,680 kg) GVW rating. Truck must have a double channel frame and minimum CA of 132 inches (334 cm). A CA of 144 to 168 inches (366 - 427 cm) is recommended. A maximum CA for live heel of 144 inches (366 cm) is required.

CAPACITY AT MAXIMUM REACH: PER SAE J2417 2410 Knuckle Boom:

Follow the instructions in this operator's manual to safely operate the Prentice log loaders. Directions in this manual are referenced from the operator's seat facing forward.

You can help improve this manual. If you nd any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter to: ATTN: TECHNICAL PUBLICATIONS, Caterpillar Forest Products Inc., 3249 S. COUNTY ROAD 45, P.O. BOX 568, OWATONNA MN 55060–0568.

32 foot (9.75 m) radius, 5 foot (1.5 m) elevation, 4,458 pounds (2,340 kg).

FORWARD

LEFT

BACK

RIGHT

This operator's manual includes information available and current at the time of approval for printing. Cater-

pillar Forest Products, Inc. reserves the right to improve its product without giving prior notice or incurring

obligation.

This operator’s manual should be regarded as part of the machine. Suppliers of both new and second

hand machines are advised to retain documentary evidence that this manual was provided with the machine.

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0209

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TO THE OPERATOR

DANGER

WARNING

NOTICE

CAUTION

SAFETY SYMBOLS

SAFETY ALERT SYMBOL

Means: ATTENTION. BE ALERT. YOUR SAFETY IS INVOLVED.

This safety symbol is used for important safety messages. When you see this symbol, follow the safety message to avoid personal injury and/or property damage.

Understand signal words: DANGER, WARNING, and CAUTION are used with the SAFETY ALERT SYMBOL.

DANGER IDENTIFIES THE HAZARD OR UNSAFE PRACTICE THAT WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH.

WARNING identies the hazard or unsafe practice that could result in severe personal injury or death.

CAUTION identies the hazard or unsafe practice

that could result in personal injury or property damage.

NOTICE identies important installation, operation, or maintenance information.

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0209

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CONTENTS

PRODUCT PROTECTION PLAN

Machine i

Attachment .........................................................................ii

To the Operator ................................................................iii

Safety Symbols .................................................................iv

Contents ...............................................................................v

01  GENERAL SAFETY ........................................................11

Safety Alert Symbol .....................................................1-1

Operator Preparation ..................................................1-1

Avoid Contact with Stabilizers .................................1-1

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

Control Shut O Lever ................................................1-2

Electric Lines ...................................................................1-3

Electric Storm .................................................................1-3

Falling or Swinging Logs ............................................1-4

Fire Prevention/First Aid .............................................1-4

Fluids Under Pressure..................................................1-5

Hand Holds & Steps .....................................................1-5

Hand Signals ...................................................................1-6

Hoses & Fittings .............................................................1-6

No Riders on Machine .................................................1-7

Operator Safety .............................................................1-7

Pinch Points ....................................................................1-7

Practice Safe Maintenance ........................................1-8

Pressure Settings ..........................................................1-8

Protective Clothing ......................................................1-9

Protective Devices/Equipment ................................1-9

Radiator Cap ...................................................................1-9

Refueling ....................................................................... 1-10

Starter Circuitry ..........................................................1-10

Unauthorized Welding ............................................. 1-10

Unstable Platform ...................................................... 1-11

02  SAFETY DECALS ...........................................................21

Loader ...........................................................................2-1

Carrier ...........................................................................2-2

Truck Mount Cab Interior ...........................................2-3

Bar Slasher/Delimber Cab Int. ..................................2-4

03  COMPONENT TERMINOLOGY .................................31

04  CONTROLS AND INSTRUMENTS ............................41

Operator’s Cab ..............................................................4-1

Instrument Console ...................................................4-2

Engine Coolant Temp. Wrng. Ind. ............................4-3

Low Coolant Warning Indicator ...............................4-3

Voltage Warning Indicator.........................................4-4

Hydraulic Oil Filter Warning Indicator ...................4-4

Fuel Gauge ......................................................................4-5

Engine Oil Pressure Warning Indicator .................4-5

Air Cleaner Warning Indicator ..................................4-6

Hydraulic Oil Temp Wrng. Indicator .......................4-6

Low Hydraulic Oil Wrng. Indicator ..........................4-6

Switch Panel ...................................................................4-7

Ignition Switch ...............................................................4-8

Dome Light .....................................................................4-8

Error Code Indicator Lights .......................................4-8

Circuit Breakers ..............................................................4-9

Heat Control Lever .......................................................4-9

Pilot Pressure Shut O ............................................. 4-10

Battery Disconnect Master Switch ...................... 4-10

Throttle ........................................................................ 4-11

Swing Pedal ................................................................. 4-11

Left Joystick .................................................................4-12

Right Joystick ..............................................................4-13

Right Joystick Rocker Switch ................................. 4-14

Stabilizer Controls .....................................................4-14

Hourmeter .................................................................... 4-14

Operator’s Seat ........................................................... 4-15

AM/FM Stereo Cassette ...........................................4-17

05  PRESTART INSPECTION ............................................51

Pre-Start Checks on the Ground .............................5-1

Pre-Start Checks on the Platform ............................5-2

Pre-Start Checks in the Cab ......................................5-3

Fire Prevention ...............................................................5-4

06  OPERATION.....................................................................61

General Guidelines .......................................................6-1

Electrocution Danger ..................................................6-2

Overhead Loads Warning ..........................................6-2

Getting on Machine .....................................................6-3

Machine Start Up ..........................................................6-3

Starting the Engine ......................................................6-4

Starting Machine with Booster Battery ................6-5

Indicator Lamp Checks ...............................................6-6

Cold Weather Starting

Engine Pump Disconnect ........................................6-8

Warm-up Period ............................................................6-9

Feathering the Controls .......................................... 6-10

Using Stabilizers ......................................................... 6-11

Landing Layout ........................................................... 6-12

Heeling - Picking up Logs .......................................6-12

Grapple Control .......................................................... 6-13

Stopping the Machine ............................................. 6-13

Getting o Machine .................................................. 6-14

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CONTENTS

07  BREAKIN PERIOD ........................................................71

After First 10 Hours ......................................................7-1

After First 100 Hours ....................................................7-2

08  TRANSPORTING ............................................................81

09  FUELS AND LUBRICANTS ..........................................91

Fuel 9-1

Engine Oil .......................................................................9-2

Hydraulic Oil ...................................................................9-3

Grease ...........................................................................9-3

Grease for Swing Drive Bearing

and Swing Drive Motor ............................................9-4

Lubricant for Pinion and

Swing Gear Teeth .......................................................9-4

Lubricant for Swing Drive Gear Box .......................9-4

Cylinder Rod Corrosion Preventive ........................9-4

Engine Coolant Specications .................................9-4

Storing Lubricants ........................................................9-5

10  MAINTENANCE SAFETY .......................................... 101

Before Maintenance.................................................. 10-1

Practice Safe Maintenance .....................................10-1

Hydraulic Safety .........................................................10-2

Protective Clothing ...................................................10-2

Servicing Cotrol Valves, Cylinders, Pump s & ...........

Motors ................................................................... 10-3

Unauthorized Welding ............................................. 10-3

During Maintenance ................................................. 10-4

Battery Safety ..............................................................10-4

Cooling Fan .................................................................. 10-4

Diesel Exhaust ............................................................. 10-5

Fluids Under Pressure...............................................10-5

Fuels & Lubricants......................................................10-6

Pinch Points .................................................................10-6

Servicing Machine with Engine Running .......... 10-6

After Maintenance ..................................................... 10-7

Disposing of Waste .................................................... 10-7

Stroing of Flamable Materials ............................... 10-7

11  SCHEDULED/PERIODIC MAINTENANCE ..................

SERVICES ...............................................................................111

Lubrication and Maintenance Intervals ............. 11-1

Lubrication Notice ..................................................... 11-1

Position Machine for Maintenance ..................... 11-1

Maintenance Charts

As Required ............................................................. 11-2

Daily or Every 10 Hours .......................................11-3

Weekly or Every 50 Hours................................... 11-5

Monthly or Every 250 Hours .............................. 11-6

Every 500 Hours ..................................................... 11-7

Every 1000 Hours .................................................. 11-8

Maintenance Details

As Required ............................................................. 11-9

Check Electrical System ......................................11-9

Clean AC Condenser ..........................................11-10

Clean/Replace Recirculation Air Filter .........11-10

Fill Windsheild Washer Fluid Reservoir ........11-11

Clean Windsheild & Windows .........................11-11

Check/Replace Polycarbonate Window ................

Skylight ...............................................................11-12

Adjust Slasher/Delimber Saw Bar Chain ................

......................................................................11-12

Drain Replace Hydraulic Oil .............................11-13

Hazard Decals .......................................................11-13

Daily or Every 10 Hours .....................................11-14

Daily Visual Inspection ......................................11-14

Lube Adapter Knuckle .......................................11-14

Lube Stabilizer Pad & Pivot Points .................11-14

Lube Stabilizer Cylinder Road Ends ..............11-15

Lube Stablizer Arm Pivot Points .....................11-15

LubeStablizer Cylinder Base Ends .................11-15

LubeMain Boom Pivot Pins ..............................11-15

Lube Main Boom Cylinder Base Ends...........11-16

LubeMain Boom Cylinder Rod Ends .............11-16

Lube Main/Stick Pivot Pins ...............................11-16

Lube Stick Boom Cylinder Base Ends ...........11-16

Lube Stick Boom Cylinder Rod Ends ............11-17

Lube Swing Bearing ...........................................11-17

Lube Pinion Gear .................................................11-17

Check Hydraulic Oil Reservoir Level .............11-18

Fill Hydraulic Reservoir ......................................11-18

Prime the Pump ...................................................11-20

Air Cleaner Maintenance ..................................11-20

Unloader Valve .....................................................11-20

Inlet Hood ..............................................................11-20

Restriction Indicator ...........................................11-21

Cleaning Primary Element ...............................11-22

Check Fire Extinguisher ....................................11-23

Fill Fuel Tank ..........................................................11-23

Inspect Cooling Fan ............................................11-23

Inspect Belts ..........................................................11-23

Drain Fuel Water Separator ..............................11-24

Check Engine Crankcase Oil Levle ................11-24

Check Radiator Coolant Level .........................11-25

Inspect Eletrical Components ........................11-26

Inspect Loader Mounting Bolts ......................11-26

Weekly or Every 50 Hours.................................11-27

Weekly Inspection...............................................11-27

Check Boom & Cylinder Attaching Pins ......11-28

Check Stablizer Attaching Pins .......................11-28

Check Hydraulic Oil Res. Hardware ...............11-28

Check Hydraulic Connections ........................11-29

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CONTENTS

Clean Radiator & Oil Cooler .............................11-29

Check Hydraulic Oil for Contaminants ........11-30

Cehck Swing Drive Gear Box Lube Level

......................................................................11-30

Monthly or Every 250 Hours ............................11-31

Change Engine Oil & Filters .............................11-31

Inspect Air Intake & Exhaust Connections

......................................................................11-32

Battery Service .....................................................11-32

Seat Maintanance ...............................................11-33

Check Swing Drive Fasteners ..........................11-34

Every 500 Hours ...................................................11-35

Replace Hydraulic Return Line Filter ............11-35

Check Cooling System .......................................11-36

Replace Fuel Lift Pump Pre-Filter ..................11-36

Replace Primary Fuel Filter/Watter Separator .....

Element ...................................................................11-37

Prime the Fuel System .......................................11-37

Replace Pilot Filter ..............................................11-38

Replace Pilot Return/Case Drain Filter .........11-39

Check Outer Swing Bearing Fastener Torque

......................................................................11-39

Check Inner Swing Bearing Fastener Torque

......................................................................11-40

Scheck Swivel Arm Fastener Torque .............11-40

Cehc Swivel Fastener Torque ..........................11-40

Check Pinion Gear Fastener Torque ..............11-40

Check Stationary Heel Fastneer Torque ......11-41

Replace Slasher/Delimber Return Line Filter

......................................................................11-41

Every 1000 Hours ................................................11-42

Change Hydraulic Reservoir Oil .....................11-42

Fill Hydraulic Reservoir ......................................11-42

Prime the Pump ...................................................11-44

Replace Hydraulic Reservoir Breather Filter .........

......................................................................11-44

Replace Pressure Vacume Relief Valve .........11-45

Flush & Fill Cooling System ..............................11-45

Drain & Replace Swing Drive Gear Box Lube

......................................................................11-47

Check Swing Drive Grease Level ....................11-47

Drain & Fill Swing Drive .....................................11-48

Check/Clean Collector Ring .............................11-48

Seat ........................................................................13-6

Electrical System ........................................................ 13-6

Cleanliness of Hydraulic Components ............... 13-7

14  SPECIFICATIONS ........................................................141

Machine Specs ............................................................ 14-1

Hydarulic Connection Torque Specs

SAE 37 Deg Flare ............................................... 14-3

Hydarulic Connection Torque Specs

O-Ring Face Seal ................................................ 14-4

Torque Chart for Fasteners ..................................... 14-5

Cylinder Torque Specs .............................................. 14-6

Pressure Settings .......................................................14-7

15  SERIAL NUMBERS ......................................................151

16  MATERIAL SAFETY DATA SHEETS .......................161

12  STORAGE ...................................................................... 121

Preparing Machine for Storage .............................12-1

Taking Machine Out of Storage ............................ 12-2

13  TROUBLESHOOTING ................................................ 131

Hydraulic System .......................................................13-1

Engine ........................................................................ 13-2

Flash Codes .................................................................. 13-4

Event Codes ................................................................. 13-5

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TO THE OPERATOR

NOTES

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GENERAL SAFETY

WARNING

GENERAL SAFETY

manual.

Do not operate this machine without reading and understanding this operator’s

SAFETY ALERT SYMBOL

Read all safety messages.

To avoid personal injury and/or property damage, follow safety messages.

OPERATOR PREPARATION

Operator must be fully trained, qualied, and authorized to operate this machine. Before operating this machine, operator must know the location and purpose of

• controls

• indicator lights

• instruments

• safety and instruction decals

(See Section 2, Safety Decals.)

AVOID CONTACT WITH STABILIZERS

Coming into contact with stabilizers can cause serious personal injury or death.

Clear all personnel from work area before raising or lowering stabilizers.

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G.043.03

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GENERAL SAFETY

WARNING

BATTERY SAFETY

sive gases that can cause severe personal injury or death.

Battery acid is poisonous and can cause severe burns. If acid is taken internally, call a physician immediately. If acid contacts skin or clothing, ush with water immediately. Keep batteries away from children.

Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Keep sparks, ames, and cigarettes away from batteries. Ventilate properly when charging or using batteries in enclosed space. Always shield eyes with goggles and wear a face shield when working near batteries. Do not lean over batteries during this operation. Always connect positive (+) to positive (+) and negative (-) to negative (-). For further instructions, see Jump Starting Battery in Section 6, Operation. If battery acid contacts eyes, ush them with water for 15 minutes and seek immediate medical attention.

Batteries produce explo-

Never charge a battery or jump start engine if battery is frozen. Warm battery to 60°F (16°C) or it may explode. Be sure vent caps are tight. When jump starting from another machine, be sure machines do not touch. This machine has a 12-volt starting system. Use equal voltage for jump starting.

CONTROL SHUT OFF LEVER

Accidental movement of turntable or booms can cause serious personal injury or death.

Before leaving cab, lift control shut o lever to disengage hydraulic pilot circuit and to free door entry/exit path.

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GENERAL SAFETY

DANGER

WARNING

ELECTRIC LINES

DEATH WILL RESULT FROM CONTACT WITH ELEC TRIC LINES.

Never move any part of machine or load closer than 10 feet plus twice the line insulator length to electric lines. A line insulator is what connects an electric line to an electric pole.

For example, if a line insulator is 6 inches long, operator must stay at least 10 feet plus twice the line insulator length (2x6 =12 inches or 1 foot) from electric line, which means machine must stay at least 11 feet from the electric line.

If machine touches an electric line, stay inside the cab. Carefully move machine or load away from electric line, without pulling the line down.

DO NOT allow anyone else to touch machine while it is touching an electric line. If machine cannot be moved away from the electric line without pulling line down, have someone contact the utility company to disconnect power from line. If this is not possible, or if machine begins to burn, jump away from machine to the ground with both feet together, in one smooth jump. Do not run or walk away from machine. Jump with feet together (“bunny hop”) away from machine. DO NOT touch machine and ground at the same time or else electricity in the line will go through your body. Get away from machine after jumping.

SERIOUS INJURY OR

Notify the utility company immediately. DO NOT let anyone near the machine while it is touching an electric line.

ELECTRICAL STORM

Electrical storms (lightning) can cause severe personal injury or death.

When lightning is striking in the vicinity of the machine, the operator should NEVER attempt the following procedures:

Mount the machine

Dismount the machine

If you are in the operator’s station during an electrical storm, stay in the operator’s station. If you are on the ground during an electrical storm, stay away from the vicinity of the machine.

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GENERAL SAFETY

CAUTION

WARNING

FALLING OR SWINGING LOGS

booms, or attachments can cause severe personal injury or death.

Never operate the boom, attachment or load over or near personnel.

Falling or swinging logs,

G.111.04

FIRE PREVENTION/FIRST AID

injury and/or machine damage.

Keep machine clean. Forest debris, rags, and trash will cause res. Remove all debris, rags, and trash from machine, especially around engine and hydraulic components.

Repair all hydraulic and fuel leaks immediately. Do not operate machine with hydraulic or fuel leaks.

Fire prevention beats re ghting. Remove debris from all compartments after every 8 hours of operation, or more often, if warranted by working conditions.

Install a rst-aid kit in the cab.

Properly maintain rst-aid kit and re extinguisher. Follow instructions provided with them.

Fires can cause personal

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GENERAL SAFETY

WARNING

FLUIDS UNDER PRESSURE

pressure can penetrate skin and cause severe personal injury or death. Wear eye and personal protection equipment (PPE)!

Always use a board or cardboard when checking oil hoses, lines, and ttings for leaks, cracks, or defects. Be sure all clamps are in their proper position and torqued as required and specied. Be sure hoses are not twisted or touching parts.

DO NOT use hands to search for leaks. Escaping uids can penetrate skin and enter the bloodstream. Before disconnecting lines, relieve all pressure.

DO NOT apply pressure to a damaged line, hose, or tting.

If ANY uid is injected into the skin, seek medical attention immediately. A serious infection or reaction can result without proper medical treatment.

Fluids escaping under

HAND HOLDS AND STEPS

Slips and falls can cause severe personal injury or death.

Use provided hand holds and steps while maintaining at least 3 points of support (1 foot and 2 hands or 2 feet and 1 hand) when getting on and o machine. Face machine when getting on and o of it.

Never use controls as hand holds. Never use steering wheel as a hand hold. Moving the steering wheel from its center position will COMPLETELY turn machine right or left.

DO NOT mount machine if hand rails or steps are broken or missing. Get them repaired rst.

DO NOT jump on or o machine unless it has touched a live electrical wire and it must be exited.

Ensure rm foot position when getting on and o machine. Be careful of slippery conditions on platform, steps, and hand holds when getting on and o machine.

Remove oil, grease, mud, ice, etc. before mounting or dismounting machine.

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To prevent slips and falls, replace skid-resistant material if it is worn, damaged or missing.

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GENERAL SAFETY

WARNING

HAND SIGNALS

vere personal injury or death.

Know and use the hand signals required for particular jobs.

Know who has the responsibility for signaling.

Accidents can cause se-

HOSES AND FITTINGS

Mismatched brands or types of hoses and ttings can blow apart and cause severe personal injury or death.

DO NOT interchange brands or types of hoses and ttings.

DO NOT install a tting from one manufacturer on a hose from a dierent manufacturer.

DO NOT install crimp ttings on hoses meant for reusable ttings.

Wear eye and personal protection equipment (PPE)!

Always use a board or cardboard when checking oil hoses, lines, and ttings periodically for leaks, cracks or defects. Be sure all clamps are in their proper position and torqued as required and specied. Be sure hoses are not twisted or touching parts.

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GENERAL SAFETY

WARNING

NO RIDERS ON MACHNE

from machine or be injured by movement of machinery, causing severe personal injury or death.

Do not allow riders on any machine that is operating or moving.

Machine riders can fall

OPERATOR SAFETY

Flying debris, tree limbs, and/or other material can cause severe personal injury or death.

When operating machine:

1. Cab door must stay closed.

2. Window material and/or cab guarding MUST be in

place.

3. All cab openings (front, side, and rear) MUST be

covered with window material (no glass) and/or protective screen.

4. Window guarding MUST be locked

in place.

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GENERAL SAFETY

WARNING

PRACTICE SAFE MAINTENANCE

Understand service procedures before performing maintenance. When performing maintenance, keep area around machine clean and dry.

DO NOT service machine while it is moving. Keep away from power-driven parts. Lower attachment to the ground. Disengage power. Shut engine down. Move controls in all directions to relieve hydraulic pressure. Remove key from ignition. Allow machine to cool down.

Support all raised equipment.

Keep all machine parts in good condition, and be sure parts are properly installed. Repair damage immediately. Repair all hydraulic and fuel leaks immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.

Disconnect battery ground cable (-) before adjusting the electrical system.

PRESSURE SETTINGS

Excessive hydraulic pressure can cause component or structural failure, which may result in severe personal injury or death.

Wear eye and personal protection equipment (PPE)!

DO NOT exceed factory-adjusted pressure settings.

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GENERAL SAFETY

CAUTION

WARNING

PROTECTIVE CLOTHING

Wear OSHA or local governing body-approved protective clothing when working on or near this machine, such as

• ear protection • hard hat

• gloves • orange vest

• goggles • steel-toed shoes

Wear snug, protective clothing that is belted where required.

Remove jewelry before working on or near this machine.

PROTECTIVE DEVICES/EQUIPMENT

ignorance of protective equipment or devices can cause severe personal injury or death.

Misuse, interference and

Alarms, re prevention equipment, ROPS/FOPS/OPS, and other safety equipment is installed on machine for your protection.

Never ignore, disconnect, disable or modify protection equipment in any manner.

RADIATOR CAP

tem can cause scalding burns.

Wear eye and personal protection equipment (PPE)!

Do not remove radiator cap unless engine is cool. Allow system to cool. Remove cap slowly to relieve pressure before removing completely.

Pressurized cooling sys-

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GENERAL SAFETY

WARNING

NOTICE

DANGER

G.020.05

REFUELING

cause severe personal injury or death.

Handle fuel with care. It is highly ammable.

DO NOT refuel machine while smoking or when near open ame or sparks.

Always stop engine before refueling. Fill fuel tank outdoors. Prevent res by keeping machine clean of trash, grease, and debris. Always clean up spilled fuel.

STARTER CIRCUITRY

Fires and explosions can

MACHINE WILL START IN GEAR IF START CIRCUITRY IS BYPASSED.

Do not attempt to start machine engine by shorting starter circuit across starter terminals. Doing so may cause unintended machine movement which could result in severe personal injury or death and serious machine and/or property damage.

UNAUTHORIZED WELDING

Unauthorized welding can cause structural failure and/or severe personal injury or death.

DO NOT weld on any structural member. Any unauthorized welding or repair will void the warranty.

2410

Once authorized, be sure to turn battery disconnect master switch OFF and place welding ground (stinger) as close to weld site as possible. Do not allow weld current to pass through bearings or pivot points.

Unauthorized welding can

cause damage to the electrical system.

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GENERAL SAFETY

WARNING

UNSTABLE PLATFORM

cause severe personal injury or death.

Lower all stabilizers before operating machine.

Unstable platform can

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GENERAL SAFETY

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SAFETY DECALS

NOTICE

SAFETY DECALS

The following safety decals are located in positions on the machine as continual reminders of HAZARDS. Serious injury or property damage can occur if safety instructions are not followed.

Keep all safety decals clean and readable. Use soft cloth, water, and soap to clean decals if they are too dirty to read. DO NOT clean safety decals with solvent. Solvent can damage them.

Replace safety decals immediately if they are damaged, missing, or hard to read. Contact an authorized dealer for replacement safety decals. Authorized dealers will provide free replacement safety decals if you give them a valid serial number for your machine.

If you replace a part that has a safety decal on it, apply a new safety decal to the replace-

ment part. Before putting a new decal on the machine or part, be sure the surface where the decal will be mounted is clean and dry.

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SAFETY DECALS

LOADER DECALS

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SAFETY DECALS

CAB DECALS

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SAFETY DECALS

TMS TRAILER DECALS

Tire Malfunction

This warning is located on each side of the machine trailer.

Do not exceed speeds of 50 mph when transporting machine. Tire malfunction can occur resulting in serious personal injury or death.

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COMPONENT TERMINOLOGY

LOADER

1. Subframe assembly

2. Stabilizer

3. Swing bearing

4. Swing motor

5. Upper frame assembly

6. Hydraulic pump assembly

7. Hydraulic oil reservoir

8. Hydraulic oil lter

9. Oil cooler

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10. Cab

11. Main boom cylinder

12. Main boom

13. Stick boom cylinder

14. Stick boom

15. Grapple

16. Grapple knuckle

17. Stationary heel (option)

18. Operator protection guard

19. Turntable assembly

Page 28

COMPONENT TERMINOLOGY

LOADER

1. SAP Chassis

2. Subframe

3. Turntable

4. Operator’s Cab

5. Engine Compartment

6. Hydraulic Pump & Drive

7. Hydraulic Oil Reservoir

8. Fuel Tank

9. Control Valves

10. Swing Motor (other side)

11. Main Boom

12. Main Boom Cylinder

13. Stick Boom

14. Stick Boom Cylinder

15. Tilt Cylinder

16. Grapple

17. Grapple Tilt Cylinder

18. Grapple Head

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Page 29

CONTROLS AND INSTRUMENTS

OPERATOR’S CAB

1. Operator’s Seat

2. Engine Throttle Control

3. Right Hand Joystick Control

11 12

G.023.03

8. Error Code Indicator Lights

9. Stabilizer Switches

10. Power Supply

4. Left Hand Joystick Control

5. Pilot Pressure Shuto Lever

6. Foot Control - Swing Pedal

7. Instrument Console

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11. Washer/Wiper and Light Switches

12. A/C Heat/Defrost Switches

13. Heat Control Lever

14. Ignition

41

Page 30

CONTROLS AND INSTRUMENTS

JOYSTICKS WITH PIPE HANDLE ATTACHMENT

1. Left hand Control - Stick, Swing & Jib

2. Rear Right Hand Control - Grapple

3. Front Right Hand Control - Steer & Drive, Switch for Brake Control

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Page 31

CONTROLS AND INSTRUMENTS

INSTRUMENT CONSOLE

Engine Coolant Temp

Engine Coolant Level

Voltage

Hydraulic Oil Filter

Fuel Level

Engine Oil Pressure

Air Cleaner Filter

Hydraulic Oil Temperature

Hydraulic Oil Level

Alarm

IMG.2414.

G.024.03

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Page 32

CONTROLS AND INSTRUMENTS

ENGINE COOLANT TEMPERATURE WARNING INDICATOR

Failure to reduce load with

engine coolant temperature warning indicator lit could cause premature engine failure or damage.

If the engine coolant temperature reaches 210°F (99°C), a warning indicator will light and an alarm will sound. When this happens, shut engine down and check for loose belts, coolant leakage, or a plugged radiator.

LOW COOLANT WARNING INDICATOR

The low coolant warning indicator will light and an alarm will sound when the coolant in the radiator is low by approximately 1.25 gallons (4.72 L) from the FULL level.

When the indicator lights, immediately shut engine down, ll radiator with coolant (50 percent mixture or clean, distilled water and ethylene glycol antifreeze), and check for leaks and/or damage.

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Page 33

CONTROLS AND INSTRUMENTS

VOLTAGE WARNING IDICATOR

DO NOT operate engine if voltage warning indicator is lit. Operating with voltage too high or too low can cause electrical system damage.

If voltage is too high or too low, the voltage warning indicator will light. Immediately shut engine down, turn key to OFF position, and check electrical system for improper charging.

HYDRAULIC OIL FILTER WARNING INDICATOR

The hydraulic oil lter warning indicator will light if any of the hydraulic system lters become restricted or plugged. Once lters are serviced, indicator light will go o.

The indicator will light at initial start up until hydraulic oil reaches normal operating temperature.

If indicator remains lit, oil is bypassing the return line lter and going directly into the tank without being ltered.

The lters should be changed immediately to prevent damage to hydraulic components. See Scheduled/Periodic Maintenance Services Section, for lter replacement instructions.

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Page 34

CONTROLS AND INSTRUMENTS

FUEL GAUGE

The fuel gauge indicates the amount of fuel in the fuel tank. A warning indicator will light if fuel level drops below .17 percent capacity.

engine to run out of fuel. Doing so will cause engine damage.

. DO NOT allow a diesel

ENGINE OIL PRESSURE WARNING INDICATOR

. If no oil pressure is indicated

within 10 to 15 seconds at start up, stop engine and check the lubricating oil system. Oil pressure does not guarantee a sucient amount of oil in the engine oil pan. Check engine oil level by observing level on the engine oil dipstick.

The engine oil pressure warning indicator will light if engine oil pressure drops below 15 psi (103 kPa). When this happens, shut engine down and check for leaks. Refer to the engine operator’s manual for more information.

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Page 35

CONTROLS AND INSTRUMENTS

AIR CLEANER WARNING INDICATOR

The air lter warning indicator will light when the engine air lter is plugged and requires cleaning or replacement. Once air lter is serviced, indicator light will go o.

In high humidity conditions, indicator may register a false reading.

See Scheduled/Periodic Maintenance Services Section or proper air lter maintenance.

HYDRAULIC OIL TEMPERATURE WARNING INDICATOR

. Possible pump or hydraulic

system damage can occur if operating for an extended period of time when hydraulic oil temperature warning indicator is lit.

A warning indicator will light and an alarm will sound if the hydraulic oil temperature reaches 200°F (93°C). If this happens, shut engine down immediately and check for a plugged oil cooler or leaks.

LOW HYDRAULIC OIL WARNING INDICATOR

The low hydraulic oil warning indicator will light when the hydraulic oil level becomes too low.

Fill reservoir immediately to prevent damage to hydraulic components.

To ll hydraulic reservoir, refer to Scheduled/Periodic Maintenance Services Section.

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Page 36

CONTROLS AND INSTRUMENTS

SWITCH PANEL

HORN SWITCH

Press switch to sound horn.

WORK LIGHT SWITCH

Press switch to turn on work lights.

WINDSHIELD WASHER SWITCH

Press switch to dispense windshield wiper uid. Wipers will operate as long as switch is depressed.

WINDSHIELD WIPER SWITCH

Two-position switch controls speed of wiper motor. Top position is OFF; middle position is low speed; bottom position is high speed.

DEFROSTER FAN SWITCH

Press switch to start defroster fan.

HEATER/AC FAN SPEED SWITCH

Two-position switch controls speed of fan motor. Top position is OFF, middle position is low speed; bottom position is high speed.

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HEAT/AC MODE SWITCH

Two-position switch controls heat/AC mode. Top position is heat mode; middle position is OFF, and bottom position is AC.

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Page 37

CONTROLS AND INSTRUMENTS

IGNITION SWITCH

Turn key in ignition switch (A) to ACC for power to the electrical components.

Turn key to ON position for power to the starter and electrical components.

Turn key OFF to shut engine down.

Before leaving machine, be

sure key is in OFF position to prevent battery drain.

Remove key so machine cannot be accidentally started, or started by unauthorized personnel.

DOME LIGHT

Press the button (B) to turn the dome light ON or OFF.

IMG.2432

ERROR CODE INDICATOR LIGHTS

The error code indicator lights (C and D) will ash when engine problems exists. For specic information on errors, refer to Operation Section.

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Page 38

CONTROLS AND INSTRUMENTS

CIRCUIT BREAKERS

Circuit breakers protect an electrical circuit from current overload.

If an overload should occur, the circuit breaker will trip, thus breaking the ow of current and prventing damage to the circuit.

To reset the circuit breaker, press the tripped breaker to its original position.

quently, consult an authorized dealer for assistance.

If circuit breakers trip fre-

IMG.2490

HEAT CONTROL LEVER

Temperature in the cab is regulated by adjusting the position of the heat control lever. For more heat, move the lever toward the side labeled WARM.

For less heat, move the lever toward the side labeled COOL.

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Page 39

CONTROLS AND INSTRUMENTS

PILOT PRESSURE SHUT OFF

The cab is equipped with a lever to shut o pilot pressure to the joystick and foot pedal controls when the operator exits the cab.

of turntable or booms can cause serious personal

injury. Before leaving cab, always push hydraulic power shut o lever up and forward to disengage hydraulic pilot circuit, and to free the door entry/ exit path.

PILOT PRESSURE DISENGAGED A

When the pilot shut o lever is in the UP position (A), the pilot controls (joystick and foot pedal functions) are disabled. Before exiting cab, always push the pilot shut o lever up and forward to disable the pilot controls and to free the entry/exit path.

Accidental movement

IMG.2576

PILOT PRESSURE ENGAGED B

When the pilot shut o lever is in the DOWN position

IMG.2577

(B), pilot controls are operational. When down, the lever blocks the cab door. The lever must be down to operate the machine.

BATTERY DISCONNECT MASTER SWITCH

The battery disconnect master switch, located behind the cab near the diesel fuel ll cap, is designed to prevent accidental starting of the engine during servicing, to prevent accidental battery drain, and to help as a vandal deterrent.

Turn switch OFF to shut o electrical system.

Turn switch ON to connect electrical system.

All systems will shut down if battery disconnect master switch is turned OFF.

IMG.2385

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Page 40

CONTROLS AND INSTRUMENTS

THROTTLE

Operate engine at FULL throttle.

Engine must run at full throttle because doing so ensures

• proper cooling of engine and hydraulic system,

• proper volume and pressure of oil to hydrostatic components; and,

• full oil ow to hydraulic circuits.

The throttle (A) controls governed engine speed from low idle to full governed speed as follows:

Low idle rpm 900

Full load governed rpm 2400

INCREASING ENGINE SPEED

Turn knob clockwise to increase engine speed.

DECREASING ENGINE SPEED

Turn knob counterclockwise to decrease engine speed.

To return to IDLE, push

throttle knob in.

SWING PEDAL

Control the upper frame swing as follows:

Press LEFT side of pedal (B) to swing upper frame to the left.

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Press RIGHT side of pedal (C) to swing upper frame to the right.

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Page 41

CONTROLS AND INSTRUMENTS

LEFT JOYSTICK

LEFT HAND JOYSTICK

The left hand joystick (A) operates the main boom, stick boom, and grapple as follows:

Push joystick lever forward (B) to lower main boom.

Push joystick lever back (C) to raise main boom.

Push joystick lever left (D) to open grapple jaws.

Push joystick lever right (E) to close grapple jaws.

G.077.03

G.086.03

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Page 42

CONTROLS AND INSTRUMENTS

RIGHT JOYSTICK

RIGHT HAND JOYSTICK

The right hand joystick (A) operates the stick boom and grapple rotation as follows:

Push joystick lever forward (B) to lower stick boom.

Pull joystick lever back (C) to raise stick boom.

Push joystick lever left (D) to rotate grapple counterclockwise.

Push joystick lever right (E) to rotate grapple clockwise.

G.077.03

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Page 43

CONTROLS AND INSTRUMENTS

RIGHT JOYSTICK ROCKER SWITCH

The rocker switch on top of the right joystick (A) activates the saw bar in and out of its storage housing, and activates saw function.

Press the rocker switch LEFT to start the saw chain and to activate saw bar function.

Press the rocker switch RIGHT to stop the saw chain and to return the saw bar to storage housing.

G.089.03

STABILIZER CONTROLS

Press top of switch to raise stabilizer. Press bottom of switch to lower stabilizer.

B. Left stabilizer

C. Front/Rear stabilizer

D. Right Stabilizer

IMG.2423A

HOURMETER

The hourmeter shows hours of machine operation in full hours and tenths hours. Use the hourmeter as a guide for maintenance intervals throughout this manual.

The hourmeter is located on the engine housing, behind the operator’s cab.

IMG.2364

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Page 44

CONTROLS AND INSTRUMENTS

OPERATOR’S SEAT

Adjust operator’s seat using the following guidelines.

CONTROL CARRIER

The armrest and joystick (A) can be swung up and back to allow easier access to the operator’s seat.

011.03

SEAT FRONT AND REAR POSITION

Lift lever (B) UP and hold.

Slide seat to desired position.

Release lever.

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Page 45

CONTROLS AND INSTRUMENTS OPERATOR’S SEAT, CONTINUED

SEAT HEIGHT

Firmly lift up and hold adjustment lever (A) until lever releases.

While holding lever in the UP position, adjust seat to desired height by adding or removing body weight to the front or rear of seat cushion.

Firmly push DOWN on lever until seat locks (a click will be heard).

SEAT SUSPENSION

While seated, rotate handwheel (B) until seat cushion is level.

021.03

BACKREST

Rotate control knob (C) to select desired backrest position.

ARMREST

Rotate control knob (D) to select desired armrest angle.

010.03

2410 1111

Pivot armrest up and parallel with backrest when not in use.

417

Page 46

CONTROLS AND INSTRUMENTS

AM/FM STEREO CASSETTE RADIO

G.050.03

1. ONOFF SWITCH/VOLUME CONTROL

Rotate knob to the right to turn unit ON. Continue rotation until desired volume level is obtained.

2. TONE CONTROL

Turn knob to right or left to adjust bass and treble levels.

3. BALANCE

Rotate knob left or right to obtain desired balance between left and right speakers.

4. SELECTING A BAND

Press button to change radio band from AM to FM. FM broadcasts will be received with the switch in the IN position, and AM broadcasts will be received with the switch in the OUT position.

5. MANUAL TUNING

Rotate knob left or right to select desired radio station. When tuning in a station, always adjust the control so full signal is received. If radio is o frequency, noise and reception problems will occur. The dial pointer will move along the dial to indicate the frequency.

6. FM STEREO INDICATOR

Indicator will illuminate during reception of FM stereo broadcasts. If indicator ickers or goes on and o as machine moves, stereo signal may be too weak to reproduce clearly.

7. ANTENNA TRIMMER

It is important to adjust the antenna trimmer for optimum AM reception. The antenna trimmer is located at the back of the tap slot. Adjust following these instructions:

• Tune in a weak station around 1400 KHz on the AM band.

• Using a small screwdriver, slowly adjust trimmer for maximum radio output.

8. FM LOCAL/DISTANT SELECTOR

This selector switch is incorporated to allow maximum reception in

both weak and strong FM signal areas. For normal reception conditions, and when receiving a wide range of signals including weak or distant stations, switch should be set to the IN position, which will allow maximum signal to the receiver. When in an extremely strong (local) signal area, set switch to local setting (OUT position). This will eliminate weak signals and suppress overly strong signals to avoid overloading receiver input. When moving out of strong signal area, return switch to the distant (IN) setting.

NOTE: The Local/Distant selector aects only FM signals.

9. CASSETTE DOOR

Hold cassette with exposed tap edge to the right and insert it into the cassette door. Depress fully until cassette is engaged and begins playing.

NOTE: Observe cassette operation cautions in the Care and Mainte- nance section of the radio operation manual.

10. FAST FORWARD/EJECT BUTTON

This button performs two functions.

To eject a cassette, depress button fully, then release. Cassette will eject and radio operation will resume.

To fast forward a tape, depress button halfway into the locked position. To stop fast forwarding, resume normal tape playback, depress button slightly then release. Do not press fully in or the cassette will be ejected.

NOTE: Never leave a cassette engaged in player when not in use. Doing so can cause damage to the cassette and/or mechanism of the unit. Always press eject button and remove cassette when leaving a vehicle.

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Page 47

PRESTART INSPECTION

WARNING

NOTICE

WARNING

PRE-START INSPECTION

Do not use this machine until you read, study, and understand this manual to learn how to properly operate this machine. Operating this machine without reading, studying, and understanding this manual could result in severe personal injury or death.

Failure to perform a daily inspection of the loader could result in machine damage and severe personal injury.

PRESTART CHECKS: ON THE GROUND

Check for protective clothing (wear it) and safety equipment (know where it is).

Check entire machine by performing a thorough walk-around inspection.

Check for loose or missing parts. Tighten loose parts. Replace any missing parts.

Check for leaks in hydraulic hoses and/or lines (replace defective hoses and/or lines).

Check hydraulic hoses and lines for wear and/or damage. Replace any defective

hoses and/or lines.

Check that machine has been properly lubricated as spelled out in the Scheduled/

Periodic Maintenance Services section of this manual.

Check shields and guards. They must be in place and undamaged.

Check that safety decals are on machine and that they are readable.

Check that shut-o valves are open (if so equipped).

Check for dirt and grime on all hydraulic components. Clean away dirt and grime to help prevent overheating.

Check for ice, snow, mud, oil, and grease on ladders and walkways. Clear away ice, snow, mud oil, and grease to prevent slips and falls.

Check for any loose skid-resistant mats. Replace mats if they are loose.

Add hydraulic oil to reservoir if necessary.

Check for combustible or ammable materials. Remove them from machine if you nd them.

Check mounting hardware for tightness.

Check that machine will not be near electrical wires. See Operation section later in this manual.

Check swing bearing for loose or missing fasteners. Tighten loose fasteners. Replace missing fasteners per maintenance instructions.

Check booms for damage, cracks, debris, mounting pin retention, and other problems. Immediately report any structural problems (cracks) to an authorized dealer for diagnosis and repair or replacement.

machine, and le the copy as a record of inspection as required per OSHA or local governing body.

2410 5-1 1111

Check that truck/trailer is on rm level, ground and that the parking brake is set.

Check that upper frame and engine area are free of leaves, twigs, branches and other debris.

Check electrical system for worn insulation or frayed wires and loose connections.

You can copy the pages in this section. Check o each inspection item before operating the

Page 48

PRESTART INSPECTION

WARNING

NOTICE

PRESTART CHECKS: ON PLATFORM

HAND HOLDS AND STEPS

severe personal injury or death.

Never use controls as hand holds. Never use steering wheel as a hand hold. Moving the steering wheel from its center position will COMPLETELY turn machine right or left.

DO NOT mount machine if hand rails or steps are broken or missing. Get them repaired rst.

DO NOT jump on or o machine unless it has touched a live electrical wire and it must be exited.

Ensure rm foot position when getting on and o machine. Be careful of slippery conditions on platform, steps, and hand holds when getting on and o machine.

Slips and falls can cause

Remove oil, grease, mud, ice, etc. before mounting or dismounting machine.

To prevent slips and falls, replace skid-resistant material if it is worn, damaged or missing.

Check hydraulic hoses in platform/boom end area for defective hoses and/or lines.

Check safety decals. They must be present and readable.

Check control levers/pedals for free movement.

Check fuel tank (ll tank at end of shift to reduce water condensation).

Check hydraulic reservoir uid level.

Check engine oil level. Add engine oil if necessary.

Check radiator coolant level and make sure radiator ns are clean. Add proper coolant mixture if necessary. Clean radiator of all debris.

Add hydraulic oil to reservoir if necessary.

wear and/or damage. Replace any

2410 5-2 1111

Check that all cab windows are clean and clear. Replace any damaged polycarbonate window material. Check for mud and debris on cab oor (clean away mud and debris).

Check air cleaner. Clean or replace air lter if necessary.

You can copy the pages in this section. Check o each inspection item before operating

the machine, and le the copy as a record of inspection as required per OSHA or local governing body.

Page 49

PRESTART INSPECTION

NOTICE

WARNING

PRESTART CHECKS: IN THE CAB

HAND HOLDS AND STEPS

severe personal injury or death.

Never use controls as hand holds. Never use steering wheel as a hand hold. Moving the steering wheel from its center position will COMPLETELY turn machine right or left.

DO NOT mount machine if hand rails or steps are broken or missing. Get them repaired rst.

DO NOT jump on or o machine unless it has touched a live electrical wire and it must be exited.

Ensure rm foot position when getting on and o machine. Be careful of slippery conditions on platform, steps, and hand holds when getting on and o machine.

Slips and falls can cause

Remove oil, grease, mud, ice, etc. before mounting or dismounting machine.

To prevent slips and falls, replace skid-resistant material if it is worn, damaged or missing.

Check that there is no mud or debris on cab oor (clean away mud and debris).

Check for free movement of controls.

Check and review safety decals, that all are present and can be clearly read.

Check that all cab window material is clean and clear. Replace any damaged polycarbonate

window material.

Check that re extinguisher is adequately charged.

Check instrument panel for broken gauges and/or broken indicator lights. Have

gauges and/or indicator lights repaired if necessary.

Check fuel gauge to be sure machine has enough fuel. Refuel machine if necessary.

Check window emergency exits.

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Check cab operator protection structure for damage. Have structure repaired if necessary.

Check that all items in cab that are not part of the machine, such as lunch boxes or

tools, are secured.

You can copy the pages in this section. Check o each inspection item before operating the

machine, and le the copy as a record of inspection as required per OSHA or local governing body.

Page 50

PRESTART INSPECTION

NOTICE

FIRE PREVENTION

Fires can cause personal

injury or machine damage.

Keep machine clean. Remove debris, especially from heat sources. Fire prevention beats re ghting. Hourly or daily inspections can reduce the possibility of res.

Forest debris can collect on the machine and cause a re. When forest debris mixes with ammable uids in a hot, conned space, the risk of a re starting greatly increases. KEEP THE MACHINE CLEAN.

Check machine daily for re hazards. Remove debris from areas of the machine that create heat and that are potential re start points. Depending on machine model, check for ammable debris in the following locations:

• Engine block • Turbocharger • Electrical connections

• Exhaust manifold • Battery • Control valves

Fire needs fuel. Remove combustible material (fuel for re) from heat sources. Keep the machine clean. Remove the following materials, and other combustible materials from areas of the machine that create heat:

• Pine needles • Twigs • Debris

• Shop rags • Oil spills • Coolant mixture

• Leaves • Sticks • Sawdust

• Grease • Bark • Diesel fuel

Keep the machine clean. Risk of re increases if combustible materials and ammable materials build up on machine. This machine is not designed to house or store combustible materials.

Regularly remove ammable materials (such as diesel fuel, engine oil, hydraulic oil, and grease) from all areas of the machine. Clean up after working. Keep the fuel and hydraulic systems in good repair.

Check hydraulic hoses, fuel lines, and ttings for leaks. Tighten loose ttings. If hoses or lines are bent, kinked, or show signs of wear, install new parts. Check electrical connections to be sure they are clean and secure.

Frayed, damaged or worn insulation on battery cables or other wires may lead to electrical res. Check cables and wires and replace if insulation is frayed, worn, or damaged.

At the end of each shift ALWAYS stay with the machine for 30 minutes after shutting down the engine to ensure there is no forest debris/trash re start up. Keep a re extinguisher ready during this 30 minute cool down.

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Page 51

OPERATION

GENERAL GUIDELINES

Only a trained, qualied, and authorized operator shall be allowed to operate

this machine. Only use this machine after carefully reading this manual and learning how to safely operate and maintain this machine. Unsafe operation can cause severe personal injury or death.

OPERATOR PREPARATION

Operator must be fully trained, qualied, and authorized to operate this machine.

Before running this machine, operator must know the location and purpose of

• controls

• indicator lights

• instruments

• local operating safety rules and procedures

• safety and instruction decals (see Safety Decals

Section)

Operators must be at least 18 years old to operate this machine (Code of Federal Regulations: Labor).

Never operate this machine while under the inuence of drugs or alcohol. Use of prescription or over-thecounter drugs or medications requires advice from a medical practitioner on whether or not machine can be safely operated.

Operators may not run this machine if subject to dizziness, seizures, or motion disturbance.

Do not operate this machine unless it is properly mounted to a truck or trailer for stability.

Never operate this machine with stabilizers in raised position.

No riders are allowed on this machine. Machine riders can fall from machine or be injured by movement of machinery, causing severe personal injury or death. Do not allow riders on a machine that is operating or moving.

FOLLOW ALL SAFETY OPERATING INSTRUCTIONS AND PRACTICES. SEE GENERAL SAFETY SECTION.

Keep machine away from power lines.

If this manual is lost, contact an authorized dealer for a new manual. Keep manual in the manual storage pouch in the cab.

Report any noticeable machine problems to people who can repair the problems before machine is used.

Be sure cab windows are clean before operating machine. Cab windows must be clear of ice and frost. Replace windows that are cracked, yellow, and/or hazy.

Remember, operators are key to the safe operation of this machine.

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Page 52

OPERATION

ELECTROCUTION DANGER

LINES WITH BOOM, LINE, OR LOAD WILL CAUSE SEVERE INJURY OR DEATH. WATCH FOR OVER HEAD POWER LINES. TREAT ANY LINE AS LIVE AND DANGEROUS. IF AT ALL POSSIBLE, HAVE THE POWER LINE DISCONNECTED BEFORE STARTING WORK.

Never move any part of machine or load closer than 10 feet plus twice the line insulator length to electric lines. A line insulator is what connects an electric line to an electric pole.

For example, if a line insulator is 6 inches long, stay at least 10 feet plus twice the line insulator length (2x6 =12 inches or 1 foot) from electric line, which means machine must stay at least 11 feet from this electric line.

If machine touches an electric line, stay inside the cab. Carefully move machine or load away from electric line, without pulling the line down.

CONTACTING ELECTRIC

DO NOT allow anyone else to touch machine while it is touching an electric line. If machine cannot be moved away from the electric line without pulling line down, have someone contact the utility company to disconnect power from line. If this is not possible, or if machine begins to burn, jump away from machine to the ground with both feet together, in one smooth jump. DO NOT touch machine and ground at the same time or else electricity in the line will go through the body. Get away from machine after jumping.

Notify utility company immediately. DO NOT let anyone near machine while it is touching an electric line.

OVERHEAD LOADS

booms can cause severe injury or death.

The loader operator is responsible for ensuring that booms or loads are never suspended over or near personnel.

Falling or swinging logs or

2410

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• Always know where other people are working at the job site in relation to the loader.

• Maintain good communication with everyone on the job.

• Stop operations if someone on the ground approaches the machine.

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Page 53

OPERATION

GETTING ON MACHINE

HAND HOLDS AND STEPS

severe personal injury or death.

Never use controls as hand holds. Never use steering wheel as a hand hold. Moving the steering wheel from its center position will COMPLETELY turn machine right or left.

DO NOT mount machine if hand rails or steps are broken or missing. Get them repaired rst.

DO NOT jump on or o machine unless it has touched a live electrical wire and it must be exited.

Ensure rm foot position when getting on and o machine. Be careful of slippery conditions on platform, steps, and hand holds when getting on and o machine.

Slips and falls can cause

Remove oil, grease, mud, ice, etc. before mounting or dismounting machine.

To prevent slips and falls, replace skid-resistant material if it is worn, damaged or missing

MACHINE START UP

1. Perform a pre-start inspection (refer to Pre-Start Inspection Section.)

2. Before start up, walk completely around machine and make sure no obstacles or personnel are in the area.

3. Sound horn before operation.

G.048.03

4. Check all controls for proper function and response before starting work (refer to Controls and Instruments Section).

5. Maintain adequate distance between machine and other equipment and personnel.

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Page 54

OPERATION

STARTING THE ENGINE

IMG.2385

Pressing starter button while

engine is running can damage starter.

1. Make sure battery disconnect master switch (A) is ON.

1. Insert key in ignition switch (B).

2. Turn key to the right (ON position). Verify that the error code indicator light (C) is not lit. If the error code indicator light is lit, see Cold Weather Starting Procedure later in this section. If the waitto-start indicator is not lit, turn key all the way to the right and hold until engine starts. Release key when engine starts. If engine fails to start after 30 seconds, allow starter to cool a few minutes. Try starting engine again. If engine still will not start, see engine operator’s manual and Starting with a Booster Battery later in this section.

4. Turn throttle knob (D) clockwise about 1/3 turn to increase engine speed.

5. Run engine at partial-throttle and no load for approximately ve minutes to allow machine to warm up.

If ambient (outside) air temperature is below 32°F (0°C), and starter aid is necessary, refer to the engine operator’s manual.

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Page 55

OPERATION

STARTING MACHINE WITH A BOOSTER BATTERY

BATTERY SAFETY

Batteries produce explo-

sive gases.

Operation Section. If battery acid contacts eyes, ush them with water for 15 minutes and seek immediate medical attention.

Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

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Machine

Battery

Booster

Battery

G.060.02

JUMP STARTING PROCEDURE

1. Turn battery disconnect master switch OFF. Re-

move key from ignition switch.

2. Clamp one end of rst booster cable to positive

terminal of discharged battery (A) (terminal connected to starter or solenoid).

3. Clamp other end of rst booster cable to positive

terminal of booster battery (B).

4. Clamp one end of second booster cable to nega-

tive terminal of booster battery (C).

5. Clamp other end of second booster cable to en-

gine block or frame of machine (D) (to keep sparks away from either battery).

6. Insert key in ignition switch. Turn battery discon-

nect master switch ON.

7. After starting engine, remove booster cables

in reverse order from how they were put on. To prevent sparks, keep booster cable clamps from touching.

65

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OPERATION

INDICATOR LAMP CHECKS

Following are the sequences of indicator lamp error codes:

WHEN STARTING ENGINE

Red error code indicator (A) and yellow error code

indicator (B) will both illuminate for 2 seconds at start up.

STARTING ENGINE WITH COLD START AID OPERA TION

Red error code indicator (A) and yellow error code indicator (B) will both illuminate until operation is complete at start up.

ERROR DETECTED AT START UP E.G. LACK OF LUBRICATION OIL PRESSURE AFTER START DELAY EXCEEDED

Red error code indicator (A) will remain illuminated after the 2 second delay.

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OPERATION

INDICATOR LAMP CHECKS, CONTINUED

WHEN STARTING ENGINE

Following are the sequences of error code indicator error codes:

IF ENGINE FAILS TO START

NO DETECTED FAULTS

Red error code indicator (A) and yellow error code indicator (B) will both not be illuminated.

ELECTRICAL FAULT WARNING

The yellow error code indicator (B) will be illuminated.

STOP ENGINE

Red error code indicator (A) will ash. Fault has been detected that prevented start of engine.

AFTER STARTING ENGINE

NO DETECTED FAULTS

Red error code indicator (A) and yellow error code indicator (B) will both not be illuminated.

OIL PRESSURE LOW

The red error code indicator will be illuminated.

COOLANT/AIR INTAKE TEMPERATURE HIGH

Yellow error code indicator (B) will ash.

STOP ENGINE FAULT/DERATE CONDITIONS

The red error code indicator (A) will be ashing.

ELECTRICAL FAULT WARNING

Yellow error code indicator (B) will be illuminated.

OIL PRESSURE LOW AND ELECTRICAL FAULT

Red error code indicator (A) and yellow error code indicator (B) will both be illuminated after start up.

STOP ENGINE FAULT/DERATE CONDITIONS AND ELECTRICAL FAULT

The red error code indicator (A) will be ashing and yellow error code indicator (B) will be illuminated.

OIL PRESSURE LOW AND COOLANT/AIR INTAKE TEMPERATURE HIGH

The red error code indicator (A) will be illuminated and yellow error code indicator (B) will be ashing.

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Page 58

OPERATION

COLD WEATHER STARTING  ENGINE/PUMP DISCONNECT OPTIONAL

1. Locate clutch disconnect lever (outside rear of cab

between rear of cab and hydraulic oil reservoir).

2. Push lever away (A) from engine to disconnect

hydraulic pumps.

3. Start engine (see procedures on Page 6-4).

4. Allow engine to warm up for approximately ten

minutes.

DO NOT engage pumps

with engine running. Engaging pumps with engine running may cause machine to move unexpectedly, which may lead to serious personal injury or death.

5. Shut engine down.

-A-

G.052.03

Side panel and top panel removed

from illustration for clarity.

-B-

G.053.03

6. Engage pumps by slowly pulling the dicsonnect

lever toward (B) the engine.

7. Start engine.

These instructions apply

to optional controls and instruments available from an authorized dealer.

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OPERATION

WARM UP PERIOD

1. Be sure area is clear of personnel.

2. Close cab door.

3. Pull down control shut o lever (A) to engage

control system.

G.048.03

hydraulic system to reach operating temperature before beginning operation. Cold and thick oil cannot ow fast enough to the pump to meet output demand. Cavitation and extreme damage may be caused by operating the machine when the hydraulic oil is too cold to ow easily.

4. Warm up the hydraulic system by

• engaging and disengaging controls to help speed

warm up of hydraulic components, and;

• cycling all controls to allow warm oil to circulate

through all cylinders and lines.

It is important to allow the

IMG.2577

Do not idle engine for excessively long periods. Long periods of idling (more than 10 minutes) can damage an engine because combustion chamber temperatures drop so low the fuel will not burn completely.

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OPERATION

FEATHERING THE CONTROLS

G.031.03

G.030.03

Rough operation can be dangerous, hard on the machine, and hard on the operator.

DO NOT jerk control levers to full speed, or from one direction to another.

Feather controls this way:

1. Move joystick control gently from neutral to start motion.

2. After a slow, smooth start, move joystick control to desired speed position.

3. Just before stopping movement, move joystick control gently back to neutral.

This method of carefully manipulating the controls is called feathering. Work can done more eciently by feathering controls than by jerking controls.

There is a rhythm to operating this machine. Feathering the controls will help the operator nd and take advantage of this rhythm.

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OPERATION

USING STABILIZERS

cause severe personal injury or machine damage. Lower all stabilizers before operating machine.

stabilizers can cause serious personal injury or death. Clear all personnel from work area before lowering stabilizers.

It is the responsibility of the operator to make sure all personnel are clear of the stabilizers before lowering them. When setting the stabilizers, make sure they are sitting on rm, solid ground.

DO NOT set stabilizers on rocks, stumps, curbs, edge of paving, etc. or on soft or unstable ground.

1. Position loader on rm, level ground with stabilizers down to ensure stability while operating.

2. Double check to ensure no persons are close to truck and/or loader.

Unstable platform can

Coming into contact with

G.132.03

G.043.03

3. Clear ice and snow from the area where the stabilizer pads will be lowered. Do not operate or position loader on slippery surfaces.

4. Lower stabilizer legs to raise truck or trailer tires about 1-1/2 to 2 inches o the ground. The entire loader should rest rmly on the stabilizer pads.

5. Follow these stabilizer operating guidelines:

• Never allow another person to be on the

loader or in and around the truck when lowering or raising stabilizers.

• Lift boom from transport position and make

a test lift to check ground conditions under stabilizers.

• Never operate machine with stabilizers in

raised position.

STABILIZER CONTROL SWITCHES

Left Stabilizer (A) Top Position: Raise stabilizer

Bottom Position: Lower stabilizer

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IMG.2423A

Front/Rear Stabilizer (B) Top Position: Rear stabilizer

Bottom Position: Front stabilizer

Right Stabilizer (C) Top Position: Raise stabilizer

Bottom Position: Lower stabilizer

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Page 62

OPERATION

LANDING LAYOUT

• The loader operator is in one of the best positions on the work site to notice a problem and warn others by sounding the horn. The loader operator is responsible for the safety of people on the ground.

• All landings (decks) should provide an area clear of suspended loads for landing personnel (deck hands) to work. Remember, logs can roll or be thrown a considerable distance.

• If clearance of suspended loads cannot be provided, STOP loading operations and lower grapple while deck hands are working on the landing.

• All obstructing trees should be removed to ensure clearance for loading.

G.034.03

• Never locate landing near overhead electrical lines. See Electrocution Dangers in this section for instructions.

HEELING  PICKING UP LOGS OR POLES

• Never operate this machine with tires touching the ground. Lower stabilizers to the ground, and raise tires slightly o the ground.

• Always lift and heel long logs from butt end of log (larger end). Place grapple on log as illustrated so the log will not hit the stick boom cylinder.

• Never pinch a log. Always make sure the grapple

G.046.03

wraps around the log.

Always place logs in heel on opposite side of boom, away from cab. This can reduce the risk of a log ying toward the cab if a log slips in the grapple.

• Never heel logs from the center — this puts the

ends of the logs too close to the boom cylinders and the cab when drag loading.

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• Never swing load or grapple over truck cab being

loaded.

• Make sure truck driver and other personnel are

away from truck and loader when operating loader.

• On booms without heels, pick up logs toward the

butt end. When lifting logs at their balance point, take care when rotating logs to make sure they clear the loader and other obstructions.

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Page 63

OPERATION

GRAPPLE CONTROL

Study and learn the grapple control functions (see Controls and Instruments Section). Improper rotation of grapple or accidental opening of grapple will cause loss of control of the load.

• Do not change function arrangement.

• Use proper grapple to match application.

G.048.03

• For log handling always use a log bypass, or com-

bination bypass/pulp grapple.

• For short wood handling, use a log bypass, combi-

nation bypass or butt-style pulpwood grapple.

• Never swing and load a single log or branch by

pinching the sides of the log or stem with the grapple jaw tips. Always clamp the log or branch within the grapple jaws.

STOPPING THE MACHINE

1. Bring machine to a complete stop.

2. Lower attachment to ground with the main and

stick booms fully extended. The grapple should be open with the jaw tips on the ground. For extra stability on unfrozen ground, jaw tips can be closed slightly so that they dig into the ground.

G.048.03

3. Slow engine to LOW IDLE. Run engine at low idle

for at least 2 minutes to cool engine.

4. Turn key switch to OFF to stop the engine.

5. Remove key from ignition switch.

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Page 64

OPERATION

GETTING OFF MACHINE

HAND HOLDS AND STEPS

severe personal injury or death.

Never use controls as hand holds. Never use steering wheel as a hand hold. Moving the steering wheel from its center position will COMPLETELY turn machine right or left.

DO NOT mount machine if hand rails or steps are broken or missing. Get them repaired rst.

DO NOT jump on or o machine unless it has touched a live electrical wire and it must be exited.

Ensure rm foot position when getting on and o machine. Be careful of slippery conditions on platform, steps, and hand holds when getting on and o machine.

Slips and falls can cause

Remove oil, grease, mud, ice, etc. before mounting or dismounting machine.

To prevent slips and falls, replace skid-resistant material if it is worn, damaged or missing

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Page 65

BREAKIN PERIOD

WARNING

NOTICE

BREAKIN PERIOD

LOADER

AFTER FIRST 10 HOURS OF OPERATION

3 4 5

G.055.03

KEY COMPONENT SERVICE SPECIFICATION

1. Hydraulic Reservoir Check uid level - 65 gallons (246 L) Full mark. Use Premium A.S. Hydraulic Fluid

2. Fuel Tank Check fuel level - 89 gallons (337 L) Full mark

3. Loader (not shown) Visually check for any loose hardware or uid leaks.

4. Outer Swing Bearing Fasteners Check Tighten to 600 ft-lbs (814 N•m)

5. Inner Swing Bearing Fasteners Check Tighten to 600 ft-lbs (814 N•m)

The above uid capacities are approximate values. Be sure to check levels after lling. DO NOT OVERFILL.

DURING THE FIRST 100 HOURS OF OPERATION

1. Use seasonal viscosity grade oil as specied in Fuels and Lubricants Section.

2. Avoid excessive engine idling.

3. Check all accessible hardware for tightness.

ner capscrews on the swing bearing can cause the upper and lower frame to separate, causing severe injury or death. Read and follow all torque instructions in this manual.

Loose outer bolts or in-

4. Check engine oil level regularly.

5. Check hydraulic uid regularly.

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BREAKIN PERIOD

WARNING

2 4

7 8 9

G.055.03

AFTER FIRST 100 HOURS OF OPERATION

KEY COMPONENT SERVICE SPECIFICATION

1. Engine Oil and Filter Drain and Replace See Fuels and Lubricants section

2. Case Drain Filter Replace Use Genuine parts

3. Hydraulic Reservoir Replace Use Genuine parts Return Line Filter

4. Fuel Filters Replace Use Cat parts

5. Pinion Gear Fastener Check tightness, torque if necessary 420 ft-lbs (569 N•m)

6. Swing Drive Fasteners Check tightness, torque if necessary 437-483 ft-lbs (593-655 N•m)

7. Outer Swing Bearing Check tightness, torque if necessary 600 ft-lbs (814 N•m) Fasteners

8. Inner Swing Bearing Check tightness, torque if necessary 600 ft-lbs (814 N•m) Fasteners

9. Heel Fasteners (opt) Check tightness, torque if necessary 162-178 ft-lbs (220-241 N•m)

10. Swivel Torque Arm Fast. Check tightness, torque if necessary 76 - 84 ft-lbs. (103-114 N•m)

11. Swivel Fasteners Check tightness, torque if necessary 266-294 ft-lbs. (360-399 N•m)

12. Engine Refer to engine operator’s manual

TO TIGHTEN A LOOSE BOLT OR CAPSCREW

Loose outer bolts or in-

ner capscrews on the swing bearing can cause the upper and lower frame to separate, causing severe injury or death. Read and follow all torque instructions in this manual.

1. Torque the bolt or capscrew to recommended ftlbs. Recheck every 10 hours until torque stabilizes.

2. Check the two adjacent bolts (on either side of loose bolt) for proper torque and recheck every 10 hours until torque stabilizes.

2410

3. If any of these bolts or capscrews do not take the torque, or come loose again, they must be replaced, including adjacent bolts/capscrews. Replace with factory-approved parts.

72

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Page 67

TRANSPORTING

13' 6" MAX.

TRAILER MOUNT

13' 6" MAX.

TRUCK MOUNT

TRANSPORTING

Failure to follow these important safety rules could result in seri-

ous personal injury or death.

• Remove any obstacles from trailer oor.

• Load and unload machine on level ground.

• Always use a ramp of proper height, loading angle, and strength.

• Engage trailer and truck brakes, and place wooden blocks around wheels.

LOADING PROCEDURE

1. Before transporting, investigate road width, bridges, road and trac conditions of planned route, as well as governing laws and regulations. Obtain required permits and/or authorization from appropriate agencies.

2. Mount loader as if for operation (see Operation section).

3. Swing upper frame clear of obstacles until it centers with grapple carrier.

4. Lower booms. Lower grapple until it rests in grapple carrier.

5. Raise stabilizers.

6. Shut engine down. Remove key from ignition.

7. Turn master battery disconnect switch to OFF.

8. Close and lock cab door.

9. Cover intake and exhaust openings to prevent damage to turbocharger and prevent water and dust from entering engine.

10. Secure grapple to grapple carrier with chain.

11. Secure any attachment(s) with chain.

12. Before transporting, make sure no part of the machine exceeds 13’6” from the ground, or special height permits may be required.

DO NOT wrap chains around machined surfaces. Travel vibration can cause

chain hammering.

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Page 68

TRANSPORTING

NOTES

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Page 69

FUELS AND LUBRICANTS

FUEL

FUEL TANK REFUELING

Fuel leaked or spilled onto hot surfaces or electrical components can cause a re, which can result in severe personal injury or death. To help prevent possible injury, turn the ignition switch OFF when changing fuel lters or water separator elements. Clean up fuel spills immediately.

Prevent re! Handle fuel

carefully!

• DO NOT ll fuel tank while engine is running.

• DO NOT smoke while lling or working on the fuel

system.

• DO check fuel tank vent. Clean if dirty or plugged.

• DO ll fuel tank at the end of each day.

• DO drain fuel tank of water once a week.

• DO clean up all spills immediately.

FUEL SPECIFICATIONS

DO NOT mix gasoline or alcohol with diesel fuel. This mixture can cause an explosion.

Refer to engine operator’s manual for recommended diesel fuel grades.

STORING FUELS

• Keep fuel containers in a protected area.

• Remove water and sediment before transporting.

• DO NOT use deicers to remove water from fuel.

• DO NOT depend on lters to remove water.

• DO install water separators at storage tank outlets.

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• KEEP FUEL CLEAN.

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Page 70

FUELS AND LUBRICANTS

ENGINE OIL

LUBRICATION, OIL PERFORMANCE, AND VISCOSITY RECOMMENDATIONS

Use of a quality engine lubricating oil combined with appropriate oil and lter change intervals are critical factors in maintaining engine performance and durability. When changing or adding engine oil, use Premium Engine Oil. For more information, refer to Cummins's engine operator’s manual.

When adding lubricants, do not mix dierent brands or grade weights. Manufacturers’

additives are not always compatible.

Cummins Engine Company Inc., recommends the use of a multi-graded lubricating oil since it has been found to improve oil consumption control and improve engine cranking in cold temperatures while maintaining lubrication at high operating temperatures.

A multi-graded oil is recommended with viscosity grades as shown in the Cummins chart below. The use of single-grade lubricating oil is not recommended except for synthetic oils used in arctic conditions.

Cummins does not recommend the use of aftermarket additives in oil. See engine operator’s manual for more information.

Limited use of low viscosity oils, may be used for easier starting and for providing sucient oil ow at ambient temperatures below 23°F (-5°C). However, continuous use of low-viscosity oils can decrease engine life due to wear.

ENGINE BREAKIN OILS

Do not use special “break-in” lubricating oils for new or rebuilt Cummins engines. Use the same type of oil during the break in period as will be used during normal operations.

ARCTIC OPERATION

If an engine is operated in ambient temperatures consistently below -10°F (-23°C), and there are no plans to keep the engine warm when it is NOT in operation, use a synthetic CD/SF engine oil with adequate low temperature properties such as 5W-20 or 5W-30.

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Anticipated Ambient Temperature

Cummins Engine Oil Chart

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Page 71

FUELS AND LUBRICANTS

HYDRAULIC OIL

Hydraulic systems have been lled from the factory with Premium All-Season Hydraulic Oil 46.

Use the following hydraulic oils in this machine.

AMBIENT TEMP AMBIENT TEMP AMBIENT TEMP 25°F TO 80°F 10°F TO 95°F 0°F TO 105°F 32°C TO 27°C 23°C TO 35°C 18°C TO 41°C

Premium All-Season Premium All-Season Premium All-Season Hydraulic Oil 32 Hydraulic Oil 46 Hydraulic Oil 68

Check with an authorized dealer for hydraulic uid recommendations and compatibilities.

BE SURE hydraulic uid selection is compatible with the hydraulic system.

BE SURE hydraulic uid selection assistance is from a reputable supplier.

BE SURE hydraulic specications meet or exceed the Premium All Season Hydraulic Oil specications. See an authorized machine dealer.

BE SURE to use a mineral-base hydraulic oil.

GREASE

Most lubricated ttings require Premium Moly-Lith EP #2 Grease. However, there are special requirements for the swing bearing and swing drive motor (see Grease for Swing Bearing and Swing Drive Motor in this section).

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FUELS AND LUBRICANTS

LUBRICANT FOR PINION AND SWING GEAR TEETH

When lubricating the pinion gear and swing gear teeth, use moly-lith open gear lubricant.

When the gear path becomes contaminated, clean with solvent to remove contamination. Relubricate gear with moly-lith open gear lubricant, available from an authorized dealer.

CYLINDER ROD CORROSION PREVENTIVE

If machine will be stored for an extended period, or stored in a corrosive environment (such as salt air or industrial pollution), apply Chrome Kote Corrosion Preventive on all portions exposed to air. See Storage section for more information.

ENGINE COOLANT SPECIFICATIONS

Engine coolant must meet or exceed the following specications:

• SAE J1941

• ASTM 4985

• GM 6038M

• TMC RP 302B

The engine coolant must contain low silicate (less than .1% anhydrous metasilicate) ethylene glycol base. The supplemental coolant additive (SCA) should be Fleetgard DCA4 or equivalent.

When preparing engine coolant, follow these steps:

1. Thoroughly mix ethylene glycol base coolant with SCA in this ratio: 93% coolant to 7% additive.

2. Mix coolant/additive compound with distilled water in this ratio: 50% coolant/additive compound to 50%

distilled water.

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FUELS AND LUBRICANTS

STORING LUBRICANTS

Store lubricants in a clean area that will keep them protected from water, dirt, or other contamination.

Always use clean containers when handling lubricants.

Storing lubricant drums or other containers outdoors is poor practice. To minimize the harmful eect of unavoidable outdoor storage, a few simple precautions and procedures can be very helpful.

1. Generally, lubricants in containers smaller than drums (55-, 30-, and 16-gallon oil drums, and 400- and 120-pound grease drums) should never be stored outdoors. When drums must be stored outdoors, a temporary shelter or lean-to, or a waterproof tarp will protect them from rain or snow.

2. Drums should be placed on their sides with the bungs approximately horizontal. In this position, bungs are below the level of the contents so that breathing of water or moisture is greatly reduced and water cannot collect inside chine (ridge of drum). For maximum protection, drums should be stood on end with bung end down on a welldrained and contained surface. Where all of these approaches are not practical, drum covers may be used. Drum covers are available in metal and plastic.

3. When drums must be stored outdoors with bung end up, they should be blocked up with bungs parallel to the block to keep water away from the bung openings.

4. Drums that have a bung on the side should be stored either on end or on their side with the bung down. Regardless of their position, drums should always be placed on blocks or racks several inches o the ground to avoid moisture damage.

DISPOSE OF USED FLUIDS PROPERLY.

If machine will be stored for an extended period, or stored in a corrosive environment (such as salt air or industrial pollution), using a sponge, apply Chrome Kote Corrosion Preventive to portions exposed to air. See

section

for more information.

Storage

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FUELS AND LUBRICANTS

NOTES

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Page 75

MAINTENANCE SAFETY

BEFORE MAINTENANCE

Maintaining this machine improperly could result in severe personal injury or

death. Read this manual before doing maintenance. Follow all safety instructions.

1. Read all safety and maintenance instructions in this operator’s manual.

2. Position equipment on rm, level ground.

3. Lower attachment to the ground.

4. Shut engine down.

5. Move controls in all directions to relieve hydraulic pressure.

6. Remove key from ignition.

PRACTICE SAFE MAINTENANCE

Read maintenance manuals and understand service procedures before performing service/maintenance.

Understand service procedures before performing maintenance. When performing maintenance, keep area around machine clean and dry.

Support all raised equipment.

Disconnect battery ground cable (-) before working on the electrical system.

Lower stabilizers to the ground. Do not support machine weight on stabilizers.

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Page 76

MAINTENANCE SAFETY

BEFORE MAINTENANCE

PROTECTIVE CLOTHING

Wear OHSA-approved protective clothing when working on or near this machine, such as

• ear protection • gloves

• goggles • hard hat

• orange vest • steel-toed boots

Wear snug, protective clothing that is belted where required.

Remove jewelry before working on or near this machine.

HYDRAULIC SAFETY

pressure can penetrate skin and cause severe personal injury or death. Wear eye and personal protection equipment (PPE).

Fluids escaping under

If ANY uid is injected into the skin, seek medical attention immediately. A serious infection or reaction can result without proper medical treatment.

Before working on the hydraulic system,

1. Lower boom and grapple to the ground.

2. Raise stabilizers so loader rests on carrier tires. Then lower stabilizers to they touch the ground without raising the loader.

3. Shut engine down.

4. Move joysticks in all directions to relieve hydraulic pressure on boom.

5. Disengage pilot controls by moving pilot shut o lever UP.

6. Remove key from ignition switch.

7. Purge air from hydraulic reservoir by depressing relief valve button.

Hot hydraulic oil can cause severe burns. DO NOT work on hydraulic system if oil temperature exceeds 120°F (49°C).

Wear eye and personal protection equipment (PPE)!

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Page 77

MAINTENANCE SAFETY

BEFORE MAINTENANCE

BOOM SAFETY

attachment can cause severe personal injury or death.

DO NOT enter danger area under or around boom if either of the following conditions apply:

1. Attachment is o the ground; or,

2. Engine is running. Before ANY work is done in this area,

1. Lower attachment to the ground.

2. Shut engine down.

3. Move joysticks until pressure is released,

4. Remove key from ignition to prevent accidental

start up.

Falling boom or

SERVICING CONTROL VALVES, CYLINDERS, PUMPS, AND MOTORS

Increasing relief valve settings could cause machine or component failure resulting in severe personal injury or death. Do not change pressure settings. Do not switch lines from one valve to another.

Special tools and training are required to service control valves, cylinders, pumps, and motors. If these parts need service, see an authorized dealer.

UNAUTHORIZED WELDING

Unauthorized welding can cause structural failure and/or severe personal injury or death.

2410

DO NOT weld on any structural member. Any unauthorized welding or repair will void the warranty.

Once authorized, be sure to turn battery disconnect master switch OFF.

Unauthorized welding can

cause damage to the electrical system.

103

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Page 78

MAINTENANCE SAFETY

DURING MAINTENANCE

BATTERY SAFETY

explosive gases that can cause severe personal injury or death.

Battery posts, terminals, and related accessories contain lead and lead components, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.

Keep sparks, ames, and cigarettes away from batteries. Ventilate properly when charging or using batteries in enclosed space. Always shield eyes with goggles and wear a face shield when working near batteries. Do not lean over batteries during this operation. Always connect positive (+) to positive (+) and negative (-) to negative (-). For further instructions, see Jump Starting Battery in Operation section. If battery acid contacts eyes, ush them with water for 15 minutes and seek immediate medical attention.

Batteries produce

Never charge a battery or jump start engine if battery is frozen. Warm battery to 60°F (16°C) or it may explode. Be sure vent caps are tight. When jump starting from another machine, be sure machines do not touch. This machine has a 12volt starting system. Use equal voltage for jump starting.

COOLING FAN

Rotating fan can cause severe personal injury or death. Cooling fan can start at any time, even with motor o. Keep away from fan at all times.

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MAINTENANCE SAFETY

DURING MAINTENANCE, CONTINUED

DIESEL EXHAUST

contain elements that are hazardous to health. Always run engine in a well ventilated area. If in an enclosed area, vent exhaust outside.

FLUIDS UNDER PRESURE

pressure can penetrate skin and cause severe personal injury or death. Wear eye and personal protection equipment (PPE)!

DO NOT use hands to search for leaks. Always use a board or cardboard when checking oil hoses, lines, and ttings for leaks, cracks, or defects. Be sure all clamps are in their proper position and torqued as required and specied. Be sure hoses are not twisted or touching parts.

Diesel exhaust fumes

Fluids escaping under

Escaping uids can penetrate skin and enter the bloodstream. Before disconnecting lines, relieve all pressure.

DO NOT apply pressure to a damaged line, hose, or tting.

If any uid is injected into the skin, seek medical attention immediately. A serious infection or reaction can result without proper medical treatment.

FUELS AND LUBRICANTS

Fires and explosions can

cause severe personal injury or death.

• Handle fuels and lubricants carefully.

• DO NOT smoke when fueling or working with or

around fuel.

• Clean up, and properly dispose of all spilled

lubricants, grease and solvents.

• Use proper tools and procedures for making

repairs.

2410

• Wear approved eye and personal protection

equipment (PPE).

105

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MAINTENANCE SAFETY

DURING MAINTENANCE, CONTINUED

PINCH POINTS

portion of the body where the machine moves can cause severe personal injury or death. Never place hands or any portion of the body where injury could occur if machine moves. Never check pin hole alignments with ngers.

SERVICING MACHINE WITH ENGINE RUNNING

engine running can cause severe injury or death. When maintenance procedure requires engine be running, ONLY qualied service technicians should service machine.

Placing hands or any

Servicing machine with

2410

106

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MAINTENANCE SAFETY

AFTER MAINTENANCE

DISPOSING OF WASTE

Follow local, state, federal, and international regulations when disposing of waste. Waste may include, but is not limited to oil, fuel, coolant, brake uid, lters, and batteries.

Use leakproof containers when draining uids. Do not use food or beverage containers. Do not pour waste on the ground, down a drain, or into any water source.

Clean up all spilled fuel, oil, grease, etc. and dispose of per local, state, federal, or international regulations.

STORING FLAMMABLE MATERIALS

• Do not smoke where ammable materials are

stored.

• Store fuels and lubricants in properly marked

containers.

• Store oily rags and other ammable materials in

protective containers.

2410

107

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MAINTENANCE SAFETY

NOTES

2410

108

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Page 83

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

SCHEDULED AND PERIODIC

MAINTENANCE SERVICES

LUBRICATION AND MAINTENANCE INTERVALS

Maintenance requirements for lubrication, adjustments and checks are shown on the maintenance charts in this section.

Intervals of maintenance are based on normal operating conditions. If operating under more demanding conditions, observe a shorter time interval between maintenance.

Demanding conditions include but are not limited to:

• Hilly terrain

• Working in or passing through deep water or mud

• Dry work area with heavy blowing dust

• Extreme cold, -20°F (-6°C) and below

• Extreme heat, 100°F ( °C) and above Use the hourmeter to help determine proper mainte-

nance intervals.

LUBRICATION NOTICE

Listed maintenance intervals are for normal use applications. When greasing lubrication ttings, if grease is not forced out the bushing ends with the recommended shots, increase number of shots used until grease is forced out. If grease cannot be forced out, check for blocked grease passageways.

If the lubricating areas are dry at the end of a normal operating day, increase the frequency of lubricating time periods instead of increasing the amount of grease used at one lubrication period.

POSITION MACHINE FOR MAINTENANCE

To avoid serious personal injury or property damage, follow the steps below before performing any maintenance on this machine.

1. Park machine on level ground.

2. Lower boom and grapple to ground.

3. Raise stabilizers so loader rests on carrier tires.

Then lower stabilizers so they touch the ground without raising the loader.

4. Shut engine down.

5. Move joysticks in all directions to relieve hydraulic

pressure on boom.

6. Disengage controls by moving control shut o

lever up.

7. Remove key from ignition switch.

2410

111

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Page 84

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

MAINTENANCE CHART USAGE

3 4

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.

AS REQUIRED

KEY COMPONENT SERVICE SPECIFICATION

1. Electrical System* Check Reset breakers or replace fuses

2. A/C Condenser Clean Compressed air

3. Recirculation Air Filter Clean/replace New lter Use Genuine parts

4. Windshield Washer Reservoir Check Fill washer uid

5. Windshield and Windows Clean Detergent and water

6. Polycarbonate Skylight Replace Polycarbonate material Use Genuine parts

7. Slasher/Delimber Saw* Adjust bar chain See details in section and (if equipped) slasher/delimber manual

8. Hydraulic Oil Drain/replace Seasonally AS Hyd. Oil

9. Safety Decals* Clean/replace Use Genuine parts

10. Slip Resistant Mats* Clean/replace Use Genuine parts

MATERIAL USED

* Not shown

2410

Be sure to refer to the engine operation and maintenance manual for additional engine maintenance recommendations and procedures.

11 2

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SCHEDULED AND PERIODIC MAINTENANCE SERVICES

MAINTENANCE CHART USAGE

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.

DAILY OR EVERY 10 HOURS

KEY COMPONENT SERVICE SPECIFICATION

*DAILY VISUAL INSPECTION** Inspect Inspect loader for damage, see detail

11. Adapter Knuckle Lubricate Lubricate until grease is forced out Prem. Grease

12. Stabilizer Pad Pivot Pin Lubricate Lubricate until grease is forced out Prem. Grease

13. Stabillizer Cylinder Rod End Lubricate Lubricate until grease is forced out Prem. Grease

14. Stabilizer Arm Pivot Pin Lubricate Lubricate until grease is forced out Prem. Grease

15. Stabilizer Cylinder Base End Lubricate Lubricate until grease is forced out Prem. Grease

16. Main Boom Pivot Pin Lubricate Lubricate until grease is forced out Prem. Grease

17. Main Boom Cylinder Base End Lubricate Lubricate until grease is forced out Prem. Grease

18. Main Boom Cylinder Rod End Lubricate Lubricate until grease is forced out Prem. Grease

19. Main/Stick Pivot Pin Lubricate Lubricate until grease is forced out Prem. Grease

10. Stick Boom Cylinder Base End Lubricate Lubricate until grease is forced out Prem. Grease

21. Stick Boom Cylinder Rod End Lubricate Lubricate until grease is forced out Prem. Grease

22. Swing Bearing Lubricate Lubricate while rotating 2 complete Prem. Grease revolutions

MATERIAL USED

* - Not shown

Moly-Lith EP #2 Grease.

Lubricate with Premium

** Do not weld on structures. Immediately report structural problems (cracks) to an authorized dealer for diagnosis and repair or replacment.

11 3

11112410

Page 86

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

MAINTENANCE CHART USAGE

28 29 30 31 32

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.

DAILY OR EVERY 10 HOURS, continued

KEY COMPONENT SERVICE SPECIFICATION

23. Pinion Gear Lubricate Lubricate gear with open gear lube Open gear lube

24. Hydraulic Oil Reservoir Check level Add hydraulic oil if necessary Hyd. Oil

25. Air Cleaner Maintenance Clean or replace element Use Genuine parts

26. Fire Extinguisher Check charge Recharge or replace

27. Fuel Tank Check level Add fuel if necessary Diesel fuel

28. Cooling Fan Inspect Replace if damaged Use Genuine parts

29. Belts Inspect Replace if damaged Use Genuine parts

30. Fuel-water Separator Drain Drain until clear fuel drains

31. Engine Crankcase Oil Check level Add engine oil if necessary Prem. Eng. Oil

32. Radiator Coolant Check level Add coolant if necessary Water/antifreeze

33. Electrical Components* Inspect Check for fraying, loose connections See details in section

34. Loader Mounting Bolts Inspect Check for stability of loader position

operation and maintenance manual for additional engine maintenance recommendations and procedures.

MATERIAL USED

Be sure to refer to the engine

* - Not shown

Moly-Lith EP #2 Grease.

2410

Lubricate with Premium

Do not weld on struc-

tures. Immediately report structural problems (cracks) to an authorized dealer for diagnosis and repair or replacment.

11 4

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Page 87

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

37 40

MAINTENANCE CHART USAGE

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.

WEEKLY OR EVERY 50 HOURS

KEY COMPONENT SERVICE SPECIFICATION

*. WEEKLY INSPECTION Inspect Check for damage, see detail

35. Boom / Cylinder Attaching Pins Check Tighten Wrench

36. Stabilizer Attaching Pins Check Tighten Wrench

37. Oil Reservoir Hardware Check Tighten Wrench

38. Hydraulic connections* Inspect Tighten Wrench

39. Radiator and Oil Cooler Clean Remove debris Water

40. Hydraulic Oil Reservoir Check oil If contaminated, replace Prem AS Hyd Oil

41. Swing Drive Gear Box Check lube level Add lubricant, if necessary GL-5 Gear Lube

* Not shown

MATERIAL USED

Be sure to refer to the engine operation and maintenance manual for additional engine maintenance recommendations and procedures.

** Do not weld on structures. Immediately report structural problems (cracks) to an authorized dealer for diagnosis and repair or replacment.

11 5

11112410

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SCHEDULED AND PERIODIC MAINTENANCE SERVICES

MAINTENANCE CHART USAGE

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.

MONTHLY OR EVERY 250 HOURS

KEY COMPONENT SERVICE SPECIFICATION

42. Engine Oil and Filter Change Drain and replace Oil and lter

43. Air Intake and Exhaust Inspect Check connections Wrench

44. Battery Check Check connections, electrolyte level Clean, distilled water

45. Seat Inspect/Lube Silicone spray

46. Swing Drive Fasteners Check Tighten to 600 ft-lbs* (813 N•m) Torque wrench *Use with Loc-Tite® or equivalent

MATERIAL USED

Be sure to refer to the engine operation and maintenance manual for additional engine maintenance recommendations and procedures.

2410

** Do not weld on structures. Immediately report structural problems (cracks) to an authorized dealer for diagnosis and repair or replacment.

11 6

0209

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Page 89

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

56 57 58

54 55

48 49 50 51 52 53

MAINTENANCE CHART USAGE

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.

EVERY 500 HOURS

KEY COMPONENT SERVICE SPECIFICATION

47. Hydraulic Oil Return Line Filter Install new* Replacement lter Use Genuine parts

48. Cooling System Check Check for leaks, sample conditioner Water conditioner

49. Fuel Lift Pump Pre-lter Install new** Replacement lter Use Cat parts

50. Primary Fuel Filter Install new** New lter Use Cat parts

51. Fuel System Prime See engine operator’s manual

52. Pilot Supply Filter Install new* New lter Use Genuine parts

53. Pilot Return/Case Drain Filter Install new* New lter Use Genuine parts

54. Outer Swing Bearing Fasteners Check Tighten to 600 ft-lbs (813 N•m) Torque wrench

55. Inner Swing Bearing Fasteners Check Tighten to 600 ft-lbs (813 N•m) Torque wrench

56. Swivel Torque Arm Fasteners Check Tighten to 76-84 ft-lbs (103-114 N•m) Torque wrench

57. Swivel Fasteners Check Tighten to 266-294 ft-lbs (360-399 N•m) Torque wrench

58. Pinion Gear Fastener (if equipped) Check Tighten to 420 ft-lbs (529 N•m) Torque wrench

59. Stationary Heel Fasteners Check*** Tighten to 112-178 ft-lbs (220-241 N•m) Torque wrench

60. Slasher/Delimber Return Line Filter Install new* New lter Use Genuine parts

MATERIAL USED

* Change interval can vary depending on operating conditions ** Change interval can vary depending on cleanliness of fuel *** Tighten head of bolt while holding nut

operation and maintenance manual for additional engine maintenance recommendations and procedures.

11 7

Be sure to refer to the engine

11112410

0209

Page 90

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

61 62 63

65 66 67

MAINTENANCE CHART USAGE

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.

EVERY 1000 HOURS

KEY COMPONENT SERVICE SPECIFICATION

61. Hydraulic Oil Drain/replace See details in section Premium AS Oil

62. Hydraulic Oil Reservoir Breather Replace Install new breather element Use Genuine parts Filter

63. Pressure Vacuum Relief Valve Replace Install new relief valve Use Genuine parts

64. Cooling System Flush and ll Replace coolant See engine manual

65. Swing Drive Gear Box Lube Drain/replace Replace with 0.9 gal (3.4 L) lubricant GL-5 Gearlube

66. Swing Drive Check level Add grease if necessary Prem. Grease

67. Swing Drive Drain and ll See details within section Mobilgear 630

68. Collector Ring Check/clean Spray contacts, check brushes Contact cleaner and wire connections

MATERIAL USED

2410

Be sure to refer to the engine operation and maintenance manual for additional engine maintenance recommendations and procedures.

11 8

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Page 91

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

AS REQUIRED

1. CHECK ELECTRICAL SYSTEM

Check circuit breakers.

Circuit breakers protect an electrical circuit from current overload.

If an overload occurs, the circuit breaker will trip, exposing the white reset button, and breaking the ow of current. This will prevent damage to the circuit.

To reset a circuit breaker, depress the tripped circuit breaker to its original position.

If breakers will not reset, replace the circuit breaker and/or have an authorized dealer diagnose and repair the problem.

IMG.2490

2410

119

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Page 92

WARNING

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

AS REQUIRED

2. CLEAN A/C CONDENSER

If the air conditioner is not cooling properly, the condenser cooling ns may require cleaning to remove debris and dirt.

1. Gain access to condenser by removing cap screws from the access door (A).

air release debris and ying particles that

IMG.2453

can cause serious personal injury. Wear a face shield and protective clothing.

2. With a maximum of 30 psi (210 kPa) compressed air, clean condenser cooling ns. If ns cannot be cleaned with compressed air, wash them with water.

3. Secure access door with cap screws removed in Step 1.

Cleaning with compressed

IMG.2458

3. CLEAN/REPLACE RECIRCULATION AIR

FILTER

1. The recirculating air lter is located beneath the operator’s seat inside the cab. Loosen retaining knobs and remove lter cover.

2. Remove, and clean lter (B) using one of the following methods.

Cleaning with compressed

air release debris and ying particles that can cause serious personal injury. Wear a face shield and protective clothing.

a. Lightly tap lter on at surface, dirty side

down.

b. Direct 30 psi (210 kPa) maximum compressed

air through lter from the opposite direction of air ow.

c. Wash lter with mild soap and water. Rinse

until clean with water from hose having a maximum pressure of 30 psi (210 kPa). Lightly shake excess water from lter and allow to dry before installing.

2410

3. Reinstall lter. If lter is damaged, replace with new.

1110

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SCHEDULED AND PERIODIC MAINTENANCE SERVICES

WARNING

AS REQUIRED

4. FILL WINDSHIELD WASHER FLUID

RESERVOIR

The washer reservoir (A) is located inside the cab, on the left side of the seat.

Add commercial windshield washer uid as necessary.

IMG.2429

5. CLEAN WINDSHIELD AND WINDOWS

The cab windshield and windows are made of tinted safety glass. The skylight is polycarbonate window material.

Do not use abrasive or highly alkaline cleaner.

IMG.2400

Do not scrape window with a metal scraper or sharp object.

Do not use benzene, gasoline, acetone or carbon tetrachloride to clean polycarbonate windows.

Do not clean polycarbonate window material skylight in hot sun or at elevated temperatures.

Fresh paint, grease and tree sap can be removed before drying by rubbing lightly with naptha, isopropyl alcohol, or butyl cellosolve (2-butoxy ethanol). Then wash with a mild soap or detergent solution. Rinse thoroughly with clean water.

Scratches and abrasions can be removed or minimized by using a mild automobile wax. Test a small area of the polycarbonate window material with the product used to be sure it does not scratch or cloud the window.

1. Open front window guard.

2. Flush away as much loose dirt and dust as possible.

3. Wash windshield and windows and skylight with a mild soap or detergent and lukewarm water. Use a clean sponge or soft cloth. Rinse with clean water. Dry with a soft cloth or chamois to prevent water spots.

2410

Falling or swinging

logs can cause severe personal injury or death. Never operate the machine without the cab guard securely in place and undamaged.

4. Close front window guard and secure into place.

1111

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Page 94

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

WARNING

AS REQUIRED

6. CHECK/REPLACE POLYCARBONATE

WINDOW SKYLIGHT

al injury or death from objects breaking through polycarbonate window material, replace them when they

• are yellow or hazed;

• are scratched on either side with scratches that

IMG.2557B

can be felt with a ngernail (.0003 inch or greater);

• have small cracks coming from edges or mounting holes; or,

• have contacted uids that have caused cloudiness.

When any of the above conditions exist, the polycarbonate windows have lost enough of their strength that they will no longer protect the operator as designed.

To prevent serious person-

Slasher saw bar position for

chain adjustment

7. ADJUST SLASHER/DELIMBER SAW

BAR CHAIN

1. Remove personnel from saw area.

2. Activate saw function, and run saw bar to halfway down from the saw box (as shown), then release button. This will stop the saw chain from rotating, and will position the saw bar for chain adjustment.

3. Shut engine down and remove key.

4. Adjust chain following instruction in the slasher/ delimber operator’s manual.

5. After chain is adjusted, remove personnel from saw area.

6. Start engine.

7. Activate saw function, and return the bar to the saw box.

2410

Delimber saw bar position for

chain adjustment

1112

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Page 95

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

NOTICE

AS REQUIRED

8. DRAIN AND REPLACE HYDRAULIC OIL

Hydraulic oil must be changed based on the ambient (outside) air temperature. Certain grades of hydraulic oil work best in certain temperature ranges.

Follow Caterpillar’s hydraulic oil specications. If oil is not changed seasonally, as required, the hydraulic system can be damaged.

Refer to Fuels and Lubricants section for hydraulic oil recommendations.

Procedures for changing hydraulic oil can be found later in this section.

Hydraulic oil capacity is 65 gallons (246 L).

or weights of hydraulic oil.

DO NOT mismatch brands

9. HAZARD DECALS

Inspect safety decals and replace as needed when damaged or unreadable.

Decals will not adhere to

dirty or wet surfaces. Thoroughly clean and dry any area where a decal or slip resistant mat is to be placed.

10. SLIP RESISTANT MATS

Inspect and clean resistant mats. Replace any slip resistant mat that has been damaged or has come loose.

Decals will not adhere to

dirty or wet surfaces. Thoroughly clean and dry any area where a decal or slip resistant mat is to be placed.

2410

1113

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Page 96

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

WARNING

NOTICE

DAILY OR EVERY 10 HOURS

PERFORM A DAILY VISUAL INSPECTION

inspection of machine can result in machine damage and severe personal injury or death.

In addition to the required daily inspection outlined in

G.048.03

Pre-Start Inspection section perform a daily inspection of the following components:

• Structures • Swing bearing

• Booms • Load-bearing items

• Cylinders • All mountings

• Turntable

can cause structural failure and/or severe personal injury or death.

DO NOT weld on any structural member. Any unauthorized welding or repair will void the warranty.

Failure to perform a daily

Unauthorized welding

Once authorized, turn battery disconnect master switch OFF and place welding ground (stinger) as close to the weld site as possible. Do not allow weld current to pass through bearings, bushings or pivot points.

Welding can cause damage

to the electrical system.

11. LUBRICATE ADAPTER KNUCKLE

Lubricate adapter knuckle (A) with Premium Moly-Lith EP #2 until grease is forced out.

IMG.2560

12. LUBRICATE STABILIZER PAD PIVOT

PINS

2410

IMG.2470

Lubricate stabilizer pad pivot pins (B) with Premium Moly-Lith EP #2 until grease is forced out.

1114

1111

Page 97

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

DAILY OR EVERY 10 HOURS

13. LUBRICATE STABILIZER CYLINDER

ROD ENDS

Lubricate stabilizer cylinder rod ends (A) with Premium Moly-Lith EP #2 until grease is forced out.

IMG.2557A

14. LUBRICATE STABILIZER ARM PIVOT

PINS

Lubricate stabilizer arm pivot pins (B) with Premium Moly-Lith EP #2 until grease is forced out.

045.03

15. LUBRICATE STABILIZER CYLINDER

BASE ENDS

Lubricate stabilizer cylinder base ends (C) with Premium Moly-Lith EP #2 until grease is forced out.

IMG.2469

16. LUBRICATE MAIN BOOM PIVOT PINS

Lubricate main boom pivot pins (D) with Premium Moly-Lith EP #2 until grease is forced out.

2410

047.03

1115

1111

Page 98

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

DAILY OR EVERY 10 HOURS

17. LUBRICATE MAIN BOOM CYLINDER

BASE ENDS

Lubricate main boom cylinder base ends (A) with Premium Moly-Lith EP #2 until grease is forced out.

IMG.2464

18. LUBRICATE MAIN BOOM CYLINDER

ROD ENDS

Lubricate main boom cylinder rod ends (B) with Premium Moly-Lith EP #2 until grease is forced out.

IMG 2466

19. LUBRICATE MAIN/STICK PIVOT PINS

Lubricate main/stick pivot pins (C) with Premium MolyLith EP #2 until grease is forced out.

IMG.2479

20. LUBRICATE STICK BOOM CYLINDER

BASE ENDS

Lubricate stick boom cylinder base ends (D) with Premium Moly-Lith EP #2 until grease is forced out.

2410

IMG.2473

1116

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SCHEDULED AND PERIODIC MAINTENANCE SERVICES

CAUTION

DAILY OR EVERY 10 HOURS

21. LUBRICATE STICK BOOM CYLINDER

ROD ENDS

Lubricate stick boom cylinder rod ends (A) with Premium Moly-Lith EP #2 until grease is forced out.

052.03

22. LUBRICATE SWING BEARING

IMG.2571

Lubricate swing bearing with Premium Moly-Lith EP #2 while rotating loader 2 complete revolutions.

There are 3 grease ttings (B) located on the oor of the right side of the cab that can be reached with a grease gun from the operator’s seat.

Rotate turntable slowly.

Boom can strike people or property, which can cause personal injury or property damage. Be sure loader is clear of obstructions, remove personnel, and make sure those not performing maintenance are clear of the machine.

23. LUBRICATE PINION GEAR

Coat gear teeth (C) with Heavy Duty Open Gear Lube to prevent bare metal contact. Spray lubricant through access hole (D) .

2410

054.03

PINION LUBE.TIF

1117

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Page 100

SCHEDULED AND PERIODIC MAINTENANCE SERVICES

DAILY OR EVERY 10 HOURS

24. CHECK HYDRAULIC OIL RESERVOIR

LEVEL

1. Position loader properly for an accurate reading. Booms should be horizontal, and grapple should be closed. Lower stabilizers so they touch the ground without raising the loader.

2. Shut engine down and move joysticks in all direc-

tions to relieve hydraulic pressure.

3. Disengage controls by moving control shut o lever UP (A).

4. Visually check the oil level by observing the sight gauge (B) on the hydraulic reservoir while oil is warm. Sight gauge is located in hydraulic lter compartment, accessed through the top of the engine compartment.

5. Add clean, ltered oil, if necessary (refer to Fill Hydraulic Reservoir below).

IMG.2576

IMG.2500

FILL HYDRAULIC RESERVOIR

1. Gain access to hydraulic reservoir hand ll pump (C) on the loader.

2. Uncoil ll hose (D).

2410

IMG.2349

1118

1111