FORWARDER 2546, 2548 OPERATOR’S MANUAL

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Page 1

OPERATOR’S MANUAL

FORWARDER

2546/2548

Part No. 30012734

February 2012

Rev. C

Page 2

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TO THE OPERATOR

2546/2548 T3 1108

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TO THE OPERATOR

2546/2548 T3

1108

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TO THE OPERATOR

INTRODUCTION

DO NOT USE THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTAND 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.

2546/2548 CAT Forwarder

To safely operate this machine, follow the instructions in this operator’s manual. Directions in this manual are referenced from the operator’s seat facing forward (see diagram below).

FORWARD

LEFT RIGHT

REAR

You can help improve this manual. If you nd any mistakes, or if you know of a way to improve procedures, please let us know. Mail your suggestions or comments to the attention of Technical Publications, Caterpillar Forest Products, Inc., 3249 South County Road 45, PO Box 568, Owatonna, MN 55060-0568.

This operator’s manual includes information available and current at the time of approval for printing. Caterpillar 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.

2546/2548 T3 1108

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TO THE OPERATOR

CAUTION

NOTICE

DANGER

WARNING

SAFETY SYMBOLS

SAFETY ALERT SYMBOL

The Safety Alert Symbol means

ATTENTION!

BE ALERT! YOUR SAFETY IS INVOLVED!

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

Understand signal words: DANGER, WARNING, and

CAUTION are used with the SAFETY ALERT SYMBOL.

DANGER IDENTIFIES A HAZARD OR UNSAFE PRACTICE THAT WILL RESULT IN SEVERE PERSON AL INJURY OR DEATH.

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

CAUTION identies a hazard or unsafe practice that could result in personal injury or property damage.

2546/2548 T3

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

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TO THE OPERATOR

CONTENTS

PRODUCT PROTECTION PLAN .............................................i

Machine ................................................................................i

TO THE OPERATOR ..................................................................iii

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

GENERAL SAFETY .................................................................11

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

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

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

Cooling Fan .....................................................................1-2

Discharge Accumulator ..............................................1-3

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

Electrical Storm .............................................................1-4

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

Fire Prevention/First Aid .............................................1-5

Fluids Under Pressure..................................................1-6

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

Hand Holds and Steps .................................................1-7

Hoses and Fittings ........................................................1-7

No Riders on Machine ................................................. 1-8

Mechanical Cab Tilt Lock ............................................1-8

Operator Safety .............................................................1-9

Practice Safe Maintenance ........................................1-9

Pinch Points ................................................................. 1-10

Pressure Settings .......................................................1-10

Protective Clothing ...................................................1-10

Protective Devices/Equipment ............................. 1-11

Radiator Cap ................................................................ 1-11

Refueling ....................................................................... 1-11

ROPS/FOPS/OPS Cab Structure ............................ 1-12

Servicing Control Valves, Cylinders, Pumps and

Motors ................................................................... 1-12

Seat Belt ........................................................................1-12

Servicing Machine with Engine Running .......... 1-13

Slope Operation ......................................................... 1-13

Starter Circuitry .......................................................... 1-14

Unauthorized Welding ............................................. 1-14

Tire Safety ..................................................................... 1-14

Use Steering (frame) Lock ....................................... 1-15

SAFETY DECALS ....................................................................21

Forwarder Exterior........................................................2-1

Forwarder Interior ........................................................2-2

COMPONENT TERMINOLOGY ..........................................31

Forwarder ........................................................................3-1

IQAN® .........................................................................................41

Main Screen ..............................................................4-1 - 2

Settings Screen ........................................................4-3 - 9

LCD/Lighting Setting ..........................................4-4

Language Setting ................................................4-5

2546/2548 T3 1108

Alarm/Sound Setting ..........................................4-6

IQAN® .....................................................................CONT.

Button (Key) Setting ............................................4-7

Date/Time Setting ...........................................4-8-9

Measure Screen ..................................................4-10 - 16

Voltage Input Measure .................................... 4-11

Digital Input Measure ...................................... 4-12

Frequency Input Measure .............................. 4-13

Direction Input Measure ................................ 4-14

Current Output Measure ................................4-15

Digit Output Measure ...................................... 4-16

Mode Screen .......................................................4-17 - 19

Copy Mode ..........................................................4-18

Reset Mode ......................................................... 4-19

Information Screen ...........................................4-20 - 23

Properties Screen ...............................................4-24 - 25

CONTROLS AND INSTRUMENTS .....................................51

Operator’s Station ........................................................5-1

Gauge Cluster Assembly ............................................5-2

Warning Indicator Panel .............................................5-3

Left Side Console ..........................................................5-4

Right Side Console .......................................................5-5

Rear Console ...................................................................5-5

Satellite Radio ................................................................5-6

Blade Control ..................................................................5-7

Axle Dierential Lock ..................................................5-8

Battery Disconnect Master Switches .....................5-9

Brake Low Pressure Indicator ................................ 5-10

Cab Tilt Control ........................................................... 5-10

Climate Controls......................................................... 5-11

Emergency Exits ......................................................... 5-11

Engine Oil Pressure Gauge ..................................... 5-12

Engine Temperature Gauge ................................... 5-12

Frame Lock Switch..................................................... 5-13

Fuel Indicator .............................................................. 5-13

Fuse and Relay Panel ................................................ 5-14

Hourmeter .................................................................... 5-14

Hydraulic Oil Temperature Indicator .................. 5-15

Hydraulic Oil Low Flow Indicator ......................... 5-15

Hydraulic Reservoir Sight Gauge .........................5-16

Ignition Switch ............................................................ 5-16

Iqan ........................................................................5-16

Joystick Function - Forward Facing ..................... 5-17

Forestry Joystick Function - Rear Facing ........... 5-18

SAE Joystick Function - Rear Facing .................... 5-19

Load Sense Dump Valve ......................................... 5-20

Operating Lights Switch ....................................5-21-22

Operator’s Seat ..................................................... 5-23-24

Park Brake ..................................................................... 5-25

Power Outlets .............................................................. 5-25

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CONTENTS

TO THE OPERATOR

CONTROLS AND INSTRUMENTS ...............................CONT.

Seat Belt ........................................................................5-26

Seat Proximity Switch ............................................... 5-26

Steering (Default) ...................................................... 5-27

Steering (Optional) .................................................... 5-28

Steering Lock ............................................................... 5-29

Tachometer .................................................................. 5-30

Throttle ........................................................................ 5-31

Transmission Controls .............................................. 5-32

Transmission Display Panel .................................... 5-33

Transmission Oil Temperature Gauge ................ 5-33

Pedals ........................................................................ 5-34

Windshield Wiper ....................................................... 5-35

PRESTART INSPECTION .....................................................61

Pre-start Checks: On the Ground ............................6-1

Pre-start Checks: In the Cab ......................................6-2

Fire Prevention ...............................................................6-3

OPERATION

General Guidelines .......................................................7-1

Getting on Machine .....................................................7-2

Starting the Engine ................................................7-3 - 4

Cold Weather Starting .................................................7-5

Jump-starting Battery .................................................7-6

Warm-up Period ............................................................7-7

Axle Dierential Lock ..................................................7-8

Blade Operation ............................................................7-9

Bogie Axle Lift Operation ........................................ 7-10

Slope Operation ......................................................... 7-11

Travel Operation......................................................... 7-12

Driving the Forwarder ...................................... 7-13 - 14

Stopping the Forwarder .......................................... 7-15

Stopping the Engine/Parking the Machine ...... 7-16

Tilting the Cab.....................................................7-18 - 21

Getting O Machine ................................................ 7-22

BREAKIN PERIOD .................................................................81

TRANSPORTING ....................................................................91

FUELS AND LUBRICANTS ................................................ 101

Fuel ........................................................................ 10-1

Engine Oil ..................................................................... 10-2

Hydraulic Oil ................................................................ 10-3

Grease ........................................................................ 10-3

Axle Fluids .................................................................... 10-4

Swing Drive Grease ................................................... 10-4

Pinion & Swing Gear Lubricant ............................. 10-4

Swing Drive Gear Box Lubricant ........................... 10-4

Corrosion Preventive, Cylinder Rod ....................10-4

Transmission Fluid ..................................................... 10-5

Storing Lubricants ..................................................... 10-5

MAINTENANCE SAFETY .................................................. 111

Before Maintenance............................................ 11-1 - 5

Practice Safe Maintenance ............................11-1

Accumulator/Hydraulic Safety .....................11-2

Steering Lock ...................................................... 11-3

Blade Safety ........................................................ 11-3

Boom Safety ........................................................ 11-4

Protective Clothing ..........................................11-4

Servicing Control Valves, Cylinders, Pumps

and Motors ................................................. 11-4

Unauthorized Welding ....................................11-5

During Maintenance .......................................... 11-6 - 8

Battery Safety .....................................................11-6

Cooling Fan ......................................................... 11-6

Diesel Exhaust .................................................... 11-7

Fluids Under Pressure ...................................... 11-7

Fuels and Lubricants ........................................ 11-7

Pinch Points ......................................................... 11-8

Servicing Machine with Engine Running . 11-8

Tier Safety ............................................................ 11-8

After Maintenance .................................................... 11-9

Disposing of Waste ...........................................11-9

Storing Flammable Materials ........................ 11-9

SCHEDULED/PERIODIC MAINTENANCE SERVICES 121

Lubrication and Maintenance Intervals ............. 12-1

Lubrication Notice ..................................................... 12-1

Position Machine for Maintenance ..................... 12-2

Forwarder Maintenance Charts

As Required .............................................................12-3

Daily or Every 10 Hours ....................................... 12-4

Weekly or Every 50 Hours ................................... 12-5

Monthly or Every 250 Hours .............................. 12-6

Every 500 Hours ..................................................... 12-7

Every 1000 Hours ................................................... 12-8

Every Three Years ................................................... 12-9

Forwarder Maintenance Details

As Required .............................................. 12-10 - 21

Clean A/C Condenser ............................12-10

Bleed Brakes .............................................12-11

Clean and/or Replace Cab Filters ......12-12

Check Electrical System .......................12-13

Clean Fuel Tank Strainer .......................12-15

Replace Fuel Filters ................................12-15

Priming the Fuel System ......................12-16

Check Oil Hoses and Fittings ..............12-16

Drain and Replace Hydraulic Oil .......12-17

Clean Radiator .........................................12-19

Grease Swing Drive Bearing ...............12-20

Replace Polycarbonate Windows .....12-20

Clean and Inspect Polycarbonate

Windows ...........................................12-21

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TO THE OPERATOR

SCHEDULED/PERIODIC MAINTENANCE SERVICES ......

................................................................................................CONT.

Daily or Every 10 Hours ........................... 12-22 - 40

Perform a Daily Inspection .................12-22

Check Parking Brake ..............................12-23

Air Cleaner Maintenance .............12-24--26

Check Engine Crankcase Oil ...............12-27

Check Radiator Coolant Level ............12-28

Check Diesel Fuel Level ........................12-29

Check Hydraulic Oil Reservoir Level 12-30

Check Hydraulic Oil Cooler .................12-31

Check Electrical System ................ 12-32-33

Lubricate Working Pivot Points .. 12-34-37 Clean Belly Pans, Engine Area and

Side Screens.....................................12-38

Drain Fuel Water Separator .................12-39

Check Fire Extinguisher Charge ........ 12-40

Inspect Seat Belt .....................................12-40

Check transmission Oil Level .............12-40

Weekly or Every 50 Hours ........................ 12-41 - 45

Perform a Weekly Inspection .............12-41

Lubricate Drive Shafts ...........................12-42

Tighten Axle Mounting Hardware ....12-43

Tighten Wheel Lug Bolts ......................12-43

Clean transmission Oil Cooler, Radiator

and Oil Cooler .................................12-44

Check Swing Drive Oil Level ...............12-44

Check Tire Pressure ................................12-45

Lubricate Extension Boom ..................12-45

Monthly or Every 250 Hours ................... 12-46 - 53

Drain and Replace Engine Oil and

Filters ..................................................12-46

Tighten Engine Mounting

Hardware ..........................................12-47

Check Swing Drive Bearing Fastener

Torque ................................................12-47

Inspect and Lubricate Swing Drive .. 12-48

Battery Service ................................. 12-49-51

Inspect Air Intake and Exhaust

System ...............................................12-52

Inspect and Lubricate Seat .................12-52

Check Single Axle Oil Level .................12-53

Tighten Barrier Mounting

Hardware ..........................................12-53

Tighten Bunk Tube Mounting

Hardware ..........................................12-53

Every 500 Hours .......................................... 12-54 - 57

Replace Hydraulic Filters .....................12-54

Inspect (Sample) Hydraulic Oil ..........12-55

Analyze Coolant ......................................12-56

Drain and Fill Swing Drive ...................12-57

SCHEDULED/PERIODIC MAINTENANCE SERVICES ......

................................................................................................CONT.

Replace Transmission Oil and

Filter ............................................................12-58

Every 1000 Hours ..................................................... 12-58 - 64

Drain and Fill Hydraulic Oil

Reservoir ....................................................12-58

Drain and Fill Dierential ........................... 12-59-60

Drain and Fill Bogie Drive .................................12-61

Flush and Fill Cooling System .........................12-62

Replace Hydraulic Tank Breather ................... 12-63

Seat Maintenance ...............................................12-63

Lubricate Door Hinges ......................................12-63

Every Three Years ..............................................................12-64

Replace Seat Belt ....................................................12-64

Every Four Years ................................................................12-64

Replace Polycarbonate Windows .....................12-64

STORAGE ...............................................................................131

Preparing Tractor for Storage ................................ 13-1

Taking Machine out of Storage ............................. 13-2

TROUBLESHOOTING ........................................................ 141

Engine ....................................................................14-1-2

Transmission ................................................................ 14-3

Hydraulic System ....................................................... 14-4

Electrical System ........................................................ 14-4

Functions ...................................................................... 14-5

Contamination of Hydraulic Comp. .................... 14-6

SPECIFICATIONS ................................................................. 151

Forwarder ..................................................................... 15-1

Hydraulic Connection Torque Specications

SAE 37° Flare Connection ................................... 15-2

O-ring Face Seal Connection ............................. 15-3

Torque Chart for Fasteners ..................................... 15-4

Cylinder Torque Specications ............................. 15-5

Battery Specications............................................... 15-6

SERIAL NUMBERS .............................................................. 161

MATERIAL SAFETY DATA SHEETS ................................ 171

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TO THE OPERATOR

2546/2548 T3

viii

1108

Page 11

GENERAL SAFETY

WARNING

GENERAL SAFETY

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

SAFETY ALERT SYMBOL

Read all safety messages.

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

G.033.02

OPERATOR PREPARATION

G.001.02

Before operating this machine Operator must:

• read and understand the Operator’s Manual

• be procient in the control of this machine

• understand the safety features of this ma-

chine

• be instructed in the local, state & federal work

sate safety rules

• be instructed in the OSHA or local regulatory

body work safety rules

2546/2548 T3 1108

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GENERAL SAFETY

WARNING

BATTERY SAFETY

sive gases.

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

G.019.02

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.

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.

Batteries produce explo-

G.013.02

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.

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.

COOLING FAN

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

2546/2548 T3 1108

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GENERAL SAFETY

WARNING

DANGER

DISCHARGE ACCUMULATOR

pressure can penetrate skin and cause severe personal injury or death. Charged accumulator can cause unexpected movement of functions with engine o.

DO NOT disconnect hoses or ttings, or attempt to service the hydraulic accumulator or pilot circuit without rst discharging the accumulator.

If ANY uid is injected into the skin, seek medical attention immediately. A serious

G.002.02

infection or reaction can result without proper medical treatment.

ELECTRIC LINES

Fluids escaping under

G.003.02

SERIOUS INJURY OR 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 2x the line insulator length (2x6 =12 inches or 1 foot from electric line, which means you 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 let anyone else touch machine while it is touching an electric line. If it is not possible to move the machine 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.

2546/2548 T3 1108

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

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GENERAL SAFETY

WARNING

ELECTRICAL STORM

ning) 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.

Electrical storms (light-

G.083.03

FALLING OR SWINGING LOGS

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.

2546/2548 T3 1108

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Page 15

GENERAL SAFETY

CAUTION

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

G.004.05

all compartments after every eight (8) hours of operation, or more often, if warranted by working conditions.

At the end of each shift ALWAYS stay with the machine for at least 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.

Fires can cause personal

G.005.02

Install a rst-aid kit and a re extinguisher in the cab.

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

2546/2548 T3 1108

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Page 16

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 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.

Fluids escaping under

G.002.02

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.

HAND SIGNALS

Accidents can cause severe personal injury or death.

Know and use hand signals required for particular jobs.

2546/2548 T3 1108

Know who has responsibility for signaling.

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Page 17

GENERAL SAFETY

WARNING

HAND HOLDS AND STEPS

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.

Slips and falls can cause

G.006.02

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.

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

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.

2546/2548 T3 1108

G.007.02

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)!

17

Page 18

GENERAL SAFETY

WARNING

DANGER

NO RIDERS ON MACHINE

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

G.009.02

MECHANICAL CAB TILT LOCK

Falling cab can result in severe personal injury or death.

To reduce the risk of severe personal injury resulting from a falling cab, always make sure that the mechanical lock is in locked position before reaching under tilted cab.

See Operation Section in this manual for instructions on properly installing mechanical cab tilt lock.

2546/2548 T3 1108

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Page 19

GENERAL SAFETY

WARNING

OPERATOR SAFETY

and/or other material can cause severe personal injury or death.

When operating machine:

G.010.02

Polycarbonate windows MUST be replaced if damaged. For details, refer to Scheduled/Periodic Maintenance Service.

Flying debris, tree limbs,

1. Keep cab door closed.

2. Polycarbonate window material and/or cab guarding MUST be in place.

3. All cab openings (front, side, and rear) MUST be covered with Polycarbonate window material (no glass) and/or protective screen.

4. Window guarding MUST be locked in place.

104.05

PRACTICE SAFE MAINTENANCE

Read service and 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.

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.

2546/2548 T3 1108

Lower stabilizers (if so equiped) to the ground. Do not support machine weight on stabilizers.

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Page 20

GENERAL SAFETY

WARNING

PINCH POINTS

tion of the body where forwarder moves can cause severe personal injury or death. NEVER place hands or any portion of the body where injury could occur if delimber moves. NEVER check pin hole alignments with ngers.

PRESSURE SETTINGS

Placing hands or any por-

G.012.02

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

DO NOT exceed factory-adjusted pressure settings.

PROTECTIVE CLOTHING

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

• ear protection • hard hat

• gloves • orange vest

• goggles • steel-toed shoes

2546/2548 T3 1108

G.051.02

Wear snug, protective clothing that is belted where required.

Remove jewelry before working on or near this machine.

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Page 21

GENERAL SAFETY

WARNING

CAUTION

WARNING

PROTECTIVE DEVICES/EQUIPMENT

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

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

Misuse, interference and

G.014.02

Pressurized cooling system

can cause scalding burns.

Allow system to cool. Wear gloves. Remove cap slowly.

REFUELING

Fires and explosions can 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.

2546/2548 T3 1108

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.

G.015.02

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Page 22

GENERAL SAFETY

WARNING

ROPS/FOPS/OPS CAB STRUCTURE

structure can cause severe personal injury or death.

If ROPS/FOPS/OPS structure is damaged (bent or cracked), it should be inspected by your Hydro-Ax dealer or by a factory representative. Replace ROPS/ FOPS/OPS structure if it fails inspection. Do not alter ROPS/FOPS/OPS structure.

G.016.02

SERVICING CONTROL VALVES, CYLINDERS, PUMPS AND MOTORS

Altering ROPS/FOPS/OPS

settings could cause delimber 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.

SEAT BELT

can cause severe personal injury or death.

To reduce risk of personal injury resulting from a roll over or sudden stop, always wear a seat belt fastened snugly when operating machine.

Increasing relief valve

A roll over or sudden stop

2546/2548 T3 1108

This machine can change directions rapidly. It can start and stop quickly. See Section 6, Operation, in this manual for instructions on properly using your seat belt.

112

Page 23

GENERAL SAFETY

WARNING

SERVICING MACHINE WITH ENGINE RUNNING

engine running can cause severe injury or death. Shut down engine and relieve hydraulic pressures before servicing unless procedure requires engine running. When maintenance procedure requires

engine running, ONLY qualied service technicians should service machine.

CHECKING ENGINE

• Lower attachment to ground.

• Block (chock) tires.

SLOPE OPERATION

Servicing machine with

Operation across a slope can cause machine to tip over resulting in severe personal injury or death.

ALWAYS wear seat belt snugly fastened.

DO NOT operate with tires sideways to a slope.

On all slopes, only operate with machine pointed up or down the slope.

Loss of traction on a steep slope can cause operator to lose control of tractor and roll over, resulting in severe personal injury or death.

ALWAYS wear seat belt, snugly fastened.

DO NOT operate machine on slopes exceeding 30 percent (16.7° angle from horizon). A 30% slope can be visualized by a three (3) foot rise in a 10 foot distance.

2546/2548 T3 1108

3 feet

10 feet

G.050.02

113

Page 24

GENERAL SAFETY

WARNING

NOTICE

WARNING

DANGER

STARTER CIRCUITRY

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

MACHINE WILL START IN

G.020.02

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.

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

Welding can cause damage to the electrical system.

TIRE SAFETY

A tire explosion can cause severe personal injury or death. DO NOT attempt to mount a tire without the proper equipment and experience to do the job.

2546/2548 T3 1108

Have tires mounted by an authorized dealer or by a qualied repair service.

Maintain proper tire pressure. DO NOT inate tires above recommended pressure.

114

Page 25

GENERAL SAFETY

WARNING

USE STEERING FRAME LOCK

with a person in center hinge crush point area, severe personal injury or death could occur.

Activating joystick could COMPLETELY turn machine right or left.

Do not use joystick as a handhold when mounting or dismounting machine.

NEVER stand in this area with engine running.

Install steering lock BEFORE performing service or

101.05

maintenance.

If steering is activated

G.021.02

2546/2548 T3 1108

115

Page 26

GENERAL SAFETY

2546/2548 T3 1108

116

Page 27

SAFETY DECALS

NOTICE

CAUTION

PRESSURIZED COOLING SYSTEM. CAN CAUSE SCALDING BURNS.

ALLOW SYSTEM TO COOL. REMOVE CAP SLOWLY WITH GLOVES ON.

10063918 6/03

CRUSH ZONE

ALWAYS TILT CAB TO FULLY TILTED ANGLE AND PLACE THE MECHANICAL LOCK IN THE LOCKED POSITION BEFORE REACHING UNDER THE CAB.

DANGER

10063337 11/02

WARNING

FLUID ESCAPING UNDER PRESSURE

CAN PENETRATE SKIN AND CAUSE

SEVERE PERSONAL INJURY.

DO NOT DISCONNECT HOSES OR FITTINGS,

OR ATTEMPT SERVICING THE HYDRAULIC

ACCUMULATOR OR PILOT CIRCUIT

WITHOUT FIRST DISCHARGING THE

ACCUMULATOR.

10055037REV A11-97

10062494 02/02

WARNING

ROTATING FAN AND EXPOSED BELTS CAN CAUSE SEVERE PERSONAL INJURY.

KEEP HANDS AWAY AT ALL TIMES.

10053766

0297

WARNING

ROTATING FAN CAN CAUSE SEVERE PERSONAL INJURY. CONDENSER FAN CAN START AT ANY TIME, EVEN WITH THE ENGINE OFF.

KEEP HANDS AWAY FROM FAN AT ALL TIMES.

CAUTION

TURN OFF MASTER

DISCONNECT BEFORE

ANY WELDING

10051827 6/97A

IF EXPOSED SHAFT IS TURNING WITH PERSON IN IMMEDIATE AREA, SEVERE INJURY COULD OCCUR.

KEEP CLEAR

NEVER STAND IN THIS AREA WITH ENGINE RUNNING.

DA N G E R

10063925 7/03

WARNING

RIDING ON MACH INE

OR ATT ACHMENT

CAN CA USE SEVE RE

INJURY OR DEAT H

• NO R IDERS AL LOWED.

17486 1/03

WARNING

DO NOT FILL FUEL FILTERS BEFORE INSTALLING NEW FUEL FILTERS. FUEL SYSTEM DAMAGE CAN OCCUR.

10504971 Rev. 1 0608

ELECTRIC PUMP WILL AUTOMATICALLY FILL FUEL FILTER.

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 a 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. Your authorized dealer will provide free replacement safety decals if you provide a valid serial number for your machine.

If you replace a part that has safety decal, apply a new safety decal to the replacement part. Before putting a new decal on the machine or part, be sure the surface where decal will be mounted is clean and dry.

2546/2548 T3

located on both sides of machine

21

located on both sides of machine

1108

Page 28

Located on header

CAUTION

CHECK DAILY FOR

DEBRIS

LEAKS

DAMAGED WIRES/HOSES

WORKING FIRE FIGHTING DEVICES

Presented by T.E.A.M.

Working Group

10063809 4/03 Rev A

WARNING

UNSAFE OPERATION O R MAINTEN ANCE CAN CA USE SEVERE INJURY OR D EATH.

DO NOT O PERATE OR W ORK ON THIS MACHINE WIT HOUT READING & UNDERSTAN DING THE OPER ATOR'S MANU AL.

FALLING ATTACHMENT OR UNINTEN DED TRACTOR MOVEMEN T CAN CAUSE SEVERE INJURY OR DEATH.

DEBRIS COMING THRO UGH CAB OPENING S CAN CAUSE SEVERE INJURY OR DEATH

CONTACT ING ELECTRI C LINES WITH LI FT ARM, ATT ACHMENT, OR LOAD CAN CAUSE SEVERE INJURY OR DEATH.

UNLAWFUL TO OPERATE THIS MACHINE, LIFT ARM, ATTACHMENT, OR LOAD WITHIN 10 F EET, PLUS 2 TIMES LINE INSULA TOR LENGTH, OF ANY E LECTRIC LIN E.

WHILE OP ERATING MAC HINE: .

KEEP BO TH CAB DOOR S CLOSED.

ALL CAB OPENINGS ( FRONT, SIDE AND RE AR) MUST BE COVERED WITH TUFFEX@ WINDOW MATERI AL (NO GLAS S) AND/OR PROTEC TIVE SCREEN .

BEFORE DISMOUNTING FROM MACHINE: .

MOVE THE MACHINE TO LEVEL GROUND. .

LOWER ATTACHMENT TO THE GROUND. .

SET PARKING BRAKE. .

SHUT OFF MACHINE. .

RELIEVE HYDRAULIC PRESSURE. .

REMOVE KEY FROM STARTER SWITCH.

WARNING WARNING WARNING WARNING WARNING

100 63 923 6/ 03 Rev B 7/ 05

FAILURE TO WEAR SEAT BELT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH.

ALWAYS WEAR SEAT BELT (ADJUSTED UNTIL SNUG) WHILE OPERATING THIS MACHINE.

OPERATION ACROSS A SLOPE COULD CAUSE THE MACHINE TO OVERTURN AND CAUSE SEVERE INJURY OR DEATH.

DO NOT OPERATE WITH TIRES SIDEWAYS TO SLOPE. ON ALL SLOPES OPERATE WITH TIRES POINTED UP AND DOWN THE SLOPE.

SAFETY DECALS

Located on entry door

2546/2548 T3

22

1108

Page 29

COMPONENT TERMINOLOGY

FORWARDER

1. Blade

2. Cab

11. Front Frame

12. Single Axle & Wheels

3. Loader Mast

4. Main Boom

5. Stick Boom

6. Extension Boom (optional)

7. Grapple Dampener Link

8. Grapple Rotator

9. Grapple

10. Engine Compartment

13. Steering Knuckle

14. Mast Swing Box Assembly

15. Rear Frame

16. Dual - Bogie Axle and Wheels

17. Barrier

18. Bunk Tubes

19. Limb Risers

2546/2548 T3

31

1108

Page 30

COMPONENT TERMINOLOGY

NOTES

2546/2548 T3

32

1108

Page 31

IQAN®

F1 F2 F3

ESC

Pressure

PSI

RPM

IQAN

INTRODUCTION

The IQAN® system is a computer-based control system that delivers precision control through the valving system. IQAN®’s menus control machine function and aid in troubleshooting.

IQAN® MDM DISPLAY

The IQAN® terminal displays information for machine instrumentation and consists of an MDM screen and ve function buttons. With this display, the operator monitors machine functions such as engine rpm, oil temperature, hydraulic pressure, and other operator-specic selections. IQAN® also displays alarm signals.

To operate the IQAN® system, ignition switch must be turned to ACC or RUN.

1. Up and down key

2. F1-F3 keys

3. Escape key

The IQAN® system has ve sub menus which can be accessed by depressing the ESC key:

Sub Menus:

Mode

Information

Settings

MAIN SCREEN - This screen appears after machine start up.

IQAN44

Measure

Properties

2546/2548 T3

41

1108

Page 32

IQAN®

F1 F2 F3

ESC

Pressure

PSI

RPM

F1 F2 F3

ESC

25 May 2005

500 Series LH Boom 03.71

09:45

IQAN® MAIN SCREEN

The IQAN® main screen appears after start up of the machine.

Hydraulic pressure (A) and RPM (B) are displayed on the main screen start up.

IQAN.44

Scroll using the up & down key to access time (C), date (D), user mode (E) and version of program (F).

IQAN.45

2546/2548 T3

42

1108

Page 33

IQAN®

F1 F2 F3

LCD LANGUAGE MORE..

ESC

SETTINGS

F1 F2 F3

LCD LANGUAGE MORE..

ESC

F1 F2 F3

ESC

Pressure

PSI

RPM

IQAN® SETTINGS SCREEN

Depress the ESC key to access the adjustment menus.

IQAN.44

Scroll using the up & down key until SETTINGS is displayed on the IQAN® screen.

IQAN.4

2546/2548 T3

43

1108

Page 34

IQAN®

F1 F2 F3

CONTRAST LIGHT

ESC

LCD SETTINGS

F1 F2 F3

LCD LANGUAGE MORE..

ESC

SETTINGS

F1 F2 F3

LCD LANGUAGE MORE..

ESC

F1 F2 F3

CONTRAST LIGHT

ESC

LCD SETTINGS

F1 F2 F3

OK CANCEL RESET

ESC

LCD CONTRAST

IQAN® LCD/LIGHT SETTINGS SCREEN

Depress F1 key to select LCD setting.

IQAN.4

Depress F1 key to adjust contrast level of screen.

IQAN.20

IQAN.21

Depress F2 key to adjust light level of screen.

To adjust screen contrast level, scroll using the up & down key.

Depress F1 key to save changes.

F2 key to cancel changes.

F3 key to restore to factory settings.

Note: Use the same process to adjust light level of screen.

2546/2548 T3

44

1108

Page 35

IQAN®

F1 F2 F3

LCD LANGUAGE MORE..

ESC

SETTINGS

F1 F2 F3

LCD LANGUAGE MORE..

ESC

F1 F2 F3

OK CANCEL

ESC

ENGLISH

IQAN® LANGUAGE SETTINGS SCREEN

Depress F2 key to select language setting.

IQAN.4

To adjust language, scroll using the up & down key .

Note:

Depress F1 key to save changes.

F2 key to cancel changes.

IQAN.22

2546/2548 T3

45

1108

Page 36

IQAN®

F1 F2 F3

LCD LANGUAGE MORE..

ESC

SETTINGS

F1 F2 F3

LCD LANGUAGE MORE..

ESC

F1 F2 F3

SOUND SET CLOCK MORE..

ESC

SETTINGS

F1 F2 F3

LCD LANGUAGE MORE..

ESC

F1 F2 F3

ALARM BUTTON

ESC

SOUND SETTING

F1 F2 F3

OK CANCEL RESET

ESC

ALARM SOUND

IQAN® ALARM SOUND SETTINGS SCREEN

Depress F3 key to access more setting adjustments.

IQAN.4

Depress F1 key to access sound setting adjustments.

IQAN.43

IQAN.25

IQAN.26

Depress F1 key to change alarm setting volume.

To adjust volume of alarm, scroll using the up & down key.

Note:

Depress F1 key to save changes.

F2 key to cancel changes.

F3 key to restore to factory settings.

2546/2548 T3

46

1108

Page 37

IQAN®

F1 F2 F3

LCD LANGUAGE MORE..

ESC

SETTINGS

F1 F2 F3

LCD LANGUAGE MORE..

ESC

F1 F2 F3

SOUND SET CLOCK MORE..

ESC

SETTINGS

F1 F2 F3

LCD LANGUAGE MORE..

ESC

F1 F2 F3

ALARM BUTTON

ESC

BUTTON SETTING

F1 F2 F3

ALARM BUTTON

ESC

BUTTON SOUND

IQAN® BUTTON KEY SOUND SETTINGS SCREEN

Depress F3 key to access more setting adjustments.

IQAN.4

Depress F1 key to access sound setting adjustments.

IQAN.43

IQAN.27

IQAN.28

Depress F2 key to change button setting volume.

To adjust volume of buttons, scroll using the up & down key.

Note:

Depress F1 key to save changes.

F2 key to cancel changes.

F3 key to restore to factory settings.

2546/2548 T3

47

1108

Page 38

IQAN®

F1 F2 F3

SELECT

ESC

SET YEAR

F1 F2 F3

SELECT

ESC

SET MONTH

F1 F2 F3

LCD LANGUAGE MORE..

ESC

SETTINGS

F1 F2 F3

LCD LANGUAGE MORE..

ESC

F1 F2 F3

SOUND SET CLOCK MORE..

ESC

SETTINGS

F1 F2 F3

LCD LANGUAGE MORE..

ESC

IQAN® DATE/TIME SCREEN

Select more information by depressing the F3 key.

IQAN.4

Depressing the F2 key to set clock.

IQAN.5

IQAN.6

Scroll using the up & down key to display function to change (example: SET YEAR). Depress the F1 key to select function to set (example: SET YEAR displayed on IQAN® screen). Using the up & down key, scroll through years. Depress the F1 key when desired year is displayed on the IQAN® screen.

Scroll using the up & down key to display function to change (example: SET MONTH). Depress the F1 key to select function to set (example: SET MONTH displayed on IQAN® screen). Using the up & down key, scroll through months of the year. Depress the F1 key when desired month is displayed on the IQAN® screen.

2546/2548 T3

IQAN.7

48

1108

Page 39

IQAN®

F1 F2 F3

SELECT

ESC

SET DAY

F1 F2 F3

SELECT

ESC

SET HOUR

F1 F2 F3

SELECT

ESC

SET MINUTE

IQAN® DATE/TIME SCREEN

Scroll using the up & down key to display function to change (example: SET DAY). Depress the F1 key to select function to set (example: SET DAY displayed on IQAN® screen). Using the up & down key, scroll through days of the week. Depress the F1 key when desired day is displayed on the IQAN® screen.

IQAN.8

Scroll using the up & down key to display function to change (example: SET HOUR). Depress the F1 key to select function to set (example: SET HOUR displayed on IQAN® screen). Using the up & down key, scroll through hours of the day. Depress the F1 key when desired hour is displayed on the IQAN® screen.

IQAN.9

IQAN.11

Scroll using the up & down key (E) to display function to change (example: SET MINUTE). Depress the F1 key (F) to select function to set (example: SET MINUTE displayed on IQAN® screen). Using the up & down key (E), scroll through minutes of the hour. Depress the F1 key (F) when desired minute is displayed on the IQAN® screen.

Note: To cancel changes in any of the above listed settings, depress the F2 key (cancel).

2546/2548 T3

49

1108

Page 40

IQAN®

NOTICE

F1 F2 F3

INPUTS OUTPUTS OTHER

ESC

MEASURE

1.01

F1 F2 F3

ESC

Pressure

PSI

RPM

IQAN® MEASURE SCREEN

Measure screen is used to visually monitor the electrical input and output of system components controlled by the IQAN®. An alarm and/or error message will appear on IQAN® screen if input or output is outside parameters required for proper system function.

functions is key to troubleshooting machine.

Depress the ESC key to access the adjustment menus.

Understanding measure

IQAN.1

IQAN.29

Scroll using the up & down key until MEASURE is displayed on the IQAN® screen.

Note: Measureable information includes Votlage inputs (5 volts or less), digital inputs (12 volts), frequency inputs (hertz), direction inputs (5 volts or less), current (milliamps), and digital outputs (12 volts).

2546/2548 T3

410

1108

Page 41

F1 F2 F3

MV SCOPE

ESC

VOLTAGE IN

XP-0 C1:2

Left JS YAX18

+88.4%

F1 F2 F3

MV SCOPE

ESC

VOLTAGE IN

XP-0 C1:2

Left JS YAX18

+88.4%

F1 F2 F3

VOLTAGE DIGITAL FREQUENCY

ESC

MEASURE INPUTS

NOTICE

IQAN®

IQAN® VOLTAGE INPUT MEASURE SCREEN

Depress the F1 key to measure inputs.

IQAN.30

Scroll using the up & down key to select control function to measure. Depress the F1 key to measure control function. IQAN® screen will display:

• control function being measured (A)

• module connected to measured input control function (B)

IQAN.31

• connector and pin number of module (C)

• percent of input to control function (D)

Understanding measure

functions is key to troubleshooting machine.

Depress the F1 key to access measured value in millivolts.

Depress the F3 key to view input in graph format.

Depress ESC key to return to previous screen.

Voltage Inputs (5 volts or less):

Allows operator to measure the status of voltage coming from the components to the computer. These components are:

Door switch

2546/2548 T3

Seat load proximity switch

Steer proximity switch

Main boom proximity switch

Swing limit proximity switch

Hydraulic pressure

Switch transmission lter

411

1108

Page 42

F1 F2 F3

MV SCOPE

ESC

DIGITAL IN

XP-0 C1:1

Arming Switch LOW

F1 F2 F3

MV SCOPE

ESC

DIGITAL IN

XP-0 C1:1

Arming Switch LOW

F1 F2 F3

VOLTAGE DIGITAL FREQUENCY

ESC

MEASURE INPUTS

NOTICE

IQAN®

IQAN® DIGITAL INPUT MEASURE SCREEN

Depress the F1 key to measure inputs.

IQAN.30

Scroll using the up & down key to select control function to measure. Depress the F1 key to measure control function. IQAN® screen will display:

• control function being measured (A)

• module connected to measured input control function (B)

IQAN.32

• connector and pin number of module (C)

• percent of input to control function (D)

Understanding measure

functions is key to troubleshooting machine.

Depress the F1 key to access measured value in millivolts.

Depress the F3 key to view input in graph format.

Depress ESC key to return to previous screen.

IQAN.32

Digital Inputs (12 volts):

Allows operator to measure the status of voltage coming from the components to the computer. These components are:

Switch hydraulic lter

2546/2548 T3

Switch retract (top of left joystick)

Switch extend (top of left joystick)

Switch grapple open (top of right joystick)

Switch grapple close (top of right joystick)

Switch bogie lift (red button on steer joystick)

412

1108

Page 43

F1 F2 F3

MV SCOPE

ESC

FREQUENCY IN

XP-0 C1:6

Engine Speed

890

RPM

F1 F2 F3

VOLTAGE DIGITAL FREQUENCY

ESC

MEASURE INPUTS

F1 F2 F3

MV SCOPE

ESC

FREQUENCY IN

XP-0 C1:6

Engine Speed

890

RPM

NOTICE

IQAN®

IQAN® FREQUENCY INPUT MEASURE SCREEN

Depress the F1 key to measure inputs.

IQAN.30

Scroll using the up & down key to select control function to measure. Depress the F1 key to measure control function. IQAN® screen will display:

• control function being measured (A)

• module connected to measured input control function (B)

IQAN.33

• connector and pin number of module (C)

• RPM (D)

Understanding measure

functions is key to troubleshooting machine.

Depress the F1 key to access measured value in hertz value.

Depress the F3 key to view input in graph format.

Depress ESC key to return to previous screen.

Frequency Inputs (hertz):

Allows operator to measure the status of voltage coming from the components to the computer. These components are:

Engine RPM

2546/2548 T3

413

1108

Page 44

F1 F2 F3

SCOPE

ESC

DIRECTION IN

LX-AO X

JS Left E-W

0.0

F1 F2 F3

VOLTAGE DIGITAL FREQUENCY

ESC

MEASURE INPUTS

NOTICE

F1 F2 F3

SCOPE

ESC

DIRECTION IN

LX-AO X

JS Left E-W

0.0

IQAN®

IQAN® DIRECTION INPUT MEASURE SCREEN

Depress the F1 key to measure inputs.

IQAN.30

Scroll using the up & down key to select control function to measure. Depress the F1 key to measure control function. IQAN® screen will display:

• control function being measured (A)

• module connected to measured input control function (B)

IQAN.53

• connector and pin number of module (C)

• percent of input to control function (D)

Understanding measure

functions is key to troubleshooting machine.

Depress the F3 key to view input in graph format.

Depress ESC key to return to previous screen.

Direction Inputs (5 volts or less):

Allows operator to measure the status of voltage coming from the components to the computer. These components are:

Right joystick

North-South (N-S)

East-West (E-W)

2546/2548 T3

Left joystick

North-South (N-S)

East-West (E-W)

Steer joystick

414

1108

Page 45

F1 F2 F3

SCOPE

ESC

CURRENT OUT

XP-0 C1:8

Steering

0.0ma

F1 F2 F3

INPUTS OUTPUTS OTHER

ESC

MEASURE

1.01

NOTICE

F1 F2 F3

SCOPE

ESC

CURRENT OUT

XP-0 C1:8

Steering

0.0ma

IQAN®

IQAN® CURRENT OUTPUT MEASURE SCREEN

Depress the F2 key to measure outputs.

IQAN.29

Scroll using the up & down key to select control function to measure. Depress the F1 key to measure control function. IQAN® screen will display:

• control function being measured (A)

• module connected to measured output control function (B)

IQAN.42

• connector number of module (C)

• Current output in milliamps (D)

Understanding measure

functions is key to troubleshooting machine.

Depress the F3 key to view output in graph format.

Depress ESC key to return to previous screen.

Current Outputs (milliamps):

Allows operator to measure the status of current from IQAN® system to hydraulic valve solenoids. These components are:

Blade

Down

Left joystick

2546/2548 T3

North-South (N-S)

East-West (E-W)

Right joystick

North-South (N-S)

East-West (E-W)

Steer joystick

Steering

Steering forward

415

1108

Page 46

F1 F2 F3

SCOPE

ESC

DIGITAL OUT

XP-0 C1:18

Grapple Open

LOW

F1 F2 F3

INPUTS OUTPUTS OTHER

ESC

MEASURE

1.01

NOTICE

F1 F2 F3

SCOPE

ESC

DIGITAL OUT

XP-0 C1:18

Grapple Open

LOW

IQAN®

IQAN® DIGITAL OUTPUT MEASURE SCREEN

Depress the F2 key to measure outputs.

IQAN.29

Scroll using the up & down key to select control function to measure. Depress the F1 key to measure control function. IQAN® screen will display:

• control function being measured (A)

• module connected to measured output control function (B)

• connector and pin number of module (C)

IQAN.36

• percent of output to control function (D)

IQAN.36

Understanding measure

functions is key to troubleshooting machine.

Depress the F3 key to view output in graph format.

Depress ESC key to return to previous screen.

Digital Outputs (12 volts):

Allows operator to measure the status of current from IQAN® system to hydraulic valve solenoids, transmission shift & blade functions. These components are:

Axle

Bogie up

Blade

Down

Boom

Extend

2546/2548 T3

Retract

Clam

Open

416

Grapple

Open

1108

Page 47

IQAN®

F1 F2 F3

ESC

OK CANCEL

SELECT MODE

F1 F2 F3

ESC

Pressure

PSI

RPM

F1 F2 F3

ESC

SELECT COPY RESET

MODE

F1 F2 F3

ESC

SELECT COPY RESET

MODE

NOTICE

F1 F2 F3

ESC

OK CANCEL

SELECT MODE

IQAN® MODE SCREEN

Depress the ESC key to access the adjustment menus.

IQAN.44

Scroll using the up & down key until MODE is displayed on the Iqan® screen.

IQAN.12

IQAN.46

Depress the F1 key to select operator mode adjustment .

Scroll using the up & down key to select operator mode.

Depress the F1 key to select desired operator mode (A) displayed on Iqan® screen (1-4).

2546/2548 T3

After selection of operator mode, IQAN® will automatically return to main menu.

Operator’s are able to set

IQAN.46

parameters to meet each operator’s specic preferences. The IQAN® can store up to 3 dierent operator modes (with mode 4 being the factory default).

417

1108

Page 48

F1 F2 F3

ESC

SELECT COPY RESET

MODE

NOTICE

F1 F2 F3

ESC

OK CANCEL

COPY FROM MODE

F1 F2 F3

ESC

COPYING..........

IQAN®

IQAN® COPY MODE SCREEN

Depress the F2 key when desired operator mode to program (A) is displayed on IQAN® screen (1-4) .

conditions, primary operator has set optimal parameters in operator mode 1, this mode can be copied and altered to second and third operator parameters. Operator mode 4 is factory default and can not be altered.

IQAN.12

Example: Operator mode 1 is being dened on screen. Select F2 key to copy parameters to operator mode 1.

Scroll using the up & down key to select desired operator mode to copy (B) is displayed on IQAN® screen (1-4) . Depress the F1 key to select copy function. Select F2 key to cancel.

Under normal operating

Example: Operator mode 1 is being dened on screen. Parameters from operator mode 4 will be copied to operator mode 1.

IQAN.13

After selection of mode to copy, copying screen will be displayed on IQAN® screen until function is complete. Operator will be returned to main mode screen after copy function is complete.

IQAN.14

2546/2548 T3

418

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Page 49

F1 F2 F3

ESC

SELECT COPY RESET

MODE

NOTICE

F1 F2 F3

ESC

OK CANCEL

CONFIRM RESET

F1 F2 F3

ESC

RESETTING......

IQAN®

IQAN® RESET MODE SCREEN

Depress the F3 key (A) when operator mode (B) to be reset is displayed on IQAN® screen (1-3) .

Operator modes 1-3 are able to be reset. Reset function will automatically reset selected operator mode to operator mode 4, factory default.

IQAN.12

IQAN® screen will ask to verify that you would like to reset . Depress F1 key to continue, F2 key to cancel and return to mode screen.

IQAN.15

After selection of mode to reset, resetting screen will be displayed on IQAN® screen until function is complete. Operator will be returned to main mode screen after reset function is complete.

2546/2548 T3

419

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Page 50

IQAN®

F1 F2 F3

ESC

Pressure

PSI

RPM

F1 F2 F3

ESC

APPLIC MODULES

INFORMATION

F1 F2 F3

ESC

050405 08:52:32 0000001FD838 Fabtek/Engineering

F1 F2 F3

ESC

050405 08:52:32 0000001FD838 Fabtek/Engineering

F1 F2 F3

ESC

500 Series LH Boom 03.71

More... Comment

IQAN® INFORMATION SCREEN

Depress the ESC key to access the adjustment menus. Scroll using the up & down key until INFORMATION is displayed on the IQAN® screen.

IQAN.44

Depress the F1 key to view basic information about the operating application.

IQAN.17

Depress the F1 key to view detailed information about the operating application.

IQAN.47

IQAN® screen will display date (A) and time of most recent update, program identication information (B) and key identication (C) of person/company performing update.

IQAN.18

2546/2548 T3

Depress ESC key to return to basic information screen.

Note: Depress ESC key again to return to main screen.

IQAN.18

420

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Page 51

IQAN®

F1 F2 F3

ESC

APPLIC MODULES

INFORMATION

F1 F2 F3

ESC

4 Operators Mode Swing Pressure

F1 F2 F3

ESC

APPLIC MODULES

INFORMATION

IQAN® INFORMATION SCREEN

Depress the F2 key to view information about the operating comments.

IQAN.17

4 operators mode swing pressure (A) will display on

IQAN.48

screen.

IQAN.17

Depress ESC to return to basic information screen.

Note: Depress ESC key again to return to main screen.

2546/2548 T3

421

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Page 52

IQAN®

F1 F2 F3

ESC

APPLIC MODULES

INFORMATION

F1 F2 F3

ESC

STATUS INFO SW INFO HW

Module: MDM

F1 F2 F3

ESC

INTERNAL

Module: MDM

Status: ENABLED

F1 F2 F3

ESC

INTERNAL

Module: MDM

Status: ENABLED

F1 F2 F3

ESC

Module: MDM

VBat : 11.9 Temp : 44.2 Util : 24.0

IQAN® INFORMATION SCREEN

Depress the F2 key to view information about the operating modules.

IQAN.17

Using the up & down key scroll through modules to be selected (MDM).

Note:

Modules information is available on are:

MDM

Lx-A2

IQAN.19

IQAN.49

LX-A1

LX-A0

XP-A0

Depress F1 to view status of module displayed on IQAN® screen (enabled/disabled) (MDM).

Note: Depress the ESC key to return to main module screen.

Depress F2 to view internal information of module displayed on IQAN® screen (MDM).

2546/2548 T3

IQAN.49

Display will provide detailed information about the battery voltage, temperature and utility pressure (A).

IQAN.50

Note: Depress the ESC key to return to main module screen.

422

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Page 53

IQAN®

F1 F2 F3

ESC

Module: MDM

HWVer : 01.39 HW Ser : 02445 Hours : 50

PDate : 010705

F1 F2 F3

ESC

STATUS INFO SW INFO HW

Module: MDM

F1 F2 F3

ESC

Module: MDM

SWVer : 03.71 SWCheck : 8F75 IDPVer : 06.02

SWEAN : 58010

F1 F2 F3

ESC

STATUS INFO SW INFO HW

Module: MDM

IQAN® INFORMATION SCREEN

Depress the F2 key to view detailed software information about the operating module selected (MDM).

Note:

Modules for which information is available are:

MDM

Lx-A2

IQAN.19

LX-A1

LX-A0

XP-A0

Display will provide software version, check, EAN and IDP version (A).

IQAN.51

IQAN.19

Note: Depress the ESC key to return to main module screen.

Depress the F3 key to view detailed hardware information about the operating module selected (MDM).

Note:

Modules for which information is available are:

MDM

Lx-A2

LX-A1

LX-A0

XP-A0

2546/2548 T3

Display will provide detailed information about the hardware version, serial number, Pdate and hours (B).

Note: Depress the ESC key to return to main module screen. Depress the ESC key again to return to main information screen.

IQAN.52

423

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Page 54

IQAN®

F1 F2 F3

OUTPUTS

ESC

PROPERTIES

F1 F2 F3

OUTPUTS

ESC

PROPERTIES

F1 F2 F3

ESC

Pressure

PSI

RPM

NOTICE

F1 F2 F3

SELECT (+) SELECT (-)

AUTO

ESC

SELECT FUNCTION

Right N-S

IQAN® PROPERTIES SCREEN

Depress the ESC key o access the adjustment menus.

IQAN.44

Scroll using the up & down key until PROPERTIES is displayed on the Iqan® screen.

IQAN.37

Depress the F2 key to read and/or adjust property outputs.

Depress F1 key to increase (+) current.

Depress F2 key to decrease (-) current.

Depress F3 key to set current by usage (auto).

2546/2548 T3

Setting control function automatically (F3) will set function to perform in manner joystick is moved with auto selected.

IQAN.39

424

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Page 55

IQAN®

IQAN® PROPERTIES SCREEN

Depress the F3 key to select other parameters.

Scroll using the up & down key until FUNC. PARAM is displayed on the Iqan® screen.

Depress the F1 key to display function settings.

2546/2548 T3

425

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Page 56

IQAN®

IQAN® PROPERTIES SCREEN

Scroll using the up & down key to select between Joystick Select and Steering Mode displayed on the Iqan® screen. Depress F1 to select function.

Scroll using the up & down key to select between Joystick 1.0 (Forestry Mode) and Joystick 2.0 (SAE Mode) displayed on the Iqan® screen. Depress F1 to select mode. Depress F2 to cancel. Depress F3 to reset.

Scroll using the up & down key to select between Steering 1.0 (Standard Mode) and Steering 2.0 (Optional Mode) displayed on the Iqan® screen. Depress F1 to select mode. Depress F2 to cancel. Depress F3 to reset.

2546/2548 T3

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Page 57

CONTROLS AND INSTRUMENTS

OPERATOR’S STATION

14a, 14b

105.08

2546/2548 T3

1. Throttle Pedal (rear facing)

2. Throttle Pedal (front facing)

3. Brake Pedal (rear facing)

4. Brake Pedal (front facing)

5. Foot Shift Pedal

6. Throttle Lock Pedal

7. Throttle Lock Release

8. Climate Control

9. Transmission Control/Side Panel

10. Rear Console

11. Front Console

12. Steering Joystick

13. Boom Control Joystick (rear facing)

14a. Boom Control Joystick (rear facing)

14b. Blade control Joystick (forward facing)

15. Arm Rest Console

16. Stereo

17. Dome Light

18. IQAN®

19. Gauge Panel

51

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Page 58

CONTROLS AND INSTRUMENTS

GAUGE CLUSTER ASSEMBLY

106.08

1. Wiper Switches

2. Light Switch

3. Transmission Temperature Gauge

4. Tachometer/Hourmeter

5. Hydraulic Temperature Gauge

6. Warning Indicator Panel

7. Oil Pressure Gauge

8. Cooling Temperature Gauge

9. Fuel Level Gauge

2546/2548 T3

52

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Page 59

CONTROLS AND INSTRUMENTS

WARNING INDICATOR PANEL

1. Park Brake Icon - Red Indicator

2. Frame Lock Icon - Green Indicator

3. Hydraulic Oil Temperature Icon - Red Indicator

4. Wait To Start Icon - Yellow Indicator

5. Engine Urgent Stop Icon - Red Indicator

6. Dierential Lock Icon - Green Indicator

7. Brake System Pressure Icon - Red Indicator

8. Hydraulic Oil Level Icon - Red Indicator

9. Engine Intake Filter Icon - Yellow Indicator

10. Engine Failure Warining Icon - Yellow Indicator

When the indicator illuminates, shut engine down and contact an authorized dealer.

2546/2548 T3

53

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Page 60

CONTROLS AND INSTRUMENTS

LEFT SIDE CONSOLE

1. Steering Joystick

2. Foot Shift Activation Switch

3. Load Sense Dump Switch

109.08

2546/2548 T3

54

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Page 61

CONTROLS AND INSTRUMENTS

RIGHT SIDE CONSOLE

1. Dierential Lock Switch

2. Frame Lock Switch

3. Park Brake Switch

4. Blade Control Switch (rear facing)

5. Horn Switch

6. Blade Float Switch (forward & rear facing)

108.05

2546/2548 T3

REAR CONSOLE

1. IQAN® Display

55

107.08

1108

Page 62

CONTROLS AND INSTRUMENTS

SATELLITE RADIO

0108 SAT

1. Eject Button - Ejects CD

2. Band Button - Switches between AM, FM1, FM2, FM 3, SAT1, SAT2, WX and Auxilary modes

3. Time Set/Display Button - Switches to time set mode/changes display

4. Power Button - Powers radio on and o

5.On/Audio Knob - Power/volume/receiver settings

6. +Tune/Seek- Button - Changes radio station or CD/MP3 track.

7. 1-6 Buttons - Selects preset stations/CD/CP3 functions

8. Pre-set Scon/Auto Button - Scans presets on current band/stores strangest stations to pre-set

9. Scan/Dim Button - Scans all stations in current band or on CD/MP3

10. Alarm Button - Selects alarm set mode

11. Random Button - Plays CD/MP3 tracks roandomly

12. CD Button - Switches to CD/MP3 mode

13. Foler +/- Buttons - Changes folders on MP3

1 9

2546/2548 T3

Refer to radio operator’s manual to program key/button functions.

56

1108

Page 63

CONTROLS AND INSTRUMENTS

BLADE CONTROL

Do not use blade for ex-

cavating, paving or removing stumps. Doing so can

result in machine damage.

FRONT BLADE FACING CONTROLS:

1. Raise blade by pulling blade joystick (A) back.

2. Lower blade by pushing blade joystick (A) forward.

REAR BOOM FACING CONTROLS:

1. Raise blade by depressing blade control switch

(B).

2. Lower blade by depressing blade control switch

(C).

BLADE FLOAT BLADE & BOOM FACING CONTROLS OPTION:

1. Select blade oat option by depressing blade

oat switch (D).

2546/2548 T3

57

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Page 64

CONTROLS AND INSTRUMENTS

AXLE DIFFERENTIAL LOCK

The dierential lock locks out the dierential. This prevents the usual loss of traction when one wheel is slipping.

When using switch on side console:

1. Shift transmission to neutral.

2. Depress switch (A) on side console.

3. Dierential lock indicator (green indicator) will illuminate when axle is locked.

light on gauge panel (b)

Lock the axles ONLY in low traction conditions. Axle damage can result if dierential is operated in the locked mode all of the time.

4. Release switch on control panel to unlock dierential lock.

0108 GAUGE PANEL

2546/2548 T3

58

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Page 65

CONTROLS AND INSTRUMENTS

BATTERY DISCONNECT MASTER SWITCHES

The battery disconnect master switches (A & B) are located in the LH engine compartment, and are

DCSF2399

designed to prevent accidental starting of the engine while servicing machine, prevent accidental battery drain, and to deter vandalism.

Turn primary battery disconnect master switch (A) OFF to disconnect the electrical system.

Turn secondary battery disconnect master switch (B) OFF to disconnect the Pro-heat system.

Do not turn either master disconnect switch o while engine is running. Doing so will cause loss of electrical power, resulting in personal injury or property damage.

Turn primary battery disconnect master switch (A) ON to connect the main electrical system.

Turn secondary battery disconnect master switch (B) ON to connect the Pro-heat electrical system.

There needs to be a minimum 30 second delay between when the engine is shut down and when the battery disconnect master is shut o to allow the ECU to store information. If this is not done, some of the historical operating parameter information will not be properly stored, and fault codes will be generated.

Pro-Heat option is functional with main battery master disconnect switch in OFF position.

2546/2548 T3

59

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Page 66

CONTROLS AND INSTRUMENTS

BRAKE LOW PRESSURE INDICATOR

with out brake pressure can cause serious personal injury or death.

Low brake pressure indicator on gauge panel (red indi-

0108 GAUGE PANEL

cator) (A) will illuminate if brake pressure is lost.

Do not operate machine with brake low pressure indicator illuminated.

Indicator will shut o when brake pressure is at specied level.

will discharge with each depression of the brake pedal. After 5 depressions light brake pressure is still available. After 8 depressions no brake pressure is available.

Operating forwarder

Brake pressure accumulator

CAB TILT CONTROL

NEVER get under a tilted cab UNLESS cab is completely tilted and locked into position. If a hydraulic hose or component failure occurs, cab could accidentally lower unexpectedly and

cause serious personal injury.

2546/2548 T3

Move hydraulic pump control lever (B) to raise or lower cab.

For more information on cab tilt procedures, see Operation section.

52413

510

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Page 67

CONTROLS AND INSTRUMENTS

CLIMATE CONTROLS

CONTROL KNOBS

A. Fan speed.

B. Temperature control.

0108 TRANS CON SOLE

C. Knob turned clockwise selects outside air, air conditioning or heat.

EMERGENCY EXITS

Debris such as limbs and branches coming through window openings can cause severe personal injury or death. Never operate forwarder without Tuax ® window locked in place.

USING SIDE WINDOW EXITS

1. Loosen window knobs until loosened.

2. Push on window until window falls out.

2546/2548 T3

0108 WINDOW E XIT

511

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Page 68

CONTROLS AND INSTRUMENTS

ENGINE OIL PRESSURE GAUGE

If NO oil pressure is indicated in 10 to 15 seconds at start-up, stop engine and check the lubricating oil system.

CATERPILLAR ENGINE Minimum engine oil pressure (A) is 10 psi (69 kPa) at idle. The minimum oil pressure at normal operating speed is 30 psi (207 kPa).

Engine operating temperature and oil viscosity will aect oil pressure readings.

0108 GAUGE PANEL

Oil pressure DOES NOT

guarantee there is a sucient amount of oil in the engine oil pan. Check engine oil level by observing the level on the dipstick.

ENGINE TEMPERATURE GAUGE

The engine temperature gauge (B) monitors the engine coolant temperature.

Normal engine coolant operating temperature is 190210°F (88-99°C).

If operating above mormal operating temperature, check radiator and oil cooler ns for debris or damage. For maximum air ow, keep area in front of the radiator clean.

0108 GAUGE PANEL

2546/2548 T3

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Page 69

CONTROLS AND INSTRUMENTS

FRAME LOCK SWITCH

The frame lock switch (A) locks the cylinder on the oscillation joint and stops the frame from oscillating.

With frame lock switch in “on” position, frame lock is automatically activated and Frame Lock icon will iluminate (green indicator) when transmission is placed in neutral.

When the foot shifter is activated, the frame lock is engaged. See transmission console and travel pedals within this section.

Frame lock should be kept “on” under normal operating conditions. If necessary to oscillate when in neutral, Frame Lock Switch can be turned o.

FUEL INDICATOR

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

The fuel gauge (B) shows the level of fuel in the fuel tank. The fuel tank capacity is 46 gallons (181 L).

Do not allow a diesel engine

2546/2548 T3

0108 GAUGE PANEL

513

1108

Page 70

CONTROLS AND INSTRUMENTS

FUSE AND RELAY PANEL

Wiring circuits are protected from short circuits by fuses. The fuse/relay panels are located in the front dash panel (A) and the LH engine compartment.

Fuses protect electrical circuits from current overload. This greatly reduces the chance of res caused by electrical problems.

To replace the fuse, make sure to have same amperage rating, gently remove fuse and replace by sliding replacement fuse into place.

524.47

amperage rating to replace “blown” fuses. Doing so can cause electrical res. Diagnose and correct the problem that caused the fuse to “blow”.

0108 ELEC ACC ESS

HOURMETER

The hourmeter (B) registers in full hours and tenths of hours.

Do not use fuses of higher

2546/2548 T3

0108 GAUGE PANEL

514

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Page 71

CONTROLS AND INSTRUMENTS

HYDRAULIC OIL TEMPERATURE INDICATOR

Possible pump or hydraulic system damage can occur if opperating for an extended period of time above 190° F (88° C).

Normal hydraulic operating temperature is 145° F to 185° F (63°C to 85°C) (A). If temperature on hydraulic oil gauge (A) exceeds

190° F (88°C) an alarm will sound. Shut engine down immediately and check for plugged oil cooler.

0108 GAUGE PANEL

HYDRAULIC OIL LOW LEVEL INDICATOR

Possible pump or hydraulic system damage can occur if operating with low hydraulic oil level.

The low hydraulic oil indicator (A) will illuminate (red indicator) if oil level drops below “add oil “ level on hydraulic oil level indicator (B).

Do not operate machine with hydraulic oil level below “add oil” indicator.

2546/2548 T3

146.05

515

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Page 72

CONTROLS AND INSTRUMENTS

HYDRAULIC RESERVOIR SIGHT GAUGE

The hydraulic reservoir sight gauge is located in the LH engine compartment.

Do not overll or operate machine with hydrualic oil level above level indicated (A).

Do not operate machine with hydraulic oil level below add oil indicator (B).

146.05

IGNITION SWITCH

Parking brake must be en-

gaged before engine will start.

Shut door.

Turn key in ignition switch (A) clockwise to start machine. Release key when engine starts.

Turn key OFF to shut engine down.

When key is in IGN position, electrical components

have power.

When leaving machine, be sure ignition switch is in OFF position, and remove key. Doing so will prevent drain on battery.

IQAN®

The IQAN® (A) system is a computer-based control system that delivers precision control through the valving system. IQAN®’s menus control machine function and aid in troubleshooting.

2546/2548 T3

0108 REAR CON SOLE

516

1108

Page 73

CONTROLS AND INSTRUMENTS

JOYSTICK FUNCTIONS  FORWARD BLADE FACING

Left Hand Joystick Right Hand Joystick

BLADE DOWN

Steering Left Hand Joystick

MACHINE

LEFT

LEFT HAND JOYSTICK

This joystick is disabled when seat is in forward (blade) facing direction.

STEERING LEFT HAND JOYSTICK

Turn Machine Left - Move joystick left.

BLADE UP

MACHINE

RIGHT

RIGHT HAND JOYSTICK

Blade Down - Push joystick forward.

Blade Up - Pull joystick back.

Neutral - When released, joystick returns to neutral (center) position.

Turn Machine Right - Move joystick right.

2546/2548 T3

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Page 74

CONTROLS AND INSTRUMENTS

NOTICE

WARNING

FORESTRY  JOYSTICK FUNCTIONS  REAR BOOM FACING

Left Hand Joystick Right Hand Joystick

MACHINE

LEFT

LEFT HAND JOYSTICK

Main Boom Down - Push joystick forward.

Main Boom Up - Pull joystick back.

Swing CCW- Move joystick left to swing upper structure left.

Swing CW - Move joystick right to swing upper structure right.

Neutral - When released, joystick returns to neutral (center) position.

STEERING LEFT HAND JOYSTICK

Turn Machine Left - Move joystick left.

Turn Machine Right - Move joystick right.

MACHINE

RIGHT

RIGHT HAND JOYSTICK

Stick Boom Down - Push joystick forward.

Stick Boom Up - Pull joystick back.

Grapple Clockwise - Move joystick left.

Grapple Counterclockwise - Move joystick right.

Neutral - When released, joystick returns to neutral (center) position.

Recommended RPM while

utilizing boom functions is 1400-1600 RPM.

DO NOT exceed 1800

RPM while utilizing boom functions. If boom is operated at excessive RPM level, machine system damage, severe personal injury or death could occur.

2546/2548 T3

518

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Page 75

CONTROLS AND INSTRUMENTS

NOTICE

WARNING

SAE  JOYSTICK FUNCTIONS  REAR BOOM FACING

Left Hand Joystick Right Hand Joystick

MACHINE

LEFT

LEFT HAND JOYSTICK

Stick Boom Down - Push joystick forward.

Stick Boom Up - Pull joystick back.

Swing CCW- Move joystick left to swing upper structure left.

Swing CW - Move joystick right to swing upper structure right.

Neutral - When released, joystick returns to neutral (center) position.

STEERING LEFT HAND JOYSTICK

Turn Machine Left - Move joystick left.

Turn Machine Right - Move joystick right.

MACHINE

RIGHT

RIGHT HAND JOYSTICK

Main Boom Down - Push joystick forward.

Main Boom Up - Pull joystick back.

Grapple Clockwise - Move joystick left.

Grapple Counterclockwise - Move joystick right.

Neutral - When released, joystick returns to neutral (center) position.

Recommended RPM while

utilizing boom functions is 1400-1600 RPM.

DO NOT exceed 1800

RPM while utilizing boom functions. If boom is operated at excessive RPM level, machine system damage, severe personal injury or death could occur.

2546/2548 T3

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CONTROLS AND INSTRUMENTS

LOAD SENSE DUMP SWITCH

1. Depress load sense dump switch (A), located on the LH side console of the seat, to prevent pressure from building in the main hydraulic pump.

Load sense dump switch should only be used under cold weather warm up operation. Refer to cold weather start, Operation Section.

2546/2548 T3

520

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Page 77

CONTROLS AND INSTRUMENTS

OPERATING LIGHTS SWITCHES

OPERATING LIGHTS

Depress switches to activate desired work light lamps.

A - Drive lamps

B - Load Lamps

0108 GAUGE PANEL

A - Drive lamps

127.05

A - Drive lamps

168.05

B - Load Lamps

2546/2548 T3

169.05

521

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Page 78

CONTROLS AND INSTRUMENTS

OPERATING LIGHTS SWITCHES

B - Load Lamps

524.45

DOME LIGHT

Depress front of lens (C) to turn dome light on.

Depress rear of lens (C) to turn dome light o.

0108 DOME

2546/2548 T3

522

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Page 79

CONTROLS AND INSTRUMENTS

OPERATOR’S SEAT

Adjust operator’s seat using the following instructions.

SEAT WEIGHT ADJUSTMENT

While seated, adjust seat using the + - adjuster lever (A - on LH of seat) until indicator tongue (B - on RH of seat) is paralell with seat back.

524158

52462

BACK REST ANGLE ADJUSTMENT

While seated with back rmly against back rest, depress lever (C) on either side of seat to adjust angle of back rest.

524158

2546/2548 T3

523

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Page 80

CONTROLS AND INSTRUMENTS

OPERATOR’S SEAT

FRONT AND REAR ADJUSTMENT

While seated, move lever (A) inward and move seat forward or backward to required position and release.

52457

SEAT CUSHION ADJUSTMENT

To adjust the front of seat cushion, pull latch (B) upwards and lift into one of four settings.

To adjust the rear of seat cushion, push on seat cushion and set into one of three settings (notches) provided.

52457

SEAT DIRECTION ADJUSTMENT

To turn seat forward (blade) and backward (boom), depress lever (C).

While seated, turn seat to desired position.

Seat will lock into place.

2546/2548 T3

52457

524

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Page 81

CONTROLS AND INSTRUMENTS

PARK BRAKE

pelled with Park Brake switch on, your system has failed. Shut down machine and contact your authorized representative.

1. Depress top of park brake switch (A) to activate (set) park brake.

2. Verify that park brake indicator is illuminated.

3. Depress bottom of park brake switch to deactivate (release) park brake (A).

If machine can be pro-

Come to a complete stop

before applying park brake.

With park brake switch in “on” position, park brakes will be applied as the machine comes to a stop.

With park brake switch in “o” position, park brakes will not apply while engine is running.

Park brake switch should be

left in the “on” position while operating loader functions.

Turn park brake switch to “o” position when not utilizing loader functions.

POWER OUTLETS

Two 12 volt, 15 amp power outlets (A) are provided for electrically powered accessories.

2546/2548 T3

0108 TRANS CON TROL

To protect batteries against accidental discharge, outlets provide power only when key switch is turned to IGN or ACC.

525

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Page 82

CONTROLS AND INSTRUMENTS

SEAT BELT

can cause severe personal injury or death.

To reduce the risk of personal injury resulting from a roll over or sudden stop, always wear a seat belt fastened snugly when operating this machine.

This machine can change directions rapidly. It can start and stop quickly. See Operation section, for instructions on properly using the seat belt.

To fasten seat belt, adjust operator’s seat to a comfortable position. Adjust the belt so that it ts snugly.

A roll over or sudden stop

SEAT PROXIMITY SWITCH

locked in either forward (blade) facing position or rear (boom) facing position. All controls will be disabled if seat is not locked into position.

Lock operator’s seat into either forward (blade) or rear (boom) facing position.

524.63

Operator’s seat must be

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CONTROLS AND INSTRUMENTS

STEERING DEFAULT 

When facing forward (blade) or facing rear (boom):

1. With machine in motion, it can be steered by

moving the steering joystick (A) in the direction desired.

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CONTROLS AND INSTRUMENTS

STEERING OPTIONAL 

The optional steering can

be selected throught the Iqan program. Refer to the Iqan section in this manual.

When facing forward (blade):

1. With machine in motion, it can be steered by moving the main joystick (A) in the direction desired.

When facing rear (boom):

2. With machine in motion, it can be steered by moving the steering joystick (B) in the direction desired.

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CONTROLS AND INSTRUMENTS

STEERING LOCK

Steering lock must be in use BEFORE performing service. Failure to use steering lock could result in unexpected movement of the forwarder. If steering is activated with

a person in center hinge “crush point” area, severe personal injury or death could occur.

INSTALLING LOCK

1. Remove locking clip (A).

2. Remove steering lock pin from storage location

0108

(B).

3. Align front and rear frame. Place pin through hole

(C).

524.08

REMOVING LOCK

Be sure to place steering lock

pin in storage location before driving forwarder.

1. Remove locking pin from hole (D) in front and

rear frame.

2546/2548 T3

2. Place in storage location. Secure with locking clip.

180.05

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CONTROLS AND INSTRUMENTS

TACHOMETER

The tachometer (A) registers the engine speed in hundreds of revolutions per minute (RPM). This is displayed through a gauge (A) in the forward (blade) facing position and through the IQAN® (B) in the rear (boom) facing position.

0108 GAUGE PANEL

IQAN.44

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CONTROLS AND INSTRUMENTS

THROTTLE

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

Low idle rpm 1000 Full load governed rpm 2700

0108 FRONT

075.05

There are two throttle pedals on the forwarder, one in the front (blade) facing position and one in the rear (boom) facing position.

INCREASING ENGINE SPEED

Depress the throttle pedal (A) to increase engine speed. With seat in rear facing (boom) position, the throttle lock (B) can be depressed, locking throttle at desired engine speed.

DECREASING ENGINE SPEED

WHEN FACING FORWARD BLADE:

Remove pressure from throttle pedal to decrease engine speed.

WHEN FACING REAR BOOM:

Remove pressure from throttle pedal to decrease engine speed.

If throttle lock (B) is engaged, depress throttle lock release (C) and remove pressure from throttle pedal to decrease engine speed.

2546/2548 T3

When seat is in rear facing position (boom), there is a throttle lock available. Verify that throttle lock is disengaged before rotating seat to front facing (blade) position.

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CONTROLS AND INSTRUMENTS

TRANSMISSION CONTROLS

The transmission console has a bump shift lever (A) to allow changing of gears. The switch (B) to arm the foot shift pedal.

When the foot shift switch is armed, the bump shift transmission control is disarmed.

WHEN OPERATOR’S SEAT IS LOCKED IN FRONT BLADE FACING POSITION:

The transmission is shifted into forward by pushing bump shift lever (A) forward. The transmission is shifted into reverse by moving bump shift lever backward.

The transmission is shifted to higher gears by moving the shift lever in the direction of the rabbit (B).

The transmission is shifted to lower gears by moving the shift lever in the direction of the turtle (C).

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CONTROLS AND INSTRUMENTS

WHEN OPERATOR’S SEAT IS LOCKED IN REAR BOOM FACING POSITION:

The transmission is shifted to higher gears by the shift lever in the direction of the rabbit (D).

The transmission is shifted to lower gears by shift lever in the direction of the turtle (E).

Apply parking brake before arming foot shifter switch.

armed, the bump shift transmission control is disarmed.

When operator’s seat is locked in rear (boom) facing position with foot shift activation switch (F) armed (depressed):

The transmission is shifted into low forward gear by applying pressure to the heel end of the foot shift pedal (G).

The transmission is shifted into low reverse gear by applying pressure to the toe end of the foot shift pedal (H).

075.05

armed, transmission can only be shifted into low gears.

When the foot shift switch is

When foot shift pedal is

moving

the

TRANSMISSION DISPLAY PANEL

The transmission display panel (A) displays which gear the transmission is in and provides diagnostic codes for troubleshooting.

0108 TRANS CON TROL

TRANSMISSION OIL TEMPERATURE GAUGE

Possible transmission system damage can occur if operating for an extended period of time above 250° F (116°C).

Transmission oil temperature gauge displays Normal hydraulic operating temperature is 200°F (116°C).

2546/2548 T3

0108 GAUGE PANEL

The transmission oil temperature gauge (A) monitors the transmission oil temperature.

Normal transmission oil operating temperature is 200°F (116°C). If the transmission temperature gauge exceeds 240°F (116°C) an alarm will sound.

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CONTROLS AND INSTRUMENTS

PEDALS

WHEN FACING FORWARD BLADE:

Left pedal - controls the brake.

Right pedal - controls the throttle function.

A. Left Pedal

B. Right Pedal

Brake operation - Push toe end of left pedall (A) down.

Machine will slow, coming to complete stop.

Increase engine speed - Push toe end of right (throttle)

pedal (B) down. Engine speed will increase.

0108 FRONT

Decrease engine speed - Remove pressure from

throttle pedal to decrease engine speed.

When seat is in rear facing position, the throttle lock is available. Verify that throttle lock is disengaged before rotating seat to front facing position.

WHEN FACING REAR BOOM:

Left pedal - controls the foot shifting function.

Center pedal - controls the brake.

Right pedal - controls the throttle function.

Throttle lock pedal - locks the throttle postiion.

A. Left Pedal

B. Center Pedal

C. Right Pedal

D. Throttle Lock Pedal

PEDAL OPERATION

2546/2548 T3

Reverse travel (with foot shift switch armed) - Push toe

end of left pedal (A) down. Machine will travel in reverse (blade direction) in low gear.

Forward travel (with foot shift switch armed) - Push

heel end of left pedal (A) down. Machine will travel forward (boom direction) in low gear.

Brake operation - Push toe end of center pedal (B)

down. Machine will slow, coming to complete stop.

Increase engine speed - Push toe end of right pedal (C)

down. Engine speed will increase.

Decrease engine speed - Remove pressure from

throttle pedal to decrease engine speed.

Throttle lock -Push toe end of throttle lock pedal (D)

down simultaneously with throttle pedal. Will hold desired engine speed.

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CONTROLS AND INSTRUMENTS

WINDSHIELD WIPER

Operating windshield wipers

on a dry window will scratch the window.

Turn wiper switch (A) to activate wiper at low or high speed.

The wiper blade will return to its stored location when switch is in the OFF position.

0108 GAUGE PANEL

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CONTROLS AND INSTRUMENTS

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PRESTART INSPECTION

WARNING

NOTICE

PRESTART INSPECTION

Do not use this machine until you read, study and understand this manual and 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 machine could result in machine damage and severe personal injury.

Inspector’s Initials

Machine Serial NumberDate of Inspection

PRESTART CHECKS: ON THE GROUND

Check fuel level; add fuel if necessary.

Check engine oil level; add engine oil if necessary.

Check radiator coolant level. Add proper coolant mixture if necessary. Clean radiator of debris.

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

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 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.

Check that battery disconnect switches are on.

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

Check for ice, snow, oil, grease and debris on steps and walkways. Clear away ice, snow, oil, grease or debris to prevent slips and falls.

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

Check hydraulic oil reservoir level. Add hydraulic oil to reservoir if necessary.

Check for combustible or ammable materials. Remove them from machine if found.

Check mounting hardware for tightness.

Check that machine will not be near electrical wires. See Operation section, for more information.

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

Check that all lights are in working order.

Check electrical system for worn or frayed wires and loose connections. Repair or replace if necessary.

2546/2548 T3

Pages in this section may be copied. Check o each inspection item before operat-

ing machine. File the copy as a record of inspection as required by OSHA or local governing body.

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PRESTART INSPECTION

NOTICE

WARNING

PRESTART CHECKS: IN THE CAB

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.

Inspector’s Initials

Check that there is no mud or debris on cab oor.

Check for free movement of controls.

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

Check that all cab polycarbonate windows are clean and clear. Replace any damaged polycarbonate material. See Scheduled and Periodic Maintenance section for more information.

Check that seat belt works properly. Replace worn or damaged seat belt .

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

Check window emergency exits. All emergency exit levers should be present and operate freely.

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

Machine Serial NumberDate of Inspection

2546/2548 T3

Pages in this section may be copied. Check o each inspection item before operat-

ing machine. File the copy as a record of inspection as required by OSHA or local governing body.

62

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PRESTART INSPECTION

CAUTION

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 of machine model, check for ammable debris in the following locations:

• Engine block • Turbocharger

• Exhaust manifold • Battery

• Electrical connections • Control valves

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

• Pine needles • Twigs • Debris

• Shop rags • Oil spills • Coolant Mixture

• Leaves • Sticks

• Grease • Bark

• Sawdust • Diesel fuel

Keep the machine clean. Risk of re increases if combustible materials and amma-

ble materials build up on machine. This machine was 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 or worn insulation on battery cable or other wires may lead to electrical res. Check cable and wires and replace if insulation is frayed, worn or damaged.

the engine to ensure there is no forest debris/trash re start up. Keep a re extinguisher ready during this 30 minute cool down.

2546/2548 T3

At the end of each shift ALWAYS stay with the machine for 30 minutes after shutting down

0808

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PRESTART INSPECTION

WHERE ARE FIRES MOST LIKELY TO START?

Fires can start almost anywhere on a logging vehicle. Here are some locations susceptible to re.

Electrical

Connections

Battery Box

Transmission

Exhaust Manifold

Engine Block

Turbocharger

Hydraulic Hoses

and Controls

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OPERATION

WARNING

OPERATION

GENERAL GUIDELINES

Only a trained, qualied, and authorized operator shall be allowed to operate this machine. Only use this machine after you have carefully read this manual and have learned 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

100.05

You must be at least eighteen (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-the-counter drugs or medications requires advice from a medical practitioner on whether or not you can safely operate this machine.

Do not operate this machine if you are subject to dizziness, seizures, or motion disturbance.

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 your authorized dealer for a new manual. Keep manual 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.

Before using this machine on hills or slopes, see information regarding slope operation in this manual.

• safety and instruction decals (see Safety Decals

section)

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

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OPERATION

WARNING

GETTING ON MACHINE

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.

Slips and falls can cause

G.006.02

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.

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

SEAT BELT

A rollover or sudden stop

can cause severe personal injury or death.

Always wear your seat belt, fastened snugly, when operating machine to reduce the risk of personal injury resulting from a rollover or sudden stop.

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NOTICE

OPERATION

STARTING THE ENGINE

Before starting engine, refer

to Pre-Start Inspection Section.

1. Be sure primary & secondary battery disconnect master switchs (A) are ON (located in LH engine compartment).

2. Close cab door and fasten seat belt snugly.

3. Remove feet from pedals before attempting to start engine.

4. Set parking brake (B).

5. Verify that transmission is in neutral (C).

6. Turn ignition key (D) to RUN position.

0108 TRANS

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NOTICE

WARNING

OPERATION

STARTING THE ENGINE, CONTINUED

7. Verify that all warning indicators (A) are not illuminated. If engine warning indicators are lit, see COLD WEATHER START procedure in this section.

Never try to start engine by pushing or towing machine. Attempting to start engine by towing or pushing machine will result in damage to your transmission.

8. Depress throttle pedal (D) to one third (1/3) power.

0108 GAUGE PANEL

9. Turn ignition key (E) to START position. Release key

when engine starts. If engine fails to start within thirty (30) seconds, turn key to OFF position and wait at least two (2) minutes to allow starting motor to cool.

If engine fails to start after four (4) attempts,

troubleshoot and correct the problem.

DO NOT turn key to START while engine is run-

ning. Doing so can cause damage to starter.

10. Run engine at one third (1/3) throttle and no load

for approximately ve (5) minutes to allow engine

146.05

to warm up.

11. After allowing engine and hydraulic compo-

nents adequate warm up time, run engine at full throttle.

12. Before driving machine, release parking brake (F).

If machine can be propelled with parking brake engaged, the system is not working as intended. Shut engine down and contact your authorized dealer immediately for system repair.

2546/2548 T3

0108 TRANS

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