1410D Forwarder

Serial Number
WJ1410D000475-

OPERATOR’S MANUAL
1410D Forwarder
OMF064197 (ENGLISH)

CALIFORNIA
Proposition 65 Warning

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth
defects, and other reproductive harm.

If this product contains a gasoline engine:

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

The State of California requires the above two warnings.

Worldwide Construction
And Forestry Division
Published in Finland
 Contents
Page Page

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

Operator’s manual for Timberjack 1410D What To Do If the Machine Catches Fire . . . . . 3-3-9
Forwarder . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-1
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1-2 Safety - Maintenance Precautions
Timberjack Contact Information . . . . . . . . . . . . 1-1-2 Service Machines Safely . . . . . . . . . . . . . . . . . 3-4-1
Technical Information Feedback Form . . . . . . . 1-1-3 Using the Xenon Worklamp . . . . . . . . . . . . . . . 3-4-2
Securing the Service Position. . . . . . . . . . . . . . 3-4-3
Warranty Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4-4
Standard warranty clauses . . . . . . . . . . . . . . . . 2-1-1 Prevent Acid Burns. . . . . . . . . . . . . . . . . . . . . . 3-4-5
250 Hour Service . . . . . . . . . . . . . . . . . . . . . . . 2-1-1 Service Cooling System Safely. . . . . . . . . . . . . 3-4-5
Prevent Battery Explosions. . . . . . . . . . . . . . . . 3-4-6
Safety - Safety Features Service Tires Safely . . . . . . . . . . . . . . . . . . . . . 3-4-6
1410D Forwarder Safety Features . . . . . . . . . . 3-1-1 Work in Clean Area . . . . . . . . . . . . . . . . . . . . . 3-4-7
Illuminate Work Area Safely . . . . . . . . . . . . . . . 3-4-7
Safety - General Precautions Use Proper Tools . . . . . . . . . . . . . . . . . . . . . . . 3-4-8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-1 Use Proper Lifting Equipment. . . . . . . . . . . . . . 3-4-8
Recognize Safety Information. . . . . . . . . . . . . . 3-2-1
Understand Signal Words. . . . . . . . . . . . . . . . . 3-2-1 Operator’s Station
Replace Safety Signs . . . . . . . . . . . . . . . . . . . . 3-2-2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-1
Maintain Safety Cabin . . . . . . . . . . . . . . . . . . . 3-2-2 Front Dashboard . . . . . . . . . . . . . . . . . . . . . . . 4-1-2
Driving and Service . . . . . . . . . . . . . . . . . . . . . 3-2-3 Start Key Positions . . . . . . . . . . . . . . . . . . . . . . 4-1-3
Use of Radio-transmitters . . . . . . . . . . . . . . . . . 3-2-3 Window Washers and Wipers. . . . . . . . . . . . . . 4-1-4
Prepare for Emergencies . . . . . . . . . . . . . . . . . 3-2-4 Signal Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5
Handle Fluids Safely—Avoid Fires . . . . . . . . . . 3-2-4 Left Arm Control Panel . . . . . . . . . . . . . . . . . . . 4-1-5
Handle Chemical Products Safely. . . . . . . . . . . 3-2-5 Right Arm Control Panel. . . . . . . . . . . . . . . . . . 4-1-6
Dispose of waste properly . . . . . . . . . . . . . . . . 3-2-5 Using Boom Control Levers . . . . . . . . . . . . . . . 4-1-7
Avoid High-Pressure Fluids . . . . . . . . . . . . . . . 3-2-6 Overhead Panel Switches . . . . . . . . . . . . . . . . 4-1-8
Wear Protective Clothing . . . . . . . . . . . . . . . . . 3-2-7 Warning Lamps and Buzzer . . . . . . . . . . . . . . . 4-1-9
Daily checks . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2-7 Preparedness for telephone . . . . . . . . . . . . . . . 4-1-9
Air Conditioner Controls . . . . . . . . . . . . . . . . . 4-1-10
Safety - Operating Precautions Operator’s seat. . . . . . . . . . . . . . . . . . . . . . . . 4-1-11
General operating instructions . . . . . . . . . . . . . 3-3-1
Handle Starting Fluid Safely . . . . . . . . . . . . . . . 3-3-2 Operating the Machine, Control System
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-2 TMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-1
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-3 ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-1
Secondary exit . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-3 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-2
Travel Safely . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-4
Do Not Short Starter. . . . . . . . . . . . . . . . . . . . . 3-3-4 Operating the machine, Operation
Operating the Machine . . . . . . . . . . . . . . . . . . . 3-3-5 Function of Seat Safety Switch. . . . . . . . . . . . . 5-2-1
Loading the Machine . . . . . . . . . . . . . . . . . . . . 3-3-6 Emergency Stopper . . . . . . . . . . . . . . . . . . . . . 5-2-1
Driving on Frozen Water. . . . . . . . . . . . . . . . . . 3-3-6 Operating the Boom . . . . . . . . . . . . . . . . . . . . . 5-2-2
Driving/Transporting on Public Roads. . . . . . . . 3-3-7
Power Cables . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3-8 Continued on next page

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

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

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 Contents

Page Page

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-3 Brake fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-16

Frame Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-4 Cab lift pump . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-17
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-5 Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-17
High/Low Gear and Rear-Wheel Drive . . . . . . . 5-2-6
Using the Differential Lock-Up . . . . . . . . . . . . . 5-2-7 Maintenance - Periodic
Operating the Decking Blade (Optional Maintenance intervals. . . . . . . . . . . . . . . . . . . . 6-1-1
Equipment) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-7
Operating the Clambunk. . . . . . . . . . . . . . . . . . 5-2-7 Maintenance - Every 10 hours or Daily
Check the hydraulic oil level . . . . . . . . . . . . . . . 6-2-1
Lifting and Lowering the Cab Check the engine oil level . . . . . . . . . . . . . . . . 6-2-2
How to Lift the Cab . . . . . . . . . . . . . . . . . . . . . 5-3-1 Check the Fuel Pre-Filter . . . . . . . . . . . . . . . . . 6-2-2
How to Lower the Cab . . . . . . . . . . . . . . . . . . . 5-3-2 Check engine coolant level. . . . . . . . . . . . . . . . 6-2-3
Check the windshield washer fluid level . . . . . . 6-2-4
Transportation of the Machine Check the radiator grille cleanness. . . . . . . . . . 6-2-5
Use hold-down straps. . . . . . . . . . . . . . . . . . . . 5-4-1 Check the driving brake oil level. . . . . . . . . . . . 6-2-6
Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-1 Check the air filter . . . . . . . . . . . . . . . . . . . . . . 6-2-6
Minilevers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-1 Check the tires for air pressure and
Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4-2 overall shape. . . . . . . . . . . . . . . . . . . . . . . . . 6-2-7
Fill up the fuel tank. . . . . . . . . . . . . . . . . . . . . . 6-2-7
Starting and Turning Off the Engine Maintain the boom . . . . . . . . . . . . . . . . . . . . . . 6-2-8
Before Starting the Engine for the First The following service and checks are to
Time in a Working Day . . . . . . . . . . . . . . . . . 5-5-1 be made at the end of each workday . . . . . . 6-2-8
Normal Start . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-2
Cold engine starting . . . . . . . . . . . . . . . . . . . . . 5-5-3 Maintenance - Every 50 hours or Weekly
After starting. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-4 Grease the center hinge bearings and
A normal operation of the engine . . . . . . . . . . . 5-5-5 steering cylinder bearings. . . . . . . . . . . . . . . 6-3-1
Turning off the engine . . . . . . . . . . . . . . . . . . . 5-5-6 Grease the decking blade1 . . . . . . . . . . . . . . . . 6-3-2
Check the air conditioner . . . . . . . . . . . . . . . . . 6-3-2
Driving the Machine Maintain the Boom . . . . . . . . . . . . . . . . . . . . . . 6-3-2
Off-Road Driving. . . . . . . . . . . . . . . . . . . . . . . . 5-6-1 Check the fire extinguisher system . . . . . . . . . . 6-3-3
Driving on Road . . . . . . . . . . . . . . . . . . . . . . . . 5-6-2
Maintenance - Every 250 hours
Towing the Machine Clean the machine . . . . . . . . . . . . . . . . . . . . . 6-4-1
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7-1 Check the high/low gear oil level. . . . . . . . . . . . 6-4-2
Stowing a Disabled Boom . . . . . . . . . . . . . . . . 5-7-4 Check Differential Oil Level . . . . . . . . . . . . . . . 6-4-3
Check Single Axle Wheel Ends ( Hub gear)
Maintenance - Machine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-4
Service, General. . . . . . . . . . . . . . . . . . . . . . . . 6-0-1 Check Bogie Housings Oil Level . . . . . . . . . . . 6-4-5
Servicing Safety Precautions . . . . . . . . . . . . . . 6-0-2 Grease Bogie Bearings . . . . . . . . . . . . . . . . . . 6-4-6
General Maintenance Instructions . . . . . . . . . . 6-0-3 Check Wheel Nut Torque . . . . . . . . . . . . . . . . . 6-4-7
Welding Instructions . . . . . . . . . . . . . . . . . . . . . 6-0-4 Check the cabine air filters . . . . . . . . . . . . . . . . 6-4-7
Cleaning the Cab windows . . . . . . . . . . . . . . . . 6-0-4 Check the air conditioner . . . . . . . . . . . . . . . . . 6-4-8
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-5 Maintain the boom . . . . . . . . . . . . . . . . . . . . . . 6-4-8
Changing Wheels . . . . . . . . . . . . . . . . . . . . . . . 6-0-6
Anti slips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-7 Maintenance - Every 500 hours
Fitting bogie tracks . . . . . . . . . . . . . . . . . . . . . . 6-0-8 Change engine oil and replace oil filter. . . . . . . 6-5-1
Recommended Lubricants and Fluids. . . . . . . 6-0-10 Change the fuel filters . . . . . . . . . . . . . . . . . . . 6-5-3
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-11 Clean crankcase vent tube . . . . . . . . . . . . . . . . 6-5-4
Diesel Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-12 Check the air intake system . . . . . . . . . . . . . . . 6-5-4
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-13 Checking belt tensioner spring tension and
Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-14 belt wear . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-4
Hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-15
Gear oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-16 Continued on next page

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 Contents

Page Page

Check engine speeds . . . . . . . . . . . . . . . . . . . . 6-5-6
Control engine grounding . . . . . . . . . . . . . . . . . 6-5-6
Remove sediment and water from the
fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-6
Renew the pressure filter of the drive
hydraulic system . . . . . . . . . . . . . . . . . . . . . . 6-5-7
Check the batteries for charge . . . . . . . . . . . . . 6-5-7
Checking cooling system . . . . . . . . . . . . . . . . . 6-5-8
Control of the diesel engine coolant . . . . . . . . . 6-5-9
Filling supplemental coolant additives
(SCA) between coolant changes . . . . . . . . . . 6-5-9
Pressure control of the cooling system . . . . . . 6-5-10
Grease the driveshafts . . . . . . . . . . . . . . . . . . 6-5-10
Maintenance - Every 1000 hours
Renew the hydraulic oil. . . . . . . . . . . . . . . . . . .
Replace the hydraulic return filter . . . . . . . . . . .
Replace the hydraulic tank breather . . . . . . . . .
Renew the high/low gear (transfer case) oil . . .
Check and tighten the screw and bolt
connections. . . . . . . . . . . . . . . . . . . . . . . . . .
Check the exhaust manifold . . . . . . . . . . . . . . .
Check the air conditioner . . . . . . . . . . . . . . . . .
Maintain the boom . . . . . . . . . . . . . . . . . . . . . .
Maintenance - Every 2000 hours
Check Valve Clearance - Engines
(200,000- ) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7-1
Checking Crankshaft Vibration Damper . . . . . . 6-7-3
Changing the Coolant. . . . . . . . . . . . . . . . . . . . 6-7-4
Change Bogie Axle Differential Oil . . . . . . . . . . 6-7-7
Change Bogie Housings Oil . . . . . . . . . . . . . . . 6-7-8
Change Single Axle Differential Oil. . . . . . . . . . 6-7-9
Change Single Axle Wheel Ends Oil . . . . . . . 6-7-10
Check and tighten the bolts for the joints
between axles and frame . . . . . . . . . . . . . . 6-7-11
Maintenance - Every 6 months
Service the fire extinguisher . . . . . . . . . . . . . . . 6-8-1
Maintenance - Every 12 months
Have the fire extinguisher system (opt. eq.)
checked . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9-1
Maintenance - As required
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bleeding the fuel system . . . . . . . . . . . . . . . .
Have the proper function of the
turbocharger checked . . . . . . . . . . . . . . . . .
Have the proper function of the alternator
checked . . . . . . . . . . . . . . . . . . . . . . . . . . .
Have the proper function of the starter
motor checked . . . . . . . . . . . . . . . . . . . . . .
Have the proper function of the atomizers
checked . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-5
Clean the Fuel Tank Filler Filter . . . . . . . . . . . 6-10-5
Replacing fan/alternator belt . . . . . . . . . . . . . . 6-10-6
Maintain the Boom . . . . . . . . . . . . . . . . . . . . . 6-10-6
Check the air conditioner . . . . . . . . . . . . . . . . 6-10-6
Cooling System Maintenance
Replenishing Supplemental Coolant
Additives (SCAs) Between Coolant
Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11-1
Pressure Testing Cooling System. . . . . . . . . . 6-11-3
Hydraulic System: Hydraulic Oil Change
Hydraulic tank and the vacuum pump. . . . . . . . 7-1-1
6-6-1 Checking the oil level in hydraulic tank. . . . . . . 7-1-1
6-6-2 Renew the hydraulic oil. . . . . . . . . . . . . . . . . . . 7-1-2
6-6-3
6-6-4 Hydraulic System: General
Working hydraulic system. . . . . . . . . . . . . . . . . 7-2-1
6-6-5 Hydrostatic system . . . . . . . . . . . . . . . . . . . . . . 7-2-1
6-6-6
6-6-6 Hydraulic System: Bleeding
6-6-6 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-1
Bleeding Drive Hydraulic System . . . . . . . . . . . 7-3-1
Bleeding Work Hydraulic System . . . . . . . . . . . 7-3-3
Bleeding the Brake System . . . . . . . . . . . . . . . 7-3-5
Hydrostatic System: Drive Pump adjusting
Checking and adjusting the charge pressure . . 7-4-1
Checking and adjusting the pressure
cut-off valve setting of the drive pump. . . . . . 7-4-2
Hydrostatic System: Drive Motor adjusting
Checking the function of hydrostatic
flushing valve . . . . . . . . . . . . . . . . . . . . . . . . 7-5-1
Checking and adjusting drive motors
pressure cut-off settings . . . . . . . . . . . . . . . . 7-5-2
Work Hydraulic System: Check and Adjust
Adjustment of Pressure Difference . . . . . . . . . . 7-6-1
Adjusting the Maximum Pressure . . . . . . . . . . . 7-6-1
Adjusting the Boom Pressure . . . . . . . . . . . . . . 7-6-2
Adjusting Auxiliary Functions . . . . . . . . . . . . . . 7-6-4
Adjusting Frame Brake . . . . . . . . . . . . . . . . . . . 7-6-4
6-10-1 Adjusting Proportional Decking Blade . . . . . . . . 7-6-5
6-10-2 Adjusting Optional Equipment. . . . . . . . . . . . . . 7-6-5
6-10-4 Brake System: Check and Adjust
Checking the brakes. . . . . . . . . . . . . . . . . . . . . 7-7-1
6-10-4 Mechanical adjustment of brakes . . . . . . . . . . . 7-7-2
6-10-4 Continued on next page

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Brake Charging Pressure . . . . . . . . . . . . . . . . . 7-7-3
Checking the Work Brake. . . . . . . . . . . . . . . . . 7-7-3
Checking the Drive Brake (Brake Pedal) . . . . . 7-7-4
Electrical System
Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-1
Location of ECU and engine sensors . . . . . . . . 8-1-2
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-3
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-5
Fuses on the Left-Hand Side in the Engine
Compartment . . . . . . . . . . . . . . . . . . . . . . . . 8-1-7
Instrument Box Fuses and Relays . . . . . . . . . . 8-1-8
The RPM Sensor of the Drive
Hydrostatics Motor . . . . . . . . . . . . . . . . . . . . 8-1-9
Hydraulic Tank Sensors . . . . . . . . . . . . . . . . . 8-1-10
Transmission
Operating Power Transmission. . . . . . . . . . . . .
High/Low Gear . . . . . . . . . . . . . . . . . . . . . . . . .
Hydrostatic System. . . . . . . . . . . . . . . . . . . . . .
Control of Transmission . . . . . . . . . . . . . . . . . .
Boom, General
A General Description of the Boom . . . . . . . . 10-0-1
Operating Safety Precautions . . . . . . . . . . . . . 10-0-2
General Operating Instructions . . . . . . . . . . . . 10-0-4
Boom Maintenance, General
Assembly Instructions. . . . . . . . . . . . . . . . . . . 10-1-1
Bleeding the Hydraulic System . . . . . . . . . . . . 10-1-1
Maintenance Schedule . . . . . . . . . . . . . . . . . . 10-1-2
Boom, Maintenance every 10 hours
Grease the grapple and link. . . . . . . . . . . . . . 10-2-1
Check boom structures. . . . . . . . . . . . . . . . . . 10-2-1
The following service and checks are to
be made at the end of each workday . . . . . 10-2-2
Boom, Maintenance every 50 hours
Check the boom slewing housing oil level . . .
Check that the joint pins of the boom
are secured. . . . . . . . . . . . . . . . . . . . . . . . .
Check the sideways clearance of the
extension booms. . . . . . . . . . . . . . . . . . . . .
Check the boom extension boom chains for
tightness. . . . . . . . . . . . . . . . . . . . . . . . . . .
Grease the rocker and cylinder bearings
of the boom and the slewing system
bearing.. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lubricate the extension boom chains
with oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the grapple . . . . . . . . . . . . . . . . . . . . .
Lubrication and Maintenance Chart . . . . . . . .
Contents
Page Page
Boom, Maintenance every 250 hours
Clean the boom.. . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Check boom structures. . . . . . . . . . . . . . . . . . 10-4-1
Check the extension booms for vertical
clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-2
Check the tightness of boom fastening
bolts, hydraulic cylinder covers, and other screw
joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-2
Boom, Maintenance every 1000 hours
Clean the magnetic plug of rotator . . . . . . . . . 10-5-1
Change the boom slewing system oil . . . . . . . 10-5-1
Clean the boom extension boom chains
(depending on the model) . . . . . . . . . . . . . . 10-5-2
Boom, Maintenance as required
Adjusting the rotator link brakes . . . . . . . . . . . 10-6-1
9-1-1
9-1-1
Boom, Technical Data
9-1-2
Boom CF7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7-1
9-1-3
Rotator and Grapple . . . . . . . . . . . . . . . . . . . . 10-7-1
Boom CF7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7-3
Equipment, Air Conditioner
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1-1
Main Parts of Air Conditioning System . . . . . . 11-1-1
Risks and Counter-Measures . . . . . . . . . . . . . 11-1-4
First Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1-5
Air Conditioner, Using. . . . . . . . . . . . . . . . . . . 11-1-6
Maintenance and Inspections: Check the
refrigerant level. . . . . . . . . . . . . . . . . . . . . . 11-1-8
Check the service moisture indicator of
the dryer every 50 hours . . . . . . . . . . . . . . .11-1-11
Service the compressor V-belt every 250
hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1-11
Service the compressor every 1000 hours . . .11-1-11
Service the evaporator element every
1000 hours . . . . . . . . . . . . . . . . . . . . . . . . .11-1-12
Service the condenser element every
10-3-1
1000 hours . . . . . . . . . . . . . . . . . . . . . . . . .11-1-12
Service the hoses and connectors every
10-3-1
1000 hours . . . . . . . . . . . . . . . . . . . . . . . . .11-1-13
10-3-2
Equipment, Engine Preheater
10-3-2 Operation and maintenence . . . . . . . . . . . . . . 11-2-1
Equipment, Fire Extinguisher System
10-3-3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3-1
Fire Alarm and Actions . . . . . . . . . . . . . . . . . . 11-3-2
10-3-3 After a fire . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3-5
10-3-3
10-3-4 Continued on next page
iv 101702
PN=4
 Contents

Page

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

Hand-held fire extinguishers . . . . . . . . . . . . . . 11-3-8

Equipment, Decking Blade

Using the Decking Blade . . . . . . . . . . . . . . . . 11-4-1
Lowering the Decking Blade . . . . . . . . . . . . . . 11-4-2
Decking Blade’s Float. . . . . . . . . . . . . . . . . . . 11-4-3

1410D Specifications
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . 12-0-1
Decals and Signs . . . . . . . . . . . . . . . . . . . . . . 12-0-2
Load area. . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-0-3
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-0-4
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . 12-0-5
Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-0-5
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-0-5
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-0-6
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . 12-0-6
Electrical System . . . . . . . . . . . . . . . . . . . . . . 12-0-6
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-0-6
Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-0-7

Hydraulic Diagrams, F622627

Hydraulic Diagrams, F622627 . . . . . . . . . . Hydraulic
Diagrams-1
Boom Hydraulics . . . . . . . . . . . Hydraulic Diagrams-2
Transmission Hydraulics . . . . . Hydraulic Diagrams-6
Brake Hydraulics . . . . . . . . . . . Hydraulic Diagrams-8
Extra Equipment Hydraulics . . . . . . . . . . . Hydraulic
Diagrams-10
Options Hydraulics . . . . . . . . Hydraulic Diagrams-12

Wiring Diagrams, 1410D

General . . . . . . . . . . . . . . . . . . . . Wiring Diagrams-1

TMC
TMC CONTROL SYSTEM ver 3G+ . . . . . . . . TMC-1

v 101702

PN=5
Contents

vi 101702

PN=6
 Introduction
Operator’s manual for Timberjack 1410D Forwarder
Manufacturer:
Timberjack Oy
P.O. Box 474
FIN-33101 Tampere, Finland
Telephone int: +358 205 84 162
Fax int: +358 205 84 163

Table to enter Machine Serial Number and Dealer information:

Machine Serial No.
Dealer

The information contained in this manual is comprised

CAUTION: Only persons whose training has
of regulations and instructions which will assist the
been approved by Timberjack are permitted
operator to operate the machine in a safe and efficient
to operate Timberjack machinery.
manner. Make sure this manual is always close at
hand and available to all who work on the machine.
Improper operation and maintenance of this
Should this manual be lost or should it deteriorate to
machine can be hazardous and could result
an unintelligible state, contact Timberjack or your
in serious injury or death.
nearest Timberjack dealer for a replacement manual.
Therefore, it is of paramount importance that
If you sell the machine, be sure to give this manual to
all the instructions given in this manual and
the new owners.
during training be followed when the
machine is operated or serviced.
Continuing improvements in the design of this machine
can lead to changes in detail which may not be
Read the safety rules from Section 3.
reflected in this manual. Consult Timberjack or your
local Timberjack dealer for the latest available
information of your machine or for questions regarding
information in this manual.

EL62757,0000159 –19–19APR02–1/1

1-1-1 101702

PN=4
 Introduction
Foreword
This manual provides you with the instructions for the
operation and maintenance of Timberjack Forwarder.
Please read the entire manual before you start
operating the machine. The instructions given will
assist you in becoming familiar with many features of
Timberjack Forwarder, showing you how to operate the
machine and how to carry out periodic maintenance
procedures and some basic adjustments.
However, we strongly advise you to contact the
nearest repair shop authorized by Timberjack when
complicated maintenance tasks or repairs come up.
Our service people have the experience and tools
needed for the job.
We designed the forwarder to carry cross-cut timber
on its deck from the logging site to the roadside.
NOTE: See Section 12 for information about maximum
payload and log length.
NOTE: Skidding long logs is only permitted with
machines specially equipped for the purpose.
The machine must not be used for other
purposes.
Timberjack Contact Information
Please, contact our web site: www.Timberjack.com.
1-1-2
We designed the forwarder to operate under difficult
off-road circumstances. Still it is important that you
always adapt your driving speed and load to the
surroundings. Use chains and tracks if necessary.
Take a good look at your forwarder always when
having a short break or when maintaining the machine.
It is worth bearing in mind that even a small failure, if
left unattended, may soon result in major problems
and a long downtime.
Do not pollute the environment. It is imperative that
you do not allow oil to leak into the ground or water
because it only takes one liter of mineral oil to
contaminate one million liters of water. Should you see
a leaky joint, fix it immediately.
Remember fire prevention. Keep the machine clean at
all times for this reduces the risk of overheating and
chance of a fire starting.
See Section 12, for technical information of the
machine.
EL62757,000015A –19–19APR02–1/1
EL62757,000015B –19–19APR02–1/1
101702
PN=5
 Introduction

Technical Information Feedback Form

We need your help to continually improve our Operator’s

Manuals please FAX or mail your comments, ideas and
improvements on this comment sheet.

SEND TO: Timberjack Oy

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

FAX NUMBER: +358 205 84 6160

Ideas, Comments, (Please state Page Number):

OVERALL, how would you rate the quality of "ALL" Operator’s Manuals provided to you? (Check one)
Poor Fair Good Very good Excellent
1 2 3 4 5 6 7 8 9 10

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

THANK YOU!

EL62757,000015C –19–19APR02–1/1

1-1-3 101702

PN=6
 Warranty
Standard warranty clauses

The machine is covered by Timberjack’s guarantee in

compliance with the standard warranty clauses accepted
by the Timberjack group.

The manufacturer will not assume responsibility for the

machines delivered should the following conditions be
violated:

• The forwarder is exclusively operated and maintained

by experienced personnel who have been trained by
Timberjack or by a dealer authorized by Timberjack.
• The forwarder must be operated and maintained in
accordance with the instructions provided in this
manual.
• Only fuels and lubricants specified in this manual are
used.
• Only genuine spare parts are used

EL62757,000015D –19–19APR02–1/1

250 Hour Service

The forwarder was checked and test driven before

delivery, and it can be put to use immediately. However,
to ensure good reliability it is very important to thoroughly
service the machine once it has been put to use.

The warranty given by Timberjack will be valid provided

that the machine is handed over for after sales
maintenance after appr. 250 running hours, the service
shop being one authorized by Timberjack.

EL62757,000015E –19–19APR02–1/1

2-1-1 101702

PN=7
 Safety - Safety Features
1410D Forwarder Safety Features

–UN–03OCT02
T160087
1—Secondary exit. The 4—Seat safety switch. No 7—Frame brake. Locks the 9—Emergency stop Stops the
right-hand cap window can function can be engaged horizontal hinge of the machine and engages the
be used as a secondary before somebody sits on machine. parking brake.
exit from the cab. the seat. 8—Hand-held fire 10—Stairs, anti-slips on the
2—ROPS. Integrated rollover 5—Safety signs. Warn and extinguishers and fire steps, handrails. Help to
and operator protective give safety information for extinguisher system (opt.) climb into the machine.
structures fully enclose the operator.
and protect the operator 6—Back-up alarm (opt). Allerts
3—Central warning light and bystanders when machine
alarms (+buzzer).Alarm is reversing.
when malfunctions occur.

Please remember, the Operator is the key to

preventing accidents.

OUTJ003,00005CF –19–10MAY01–1/1

3-1-1 101702

PN=8
 Safety - General Precautions
General

Comply with instructions in this manual and also your

company’s regulations.

Should there be any information or instructions in this

manual that are not in compliance with local laws and
regulations in force in the country or region where this
equipment is operated, the local laws and regulations
must take precedence.

This machine should not be operated or maintained by

personnel other than those who have been thoroughly
trained.

As the maintainer ensure that you become familiar with all

occupational safety regulations pertaining to forest
machinery as well as all safety instructions pertaining to
this equipment. Observe the instructions provided in this
manual and on all hazard and information decals on the
machine.

OUTJ003,00004A0 –19–15FEB01–1/1

Recognize Safety Information

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

–UN–28AUG00
on your machine or in this manual, be alert to the
potential for personal injury.

Follow recommended precautions and safe operating

T133555
practices.

DX,ALERT –19–29SEP98–1/1

Understand Signal Words

A signal word—DANGER, WARNING, or CAUTION—is

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

DANGER or WARNING safety signs are located near

–19–30SEP88

specific hazards. General precautions are listed on

CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
TS187

DX,SIGNAL –19–03MAR93–1/1

3-2-1 101702

PN=9
 Safety - General Precautions

Replace Safety Signs

Carefully study all of the safety messages that are in this

manual and on the machine.

More specific measures are illustrated with pictographs

which may also be attached to the machine in locations

–UN–23AUG88
pertinent to their respective message.

Keep safety signs in good condition. Repair or replace

damaged signs.

TS201
DX,SIGNS1 –19–04JUN90–1/1

Maintain Safety Cabin

Cabin is safety tested according to international ROPS,

FOPS and OPS standards.

Do not operate the machine with the door open or any of

the safety covers or protective devices removed.

It is important to keep the operator protective structure in

place (doors, screens, windows, windshield, etc.) to
minimize hazards from whipping or intruding objects.

The protection offered by ROPS, FOPS and OPS will be

impaired if cabin

• is subjected to structural damage

• is involved in an overturn incident
• is in any way altered by welding, bending, drilling, or
cutting

To maintain ROPS, FOPS and OPS protection, replace

damaged cabin parts immediately. A damaged structure
should be replaced, not reused.

Do not attach any parts on the cabin by welding nor drill

any holes on it because it is a safety cabin. It is forbidden
to modify the window fastening.

AK12300,000010A –19–05NOV01–1/1

3-2-2 101702

PN=10
 Safety - General Precautions

Driving and Service

The machine may only be used or repaired by personnel

who have received training that is approved by
Timberjack.

–UN–20MAR02
IMPORTANT: Do not let an untrained person operate
the machine.

• Carry no passengers. The vehicle is provided and

T152788
approved with seating for the operator only.
• Use the handrails and steps provided when mounting
and dismounting from the machine. Do not climb onto
the machine in any other fashion.
• The machine must not be operated by anyone under
the influence of alcohol or drugs.
• Avoid operating the machine if you are tired or ill, as
there is a greater risk of accident. Take sufficient breaks
and observe local regulations on working hours.

EL62757,000015F –19–19APR02–1/1

Use of Radio-transmitters

IMPORTANT: Any use of equipment containing a

radio transmitter (e.g., telephone,
communications radio) that has an
antenna inside the cab is strictly
prohibited.

Such equipment must be permanently installed in a proper

manner with an antenna on a suitable grounded plate
outside the cab.

Never mount an antenna inside the cabin because it may

cause malfunction in electrical devices!

CAUTION: Never use a headset when there is

thunder or lightening. Observe the danger of an
outer antenna so that it does not come into
contact with power lines.

EL62757,000005B –19–24SEP01–1/1

3-2-3 101702

PN=11
 Safety - General Precautions

Prepare for Emergencies

Be prepared if a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

–UN–23AUG88
hospital, and fire department near your telephone.

TS291
DX,FIRE2 –19–03MAR93–1/1

Handle Fluids Safely—Avoid Fires

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

heaters or other fire hazards.

Store flammable fluids away from fire hazards. Do not

incinerate or puncture pressurized containers.

–UN–23AUG88
Make sure machine is clean of trash, grease, and debris.

Do not store oily rags; they can ignite and burn

TS227
spontaneously.

DX,FLAME –19–29SEP98–1/1

3-2-4 101702

PN=12
 Safety - General Precautions

Handle Chemical Products Safely

Direct exposure to hazardous chemicals can cause

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

–UN–26NOV90
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.

TS1132
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.

See your authorized dealer for MSDS’s on chemical

products used with your machine.

TX,05,DH2500 –19–02OCT92–1/1

Dispose of waste properly

Improperly disposing of waste can threaten the

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

–UN–26NOV90
Use leakproof containers when draining fluids. Do not use
food or beverage containers that may mislead someone
into drinking from them.

TS1133
Do not pour waste onto the ground, down a drain, or into
any water source.

Air conditioning refrigerants escaping into the air can

damage the Earth’s atmosphere. Government regulations
may require a certified air conditioning service center to
recover and recycle used air conditioning refrigerants.

Inquire on the proper way to recycle or dispose of waste

from your local environmental or recycling center, or from
your authorized dealer.

EL62757,0000160 –19–19APR02–1/1

3-2-5 101702

PN=13
 Safety - General Precautions

Avoid High-Pressure Fluids

Escaping fluid under pressure can penetrate the skin

causing serious injury.

Avoid the hazard by relieving pressure before

–UN–23AUG88
disconnecting hydraulic or other lines. Tighten all
connections before applying pressure.

Search for leaks with a piece of cardboard. Protect hands

X9811
and body from high pressure fluids.

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

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

CED,TX14740,7088 –19–30JUN00–1/1

3-2-6 101702

PN=14
 Safety - General Precautions

Wear Protective Clothing

Wear close fitting clothing and safety equipment

appropriate to the job.

Prolonged exposure to loud noise can cause impairment

or loss of hearing.

–UN–23AUG88
Wear a suitable hearing protective device such as
earmuffs or earplugs to protect against objectionable or
uncomfortable loud noises.

TS206
Safety face shield, glasses, or goggles should always be
used as protection from pressurized fluid spray, flying
debris, and other airborne matter when working with tools,
power tools, welding equipment, and corrosive or
dangerous chemicals.

Wear protective clothing as required by the job. Use a

rubber apron and rubber gloves when working with
corrosives and wear heavy work gloves and safety shoes
when handling large heavy or sharp objects and cables.

Operating equipment safely requires the full attention of

the operator. Do not wear radio or music headphones
while operating machine.

OUTJ003,00005AA –19–09MAY01–1/1

Daily checks

inspect the machine daily for signs of damage, unusual

wear, fluid leaks, or faulty operation.

Repair all defects.

Keep windows clean.

Keep floors, steps, and running boards clean and free of

oil, ice, mud, and loose objects.

NOTE: Adhere to the maintenance schedule in the

operator’s manual. This will contribute to a safe
working environment.

EL62757,0000161 –19–19APR02–1/1

3-2-7 101702

PN=15
 Safety - Operating Precautions
General operating instructions

Operate the machine only from a seated position in the

operator’s seat. Always use the seat belt.

Before lifting or lowering the hydraulic stairs make sure

that they don’t hit any obstacles.

–UN–23AUG88
Keep the door closed when driving the machine.

Do not operate the machine with any of the safety covers

TS205
or protective devices removed.

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

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

Maintain a safe operating distance between the equipment

and other personnel. Never swing the boom over the

–UN–06JUN01
heads of bystander

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

applies when the machine is in operation. The

T139370
operator is personally responsible for
maintaining this safety rule in the absence of
the foreman.

IMPORTANT: The manufacturer shall assume no

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

EL62757,0000162 –19–19APR02–1/1

3-3-1 101702

PN=16
 Safety - Operating Precautions

Handle Starting Fluid Safely

Starting fluid is highly flammable.

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

–UN–18MAR92
To prevent accidental discharge when storing the
pressurized can, keep the cap on the container, and store
in a cool, protected location.

TS1356
Do not incinerate or puncture a starting fluid container.

OUTJ003,000068F –19–14MAY01–1/1

Controls

Prior to commencing work, make sure that all machine

and crane controls function correctly.

IMPORTANT: It is not permissible to operate the

machine if there is something wrong
with the controls of the machine or if
they have not been properly adjusted.

Check the operation of the emergency stop every day.

Check the braking capacity before each shift:

❒ Choose low gear.

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

EL62757,0000163 –19–19APR02–1/1

3-3-2 101702

PN=17
 Safety - Operating Precautions

Alarms

A warning light and alarm light will be activated in the

event of machine faults. See Section 4.

Never continue running a machine when the alarm has

been given, unless you have checked the cause and
taken necessary action.

EL62757,0000164 –19–19APR02–1/1

Secondary exit

There is an emergency exit through the front right hand

side window.

IMPORTANT: Remove the lock pin (1) from behind the

window latch before you start to work.

CAUTION: Always remember to remove the lock

pin before you start the machine. If not, the
window can’t be opened from the outside in
case of emergency.

IMPORTANT: In case of emergency the window can

be opened from outside and inside.

From the inside : Pull the hinge pin (2) entirely out and
push the window fully open.

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

–UN–20MAR02
Push in the releasing handle (4). The window can be
opened so much that you are able to pull the hinge pin (2)
out and open the window fully.

T152785
IMPORTANT: Replace the lock pin (1) again when
locking the cab. That is to prevent
unauthorized access to the cab through
1—Lock pin
the window
2—Hinge pin
3—Window hatch
4—Releasing handle

EL62757,0000165 –19–19APR02–1/1

3-3-3 101702

PN=18
 Safety - Operating Precautions

Travel Safely

Know the location of bystanders before moving the

machine.

Always keep the reverse warning alarm, if equipped, in

–UN–20DEC88
working condition. It warns people when the machine
starts to move in reverse.

Use a signal person when moving the machine in

T6964AD
congested areas. Coordinate hand signals before starting
the machine.

TX,05,FF3319 –19–08FEB93–1/1

Do Not Short Starter

Start the engine from the operators seat only. Never

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

–UN–06JUN01
T139380
EL62757,0000169 –19–19APR02–1/1

3-3-4 101702

PN=19
 Safety - Operating Precautions

Operating the Machine

Choose low gear and adapt driving speed to prevailing

ground conditions. Where necessary use anti-skid device,
e.g. chains.

On steep slopes always try to drive directly uphill or

downhill and avoid changes in direction or driving
diagonally (risk of toppling).

CAUTION: Do not jump from the cab. If the

machine tips over hold on to the armrests.

If you find yourself in a precarious situation, don’t take any

risks, call for towing assistance.

In the event of strong wind, trees leaning over or are

otherwise difficult to reach, take care and longer time
rather than taking greater risk.

When you stop working, even temporary (for example

while using the phone), lower the crane and engage the
parking brake.

NOTE: ALWAYS put the direction selector in neutral and

apply the parking brake before leaving the cab

Never leave the machine unattended while the engine is

running.

Turn the main switch off if the machine is to stand still for
a prolonged period of time (overnight, for example).

EL62757,0000166 –19–19APR02–1/1

3-3-5 101702

PN=20
 Safety - Operating Precautions

Loading the Machine

CAUTION: Do not overload the machine.

Likewise, do not carry a load that exceeds the
limits of the headboard. A load that is stacked
too high can cause the machine to overturn, or
the topmost logs may slide over the headboard
and cause a fatal injury to the driver.

The crane grapple must be supported on the load carrier

frame or on top of the load. Do not ever leave the boom
and grapple unsupported or resting on the ground.

CAUTION: A load that exceeds the limits of the

headboard may cause serious or fatal injury.

EL62757,0000167 –19–19APR02–1/1

Driving on Frozen Water

Pay extra attention while driving on frozen water:

• Be ready for quick evacuation from the cabin before

driving on a frozen lake, etc.
• Release your safety belt.
• Ensure that the doors are unlocked.
• Ensure that there is nothing to obstruct quick
evacuation.
• Restore the above precautions on reaching firm ground.

CAUTION: Never park the machine on a frozen

lake, etc.

EL62757,000005E –19–24SEP01–1/1

3-3-6 101702

PN=21
 Safety - Operating Precautions

Driving/Transporting on Public Roads

When traveling on public roads, use accessory lights and

other cautionary devices to bring your approach to the
attention of other vehicle operators. Ensure that the
vehicle meets all regulatory requirements.

If the machine must be transported, make sure it is

adequately secured to the transporting vehicle. Even
though the brakes may be fully engaged, the wheels must
be blocked and the machine secured with chains, wire, or
rope to prevent movement during transport.

Position and secure the implement attachment, including

the boom, so that the equipment will not move and cause
imbalance during transport.

Ensure that the overall height does not exceed local or

state maximum height regulation.

OUTJ003,00004B0 –19–15FEB01–1/1

3-3-7 101702

PN=22
 Safety - Operating Precautions

Power Cables

When planning the work, check with the local power

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

–UN–03OCT02
NOTE: Avoid operating under overhanging electrical
powerlines for a high voltage can ’jump’ over a
distance of several meters in the air.

T152796
Safety distances to electric lines

Rated voltage Min. distance (m) Min. distance (m)

kV under on the side
1 2 2
1...45 2 3
110 3 5
220 4 5
400 5 5

Normally stay in the cab and back up away from a

powerline.

If the engine stops and the machine comes into contact

with a powerline and you have to come out of the
machine do as follows:

• grapple firmly with a bare hand on the wrist of the other

hand holding a handle while pushing the door open.
• Jump out of the cab both feet together.
• Keep on jumping feet together until you are at least 10
meters from the machine and the powerline.
If you fall earlier do not stand up, but keep on rolling on
the ground toward the same direction.

You run the greatest risk if you are in simultaneous

contact with the machine and the ground.

Jump clear from the machine to the ground.

EL62757,0000168 –19–19APR02–1/1

3-3-8 101702

PN=23
 Safety - Operating Precautions

Fire Prevention

When working in a forest environment, it is impossible to

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

–UN–23AUG88
To reduce the chance of a fire starting, observe the
following instructions:

TS227
• Clean dust and debris from the machine regularly.
• Clean the radiator and oil cooler regularly to ensure
components operate at efficient working temperatures.
• Inspect the machine daily for potential fire hazards and

–UN–07SEP00
make any necessary repairs immediately.
• Inspect electrical wiring and connections, fuel and
hydraulic hose runs to ensure they are secure and not

T133553
rubbing against other components.
• Clean up any excess grease, oil accumulation, and
spillage immediately.
• Use only nonflammable solutions for cleaning the
machine or components.
• Store rags and other combustible materials in a safe,
fireproof location.
• Before starting repair work, such as welding, the
surrounding area should be cleaned and a fire
extinguisher should be close by.
• Maintain a charged fire extinguisher on the vehicle at all
times and KNOW HOW TO USE IT.

OUTJ003,00004B1 –19–15FEB01–1/1

What To Do If the Machine Catches Fire

–UN–07SEP00

• Turn the engine off.

• Turn the master disconnect switch off
• If possible, fight the fire using the portable fire
T133554

extinguisher or other fire suppression equipment.

• Ensure that the fire does not spread to the surrounding
area.
• Call for help!

OUTJ003,00004B2 –19–15FEB01–1/1

3-3-9 101702

PN=24
 Safety - Maintenance Precautions
Service Machines Safely

Prior to servicing or repairing the machine, ensure that the

machine is level and the parking brake is engaged.

If repairing the brakes, make sure that the machine

cannot start moving.

CAUTION: You are strictly prohibited from

carrying out service on the machine while the
diesel engine is running.

Position the boom firmly and safely on the ground so that

it cannot move.

Keep clear of the raised boom.

Make sure that unauthorized persons are not allowed near

the machine.

Shut the engine down and turn the main switch off.

–UN–23AUG88
Disconnect the negative (-) battery cable from the battery,
if you work on electrical equipment.

TS218
NOTE: When handling the battery beware of the risk of a
short-circuit and watch out for the corrosive acid
in the battery.

–UN–20MAR02
T152787

DX,LOOSE –19–04JUN90–1/1

3-4-1 101702

PN=25
 Safety - Maintenance Precautions
Using the Xenon Worklamp
When using the lamp, please notice the following:
• Avoid looking directly into the intensive light
• The lens may occasionally be cleaned
• No aggressive or abrasive cleaners may be used
IMPORTANT: Do not wash the lens with liquid
substances while switched on or
while the lens is still warm, as the
lens might crack.
Safety instructions for replacing the Xenon bulb
Please observe the following safety instructions when
replacing the Xenon bulb:
• Always switch off the headlamp before exchanging
bulbs and disconnect from the power supply.
• Never insert foreign objects of fingers into the bulb
holder.
• The electrician connection between headlamp and
lamp ballast is under high voltage and must not be
disconnected.
• The ballast unit must never be operated without a
bulb, as dangerous voltage spark-over, which leads
to damage, may occur at the bulb holder.
3-4-2
• Allow the bulb cool off.
• Wear safety goggles and gloves when exchanging
bulb.
CAUTION: The glass body of the Xenon bulb
is filled with various gasses and metal
gasses under pressure (danger of
splintering).
• Never touch the glass bulb of the Xenon lamp, touch
the bulb at its base only.
• Use a clean cloth and alcohol to remove any
fingerprints from the glass bulb.
• The Xenon lamp has to be operated only in the
closed work lamp.
IMPORTANT: If a Xenon bulb breaks in a closed
room (workshop), the room is to be
aired and everyone must leave the
room for 20 minutes to exclude any
danger to health due to escaped gas.
• Dispose of used Xenon bulbs as hazardous waste.
EL62757,0000050 –54–16SEP02–1/1
101702
PN=26
 Safety - Maintenance Precautions

Securing the Service Position

Before dismantling parts subjected to load, hydraulic

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

–UN–06JUN01
Having raised the cab to its full height, always lock the
safety support in place. Do not use any middle position.
Make sure that nobody comes close to the cab when
raising or lowering it.

T139371
CAUTION: When lowering cab, its lowering
speed may accelerate when the cab is appr. 5
centimeters from the fastening studs. Make
sure that nobody comes too close to the cab
when lowering it.

CAUTION: The use of engine hoods and belly

pans may have been facilitated by means of lift
supports. Should these supports become
defective, the cover may unexpectedly come
down. Do not go under these parts when
lifting/lowering them or before they are properly
secured in the uppermost position.

Before disconnecting any load-bearing parts, secure the

–UN–19MAR02
vertical hinge of the machine.

Likewise, also secure the horizontal hinge, if necessary,

as applicable under the circumstances.

T152685
If the machine breaks down in difficult terrain, and cannot 1
be moved prior to being repaired, take extra care to fully
immobilize the machine and all rotating or moving parts. 1—Frame lock

Install the frame lock (1) to prevent accidental articulation

of the machine.

Read the manual carefully and follow the maintenance

procedures provided.

NOTE: The operator and serviceman are responsible for

safety on and around the machine.

EL62757,000016A –19–19APR02–1/1

3-4-3 101702

PN=27
 Safety - Maintenance Precautions

Fluids

Fluid leaks under pressure may not be visible.

Pressure can be maintained in a hydraulic system long

after the power source and pump have been shut down.
Lower the implements to the ground and relieve trapped
pressure before performing maintenance work on
components.

Do not disconnect any hoses before making sure that all

pressure has been eliminated.

Do not fill up the oil tanks or fuel tank if the engine is

running.

Do not modify any pressure adjustments without a

permission from the manufacturer.

Use extreme caution when draining hot fluids from the

machine. Splashing hot fluid can cause serious burns.

Open the expansion tank cap slowly if the cooling system

is hot. This allows the pressure to even out.

EL62757,000016B –19–19APR02–1/1

3-4-4 101702

PN=28
 Safety - Maintenance Precautions

Prevent Acid Burns

Sulfuric acid in battery electrolyte is poisonous. It is strong

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

Avoid the hazard by:

1. Filling batteries in a well-valveated area.

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

If you spill acid on yourself:

1. Flush your skin with water.

2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 15—30 minutes. Get
medical attention immediately.

–UN–23AUG88
If acid is swallowed:

1. Do not induce vomiting.

2. Drink large amounts of water or milk, but do not

TS203
exceed 2 L (2 quarts).
3. Get medical attention immediately.

DX,POISON –19–21APR93–1/1

Service Cooling System Safely

Explosive release of fluids from pressurized cooling

system can cause serious burns.

Shut off engine. Only remove filler cap when cool enough
to touch with bare hands. Slowly loosen cap to first stop
–UN–23AUG88

to relieve pressure before removing completely.

TS281

DX,RCAP –19–04JUN90–1/1

3-4-5 101702

PN=29
 Safety - Maintenance Precautions

Prevent Battery Explosions

Keep sparks, lighted matches, and open flame away from

the top of battery. Battery gas can explode.

Never check battery charge by placing a metal object

across the posts. Use a voltmeter or hydrometer.

–UN–23AUG88
Do not charge a frozen battery; it may explode. Warm
battery to 16°C (60°F).

TS204
DX,SPARKS –19–03MAR93–1/1

Service Tires Safely

Explosive separation of a tire and rim parts can cause

serious injury or death.

Do not attempt to mount a tire unless you have the proper

equipment and experience to perform the job.

Always maintain the correct tire pressure. Do not inflate

the tires above the recommended pressure. Never weld or
heat a wheel and tire assembly. The heat can cause an
increase in air pressure resulting in a tire explosion.
Welding can structurally weaken or deform the wheel.

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

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

Check wheels for low pressure, cuts, bubbles, damaged

rims or missing lug bolts and nuts.

–UN–23AUG88
TS211
DX,RIM –19–24AUG90–1/1

3-4-6 101702

PN=30
 Safety - Maintenance Precautions

Work in Clean Area

Work in a valveated area only.

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

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

–UN–23AUG88
adjustments.

If you don’t have an exhaust pipe extension, either work

outside, or open the shop doors.

TS220
DX,CLEAN –19–04JUN90–1/1

Illuminate Work Area Safely

Illuminate your work area adequately but safely. Use a

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

–UN–23AUG88
TS223
DX,LIGHT –19–04JUN90–1/1

3-4-7 101702

PN=31
 Safety - Maintenance Precautions

Use Proper Tools

Use tools appropriate to the work. Makeshift tools and

procedures can create safety hazards.

Use power tools only to loosen threaded parts and

fasteners.

–UN–08NOV89
For loosening and tightening hardware, use the correct
size tools. DO NOT use U.S. measurement tools on
metric fasteners. Avoid bodily injury caused by slipping

TS779
wrenches.

Make sure that jack stands and lifting equipment are in

good condition and of adequate capacity. Repair or
replace worn or damaged tools, including lifting
equipment, before initiating repair work on your machine.

Use only service parts meeting manufacturer’s

specifications.

OUTJ003,00005AB –19–09MAY01–1/1

Use Proper Lifting Equipment

Lifting heavy components incorrectly can cause severe

injury or machine damage.

Follow recommended procedure for removal and

installation of components in the manual.

–UN–23AUG88
TS226
DX,LIFT –19–04JUN90–1/1

3-4-8 101702

PN=32
 Operator’s Station
General

Warning lights are located on the front dashboard.

Bear in mind that should a warning light go on or the

central warning light blink, this always indicates that there
is something that does not function properly within the
system. This being the case, discontinue loading and turn
off the engine. See the Instructions for use of Timberjack
TMC (Total Machine Control), Appendix.

The operation of the alarm system is detailed in the

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

–UN–12SEP02
T152190

Cab Component Locator

TMC is a registered trade mark of Timberjack. EL62757,000016C –19–19APR02–1/1

4-1-1 101702

PN=33
 Operator’s Station

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

–UN–17OCT02
T152191

1
See: Equipment, Decking blade
EL62757,000016D –19–19APR02–1/1

4-1-2 101702

PN=34
 Operator’s Station

Start Key Positions

P—Vacuum pump (opt. eq.)

STOP—Engine turn-off

–UN–05MAR02
I—Power on

II— Empty

START—Starting.

T152192
In positions Start and II the load on the working
hydraulic pump is relieved making it easier for the
engine to run

EL62757,000016E –19–19APR02–1/1

4-1-3 101702

PN=35
 Operator’s Station

Window Washers and Wipers

–UN–05MAR02
T152193
1—Switch for Windscreen 2—Windscreen washer 4—Left side window wiper 6— Rear window washer
wiper 3—Windscreen wiper 5—Right side window wiper 7—Rear window wiper

The wiper switches on the side panel activate a • 1 press on key (1).
continuous function of the wipers. The windscreen wiper makes a single move.
• 2 presses (the 2nd press within 30 seconds) on key
Control of the wiper interval action: (1).
Time between these two presses determines the wiper
You can control the wiper action with a key (1) on the interval.
right arm-rest panel. • 3rd press on key (1).
The 3rd press stops the wiper action.
A single move of the windscreen wiper can be
engaged when the seat is facing forward and a rear
single move (optional) can be engaged when the seat
is facing backward.

EL62757,000016F –19–19APR02–1/1

4-1-4 101702

PN=36
 Operator’s Station

Signal Lights

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

–UN–20SEP02
T152194
EL62757,0000170 –19–19APR02–1/1

Left Arm Control Panel

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

–UN–17OCT02
T160562

1
see section 5-2, Using differential locks
EL62757,0000171 –19–19APR02–1/1

4-1-5 101702

PN=37
 Operator’s Station

Right Arm Control Panel

1—Driving direction switch

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

–UN–15OCT02
T152196
1
Operation of the decking blade, see section 11, Decking blade
EL62757,0000172 –19–19APR02–1/1

4-1-6 101702

PN=38
 Operator’s Station

Using Boom Control Levers

–UN–05MAR02
T152197
1. LEFT BOOM LEVER 2. RIGHT BOOM LEVER
+Y Outer boom out +Y Main boom down / Blade down
-Y Outer boom in -Y Main boom up / Blade up
+X Boom slew clockwise +X Grapple rotation clockwise
-X Boom slew counterclockwise -X Grapple rotation
counterclockwise
+Z Extension boom out +Z Grapple open
-Z Extension boom in -Z Grapple press together

EL62757,0000173 –19–19APR02–1/1

4-1-7 101702

PN=39
 Operator’s Station

Overhead Panel Switches

1—Cab light
2—Service light under the cab
3—Track light, (opt. eq.)
4—Work spot light; front
5—Work spot light; left side
6—Work spot light; left and
right sides, (opt. eq.)
7—Work spot light; right side
–UN–05MAR02
T152198
8—Work spot light; rear 11—Inside air recirculation,
9—Work spot light; bottom (opt. eq.)
corner of cab, (opt.eq.)
10—Work spot light; boom,
(opt. eq.)

EL62757,0000174 –19–19APR02–1/1

4-1-8 101702

PN=40
 Operator’s Station

Warning Lamps and Buzzer

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

that something is wrong. The TMC display indicates
what is wrong.
2. Fire alarm lamp (red) The fire alarm flashes and the

–UN–12SEP02
alarm sounds if fire is registered by the detectors. You
should then trigger the fire extinguisher1 system. See
section 11-4.
3. Control unit for fire extinguisher system.

T152199
1
in certain markets / optional equipment
EL62757,0000175 –19–19APR02–1/1

Preparedness for telephone

A mobile phone or a radiotelephone can be mounted into

the cabin. Preparedness for the phone consists of 12 V
power transmission which can be connected to connection
X17 in the instrument box.

The end of aerial lead (50 W) is situated close to

connection X17 in the instrument box.

The other end of aerial lead (50 W) is on the roof

EL62757,0000176 –19–19APR02–1/1

4-1-9 101702

PN=41
 Operator’s Station

Air Conditioner Controls

Instructions for use, see section 11-1.

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

–UN–02OCT02
T152201
EL62757,0000177 –19–19APR02–1/1

4-1-10 101702

PN=42
 Operator’s Station

Operator’s seat

–UN–12SEP02
T159289

Kab 544, 564, 569

1. Armrest • The function is ON when the power is ON.

• The armrest is adjustable i all directions
3. Chair module
2. Control Panel • Most of the controls and swithes are installed to
• There is a push button on the right side of the the Chair2-module.
right control panel. Button is used to release or
stop the swing of the seat. 4. Seat safety switch

Continued on next page EL62757,000004D –54–15SEP02–1/2

4-1-11 101702

PN=43
 Operator’s Station

• Function of the seat safety switch is explained in • The height could be set in 5 positions
group 5-2. • Pull rear handle for adjustment of the rear part
of the seat
5. Weight setting with a mechanical knob (depending • Pull from handle for adjustment of the front part
on model) of the seat
• Turn knob for appropiate weight.
11. Backrest angle
6. Mechanical swing (depending on model) • Could be adjusted forward of backwards
7. Ventilation • Pull handle for required position
8. Weight setting (depending on model)
• Push for harder suspension 12. ACS - Air Comfort System (depending on the
• Pull for softer suspension model)
a. Thight support
9. Heater b. Side support, seat
• Adjustable c. Side support, back
• Temperature between +27° to 42° C. d. Trippel lumbar support
More support, press “+”
10. Heightriser Less support, press “-”

EL62757,000004D –54–15SEP02–2/2

4-1-12 101702

PN=44
 Operating the Machine, Control System
TMC

The TMC control system is used for controlling the DM

Ch
boom and the hydrostatic power transmission of the
forwarder, as well as the auxiliary functions related to the Hub Cr
boom and the hydrostatic power transmission.
Tr
When operating the machine in an ordinary manner, the
TMC display is in the run-time mode and it shows you
data that is necessary for usage.

For the instructions for the adjustment of parameters

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

–UN–12SEP02
ECU—Engine Control Unit
Tr—Transmission module ECU
Hub—Hub module

T159329
DM—Display module
Ch—Chair module
Cr—Crane module Placing of TMC modules and Engine Control Unit in 1410D

EL62757,0000179 –19–21APR02–1/1

ECU

ECU (Engine Control Unit) is a controlling unit that guides

and controls the functions of the engine.

The flow of information between TMC and ECU goes

through CAN-bus.

ECU adjusts the engine rpms according the instruction

that comes from TMC (from the accelerator or the rpm
switch).

EL62757,000017A –19–21APR02–1/1

5-1-1 101702

PN=45
 Operating the Machine, Control System

Alarms

The TMC control system is equipped with a

condition-monitoring system that greatly facilitates the use
and maintenance of the system. The alarms are recorded
in the alarm log.

The alarms are registered in ECU but they can bee

glanced only in TMC.

There are two kind of alarms: active and previous active

(see the TMC manual1 attached).

1
See alarms -section in TMC manual.
EL62757,000017B –19–21APR02–1/1

5-1-2 101702

PN=46
 Operating the machine, Operation
Function of Seat Safety Switch

The activation of the seat safety switch is a prerequisite

for all other functions. What this means is that no function
can be engaged before somebody sits on the seat.

When you are operating the boom controls, articulated

frame steering, or the pedal, you can stand up for a
moment and the operation will not be interrupted, but the
TMC system will sound an alarm together with instructions
displayed on screen.

When you are sending a new control input you have to sit
on the seat.

EL62757,000017C –19–21APR02–1/1

Emergency Stopper

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

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

–UN–05MAR02
turning the knob clockwise.

1—Emergency stopper

T152202
EL62757,000017D –19–21APR02–1/1

5-2-1 101702

PN=47
 Operating the machine, Operation

Operating the Boom

–UN–05MAR02
The boom can be operated if:

1. The operator sits on the seat.

T152203
2. The parking brake has been released
3. The boom has been engaged.

If these conditions have been met, the boom is 1—Machine rpms

automatically engaged when the seat is turned to face the 2—Boom symbol
rear of the machine.

If the seat faces the front of the machine, the boom can
be activated if necessary by means of the boom switch in
the right-hand-side control panel.

The boom can always be used when the TMC-display

shows the boom symbol. It is also possible to move the
machine while operating the boom.

For instructions for safe and efficient boom operation see

Section 10..

EL62757,000017E –19–21APR02–1/1

5-2-2 101702

PN=48
 Operating the machine, Operation

Brakes

The brake system of the machine involves the following:

1. Drive brake
The drive brake functions by means of hydraulic
pressure. The brake is operated with a pedal.
2. Work brake
Also the work brake functions by means of hydraulic
pressure. The brake is automatically engaged always
when the machine stops, and it is disengaged when
the machine is moved again.
When the work brake is engaged, an ’S’ symbol is
shown on the TMC display.

–UN–05MAR02
3. Parking brake
The parking brake is operated with the switch (1)
located in the side panel. The warning light of the
switch is on when the brake is engaged.

T152204
IMPORTANT: It is important to engage the brake
always when you leave the cab.
1—Switch, park brake
The engagement of the parking brake is
spring-actuated, and the brake is released by means of
hydraulic pressure.
If there is no hydraulic pressure the parking brake
stays engaged. When the parking brake is engaged,
an ’P’ symbol is shown on the TMC display.

NOTE: Don’t use the brake pedal while the work/parking

brake is engaged.

EL62757,000017F –19–21APR02–1/1

5-2-3 101702

PN=49
 Operating the machine, Operation

Frame Brake

The frame brake is a means to lock the horizontal hinge

of the machine. The frame brake is always automatically
engaged when the machine stops, and the brake is
disengaged when the machine starts moving again. The
brake can also be entirely disengaged through a key (1).

IMPORTANT: Bear in mind that the frame brake is

always open when loading during
driving.

1—Switch, frame brake

–UN–16OCT02
T160561
EL62757,0000180 –19–21APR02–1/1

5-2-4 101702

PN=50
 Operating the machine, Operation

Steering

The machine is steered by means of a ministick (1) in the

left control panel. If the stick is turned in the desired
direction the machine will turn in the same direction. This
is also the case when the seat faces the rear of the
machine.

The moving speed of the steering cylinders is slowed

down by the end damping function of the steering system
at both extreme turning positions when the limit switch is
activated.

If the machine is equipped with hydraulic steering stick

(optional equipment) the ministick steering can be
disengaged through the switch (2) on the side instrument
panel.

NOTE: On certain markets the use of ministick steering is

not possible when driving with the high gear.

The hydraulic steering stick (3) is located in the right side

panel. When the stick is pushed forward the machine will
turn to the left. When the stick is pulled backward the
machine will turn to the right.

In some machines, there is a back-up alarm which goes

on when reversing.
1—Ministick
2—Switch, ministick operation
3—Hydraulic steering stick

–UN–16OCT02
T160564

EL62757,0000181 –19–21APR02–1/1

5-2-5 101702

PN=51
 Operating the machine, Operation

High/Low Gear and Rear-Wheel Drive

The machine is equipped with mechanical high/low gear

and with an adjustable speed range (%). These can be
engaged through the selector switch (2) in the right control
panel.

Shifting the high/low gear is only possible when the

machine stands still, the work brake has been engaged
(and the switch (1) for driving direction is in the center
position).

The high gear will be replaced by the low gear when the
seat is turned to face to rear of the machine.

• When shifting the pump receives short pulses (forward

and backward), which is to make sure that the gear has
been engaged.
• Wait five seconds. If the high gear cannot be engaged,
the low gear is on.

NOTE: If the gear (high or low) is not properly engaged

(the gear symbol is not visible in the display), the
work brakes will remain engaged on and the
machine will not move.

If the driving direction has been selected and the switch

(2) is pressed, the system enters the adjustable speed
range (snail) (%) or leaves it.

When operating with the low gear on, the rear-wheel drive
is always engaged. If the high gear is selected the
rear-wheel drive is automatically disengaged.

If necessary, the rear-wheel drive can be engaged also

when the high gear is on. This is done with a switch (3)
on the side panel.

NOTE: Use low gear when the machine is loaded

1—Driving direction
2—Switch, adjustable speed range
3—Rear-wheel drive engagement
–UN–05MAR02
T152207

EL62757,0000182 –19–21APR02–1/1

5-2-6 101702

PN=52
 Operating the machine, Operation

Using the Differential Lock-Up

The switches (1 and 2) for the lock-up of the front axle

and rear axle differential are located on the left-hand-side
control panel.

NOTE: The locks can only be engaged when the machine

stands still.

❒ The switch has to be held down until the machine

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

IMPORTANT: Exercise great caution when using the

locks, and keep them engaged for short

–UN–16OCT02
periods only. When the differential is
locked, avoid turning the machine
sharply.

T160563
1—Switch, differential lock-up
2—Switch, differential lock-up
A flashing symbol in the TMC display indicates that the differential
locks are engaged.

EL62757,0000183 –19–21APR02–1/1

Operating the Decking Blade (Optional

Equipment)

See ssection 11-4. Equipment, Decking Blade.

EL62757,0000184 –19–21APR02–1/1

Operating the Clambunk

See section 11-4. Equipment, Clambunk.

EL62757,0000185 –19–21APR02–1/1

5-2-7 101702

PN=53
 Lifting and Lowering the Cab
How to Lift the Cab

IMPORTANT: See to it that nobody comes too close

to the machine when you lift or lower
the cab.

1. Remove the cab attaching bolts (1).

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

–UN–05MAR02
IMPORTANT: Do not lift the cab if the machine is not
standing on level ground. Do not drive
the machine if the cab is in the upper

T152216
position. You can run the engine while
the cab is up (if you are adjusting the
pressures, for instance).
1—Attaching bolts
2—Up/down valve
3—Pumping lever

EL62757,0000187 –19–21APR02–1/1

5-3-1 101702

PN=54
 Lifting and Lowering the Cab

How to Lower the Cab

–UN–05MAR02
T152217
4—Lock bar

1. Lower the lock bars (4) of the cab

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

Specification
Cab attaching bolts—Torque ................................ 100 Nm (73.7 lbt-ft)

EL62757,0000188 –19–21APR02–1/1

5-3-2 101702

PN=55
 Transportation of the Machine
Use hold-down straps

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

EL62757,0000189 –19–21APR02–1/1

Positioning

When positioning the forwarder onto the trailer, ensure

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

EL62757,000018A –19–21APR02–1/1

Minilevers

For the transport minilevers are clamped to the extreme

position with rubber loops situated on outer side of control
panels.

EL62757,000018B –19–21APR02–1/1

5-4-1 101702

PN=56
 Transportation of the Machine

Chains

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

NOTE: When travelling on public roads, all regulatory

requirements must be met in full.

EL62757,000018C –19–21APR02–1/1

5-4-2 101702

PN=57
 Starting and Turning Off the Engine
Before Starting the Engine for the First Time
in a Working Day

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

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

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

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

–UN–05MAR02
1—Main switch

T152211
EL62757,000018D –19–21APR02–1/1

5-5-1 101702

PN=58
 Starting and Turning Off the Engine

Normal Start

NOTE: Make sure that there are no people within the

danger zone around the forwarder.

–UN–07OCT02
1. Engage the parking brake (1) (the forwarder will start
only if the parking brake is on).
2. Check that the switch for driving direction (3) is in the
middle position and the emergency stopper (2) in the

T160198
upper position.

IMPORTANT: Do not start the engine when the

preheater is on.

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

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

–UN–16OCT02
IMPORTANT: Don’t operate the starting motor longer
than 30 seconds at the time. The starter
may overheat.

T160197
Allow the starter motor to cool down for
appr.2 minutes. After that, try again.
Should the engine still refuse to start
after four tries, find out what is wrong.

NOTE: The engine and starter motor must be at a

complete standstill before you try to start again.

–UN–05MAR02
9. Check that all gauges function correctly.

T152192

EL62757,000018E –19–21APR02–1/1

5-5-2 101702

PN=59
 Starting and Turning Off the Engine

Cold engine starting

CAUTION: Never use a liquid starting aid to

start the engine. The use with the pre-heat
device will cause an explosion in the intake
manifold.

NOTE: When the temperature drops below 5°C we

strongly recommend that you use the pre-heating
(optional equipment) of the engine coolant 1/2 ...
1 hour before starting the engine.

Using correct grade oil is critical to achieving adequate

cold weather cranking speed!

1. When the temperature is below 0° C the engine is

basically started as described above but:
2. Use the pre-heating of the engine intake air. Turn the
ignition key to position II. Use the glow operation for 5
... 15 seconds before starting, depending on the
outside temperature.
3. Turn the ignition key to position III (start). Press the
accelerator pedal all the way down. Release the key
when the engine fires and decrease the throttle to
prevent the engine speed from exceeding 1000 rpm.
4. If the engine fails to fire repeat the glow procedure
before attempting to start again.
5. Once the engine has started you may, where
necessary, release the ignition key to position II and
keep it there for around 10 seconds. In this case the
load on the working hydraulic pump is relieved making
it easier for the engine to run.

NOTE: (Grid heater) glowing discharges the batteries a

great deal. If the indicator light for glowing stays
on after glowing, turn the master disconnect
switch off.

EL62757,000005C –19–15OCT02–1/1

5-5-3 101702

PN=60
 Starting and Turning Off the Engine

After starting

1. After starting, operate the engine for 1 ... 2 minutes at

appr. 1200 rpm before full loads are applied.
• Make the time longer if the outside temperature is
beyond the freezing point.

2. Therefore, do not operate the engine at speeds beyond

1400 rpm before the hydraulic oil has warmed up.
When the hydraulic oil is still cold, too high an engine
speed results, among other things, in excessive
pressures in the pump’s and motors. This may inflict
damage on shaft packings etc.

NOTE: NOTE! Avoid prolonged idling periods (more than

5 minutes). Carbon deposits will appear in the
engine and the lubrication of various components
will not be efficient.

IMPORTANT: Never turn off the main switch while the

engine is running (with the exception of
a potential emergency).

EL62757,000018F –19–21APR02–1/1

5-5-4 101702

PN=61
 Starting and Turning Off the Engine

A normal operation of the engine

Observe engine coolant temperature and engine oil

pressure. Temperatures and pressures will vary between
engines and with changing operating conditions,
temperatures, and loads.

NOTE: Normal engine coolant operating temperature

range is 82°...94° C (179°...201°F) If coolant
temperature rises above 105° C (221° F), TMC
will give an alarm (alarm 38).

❒ Unless temperature drops quickly, stop all

operations and let the engine idle..
❒ Determine cause before resuming operation

NOTE: When coolant temperature is excessive (above

115° C (239° F) engine will reduce power (40 %)
automatically.

NOTE: Contact your local Timberjack service for more

information.

Operate the engine under a lighter load and at slower

than normal speed for first 15 minutes after start-up. DO
NOT run engine at slow idle.

Stop engine immediately if there are any signs of part

failure. Symptoms that may be early signs of engine
problems are:

• Sudden drop in oil pressure

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

EL62757,0000190 –19–21APR02–1/1

5-5-5 101702

PN=62
 Starting and Turning Off the Engine

Turning off the engine

1. First, make sure that the switch for driving direction is

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

EL62757,0000191 –19–21APR02–1/1

5-5-6 101702

PN=63
 Driving the Machine
T152212 –UN–05MAR02

Off-Road Driving

During off-road operation the low gear is engaged

(all-wheel-drive mode is on).

NOTE: The stairs must be in the upper position when the

driving direction is selected, or the machine will
not start moving.

Operating under difficult conditions it is recommended to

switch on the adjustable speed range (%).

EL62757,0000192 –19–21APR02–1/3

T152213 –UN–05MAR02

Off-Road Driving with the Working rpm

1. Engage the low gear (the driving direction switch has

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

Continued on next page EL62757,0000192 –19–21APR02–2/3

5-6-1 101702

PN=64
 Driving the Machine

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

driving direction has been selected, the system will
move to the adjustable speed range (%). What will be
shown as a speed range symbol on the TMC display is
a snail underneath of which can be seen the driving
speed setting. Speed can be adjusted through the Z

–UN–05MAR02
movement of the right ministick.
6. The machine is steered by means of the ministick of
the left control panel.

T152214
Off-Road Driving with the Working rpm off

If you do not want to use the working rpm in off-road

driving, the operation is similar to what has been
described above, but:

• Regulating the machine speed with the drive pedal has

a direct impact on the speed of the diesel engine
• You cannot operate the boom.

EL62757,0000192 –19–21APR02–3/3

Driving on Road

The high gear can be used for driving on road. This is

when the rear-wheel drive is disengaged.

However, it is possible to engage the rear-wheel drive

with a separate switch.

NOTE: The high gear cannot be engaged if the seat is

facing the back of the machine.

1. Disengage working rpm.

Continued on next page EL62757,0000193 –19–21APR02–1/3

5-6-2 101702

PN=65
 Driving the Machine
T152215 –UN–05MAR02

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

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

EL62757,0000193 –19–21APR02–2/3

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

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

–UN–05MAR02
NOTE: There are countries where the use of the ministick
for driving on public roads (with the high gear
engaged) is forbidden (Germany) or blocked
(Sweden) because of road traffic regulations

T152214
8. Before you embark on driving on public roads,
remember the following:
• Install the rear lights and front turn indicators and
check their function.
• Adjust the side-view mirrors

EL62757,0000193 –19–21APR02–3/3

5-6-3 101702

PN=66
 Towing the Machine
Towing

As a result of a machine failure it may be necessary to

tow the machine when it comes to a halt on a public road
or if you have to transfer the machine to proper repair
facilities.

The machine cannot be towed unless some or all of the

following actions are taken:

1. Release the parking brake.

2. Release the driving power transmission system
3. Release the work brake.
4. Release the steering.

EL62757,0000194 –19–21APR02–1/5

CAUTION: Once the above steps have been

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

–UN–18JUL01
enters the risk zone around the machine.

NOTE: We strongly recommend you use a rigid towing

linkage for towing. Make sure that the machine is

T144065
adequately supported before anybody embarks on
repairing the machine.

How to Release the Parking Brake

• Open the underpan.

• Remove the cover at the end of the brake cylinder.
• Screw down the release screw (under the cover) to
release the brake. –UN–13JUN01
• Repeat the procedure for each brake cylinder.
• After towing, the release screws must be removed.
T142813

There are four brake cylinders in all. Two of these are for
the front axle and two for the rear axle.

1—Brake cylinders
2—Brake cylinder cover
3—Release screw of the brakes

Continued on next page EL62757,0000194 –19–21APR02–2/5

5-7-1 101702

PN=67
 Towing the Machine

How to Disengage the Power Transmission System

(bypass function)

• Lift up the cabin

• Turn the screw (1)) of shock pressure valves (209),
(211) of the drive pump to such an extent that the valve

–UN–16OCT02
cartridge is released and free oil circulation is possible.

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

release the power transmission system. Otherwise

T160481
release the drive shafts.
Drive pump, Drive pressure relief valves
Once towing is over the valves need to be closed again.
Torque to 200 ± 10 Nm (148 ± 7,4 lb-ft)

T156362

–UN–
T156362
EL62757,0000194 –19–21APR02–3/5

How to Release the Work Brake

• Lift up the cabin.

• Disconnect the solenoid valve Y41W coupler of the
work brake

–UN–08OCT02
NOTE: Re-connect the connector after towing

T159878
Continued on next page EL62757,0000194 –19–21APR02–4/5

5-7-2 101702

PN=68
 Towing the Machine

Disconnecting the steering cylinders

The steering valve block Y66 is located in the loader

valve.

• Open the relief valve plug and remove the spring (1)
and cartridge (2)
• Install the plug with gasket and tighten.
• After towing, install the spring and cartridge

NOTE: Secure all loose parts and the valve housing

against dirt

–UN–05MAR02
T152221
EL62757,0000194 –19–21APR02–5/5

5-7-3 101702

PN=69
 Towing the Machine

Stowing a Disabled Boom

If the engine is stopped with the boom in an extended

position it may be necessary to manually retract and stow
the boom before the Forwarder can be towed.

The boom hydraulics are released by by-passing the port

reliefs in the Loader Control Valve and the boom is
maneuvered using a second Forwarder or a suitable lifting
device.

CAUTION: If the boom is stopped in a raised

position it must be completely supported in that
position before the hydraulics are released.

If the boom load is not completely disabled, oil

might be pressurized and the oil flow is heavy
at the beginning.

Failure to follow proper safety precautions may

lead to personal injury or damage to the
machine.

Securely block the wheels. Support the boom using blocks

or a second machine. Each boom function is controlled
from its spool section on the Crane valve. Each spool
must be by-passed in order to move the boom in that
direction.

Continued on next page EL62757,0000195 –19–21APR02–1/2

5-7-4 101702

PN=70
 Towing the Machine

At each spool section:

• Remove the pressure relief valves. Open the relief valve

plug and remove the spring (1) and cartridge (2).
• Replace the valves with by-pass plugs. Install the plug
with gasket and tighten.
• Maneuver the boom using a second forwarder boom or
suitable lifting device.
• Replace the valves.

NOTE: Do not mix the valves after they have been

removed. Replace the valves as originally
installed.

For example, to raise or lower the main boom:

• Support the boom in position carefully. There must not

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

–UN–05MAR02
device
• Replace the pressure relief valves

T152221
NOTE: Secure all loose parts and the valve housing
against dirt.

EL62757,0000195 –19–21APR02–2/2

5-7-5 101702

PN=71
 Maintenance - Machine
Service, General

This maintenance section contains a number of servicing

and checking procedures that are performed regularly.
Some of these are carried out by the operator.

When it comes to maintenance and repairs that require

special skills and tools, contact the nearest authorized
repair shop.

Any defect or shortcoming that compromises the

operational safety must be remedied immediately.

If the aim is a reliable and safe operation, the most

important (and the most inexpensive) contribution is
regular machine checks and maintenance.

Maintenance periods have been categorized as follows:

❒ Daily maintenance or after every ten running hours

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

60 –19–22APR02–1/1

6-0-1 101702

PN=72
 Maintenance - Machine

Servicing Safety Precautions

Carefully study the safety instructions in section 3-4

before starting maintenance work.

❒ Make sure the machine is level and cannot move

(brakes applied) and wheels chocked if necessary
❒ Keep clear of the raised boom
❒ Make sure that no outsiders come close to the machine
during servicing or repairs
❒ The operator and serviceman are responsible for safety
on and around the machine.

IMPORTANT: The operator, mechanic, and foreman

must be familiar with the safety rules
and regulations provided in this service
manual and in the decals of the
machine, as well as with those related
to national road traffic and occupational
safety. All safety rules and regulations
in effect pertaining to the machine and
workplace must be obeyed.

CAUTION: The use of engine hoods and belly

pans has been facilitated by means of lift
supports. Should these supports become
defective, the cover may unexpectedly come
down. Do not go under these parts when
lifting/lowering them or before they are properly
secured in the uppermost position.

EL62757,0000146 –19–18APR02–1/1

6-0-2 101702

PN=73
 Maintenance - Machine

General Maintenance Instructions

When the machine is new, check all bolted joints daily,

especially those between the boom and the frame and
those between the axles and the frame.

Keep tightening until the bolts maintain their tightness.

Check the hose joints, too. During ordinary operation, the

joints should be frequently checked in addition to
scheduled maintenance.

Bolt torque values

JOINT QTY SIZE GRADE TORQUE

Nm
Wheel bolts 550
( 405 lb -f t)
Cab fastenings 100
( 74 l b -f t )
Cab base fastenings 170
( 125 lb -f t)
Joints between axles and frame
Horizontal bolts 950
(700 lb -f t)
Vertical bolts 950
( 700 lb -f t)
BOOM
Fastening 8 M24x100 12.9 1120
( 826 lb -f t)
Base, support plate 6 M10x25 8.8 49
( 36 lb -f t)
M12x40 12.9 137
( 101 lb -f t)
Slewing cylinder 4x12 M12x70 12.9 110
( 81 l b -f t )
Main boom cylinder 2 M65x2 1890
( 1394 lb -f t)
Outer boom cylinder 2 M65x2 1890
( 1394 lb -f t)
Extension boom cylinder
2 M40x2 440
( 325 lb -f t)
2 M20x1.5 200
(147,5 lb -f t)

EL62757,0000147 –19–18APR02–1/1

6-0-3 101702

PN=74
 Maintenance - Machine

Welding Instructions

See welding instructions from Section 8-1.

EL62757,0000148 –19–18APR02–1/1

Cleaning the Cab windows

When washing the cab windows, use mild detergent only

that is environmentally friendly. Use lots of water for
rinsing. Soft towels are recommended for wiping and
drying the windows. Always when you use the wipers,
operate the washer, too.

NOTE: Never clean the windows with gasoline or any

other solvents.

NOTE: Do not clear the windows of ice and snow with a

sharp scraper because the safety glass made of
polycarbonate is easily scratched.

EL62757,0000149 –19–18APR02–1/1

6-0-4 101702

PN=75
 Maintenance - Machine

Tires

Tire pressures

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

pressure gauge to check the pressure.

Tire pressures
8-wheel
FRONT PRESSURE REAR PRESSURE
710/45-26.5 20PR 300..350 kpa 710/45-26.5 20PR 500... 550
Nokian (43,5...50,8 psi) Nokian 72,5...79,8 psi)
800/40-26.5 20PR 300..350 800/40-26.5 20PR 450... 500
Nokian (43,5...50,8 psi) Nokian 65,3...72,5 psi)
700/50-26.5 20PR 300...350 700/50-26.5 20PR 500...550
Nokian (43,5...50,8 psi) Nokian 72,5...79,8 psi)

6-wheel
700/55-34 14PR 220...230 710/45-26.5 20PR 500...550
Nokian 31,9...33,4 psi) 72,5...79,8 psi)
800/40-26.5 20PR 450...500
65,3...72,5 psi)
700/50-26.5 20PR 500...550
Nokian 72,5...79,8 psi)

NOTE: When operating with heavy loads in harsh, rugged

terrain, it is good to use maximum tire pressures.

NOTE: When operating with heavy loads in harsh, rugged

terrain, it is good to use maximum tire pressures.
Running a tire with too low pressure can lead to
immediate tire failure.

NOTE: Too low pressure can lead to sidewall damage

and rim chafing, possible even to rim slippage.

NOTE: Min.pressures must be found in wheels even in

cold winter days (cold weather reduces the tire
pressures about 10 kPa / 10°C).

EL62757,000014A –19–18APR02–1/1

6-0-5 101702

PN=76
 Maintenance - Machine

Changing Wheels

Park the machine on firm, level and smooth ground.

Position the jack underneath the flat part of the axle or
bogie casing, see figures. Make sure neither the machine
nor the jack can move during the lift.

It is especially important to retighten the wheel nuts if the

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

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

rims. Replace badly damaged rims.

CAUTION: Always apply the parking brake

before leaving the cab.

Item Measurement Specification

Wheel nuts Torque 550 Nm (405 lb-ft).

EL62757,000014B –19–18APR02–1/1

6-0-6 101702

PN=77
 Maintenance - Machine

Anti slips

Choose fairly smooth ground when fitting the anti-slip.

• Ensure that the anti-slips are in good condition.

• Turn them the right way.

–UN–02MAY02
• Lay the anti-slip out in front of the wheel, see fig
• Tie a 1.5 metre (5 ft) long piece of rope, or something
similar, to the anti-slip and place it over the tire as
illustrated

T152224
• Carefully move the machine. If needed stop the
machine and adjust the anti-slip. Continue until the ends
of the anti-slip lie near each other, and connect the
ends together with the coupling links.

–UN–05MAR02
T152223
EL62757,000014C –19–18APR02–1/1

6-0-7 101702

PN=78
 Maintenance - Machine

Fitting bogie tracks

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

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

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

–UN–05MAR02
otherwise the track will be unbalanced.

NOTE: Do not over-tighten the tracks.

T152225
Continued on next page EL62757,000014D –19–18APR02–1/2

6-0-8 101702

PN=79
 Maintenance - Machine

7. Reverse the machine carefully until the joint is midway

between the wheels. The track is now stretched and
the chain 1 in the middle should be slack. If the track
needs to be tightened more, shorten these, reverse
and fit a suitable track lock, see fig. 7.

CAUTION: Make sure no-one is nearby when

you tighten the tracks.

8. Fit the track lock with the loop on the inside against the
tire.
9. Then drive forward until the tensioning chains are
slack. Remove them.
10. Drive the machine forward and back a couple of
times. Check the track tension as shown in fig. 8.
Dimension A should be 50...100 mm (2...4 in).

Tip! If the tensioning chains do not pull the track together

enough: Fit an extra chain between the ends and then
drive forward again. This will now hold the track together
so that the tensioning chains can be tightened more, see
fig. 5.

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

tire).

–UN–05MAR02
T152227

EL62757,000014D –19–18APR02–2/2

6-0-9 101702

PN=80
 Maintenance - Machine

Recommended Lubricants and Fluids

General instructions for checking oil levels and fill-ups:

❒ The machine must stand on level ground when you

check any of the oil levels
❒ Check the oil level in the morning for that is when the
oil is cold and it has seeped down into the lower parts
of the component.
❒ Renew the oil while the engine is warm. Thus it is
easier to remove the old oil
❒ To even the pressure at the oil space, open a plug
located above the oil level (e.g. filling plug) before
opening the drain plug.
❒ Avoid direct contact with oil, particularly heated oil.

NOTE: Oil on the skin should be washed off immediately.

Basic rules when changing oil and filters, checking

hydraulic pressures, repairing etc.:

• Clean thoroughly the area around the components to be

opened to ensure that no dirt enters the system.
• Keep the hydraulic hoses plugged as well as the filters
in their packs until they are installed to the machine.
• Plug removed components
• Ensure that all parts are clean before assembly

EL62757,000014E –19–18APR02–1/1

6-0-10 101702

PN=81
 Maintenance - Machine

Capacities
Fluids and lubricants Liters Gallons
Engine oil + filter 25 6.6
Coolant 27.5 7.3
High/low gear 4.5 1.2
Differential; front - 6-wheeled 27 7.1
Differential; front - 8-wheeled 12 3.1
Differential; rear 12 3.1
Hub gearings - 6-wheeled 2x4 2 x 1.05
Bogie housing/each 52 13.7
Boom slew housing 9.5 2.5
Hydraulic fluid - max. level 150 39.6
Hydraulic fluid - min. level 79 20.9
Fuel tank 165 43.5
Windshield washer fluid tank 2x5 2x1.3
Cab lift 0.8 0.2
Driving brake oil level (ATF oil) 0.5 0.1

The filling capacities given are guidelines only. Having

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

EL62757,000014F –19–18APR02–1/2

The drain hoses are located on the underpan under the

engine. The hose clamps have been numbered:

1—Hydraulic oil; hydraulic tank

2—The drainage of the hydraulic suction hose.
3—Engine oil; draining
–UN–05MAR02

4—Fuel tank; draining

T152229

EL62757,000014F –19–18APR02–2/2

6-0-11 101702

PN=82
 Maintenance - Machine

Diesel Fuel
Capacity Fuel tank 165 l
(43.6 gal)

Recommended quality requirements for diesel fuel:

1. Cetane number of 40 minimum. Cetane number

greater than 50 is preferred, especially for
temperatures below -20°C (-4 °F).
2. Sulfur content:
• Sulfur content should not exceed 0.5%. Sulfur
content less than 0.05% is preferred.
• The period for changing the engine oil must be
reduced by half if diesel fuel containing more than
0.5% sulphur is used.
• Do not use diesel fuel with sulfur content greater
than 1.0%.

Bio-diesel fuels may be used ONLY if the fuel properties

meet DIN 51606 or equivalent specification.

When operating in cold circumstances use fuel that is

suitable for winter operation and has a cloud point
appearing at a lower level than the operating
temperatures.

Avoid condensation by keeping the fuel tank full. Alcohol

may not be added to the fuel, even a small amount could
damage the fuel system.

IMPORTANT: Use only pure fuel. DO NOT mix used

engine oil or any other type of lubricant
with diesel fuel.

EL62757,0000151 –19–18APR02–1/1

6-0-12 101702

PN=83
 Maintenance - Machine

Engine Oil
Capacity Engine 25 l
(6.6 gal)
50˚C 122˚F

NOTE: Consult your Timberjack service for use and

40˚C 104˚F
availability of John Deere engine oils.
30˚C 86˚F
1. ENGINE BREAK-IN OIL

SAE 15W-40

SAE 30
SAE 10W-40
New engines are filled at the factory with John Deere 20˚C 68˚F
ENGINE BREAK-IN OIL.

SAE 5W-40
SAE 5W-30
Within the first 250 operating hours, use: 10˚C 50˚F
❒ John Deere ENGINE BREAK-IN OIL :
❒ or oil that meets the requirements of API CE or 0˚C 32˚F
ACEA E1
-10˚C 14˚F
NOTE: Change the oil after the first 250 operating hours.
After that a normal oil change every 500 hours. -20˚C -4˚F

2. OIL CHANGE EVERY 500 HOURS -30˚C -22˚F

John Deere preferes following oils:

–UN–05OCT01
• John Deere PLUS-50 -40˚C -40˚F
• ACEA E4
• ACEA E5

TS1668
3. OIL CHANGE EVERY 250 HOURS

• when using following oil qualities:

– ACEA E3
– API CH-4
– API CI-4
• if diesel fuel with sulfur content greater than 0.5% is
used

NOTE: Always use the original oil filter at oil changes.

Multi-viscocity oils are preferred.

Use oil viscosity based on the expected air temperature

range during the period between oil changes.

IMPORTANT: It is forbidden to use other oils (except

during the break-in period).

PLUS-50 is a registered trademark of Deere & Company. EL62757,0000152 –19–18APR02–1/1

6-0-13 101702

PN=84
 Maintenance - Machine

Coolant
Capacity Engine cooling 27,5 l
system (7,3 gal)

The engine cooling system is filled to provide year-round

protection against corrosion and cylinder liner pitting, and
winter freeze protection to -37°C (-34°F).

Use a coolant mixture consisting of 50 percent of water

and 50 percent of antifreeze in the system all year round.
The antifreeze must consist of ethylene glycol or
propylene glycol and that complies with grade ASTM4985
or ASTM5345.

Coolant chart
Antifreeze, in percents Freezing point of volume, °C
40 -24 (-11 °F)
50 -37 (-34 °F)

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

glycol is greater than 60%.

If it is necessary to add coolant to the system make sure

that the new coolant is similar to the original. Allow the
engine to cool down before adding new coolant.

Check the coolant concentration before the ambient

temperature drops below 0°C (32°F).

EL62757,0000153 –19–18APR02–1/1

6-0-14 101702

PN=85
 Maintenance - Machine

Hydraulic oil
Capacity Hydraulic tank min. 79 l (20.9 gal)
max. 150 l (39.6 gal)

If you use mineral oil:

Comply with SH 68 (SMR classification) in summer.

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

If you use synthetic biodegradeable oil:

Neste Biohydrauli SE 46

IMPORTANT: Do not mix different types of oils as this

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

EL62757,0000155 –19–18APR02–1/1

6-0-15 101702

PN=86
 Maintenance - Machine

Gear oil
Capacity High/low gear 4.5 l
(1.2 gal)
Differentials, rear 12 l
(3.2 gal)
Differentials, front, 8-wheel 12 l
(3.2 gal)
Differentials, front, 6-wheel 27 l
(7.1 gal)
Hub gears, 6-wheel 2x4l
2 x 1.05 gal)
Bogie casings 52 l
(13.7 gal)
Boom slew housing 9.5 l
(2.5gal)

Use hypoid oil that complies with the classification: API

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

The following viscosity categories can be used:

• SAE 90
• SAE 85W/90
• SAE 80W/90
• SAE 75W/90

EL62757,0000157 –19–18APR02–1/1

Brake fluid
Capacity Brake fluid tank appr.0.5 l
(0.1 gal)

Use ATF-oil.

EL62757,0000156 –19–18APR02–1/1

6-0-16 101702

PN=87
 Maintenance - Machine

Cab lift pump

Capacity Cab lift pump 0.8 l
(0.2 gal)

Factory has filled the pump with Biohydr. 15 oil.

NOTE: Don’t mix oils together.

If the pump is emptied, it can also be filled with ATF-oil.

EL62757,0000158 –19–18APR02–1/1

Grease

IMPORTANT: Contact Timberjack service about

availability of John Deere greases.

Apply lithium grease, some examples:

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

NOTE: Use enough grease!

NOTE: Don’t mix different type of grease together.

EL62757,0000154 –19–18APR02–1/1

6-0-17 101702

PN=88
 Maintenance - Periodic
Maintenance intervals

Service the machine according to following maintenance

intervals:

NOTE: Bear in mind that, when servicing the machine,

the maintenance that comes after every 2000
running hours, for example, also includes the daily
maintenance as well as the maintenance that
comes after every 50, 250, 500 and 1000 running
hours.

Maintenance - Every 10 hours or Daily

❒ Check the hydraulic oil level ❒ Check the radiator grille cleanness
❒ Check the engine oil level ❒ Check the air filter
❒ Check pre-fuel filter ❒ Check the tires for air pressure and overall shape.
❒ Check engine coolant level. ❒ Fill up the fuel tank
❒ Check the windshield washer fluid level ❒ Maintain the Boom, see Section 10-2
❒ Check the driving brake oil level
Maintenance - Every 50 hours or Weekly
❒ Grease the center hinge bearings and steering cylinder bearings. ❒ Check the air conditioner, see
❒ Grease the decking blade ❒ Check the fire extinguisher system, see .
❒ Maintain the Boom, see Section 10-3
Maintenance - Every 250 hours
❒ Clean the machine ❒ Grease Bogie Bearings
❒ Check the high/low gear oil level. ❒ Check Wheel Nut Torque
❒ Check Differential Oil Level ❒ Check the cabine air filters
❒ Check Single Axle Wheel Ends ( Hub gear) Oil Level. ❒ Check the air conditioner, see section 11-1
❒ Check Bogie Housings Oil Level ❒ Maintain the Boom, see Section 10-4
Maintenance - Every 500 hours
❒ Change the engine oil and filter ❒ Remove sediment and water from the fuel tanks
❒ Change fuel filters ❒ Checking cooling system
❒ Clean crankcase vent tube ❒ Renew the pressure filter of the drive hydraulic system
❒ Check the air intake system ❒ Check the batteries for charge
❒ Checking belt wear ❒ Grease the driveshafts
❒ Check engine speeds
❒ Control engine grounding

Continued on next page 61 –19–21JAN02–1/2

6-1-1 101702

PN=89
 Maintenance - Periodic

Maintenance - Every 1000 hours

❒ Renew the hydraulic oil. ❒ Check and tighten the screw and bolt connections
❒ Replace the hydraulic return filter ❒ Check the exhaust manifold
❒ Replace the hydraulic tank breather ❒ Check the air conditioner, see section 11-1
❒ Renew the high/low gear (transfer case) oil ❒ Maintain the Boom, see Section 10-5
Maintenance - Every 2000 hours
❒ Change Coolant ❒ Change Bogie Housings Oil
❒ Check valve clearance ❒ Change Single Axle Differential Oil
❒ Flushing the cooling system ❒ Change Single Axle Wheel Ends Oil
❒ Change Bogie Axle Differential Oil ❒ Check and tighten the bolts for the joints between axles and frame
❒ Control of the vibrations damper
Maintenance - Every 6 months
❒ Service the fire extinguisher
Maintenance - Every 12 months
❒ Have the fire extinguisher system (opt. eq.) checked
Maintenance - As required
❒ Bleeding the fuel system ❒ Have the proper function of the starter motor checked
❒ Replacing fan/alternator belt ❒ Clean the Fuel Tank Filler Filter
❒ Have the proper function of the atomizers checked
❒ Have the proper function of the turbocharger checked ❒ Check the air conditioner, see section 11-1
❒ Have the proper function of the alternator checked ❒ Maintain the Boom, see Section 10-5

61 –19–21JAN02–2/2

6-1-2 101702

PN=90
 Maintenance - Every 10 hours or Daily
Check the hydraulic oil level

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

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

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

–UN–05MAR02
NOTE: Do not exceed the ’MAX’ mark. There always has
to be enough air space in the hydraulic oil tank,
because the fluid level goes up and down during

T152230
the operation.

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

NOTE: Do not mix different type of oils.

Capacities Hydraulic tank min. 79 l (20.8 gal) /

max. 150 l (39.6 gal)
Mineral oil Summer oil SMRs norm SH 68
Winter oil SMRs norm SHS 32
Year-round oil SMRs norm SHS 46
If you use synthetic Neste Biohydrauli SE
biodegradeable oil: 46

–UN–07APR02
1—Oil level sight class
2—Venting screw
3—Switch, fill-up pump
4—Quick coupler - oil fill
5—Switch, vacuum pump

T152231

EL62757,00000E8 –19–10APR02–1/1

6-2-1 101702

PN=91
 Maintenance - Every 10 hours or Daily

Check the engine oil level

IMPORTANT: DO NOT add makeup oil until the oil

level is BELOW the ADD-mark.

The most accurate oil level reading is obtained when the

–UN–16JUN00
engine is cold before starting the engine for the day’s
operation.

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

RG8009A
engine
❒ If needed add oil through the oil filler cap (A).
RG8028 –UN–15JAN99

IMPORTANT: DO NOT fill above the top mark on the

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

Capacities Engine oil + filter 25 l (6,6 gal)

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

EL62757,00000F4 –19–10APR02–1/1

Check the Fuel Pre-Filter

2
IMPORTANT: Drain the fuel into a suitable container
3
and dispose of properly.

To drain water or depris, proceed as follows:

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

solenoid and the tank valve.
2. Loosen drain plug (1) in the bottom of bowl two or
three turns.
3. Loosen air bleed vent screw (2) two full turns on fuel
filter mounting and drain water from bottom until fuel
starts to drain out.
–UN–01OCT02

4. Tighten drain plug securely.

After draining water from the fuel filter the filter must be
primed by bleeding air from the fuel system.
T160017

4 1
1. Loosen the air bleed vent screw (3) two full turns by
hand on final fuel filter base.
2. Operate fuel supply pump prime lever (4) until fuel flow
is free from air bubbles.
3. Tighten bleed plug securely, continue operating hand
primer until pumping action is not felt. Push hand
primer inward engine as far as it will go.
EL62757,000005F –67–16OCT02–1/1

6-2-2 101702

PN=92
 Maintenance - Every 10 hours or Daily

Check engine coolant level.

With the engine cold, coolant level must be between MAX

and MIN marks on the expansion tank (A).

If coolant is below the MIN mark, add coolant to the tank.

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

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

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

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

–UN–17SEP02
tank.

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

T159304
EL62757,00000F5 –19–10APR02–1/2

CAUTION: Prevent possible injury from hot

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

–UN–01NOV88
Capacities Cooling system 27,5 l (7,3 gal)
50% Water /50% Ethylene or ASTM4985 or ASTM
Antifreeze Propylene glycol D5345

T6642EK

EL62757,00000F5 –19–10APR02–2/2

6-2-3 101702

PN=93
 Maintenance - Every 10 hours or Daily

Check the windshield washer fluid level

The windshield washer tank is located in the engine

compartment. Ensure that there is enough of the fluid.

–UN–11SEP02
T159303
EL62757,00000F6 –19–10APR02–1/1

6-2-4 101702

PN=94
 Maintenance - Every 10 hours or Daily

Check the radiator grille cleanness

NOTE: Depending on the operating conditions, it is

important to clean the radiator grille frequently in
order to prevent the engine and hydraulic system
from overheating.

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

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

CAUTION: Prevent possible injury from flying

–UN–11SEP02
chips if compressed air is more than 210 kPa
(2.1 bar) (30 psi). Clear area of bystanders,
guard against flying chips, and wear personal
protection equipment including eye equipment.

T159302
4. Clean the radiator grille with a brush or compressed
air. Lightly clean the condenser, too.

NOTE: Do not cover the grille when the engine is

running.

1—Fasteners
2—Net
3—Condenser
4—Cooling element

–UN–11SEP02
T159301

EL62757,00000F8 –19–10APR02–1/1

6-2-5 101702

PN=95
 Maintenance - Every 10 hours or Daily

Check the driving brake oil level

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

1—ATF oil tank

–UN–05MAR02
T152233
EL62757,00000F7 –19–10APR02–1/1

Check the air filter

When the red warning area of the restriction indicator (A)

of the air filter (1) is fully visible after the engine is
stopped, the air filter element must be cleaned or
replaced.

Having changed the filter element press the button at the

bottom of the restriction indicator. This will make the red
area disappear.

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

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

–UN–11SEP02
NOTE: When replacing the air filt er element it is
important to make sure that no dirt enters the
intake manifold.

T159300
Clean also the inside of the filter casing.

Remove dust from the valve (D). Ensure that the sides of
the valve close completely together and they can separate
freely.

IMPORTANT: In dusty circumstances the air filter

must be controlled more often.
–UN–11SEP02
T159299

EL62757,00000F9 –19–10APR02–1/1

6-2-6 101702

PN=96
 Maintenance - Every 10 hours or Daily

Check the tires for air pressure and overall

shape.

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

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

–UN–06MAR02
T152362
EL62757,00000FA –19–10APR02–1/1

Fill up the fuel tank

UUse only clean fuel to make sure that the diesel engine
will not run erratically.

• If necessary, drain the dirt deposited in the fuel tank

through the fuel tank drain hose (4).
• Fill up the tank every evening. This prevents
condensation from accumulating in an empty tank.

Specification
Fuel tank—Volume ............................................................. 165 l (43,5 gal)

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

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

as an extra equipment.

–UN–07OCT02
Automatic stop is engaged when the tank is full. After the
stop a manual use is also possible. The pump stops when
turning the switch in the opposite direction.

T160196
NOTE: TMC has to be ON as a pre-requisite for
automatics.
1—Top
2—Quick coupler
3—Drain hose

EL62757,00000FB –19–10APR02–1/1

6-2-7 101702

PN=97
 Maintenance - Every 10 hours or Daily

Maintain the boom

See Section 10-2

1. Grease the grapple and link.

2. Check boom structures

EL62757,00000FC –19–10APR02–1/1

The following service and checks are to be

made at the end of each workday

❒ Clean the machine

• Inspect all covered compartments, including engine
bay, belly plates etc. It is particularly important to
clean the machine in the winter because snow and
debris easily gets stuck to the machine

❒ Make sure that there are no defects or leaks

• Check the machine in daylight
• Repair any defects found or contact the service
personnel.

❒ Renew oils and grease (if necessary) the machine

while it is still warm.
❒ Check the tightness and mounting of the possible
chains.
❒ Replace the lock pin of the emergency exit
❒ Lock the cab door
❒ Turn off the main switch.
• If the machine is equipped with an automatic fire
extinguishing system (optional equipment), the
system will be engaged when the main switch is
turned off.

EL62757,00000FD –19–10APR02–1/1

6-2-8 101702

PN=98
 Maintenance - Every 50 hours or Weekly
Grease the center hinge bearings and
steering cylinder bearings.

CAUTION: Crushing injury may result to

persons in the hinge area if machine is turned.
Install frame locking bar before working in this
area.

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

–UN–06MAR02
T152346
Center hinge bearing, left

–UN–06MAR02
T152347
Center hinge bearing, right

EL62757,00000E9 –19–10APR02–1/1

6-3-1 101702

PN=99
 Maintenance - Every 50 hours or Weekly

Grease the decking blade1

Grease the decking blade pins.

NOTE: There are six greasing points for the decking

blade. Four greasing points are external and two

–UN–06MAR02
are inside the frame. The belly pan must be
lowered to access the greasing points inside the
frame. Use a 1/2” wrench to lower the belly pan.

T152349
NOTE: Working in difficult circumstances, if necessary,
grease the decking blade daily.

1
Decking blade is an optional equipment.
EL62757,00000FE –19–10APR02–1/1

Check the air conditioner

Check the service moisture indicator.

See section, 11-1.

EL62757,00000FF –19–10APR02–1/1

Maintain the Boom

1. Check the boom slewing housing oil level

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

See section 10-3.

EL62757,0000101 –19–10APR02–1/1

6-3-2 101702

PN=100
 Maintenance - Every 50 hours or Weekly

Check the fire extinguisher system

Fire extinguisher system is an extra equipment. See

section 11-4.

EL62757,0000100 –19–10APR02–1/1

6-3-3 101702

PN=101
 Maintenance - Every 250 hours
Clean the machine

• Remove dirt and wash the machine

• Use a spray of warm water to clean the cooling ducts
(1). Clean from the engine side, blowing against the
normal flowing direction of the cooling air. Do not
employ a strong pressure when cleaning the air
conditioner condenser (2).

If you operate under dusty circumstances, clean the ducts

with compressed air more frequently, even daily if
necessary.

1—Cooling ducts

–UN–06MAR02
2—Condenser

T152350
EL62757,00000EA –19–10APR02–1/1

6-4-1 101702

PN=102
 Maintenance - Every 250 hours

Check the high/low gear oil level.

1. Park the machine on a level surface. Lower decking

blade to the ground and secure grapple to Rear frame.
2. Engage park brake. Turn key switch OFF.

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame
locking bar before working in frame pivot area.

3. Install frame locking bar.

4. Check oil level dipstick that the oil level stays between
the ’MIN’ and ’MAX’ marks.
Dipstick is placed between the hydraulic tank and the

–UN–06MAR02
fuel tank.
5. If necessary add oil through the dipstick hole or
through the filler plug (3) on top of the high/low gear
• High/ low gear can be accessed by moving the fuel

T152348
tank aside. Remove two bolts (2).

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

dipstick.
3
Capacities High / low gear 4.5 l (1.2 gal)
Hypoid oil API GL-5 or MIL-L-2105 B or D
Viscosity SAE 90
SAE 85W/90
SAE 80W/90
SAE 75W/90

1—Dipstick
2—Bolts
3—Filling plug

–UN–20MAR02
T152824
EL62757,0000102 –19–10APR02–1/1

6-4-2 101702

PN=103
 Maintenance - Every 250 hours

Check Differential Oil Level

NOTE: The differential is similar on the single axle and

the bogie axle.

The oil levels in the differential and wheel ends or

bogie housings must be checked separately.

1. To access the dipstick and filler plugs on the rear axle,

remove the service covers on top of the Rear frame.

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

tilt the cab to the service position.

–UN–21JUN01
3. Check the oil level in the differential gear on the
dipstick.

T142883
4. If required, add oil through one of the filler plugs on top
of the axle. Alternatively, add oil through the level plug
on the differential.

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

seal or copper washer.

Capacities Differentials, rear 12 l (3.1 gal)

Differentials, front, 12 l (3.1 gal)

–UN–21JUN01
8-wheel
Differentials, front, 27 l (7.1 gal)
6-wheel
Hypoid oil API GL-5 or MIL-L-2105 B or D

T142884
Viscosity SAE 90
SAE 85W/90
SAE 80W/90
SAE 75W/90 1—Differential Oil Level Dipstick
2—Filler Plugs
3—Level Plug

OUTJ003,00006A8 –19–16MAY01–1/1

6-4-3 101702

PN=104
 Maintenance - Every 250 hours

Check Single Axle Wheel Ends ( Hub gear)

Oil Level

NOTE: Although oil can pass from the differential to the

wheel ends, it is necessary to check the oil level
in the differential and each wheel end separately.

1. Position the wheel end so that the drain port (1) is on

the horizontal centerline of the axle.

2. Remove the drain plug. The oil level must be up to the

drain port.

3. Add oil, if necessary, through the fill port (2).

4. Install the drain plug.

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

–UN–19JUL01
seal or copper washer.

Capacities Hub gears, 6-wheel 2 x 4 l (2 x 1.05 gal)

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

T144162
Viscosity SAE 90
SAE 85W/90
SAE 80W/90
SAE 75W/90 1—Drain Plug
2—Fill Plug

OUTJ003,00006F6 –19–17JUL01–1/1

6-4-4 101702

PN=105
 Maintenance - Every 250 hours

Check Bogie Housings Oil Level

1. Clean the area around the plugs.

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

–UN–21JUN01
3. Remove the inspection plug. The oil level must be up
to the inspection port.

T142885
NOTE: The oil levels in the differential and both bogie
housings must be checked separately.

4. If necessary, add oil to the bogie housing through the 1—Filler Plug
filler port. 2—Inspection Plug

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

seal or copper washer.

Capacities Bogie housing 52 l (13.7 gal)

Hypoid oil API GL-5 or MIL-L-2105 B or D
Viscosity SAE 90
SAE 85W/90
SAE 80W/90
SAE 75W/90

OUTJ003,00006A9 –19–16MAY01–1/1

6-4-5 101702

PN=106
 Maintenance - Every 250 hours

Grease Bogie Bearings

Each bogie housing has ten grease fittings on each side

of the housing which must be greased to properly
lubricate the bogie bearings.

–UN–13JUN01
Cover the grease fittings with white plastic caps.

1—Grease Fittings

T142886
Bogie Housing Grease Points, 3 Upper Ports

–UN–13JUN01
T142887
Bogie Housing Grease Points, 3 Lower Ports

–UN–13JUN01
T142888
Bogie Housing Grease Points, 4 Side Ports

OUTJ003,00006AA –19–16MAY01–1/1

6-4-6 101702

PN=107
 Maintenance - Every 250 hours

Check Wheel Nut Torque

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

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

–UN–04DEC01
Check the wheel nuts torque.

Replacement hardware should be tightened to

T142843
specification.

Specification
Wheel Nut—Torque ..................................................... 550 N•m (405 lb-ft)

Check wheel rims for dents and cuts. Replace damaged

wheel rims.

OUTJ003,00006AB –19–16MAY01–1/1

Check the cabine air filters

1. The hatch for the cabine outside and inside air filter is
located underneath the first side window.
Open the hatch on the right-hand side of the cabin.
2. Inside the cabine, at the back side of the floor, there is
a filter (2)for cabine’s heater.
3. Controll and clean the filters, replace if necessary.

NOTE: If necessary, due to circumstances, the filters

must be checked and cleaned or replaced even
more often.

1—Cabine Air Filter

2—Heater’s Air Filter

–UN–11SEP02
T159298

EL62757,0000107 –19–10APR02–1/1

6-4-7 101702

PN=108
 Maintenance - Every 250 hours

Check the air conditioner

See section 11-1.

1. Check AC Compressor V-belt

2. Check fresh outside air filter and inside filter.
3. Check AC Compressor

EL62757,0000108 –19–10APR02–1/1

Maintain the boom

See Section 10-4.

1. Clean the boom.

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

EL62757,0000109 –19–10APR02–1/1

6-4-8 101702

PN=109
 Maintenance - Every 500 hours
Change engine oil and replace oil filter

IMPORTANT: Change the engine oil and filter for the

first time after 250 hours maximal of
operation, then every 500 hours
thereafter.

–UN–05MAR02
Capacities Engine oil + filter 25 l (6.6 gal)
John Deere PLUS-50, ACEA E5, ACEA E4. See also chapter 6-0.

T152229
1. Run engine approximately 5 minutes to warm up oil.
Shut engine off.

2. Lower the belly pan. Open the plug of the drain hose
(3) and drain the oil into a container.

3. Oil filter (A) is placed at the right side of the engine.

Clean the area around the filter bowl.

–UN–24OCT01
4. Remove old oil filter element turning it
counterclockwise. Make sure the old seling comes off
with filter. Clean the sealing surface of the filter foot.

RG11616
IMPORTANT: Filtration of oils is critical to proper
lubrication. Always change filter
regularly. Use filter meeting John Deere
performance specifications

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

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

–UN–08OCT02
housing.

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

T160264
Y01
Specification
Oil pan drain plug—Torque ............................................. 80 Nm (59 lb-ft)
3—Oil drain hose
A—Oil filter
7. Fill engine crankcase with engine oil through oil filler
cap.

Continued on next page DPSG,OUOE003,8005 –19–18JUN99–1/2

6-5-1 101702

PN=110
 Maintenance - Every 500 hours

IMPORTANT: Immediately after completing any oil

change, crank engine for 30 seconds
without permitting engine to start. This
will help insure adequate lubrication to
engine components before engine
starts.

9. Detach the connection (Y01) from the control unit of

the fuel pump and operate the engine by means of the
starter motor about 30 seconds. Reconnect the
connector again. Start engine and run to check for
possible leaks.

10. Stop engine and check oil level after 10 minutes. Oil
level reading should be within crosshatch of dipstick.

DPSG,OUOE003,8005 –19–18JUN99–2/2

6-5-2 101702

PN=111
 Maintenance - Every 500 hours

Change the fuel filters

1. Clean dirt and debris from and around the fuel filter
assembly

2. Open drain plug (1) in the bottom of the filter and vent
screw (2) on the filter. Drain the fuel into a container.

NOTE: Lifting up on retaining ring as it is rotated helps to

get it past raised locators.

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

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

–UN–01OCT02
4. Inspect filter mounting base for cleanliness. Clean as
required.

T160018
5. Remove filter element from water separator bowl (4). B
Drain and clean separator bowl. Dry with compressed
air. Check also O-ring; change if needed. Install water
separator bowl onto new element. Tighten securely.
2
6. Fill the new filters with clean fuel. Fit the filters back.

7. Install retaining ring onto mounting base making certain

dust seal is in place on filter base. Hand tighten ring
(about 1/3 turn) until it “snaps” into the detent. DO
NOT overtighten retaining ring.
3
8. Bleed the fuel system. See chapter: Maintenance as
required.

B—Fuel Pre Filter

A—Final Fuel Filter

–UN–01OCT02
1—Drain plug
2—Vent screw
3—Retaining ring
4—Water bowl 4

T160019
1
EL62757,0000060 –67–16OCT02–1/1

6-5-3 101702

PN=112
 Maintenance - Every 500 hours

Clean crankcase vent tube

If the engine has been operated in dusty circumstances,

clean the tube(A) more often.

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

–UN–19JUN00
2. Install the vent tube. Be sure the O-ring fits correctly in
the rocker arm cover for elbow adapter. Tighten hose
clamp securely.

RG8017A
A—Crankcase Vent tube

EL62757,000010A –19–10APR02–1/1

Check the air intake system

IMPORTANT: The air intake system must not leak

Inspect the intake piping and aftercooler for cracked

hoses or loose clamps which can allow dirt and debris to

–UN–20JUL01
enter the engine. Clean and fix if necessary.

T138992
EL62757,000010B –19–10APR02–1/1

Checking belt tensioner spring tension and

belt wear

Checking belt wear

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

–UN–18NOV97

assembly.

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

stop (B), check mounting brackets (alternator, belt
RG8098

tensioner, idler pulley, etc.) and the belt length. Replace

belt as needed.

A—Tensioner Stop
B—Fixed Stop

Continued on next page EL62757,000010F –19–10APR02–1/3

6-5-4 101702

PN=113
 Maintenance - Every 500 hours

Checking tensioner spring tension

A belt tension gauge will not give an accurate measure of

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

–UN–14NOV97
1. Release tension on belt using a long-handle 1/2 inch
breaker bar in tension arm. Remove belt from pulleys.

RG7977
2. Release tension on tension arm and remove breaker
bar

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

–UN–08JAN02
RG12054
EL62757,000010F –19–10APR02–2/3

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

mark (B) on tensioner mounting base.

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

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

–UN–28JAN02
aligned.

6. Record torque wrench measurement and compare with

specification below. Replace tensioner assembly as

RG12065
required

Specification
Spring Tension—Torque ..................................... 18-22 N•m (13-16 lb-ft)

A—Mark On Swing Arm

B—Mark On Tensioner Mounting Base
C—Torque Wrench
–UN–28NOV97
RG7381

EL62757,000010F –19–10APR02–3/3

6-5-5 101702

PN=114
 Maintenance - Every 500 hours

Check engine speeds

Check the engine rpm’s at the TMC display.

EL62757,0000114 –19–10APR02–1/1

Control engine grounding

Check engine ground connection to be sure it is secure

and clean. This will prevent electrical arcing which can
damage engine.

EL62757,0000115 –19–10APR02–1/1

Remove sediment and water from the fuel

tanks

Drain water and sediment from the sediment cup of the

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

–UN–05MAR02
4—Fuel tank drain hose

T152229
EL62757,000011B –19–10APR02–1/1

6-5-6 101702

PN=115
 Maintenance - Every 500 hours

Renew the pressure filter of the drive

hydraulic system

1. Lower down the belly plate. The transmission filter is

located under the transmission pump.

2. Turn filter counterclockwise to remove.

3. Clean mounting surface. Apply thin film of oil to gasket

of new filter.

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

–UN–22SEP02
5. Start engine. Check for leaks around the filter base.
Tighten filter only enough to stop leaks.

T159654
6. Stop engine.

7. Check oil level at sight glass on hydraulic tank. Add oil,

1—Pressure filter
if necessary. See Section 6-0, for recommended
hydraulic fluids.

EL62757,0000117 –19–10APR02–1/1

Check the batteries for charge

CAUTION: Keep sparks, lighted matches, and

open flame away from the top of battery.
Battery gas can explode.

Sulfuric acid in battery electrolyte is poisonous. It is strong

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

–UN–23AUG88
TS203

Continued on next page EL62757,000011A –19–10APR02–1/2

6-5-7 101702

PN=116
 Maintenance - Every 500 hours

Measure the specific gravity of the battery electrolyte.

The density (specific gravity) of the electrolyte must be

between 1.23 and 1.28.

If the density (specific gravity) of the electrolyte has

–UN–13JUN01
dropped below 1.23, the battery must be recharged.

NOTE: The electrolyte of a discharged battery can freeze

at temperatures as high as -10°C (14°F.),

T142899
destroying the battery.

Make sure the battery cable are correctly connected. Look

at the electrical scheme.

EL62757,000011A –19–10APR02–2/2

Checking cooling system

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious
burns. Shut off engine. Only remove filler cap
when cool enough to touch with bare hands.

–UN–23AUG88
Slowly loosen cap to first stop to relieve
pressure before removing completely.

IMPORTANT: Air must be expelled from cooling

TS281
system when system is refilled. Loosen
temperature sending unit fitting at rear
of cylinder head or plug in thermostat
housing to allow air to escape when
filling system. Retighten fitting or plug
when all the air has been expelled.

1. Check entire cooling system for leaks. Tighten all

clamps securely

2. Thoroughly inspect all cooling system hoses. Replace

hoses when hard, flimsy, or cracked

EL62757,0000110 –19–10APR02–1/1

6-5-8 101702

PN=117
 Maintenance - Every 500 hours

Control of the diesel engine coolant

Maintaining adequate concentrations of glycol and

inhibiting additives in the coolant is critical to protect the
engine and cooling system against freezing, corrosion,
and cylinder liner erosion and pitting.

Test the coolant solution at intervals of 12 months or less

and whenever excessive coolant is lost through leaks or
overheating.

Coolant Test Strips:

Coolant test strips are available from your local dealer.

These test strips provide a simple, effective method to
check the freeze point and additive levels of your engine
coolant.

Compare the results to the supplemental coolant additive

(SCA) chart to determine the amount of inhibiting
additives in your coolant and whether more John Deere
COOLANT CONDITIONER should be added.

EL62757,0000111 –19–10APR02–1/1

Filling supplemental coolant additives (SCA)

between coolant changes

IMPORTANT: Do not add supplemental coolant

additives when the cooling system is
drained and refilled with John Deere
ANTIFREEZE/SUMMER COOLANT or
COOL- GARD

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

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

See Section 6-11: Filling supplemental coolant additives

(SCA) between coolant changes

EL62757,0000112 –19–10APR02–1/1

6-5-9 101702

PN=118
 Maintenance - Every 500 hours

Pressure control of the cooling system

CAUTION: Explosive release of fluids from

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

See Section 6-11: Pressure control of the cooling system

EL62757,0000113 –19–10APR02–1/1

Grease the driveshafts

–UN–02OCT02
T159651
• Nipples (1), (2) and (3) Front driveshaft, grease • Nipples (4) and (5) Center driveshaft
through the service openings under the frame.

Continued on next page EL62757,0000119 –19–10APR02–1/2

6-5-10 101702

PN=119
 Maintenance - Every 500 hours

–UN–02OCT02
T159652
Short rear frame

–UN–02OCT02
T159653
Long rear frame

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

Rear driveshaft, grease through the service
openings on top of the frame (nipple (6) and nipples
(7) and (8) and (nipple 9).
EL62757,0000119 –19–10APR02–2/2

6-5-11 101702

PN=120
 Maintenance - Every 1000 hours
Renew the hydraulic oil.

NOTE: Change hydraulic oil when it is warm and

contaminants are in suspension.

You can use a vacuum pump (optional equipment) to

drain the hydraulic tank. The vacuum pump is used to
avoid oil spill, e.g., in the event of hose rupture or other
leakage. See section 7-1 for instructions to use a vacuum
pump.

You can use a hydraulic fill-up pump (optional equipment)

to add oil to the tank. Oil is added through a quick coupler
which is mounted in a way that the new oil enters the
system through the filter. Also a manual pump can be
used.

See section 7-1 for instructions to renew the hydraulic oil.

IMPORTANT: Do not mix oils.

EL62757,00000EC –19–10APR02–1/1

6-6-1 101702

PN=121
 Maintenance - Every 1000 hours

Replace the hydraulic return filter

CAUTION: Before working on the hydraulics,

park the machine on a level surface, lower the
decking blade, grapple to the ground, shut off
the engine.

IMPORTANT: When replacing the filter make sure that

no dirt enters the hydraulic system.

1. Open the vent screw (1) on top of the tank

2. Remove the screws of cover (10)

CAUTION: The filter cover is under spring

tension. Hold cover down while removing
screws

Clamp guarantees that the filter functions properly.

NOTE: Filter assembly consists of a filter element (7) and

a canister (6). Filter is in lock position inside the
canister.

IMPORTANT: The filter and the canister must be lifted

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

–UN–11SEP02
3. Put the filter element and the canister into an oil
collecting sump

T159297
4. Unlock the filter element by twisting it counterclockwise

5. Remove the filter element and clean the canister 1—Vent screw
2—Lock position
6. Replace the filter element and put it inside the canister. 3—O-ring
4—Spacer ring
5—O-ring
Twist the filter element clockwise and check that it 6—Canister
is locked inside the canister! You maybe need to 7—Filter element
press the filter while twisting it. 8—Spring
9—O-ring
10—Cover
7. Place the filter assembly in the tank together with the
11—Screw
spring (8). Screw the cover (10) on.

8. Start the engine and run for 5 minutes. Stop the engine

9. Check for any leakage at filter cover.

Continued on next page EL62757,000011C –19–10APR02–1/2

6-6-2 101702

PN=122
 Maintenance - Every 1000 hours

10. Close the vent screw.

11. Check oil level in tank. Add oil if necessary.

The filters are equipped with a pressure sensor. If the

pressure sensor sets off an alarm, renew the filter.
Otherwise, stick to maintenance periods.

EL62757,000011C –19–10APR02–2/2

Replace the hydraulic tank breather

Check the hydraulic oil tank breather. Clean the breather

if necessary.

1—Hydraulic tank breather.

–UN–08MAR02
T152538
EL62757,000011D –19–10APR02–1/1

6-6-3 101702

PN=123
 Maintenance - Every 1000 hours

Renew the high/low gear (transfer case) oil

1. Park machine on a level surface. Lower decking blade

to the ground and secure grapple to Rear frame.

2. Engage park brake. Turn key switch OFF.

CAUTION: Prevent possible injury from

unexpected machine movement. Install frame
locking bar before working in frame pivot area.

3. Install frame locking bar.

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

–UN–20MAR02
cover on the underside of the front frame.

5. Remove the drain plug and drain the transfer case oil
into a suitable container.

T152797
NOTE: Dispose of waste properly.

6. After draining, install the plug and replace the access 3

cover.

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

dipstick.

1—Drain plug
3—Fill plug

–UN–20MAR02
T152824
Continued on next page EL62757,000011E –19–10APR02–1/2

6-6-4 101702

PN=124
 Maintenance - Every 1000 hours

8. Check oil level on dipstick. Oil level must be at the

FULL notch.

9. Install fill plug.

Capacities High / low gear 4.5 l (1.2 gal)

Hypoid oil API GL-5 or MIL-L-2105 B or D
Viscosity SAE 90
SAE 85W/90
SAE 80W/90
SAE 75W/90

–UN–06MAR02
1—Dipstick
2—Screws

T152348
EL62757,000011E –19–10APR02–2/2

Check and tighten the screw and bolt

connections

It is especially important to retighten the wheel nuts if the

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

–UN–04DEC01
Periodically see to it that there are no dents or cuts in the
rims. Replace badly damaged rims.

T142843
Item Measurement Specification

Wheel nuts Torque 550 Nm (405 lb-ft)

EL62757,0000122 –19–10APR02–1/1

6-6-5 101702

PN=125
 Maintenance - Every 1000 hours

Check the exhaust manifold

IMPORTANT: Allow exhaust system to cool before

service

See to it that all attaching bolts are firmly secured, all

joints are tight, and that there are no breaks in the
manifold.

EL62757,0000121 –19–10APR02–1/1

Check the air conditioner

See Section 11-1. .

1. Service the compressor

2. Service the compressor clutch
3. Service the evaporator element
4. Service the condenser element
5. Service the hoses and connectors

EL62757,0000120 –19–10APR02–1/1

Maintain the boom

See section 10-5.

1. Clean the magnetic plug of rotator

2. Change the boom slewing system oil

EL62757,000011F –19–10APR02–1/1

6-6-6 101702

PN=126
 Maintenance - Every 2000 hours
Check valve clearance

CAUTION: To prevent accidental starting of

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

–UN–06AUG96
IMPORTANT: Valve clearance MUST BE checked and
adjusted with engine COLD.

RG7408
1. Remove rocker arm cover and crankcase ventilator
tube.
A—Timing/Rotation Hole
IMPORTANT: Visually inspect contact surfaces of B—Timing Pin Hole
valve tips and rocker arm wear pads.
Check all parts for excessive wear,
breakage, or cracks. Replace parts that
show visible damage.

Rocker arms that exhibit excessive

valve clearance should be inspected
more thoroughly to identify damaged
parts.

2. Remove plastic plugs or cover plate from engine

timing/rotation hole (A) and timing pin hole (B).

3. Using JDE83 or JD81-1 Flywheel Turning Tool, rotate

engine flywheel in running direction (clockwise viewed
from front) until No. 1 cylinder is at TDC compression
stroke. Insert JDG1571 or JDE81-4 Timing Pin in
flywheel.

If the rocker arms for No. 1 (front) cylinder are loose,

the engine is at No. 1 “TDC-Compression.”

If No. 1 cylinder rocker arms are not loose, rotate

engine one full revolution (360°) to No. 1 TDC
compression.

Continued on next page RG41165,0000032 –19–12DEC00–1/2

6-7-1 101702

PN=127
 Maintenance - Every 2000 hours

4. With engine lock-pinned at TDC of No. 1 piston’s

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

Specification

–UN–31OCT97
Intake Valve Clearance Checking
(Rocker Arm-to-Valve Tip With
Engine Cold)—Clearance ................................................... 0.31..-0.38 mm
(0.012...0.015 in.)
Exhaust Valve Clearance

RG4777
Checking (Rocker Arm-to-Valve
Tip With Engine Cold)—
Clearance ........................................................................... 0.41...0.48 mm
(0.016...0.019 in.) A—Front of Engine
B—No. 1 Piston TDC Compression
5. Rotate flywheel 360° until No. 6 piston is at “TDC” of C—No. 6 Piston TDC Compression
its compression stroke. Rocker arms for No. 6 piston E—Exhaust Valve
I—Intake Valve
should be loose.

6. Check valve clearance to the same specifications on

Nos. 2, 4, and 6 exhaust and Nos. 3, 5, and 6 intake
valves.

7. If valve clearance needs to be adjusted, let an

authorized workshop do that.

8. Install rocker arm cover with vent tube and tighten cap
screws to specifications in order shown.

RG41165,0000032 –19–12DEC00–2/2

6-7-2 101702

PN=128
 Maintenance - Every 2000 hours

Checking Crankshaft Vibration Damper

IMPORTANT: The vibration damper assembly is not

repairable and should be replaced every
4500 hours or 60 months, whichever
occurs first.

–UN–15JAN99
1. Remove belts (shown removed).

2. Grasp vibration damper with both hands and attempt to

RG8018
turn it in both directions. If rotation is felt, damper is
defective and should be replaced.

3. Check vibration damper radial runout by positioning a

dial indicator (A) so probe contacts damper outer
diameter.

4. Rotate crankshaft using JDE83 or JD81-1 Flywheel

Turning Tool.

–UN–23NOV97
5. Note dial indicator reading.

If runout exceeds specifications, replace vibration

RG7508
damper.

Item Measurement Specification

Damper Radial Runout 1.50 mm (0.060 in.)

EL62757,0000116 –19–10APR02–1/1

6-7-3 101702

PN=129
 Maintenance - Every 2000 hours

Changing the Coolant

CAUTION: Explosive release of fluids from

pressurized cooling system can cause serious
burns.

–UN–23AUG88
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands. Slowly
loosen cap to first stop to relieve pressure
before removing completely.

TS281
NOTE: Drain the initial factory fill engine coolant after the High Pressure Fluids
first 3000 hours or 3 years of operation.
Subsequent drain intervals are determined by the
coolant used for service.

When John Deere COOL-GARD is used, the drain

interval is 3000 hours or 3 years. The drain
interval may be extended to 5000 hours or 5

–UN–19JUN00
years of operation provided that the coolant is
tested annually AND additives are replenished
as needed, by adding a supplemental cooling
additive (SCA).

RG8019A
If COOL-GARD is not used, the drain interval is
reduced to 2000 hours or 2 years of operation. Cooling System Drains

Drain old coolant, flush the entire cooling system, replace

thermostats, and fill with recommended clean coolant.

1. Make sure that the machine is standing horizontally.

Set the cabin heating control to its maximum open
position.
–UN–07OCT02

2. Carefully open the expansion tank cap to relieve

pressure and allow coolant to drain faster.
T159296

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

Drain all coolant from engine block.
fOpen radiator drain valve (C) and
A—Pump Drain Valve
drain coolant from radiator.
C—Radiator Drain Valve
4. Remove thermostats. Install cover and tighten cap
screws to 20 Nm (15 lb-ft).

Continued on next page AK12300,000001A –19–30JAN02–1/3

6-7-4 101702

PN=130
 Maintenance - Every 2000 hours

5. Close all drain valves and fill the cooling system with
clean water. Run the engine about 10 minutes to stir
up possible rust or sediment.

6. Stop engine and immediately drain the water from

system before rust and sediment settle.

7. After draining water, close drain valves and fill the

cooling system with clean water and a heavy duty
cooling system cleaner such as FLEETGUARD
RESTORE or RESTORE PLUS. Follow
manufacturer’s directions on label.

8. After cleaning the cooling system, drain cleaner and fill

with water to flush the system. Run the engine about
10 minutes, then drain out flushing water.

9. Close all drain valves on engine and radiator. Install

thermostats using a new gasket.

IMPORTANT: Never pour cold liquid into a hot

engine, as it may crack cylinder head or
block.

IMPORTANT: Air must be expelled from cooling

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

10. When adding coolant to the system, use the

appropriate coolant solution.

FLEETGUARD is a trademark of Cummins Engine Company, Inc.

RESTORE is a trademark of Fleetguard Inc.
RESTORE PLUS is a trademark of Fleetguard Inc. Continued on next page AK12300,000001A –19–30JAN02–2/3

6-7-5 101702

PN=131
 Maintenance - Every 2000 hours

Add coolant via expansion tank. Ensure that the coolant

level stays between the “MIN” and “MAX” marks.

Capacities Cooling system 27.5 l (7,3 gal)

50% Water /50% Propylene glycol ASTM4985 or ASTM
Antifreeze D5345

11. Run engine until it reaches operating temperature

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

12. After running the engine, check coolant level and

entire cooling system for leaks.

–UN–17SEP02
T159304
AK12300,000001A –19–30JAN02–3/3

6-7-6 101702

PN=132
 Maintenance - Every 2000 hours

Change Bogie Axle Differential Oil

NOTE: Change the oil while it is warm.

1. Park the machine on a level surface. Engage the

parking brake. Install the frame lock.

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

remove the service covers on top of the Rear frame.

3. Clean the area around the plugs.

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

–UN–21JUN01
the differential.

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

T142883
NOTE: Dispose of waste properly. Do not dump oil on
ground or in sewers.

6. Clean and install the drain plug.

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

copper washers should be replaced.

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

–UN–15JUN01
axle. Alternatively, add oil through the level plug on the
differential.

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

T142920
NOTE: Any time plugs are removed, the O-ring seals or
copper washers should be replaced.
1—Differential Oil Level Dipstick
Capacities Differentials, rear 12 l (3.1 gal) 2—Filler Plugs
3—Level Plug
Differentials, front, 12 l (3.1 gal) 4—Drain Plug
8-wheel
Hypoid oil API GL-5 or MIL-L-2105 B or D
Viscosity SAE 90
SAE 85W/90
SAE 80W/90
SAE 75W/90

OUTJ003,00006B9 –19–16MAY01–1/1

6-7-7 101702

PN=133
 Maintenance - Every 2000 hours

Change Bogie Housings Oil

NOTE: Before changing the bogie housing oil, let the

machine stand for 30 minutes to allow impurities
to settle to the bottom.

–UN–13JUN01
1. Park the machine on a level surface. Engage the
parking brake. Install the frame lock.

2. Clean the area around the plugs.

T142919
3. Remove the filler plug to vent the bogie housing.

4. Remove the inspection plug. 1—Filler Plug

2—Inspection Plug
3—Drain Plug
5. Remove the drain plug. Drain a sample of oil (5 l / 1,3
gal) into a suitable container.

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

new oil.

NOTE: The oil sample taken from the bogie housing is

not reusable.

If the oil is cloudy, replace all the oil in the bogie

housing.

NOTE: Dispose of waste properly. Do not dump oil on

ground or in sewers.

6. Install the drain plug. Add oil to the bogie housing

through the filler port until the oil level is up to the
inspection port.

7. Install the filler and inspection plugs.

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

should be replaced.

8. Repeat the procedure at each bogie.

Capacities Bogie housing 52 l (13.7 gal)

Hypoid oil API GL-5 or MIL-L-2105 B or D
Viscosity SAE 90
SAE 85W/90
SAE 80W/90
SAE 75W/90

OUTJ003,00006B8 –19–16MAY01–1/1

6-7-8 101702

PN=134
 Maintenance - Every 2000 hours

Change Single Axle Differential Oil

–UN–19JUL01
T144163
1—Dipstick 3—Differential Level Port 4—Axle Beam Drain Ports 5—Differential Drain Port
2—Axle Beam Fill Ports

NOTE: Change the oil while it is warm.
1. Park the machine on a level surface. Engage the
parking brake. Install the frame lock.
2. To access the dipstick and filler plugs on the rear
axle, remove the service covers on top of the Rear
frame.
3. To access the dipstick and filler plugs on the front
axle, tilt the cab to the service position.
4. Open the bellypan to access the underside of the
differential.
7. Remove drain plugs from the differential and both
axle beams. Drain oil into suitable container.
NOTE: Dispose of waste properly. Do not dump oil on
ground or in sewers.
8. Clean and install the drain plugs.
NOTE: Any time plugs are removed, the O-ring seals
or copper washers should be replaced.
9. Add new oil through one of the filler plugs on top of
the axle beams. Alternatively, add oil through the
level plug on the differential.

5. Clean the area around the plugs. 10. Check oil level on dipstick. Install the filler plug.

6. Lift the dipstick or remove the differential filler plug

to vent the differential.

Continued on next page OUTJ003,00006F7 –19–17JUL01–1/2

6-7-9 101702

PN=135
 Maintenance - Every 2000 hours

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

or copper washers should be replaced.

Capacities Differentials, front, 27 l (7.1 gal)

6-wheel
Hypoid oil API GL-5 or MIL-L-2105 B or D
Viscosity SAE 90
SAE 85W/90
SAE 80W/90
SAE 75W/90

OUTJ003,00006F7 –19–17JUL01–2/2

Change Single Axle Wheel Ends Oil

NOTE: Although oil can pass from the differential to the

wheel ends, it is necessary to change the oil level
in the differential and each wheel end separately.

–UN–19JUL01
NOTE: Change the oil while it is warm.

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

bottom.

T144165
2. Clean the area around the plugs.
Wheel End - Drain Position
3. Remove the filler plug to vent the wheel end.
1—Drain Plug
2—Filler Plug
4. Remove drain plug. Drain oil into suitable container.

NOTE: Dispose of waste properly. Do not dump oil on

ground or in sewers.

Continued on next page OUTJ003,00006F8 –19–17JUL01–1/2

6-7-10 101702

PN=136
 Maintenance - Every 2000 hours

5. Position the wheel end with the drain plug on the

horizontal centerline of the axle.

6. Add new oil through the filler port until the level is at
the drain plug.

–UN–19JUL01
7. Clean and install the drain plug and the filler plug.

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

copper washers should be replaced.

T144166
8. Repeat the procedure at each wheel end.
Wheel End - Fill Position
Capacities Hub gears, 6-wheel 2 x 4 l (2 x 1.05 gal)
1—Drain Plug
Hypoid oil API GL-5 or MIL-L-2105 B or D 2—Filler Plug
Viscosity SAE 90
SAE 85W/90
SAE 80W/90
SAE 75W/90

OUTJ003,00006F8 –19–17JUL01–2/2

Check and tighten the bolts for the joints

between axles and frame

Item Measurement Specification

Horizontal and Vertical bolts Torque 1000 Nm (737.5 lb -ft)

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

EL62757,0000123 –19–10APR02–1/1

6-7-11 101702

PN=137
 Maintenance - Every 6 months
Service the fire extinguisher

The fire extinguishers must be checked, serviced and

stamped by an authorized dealer. On certain markets fire
insurance terms stipulate that fire extinguishers must be
checked after every six months.

Contact your insurance company for all the details.

–UN–11MAR02
T152581
EL62757,00000EE –19–10APR02–1/1

6-8-1 101702

PN=138
 Maintenance - Every 12 months
Have the fire extinguisher system (opt. eq.)
checked

The system is to be inspected once a year by authorized

service personnel.

This inspection is a condition of the insurance companies.

See section 11-4, annual inspection.

EL62757,00000EF –19–10APR02–1/1

6-9-1 101702

PN=139
 Maintenance - As required
General

IMPORTANT: Do not modify fuel system!

CAUTION: Modification or alteration of the

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

EL62757,000013C –19–11APR02–1/1

6-10-1 101702

PN=140
 Maintenance - As required

Bleeding the fuel system

Bleeding the fuel system:

Whenever the fuel system has been opened up for

service (lines disconnected or filters removed), it will be

–UN–23AUG88
necessary to bleed air from the system.

CAUTION: Escaping fluid under pressure can

penetrate the skin causing serious injury.

X9811
Relieve pressure before disconnecting fuel or
other lines. Tighten all connections before
applying pressure. Keep hands and body away
from pinholes and nozzles that eject fluids
under high pressure. Use a piece of cardboard
or paper to search for leaks. Do not use your
hand.

Small amounts of air will be vented automatically from the

injection pump supply line. However, manual bleeding will
be required if:

❒ The fuel tank is drained during ordinary operation

❒ A part of the fuel supply line has leaked. Fuel filters are
not filled prior to installation.
❒ Injection pump or high pressure fuel lines are replaced.

In order to eliminate air from the fuel system, proceed as

follows:

Continued on next page EL62757,0000136 –19–10APR02–1/4

6-10-2 101702

PN=141
 Maintenance - As required

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

solenoid and the tank valve.
1
2. Loosen the air bleed vent screw (1) two full turns by
hand on fuel filter base.

3. Operate supply pump primer lever (2) until fuel flow is

free from air bubbles.

4. Tighten bleed plug securely, continue operating hand

primer until pumping action is not felt. Push hand
primer inward (toward engine) as far as it will go.

5. Start engine and check for leaks.

–UN–01OCT02
6. If engine will not start, it may be necessary to bleed air
from fuel system at fuel injection pump or injection
nozzles as explained next.

T160020
2
1—Primary filter vent screw
2—Hand primer

EL62757,0000136 –19–10APR02–2/4

At Fuel Injection Pump

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

solenoid and the tank valve.

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

–UN–03NOV97
injection pump.

3. Operate fuel supply pump primer lever until fuel,

without air bubbles, flows from fuel return line

RG6264
connection.

4. Tighten return line connector to 27 N•m (20 lb-ft). Stanadyne Rotary Fuel Injection Pump

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

position.

Continued on next page EL62757,0000136 –19–10APR02–3/4

6-10-3 101702

PN=142
 Maintenance - As required

At Fuel Injection Nozzles

IMPORTANT: Always use a backup wrench when

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

–UN–08JAN97
1. Using two open-end wrenches, loosen fuel line
connection at injection nozzle as shown.
2. Crank engine over with starter motor, (but do not start

RG7725
engine), until fuel free from bubbles flows out of
loosened connection. Retighten connection to 27 N•m
(20 lb-ft). Fuel Line Connection
3. Start the engine

EL62757,0000136 –19–10APR02–4/4

Have the proper function of the turbocharger

checked

Let an authorized service person do this check.

EL62757,00000F0 –19–10APR02–1/1

Have the proper function of the alternator

checked

Let an authorized service person do this check.

EL62757,000012A –19–10APR02–1/1

Have the proper function of the starter motor

checked

Let an authorized service person do this check.

EL62757,0000129 –19–10APR02–1/1

6-10-4 101702

PN=143
 Maintenance - As required

Have the proper function of the atomizers

checked

Let an authorized service person do this check.

The first indications of a faulty atomizer are as follows:

• The engine runs erratically

• The engine knocks
• The engine overheats.
• There is not enough power
• The exhaust smoke is black.
• Fuel consumption is high

CAUTION: Ensure that the high-pressure fuel

does not spray onto your skin.

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

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

EL62757,0000128 –19–10APR02–1/1

Clean the Fuel Tank Filler Filter

When the fuel tank is not full, the filler filter (1) can be
cleaned with a vacuum cleaner through the filler opening.

If it is necessary to remove the filter, first remove the

cover (2) on which the filter has been attached.

When installing the cover, make sure that the sensor pipe
(3) meets the guide at the bottom of the tank.

1—Filler filter
2—Cover
3—Sensor pipe
–UN–11MAR02
T152580

EL62757,0000127 –19–10APR02–1/1

6-10-5 101702

PN=144
 Maintenance - As required

Replacing fan/alternator belt

1. Release tension on belt

2. Remove belt from pulleys and discard belt.

–UN–18NOV97
3. Install new belt, be sure that belt is correctly seated in
all pulley grooves.

RG8098
4. Apply tension to belt with tensioner. Remove ratchet

5. Start engine and check belt alignment

RG,RG34710,3602 –19–30AUG96–1/1

Maintain the Boom

1. Adjusting the rotator link brakes

Sea section 10-5.

EL62757,000013B –19–11APR02–1/1

Check the air conditioner

See Section 11-1.

Maintenance every 24 months:

The filter-dryer-receiver must be replaced always when

the hoses are replaced or if the service moisture indicator
has turned to pink.

EL62757,0000140 –19–12APR02–1/1

6-10-6 101702
PN=145
 Cooling System Maintenance
Replenishing supplemental coolant additives
(SCAs) between coolant changes

IMPORTANT: Do not add supplemental coolant

additives when the cooling system is
drained and refilled with John Deere
ANTIFREEZE/SUMMER COOLANT or
COOL-GARD

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

contain SCAs, the coolant must be precharged.

–UN–05DEC97
Determine the total system capacity and premix
with 3% John Deere Coolant Conditioner.

Through time and use, the concentration of coolant

RG6262
additives is gradually depleted during engine operation.
Periodic replenishment of inhibitors is required, even when JTO7298 Coolant/Battery Tester
John Deere ANTIFREEZE/SUMMER COOLANT is used.
The cooling system must be recharged with additional
supplemental coolant additives available in the form of
liquid coolant conditioner.

Maintaining the correct coolant conditioner concentration

(SCAs) and freeze point is essential in your cooling
system to protect against rust, liner pitting and corrosion,
and freeze-ups due to incorrect coolant dilution.

John Deere LIQUID COOLANT CONDITIONER is

recommended as a supplemental coolant additive in
John Deere engines.

DO NOT mix one brand of SCA with a different brand.

Test the coolant solution at 600 hours or 12 months of

operation using either John Deere coolant test strips or a
COOLSCAN analysis. If a COOLSCAN analysis is not
available, recharge the system per instructions printed on
label of John Deere Liquid Coolant Conditioner.

COOL-GARD is a trademark of Deere & Company

COOLSCAN is a trademark of Deere & Company Continued on next page DPSG,OUOD002,1921 –19–12DEC00–1/2

6-11-1 101702

PN=146
 Cooling System Maintenance

IMPORTANT: ALWAYS maintain coolant at correct

level and concentration. DO NOT
operate engine without coolant even for
a few minutes.

If frequent coolant makeup is required,

the glycol concentration should be
checked with JTO7298 Coolant/Battery
Tester to ensure that the desired freeze
point is maintained. Follow
manufacturer’s instructions provided
with Coolant/Battery Tester.

Add the manufacturer’s recommended concentration of

supplemental coolant additive. DO NOT add more than
the recommended amount.

The use of non-recommended supplemental coolant

additives may result in additive drop-out and gelation of
the coolant.

If other coolants are used, consult the coolant supplier

and follow the manufacturer’s recommendation for use of
supplemental coolant additives.

See DIESEL ENGINE COOLANTS AND

SUPPLEMENTAL ADDITIVE INFORMATION for proper
mixing of coolant ingredients before adding to the cooling
system.

DPSG,OUOD002,1921 –19–12DEC00–2/2

6-11-2 101702

PN=147
 Cooling System Maintenance

Pressure testing cooling system

–UN–20JAN93

–UN–20JAN93
RG6557
Test Radiator Cap

RG6558
Test Cooling System

1. Allow engine to cool, then carefully remove radiator

CAUTION: Explosive release of fluids from
cap.
pressurized cooling system can cause
serious burns.
2. Fill radiator with coolant to the normal operating
level.
Shut off engine. Only remove filler cap when
cool enough to touch with bare hands.
IMPORTANT: DO NOT apply excessive pressure to
Slowly loosen cap to first stop to relieve
cooling system, doing so may
pressure before removing completely.
damage radiator and hoses.
Test Radiator Cap
3. Connect gauge and adapter to radiator filler neck.
Pressurize cooling system to 67 kPa (0.7 bar) (10
1. Remove radiator cap and attach to D05104ST
psi)1.
Tester as shown.
4. With pressure applied, check all cooling system
2. Pressurize cap to 67 kPa (0.7 bar) (10 psi)1. Gauge
hose connections, radiator, and overall engine for
should hold pressure for 10 seconds within the
leaks.
normal range if cap is acceptable.
If leakage is detected, correct as necessary and
If gauge does not hold pressure, replace radiator
pressure test system again.
cap.
If no leakage is detected, but the gauge indicated a
3. Remove the cap from gauge, turn it 180°, and
drop in pressure, coolant may be leaking internally
retest cap. This will verify that the first
within the system or at the block-to-head gasket.
measurement was accurate.
Have your servicing dealer or distributor correct this
problem immediately.
Test Cooling System

NOTE: Engine should be warmed up to test overall

cooling system.

1
Test pressures recommended are for all Deere OEM cooling
systems. On specific vehicle applications, test cooling system and
pressure cap according to the recommended pressure for that
vehicle.
RG,RG34710,4083 –19–01JAN96–1/1

6-11-3 101702

PN=148
 Hydraulic System: Hydraulic Oil Change
Hydraulic tank and the vacuum pump

Using the vacuum pump

The vacuum pump is used to avoid oil spill, e.g., in the

event of hose rupture or other leakage.

IMPORTANT: Before starting and using the vacuum

pump, make sure the machine is level
and that the hydraulic fluid is not above
maximum level, see the sight glass.

Otherwise the hydraulic fluid might

reach up to the suction connection in

–UN–07APR02
the tank!

1. Stop the engine.

• Set the ignition lock to the vacuum pump mode (P)

T152231
before activating switch (5)

NOTE: The vacuum pump will be disconnected

automatically if the machine is started

–UN–23SEP02
2. Run for 2 or 3 minutes before doing anything with the
hydraulic system
3. After the vacuum pump has been turned off start the

T159295
engine and let it idle for a couple of minutes.

3—Switch, fill-up pump (optional equipment)

4—Quick coupler
5—Switch, vacuum pump

EL62757,000004F –54–15SEP02–1/1

Checking the oil level in hydraulic tank

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

the tank. When you do this, the lift and shift cylinders
have to be in the innermost position.
2. If necessary add oil.

Capacities Hydraulic tank min. 79 l (20.9 gal) / max. 150 l (39.6 gal)
Mineral oil Summer oil SMRs norm SH 68
Winter oil SMRs norm SHS 32
Year-round oil SMRs norm SHS 46
If you use synthetic biodegradeable oil: Neste Biohydrauli SE 46

EL62757,0000131 –19–10APR02–1/1

7-1-1 101702

PN=149
 Hydraulic System: Hydraulic Oil Change

Renew the hydraulic oil.

NOTE: Change hydraulic oil when it is warm and

contaminants are in suspension.

During the oil change, open the vent tap (2) first.

1—Sight glass
2—Vent tap

–UN–05MAR02
T152230
EL62757,00000EC –19–10APR02–1/3

Draining the oil

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

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

–UN–05MAR02
2. The hydraulic oil of the working hydraulic pump is
drained by opening the plug (2) at the end of the drain
pipe

T152229
NOTE: Dispose of waste properly.

3. Clean the hydraulic tank.

4. After every 1000 hours: change the hydraulic return 1—Drain hose, hydraulic oil from the tank
2—Drain hose, hydraulic oil from work pump
filter and the breather. See section 6-6.
5. Close the plug of the drain pipe.

Continued on next page EL62757,00000EC –19–10APR02–2/3

7-1-2 101702

PN=150
 Hydraulic System: Hydraulic Oil Change

Filling the oil

IMPORTANT: Do not exceed the ’MAX’ mark.

There always has to be enough air

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

IMPORTANT: Do not mix different type of oils.

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

–UN–07APR02
through the filter.

NOTE: During the fill up, open the vent tap of the
hydraulic tank.

T152231
1. Clean the filling hose and remove the dust cap.
2. Place the hose into the canister containing new
hydraulic oil. 3—Switch for hydraulic fill-up pump
4—Quick coupler
3. Start the filling pump with switch (3). 5—Switch for vacuum pump
4. Close the vent tap.

NOTE: Also a manual pump can be used.

EL62757,00000EC –19–10APR02–3/3

7-1-3 101702

PN=151
 Hydraulic System: General
Working hydraulic system

The working hydraulics system includes all other hydraulic

functions except driving hydrostatics.

The hydraulic system is load sensing, i.e., it senses how

much pressure is required when a particular function is
activated.

The pump supplies only the amount of fluid required in

each situation, and no fluid is circulated by the pump
when all functions are at rest.

EL62757,0000196 –19–21APR02–1/1

Hydrostatic system

The hydraulic part is a hydrostatic link between the engine

and gearbox, consisting of a hydraulic pump and a
hydraulic motor. Infinitely variable speed control and gear
shifting between forward and reverse is achieved.

See also Section 9.

EL62757,0000197 –19–21APR02–1/1

7-2-1 101702

PN=152
 Hydraulic System: Bleeding
General

If air enters the working or driving hydraulic system while

parts are changed, the air must be eliminated from the
components affected before the machine can be operated
again.

Follow the instructions provided on the next pages.

EL62757,0000199 –19–21APR02–1/1

Bleeding Drive Hydraulic System

Air must be eliminated from the drive hydraulics after the

system has been serviced or repaired, before the machine
is used again.

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

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

–UN–02OCT02
3. Press down the emergency stopper in the instrument
panel to ensure that the engine will not start during the
air bleeding process

T159885
4. Make sure that the switch for driving direction is in the
center position. This ensures that the drive pump stays
at a zero angle
B—Drive pump bleed connect, Drive motor bleed
connect

Continued on next page EL62757,000019A –19–21APR02–1/2

7-3-1 101702

PN=153
 Hydraulic System: Bleeding

5. Connect bleed hoses to the measuring points of the

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

6. Operate the starter motor for appr. five seconds

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

–UN–01SEP02
8. Disconnect the bleed hoses

(204)—Supply pressure
(206)—Drive pressure backwards

T153143
(214)—Drive pressure forward

EL62757,000019A –19–21APR02–2/2

7-3-2 101702

PN=154
 Hydraulic System: Bleeding

Bleeding Work Hydraulic System

Before the machine is used again air must be eliminated

from all hydraulic system components that have been
serviced or repaired.

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

housing of the working pump through the bleed
connect (B) until the housing is half full.

–UN–08OCT02
1. Next, fill up the hydraulic tank.

Make sure that the low-pressure hose of the working

T160060
pump is also filled with oil (loosen the hose connector
for the fill-up).

2. Start the engine and allow it to idle.

3. Connect bleed hoses to the following measuring points

in the working hydraulic system:

a. The working pump pressure (111)

–UN–01OCT02
b. The reduced pressure of the auxiliary functions
(114)

T159884
c. Pilot pressure of the crane valve (123)
Attachement valve
4. Disconnect the bleed hoses as soon as no more air
comes out of them. B—Work pump bleed connect
111—Work pump pressure
5. Connect a bleed hose to the measuring point (114) of 117—Work pump LS pressure
114—Reduced pressure of the auxiliary functions
the LS pressure line going to the working pump.

6. Operate the rotator for appr. one minute in the other

direction.

7. Disconnect the bleed hose as soon as no more air

comes out of it.

8. Stop the engine and let air be removed from the oil
tank (for appr. five minutes).

Continued on next page EL62757,000019B –19–21APR02–1/2

7-3-3 101702

PN=155
 Hydraulic System: Bleeding

Bleeding the solenoids of the loader valve

1. Loose the bleeding screws (A) on top of the solenoids

and operate the boom movements for appr. one
minute.
2. Close the screws.

Bleeding the cylinders

1. Slowly operate the functions all the way to their

extreme positions. Do this at least twice.
2. If necessary, you can also check the directions of
travel for the various functions at the same time.
• Stop the engine and let air be removed from the oil

–UN–13OCT02
in the tank (for appr. five minutes).
• Add oil until the level reaches the upper mark in the
measuring glass

T159882
123—Measuring crane valve pilot pressure
A—Vent screws

EL62757,000019B –19–21APR02–2/2

7-3-4 101702

PN=156
 Hydraulic System: Bleeding

Bleeding the Brake System

CAUTION: With the engine running, the brake

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

–UN–06JUN01
Bleeding the brake cylinders

1. Start the diesel engine.

T139063
2. Release the parking brake (see the symbol on TMC
display).
3. Bleed the work brake cylinders through vent screws
RB6, RB7, RB8 and RB9

1—Vent screw of work brake cylinder

–UN–06JUN01
T139064

–UN–06JUN01
T139065

Continued on next page EL62757,000019C –19–21APR02–1/3

7-3-5 101702

PN=157
 Hydraulic System: Bleeding

4. Bleed the parking brake cylinders through vent screws

RB2, RB3, RB4 and RB5.

1—Vent screw of parking brake cylinder

–UN–06JUN01
T139066
–UN–06JUN01
T139067

–UN–06JUN01
T139068

Continued on next page EL62757,000019C –19–21APR02–2/3

7-3-6 101702

PN=158
 Hydraulic System: Bleeding

Bleeding the brake pedal

If necessary, the brake pedal circuit can be bled as

follows:

NOTE: Two people are needed for bleeding of the brake

pedal.

NOTE: Do not start the diesel engine.

NOTE: Check that there is sufficient brake fluid in the

fluid bottle (3)

The process is the same as for a normal fluid brake

–UN–20MAR02
1. Press the pedal several times,
2. Keep the pedal pressed and open the bleed screw (1).
3. Close the bleed screw and release the pedal.

T152820
4. Repeat until no air comes out with fluid.
5. Do the same procedure for the other brake pedal.
6. Check that air is properly removed from both of the
brake pedals by driving the machine when the brake is
on.

3—ATF tank
1—Bleed screw

–UN–01OCT02
T159877
EL62757,000019C –19–21APR02–3/3

7-3-7 101702

PN=159
 Hydrostatic System: Drive Pump adjusting
Checking and adjusting the charge pressure

1. Disconnect the parking brake solenoid Y41 from the

valve block. After this, the parking brake will stay
engaged
2. Connect a pressure gauge (0 ... 6 MPa) (0... 870 psi)

–UN–22AUG01
to pressure measuring point (204). When the engine
RPM is 1600, the pressure should be 2.8 ... 3.2 MPa
(406 ...464 psi).
3. If necessary, adjust the pressure with adjusting screw

T138248
(207).
4. Fit the solenoid into the valve and tighten the
lockscrew hand tight.

Y41—Park brake solenoid

(204)—Measure point
(207)—Adjust screw

–UN–01SEP02
T153143
EL62757,000019D –19–21APR02–1/1

7-4-1 101702

PN=160
 Hydrostatic System: Drive Pump adjusting

Checking and adjusting the pressure cut-off

valve setting of the drive pump

1. Disconnect the parking brake solenoid Y41 from the

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

–UN–22AUG01
2. Connect pressure gauges (60 MPa) (8702 psi) to
measuring points (214) (forward) and (206) (reverse).

T138248
3. Engage high gear.

4. Drive the machine both forward and backward even

though the brake is on. Do not do this longer than for
five seconds at a time.

5. The pressure should rise to 45,0 + 0,5 MPa (6526,70

psi) (both directions).

6. If necessary, adjust the pressure with adjusting screw

(210) (forward/reverse).

7. After making the adjustment, check the pressures once

again.

8. Fit the solenoid into the valve and tighten the

lockscrew hand tight.

–UN–28MAR02
(206)—Measure point, drive pressure backwards
(210)—Adjust screw
(214)—Measure point, drive pressure backwards

T153142
–UN–01SEP02
T153143

EL62757,000019F –19–21APR02–1/1

7-4-2 101702

PN=161
 Hydrostatic System: Drive Motor adjusting
Checking the function of hydrostatic flushing
valve

The function of hydrostatic flushing valve is checked by

measuring the supply pressure (204).

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

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

–UN–01SEP02
2. First, press the brake pedal all the way down

3. Press the accelerator pedal until the machine tries to

T153143
start moving.

4. The very moment the machine ’should’ start moving

(i.e. the pressure measuring point (206) rises) the (204)—Measure point, supply pressure
(206)—Measure point, drive pressure backwards
pressure at the measuring point (204) must drop by
appr. 0,1...0,6 MPa (14...87 psi).

NOTE: The hydrostatic flushing valve cannot be adjusted.

EL62757,000019E –19–21APR02–1/1

7-5-1 101702

PN=162
 Hydrostatic System: Drive Motor adjusting

Checking and adjusting drive motors

pressure cut-off settings

The tools needed: 3-mm hex key and 10-mm wrench

1. Disconnect the parking brake solenoid Y41 from the

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

2. Connect a pressure sensor to measuring point (206)

(...60 MPa) (0...8702 psi) and a pressure gauge to
measuring point (216) (...60 MPa) (0...8702 psi)

3. Disconnect the connector of the motor steering (pos.

C) A B
4. Connect a 24 V tension with a separate cable from the 217
power outlet next to the main switch to the motor
steering (pos.C).

–UN–19MAR02
5. Start the engine

6. Engage high gear and rear wheel drive. Let the engine 216

T152684
idle. C

7. Select the driving direction forward.

8. Set the adjustable speed range (snail) to 15 %

9. Press smoothly the drive pedal, the pressure will first

start to rise at measuring points (216) and (206).

10. The engine rpm and the pressures are increasing, but
at a certain point the pressure of (216) stops to
increase and finally it starts to decrease.
–UN–01SEP02

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

psi) the pressure at (216) should then be 14 ± 2 MPa
(2030 ± 290 psi).
T153143

a. If (206) reaches 33 MPa (4786 psi) and the value

at (216) is higher than 14± 2 MPa (2030 ± 290
psi) , turn the adjusting screw (217) C—Adjusting screw
counterclockwise in small increments and repeat (216)—Measure point,
(217)—Adjusting screw, cut-of
the test.

Continued on next page EL62757,00001A0 –19–21APR02–1/3

7-5-2 101702

PN=163
 Hydrostatic System: Drive Motor adjusting

b. If (206) reaches 33 MPa (4786 psi) and the value

at (216) is lower than 14± 2 MPa (2030 ± 290
psi), turn the adjusting screw (217) clockwise in
small increments and repeat the test.

EL62757,00001A0 –19–21APR02–2/3

12. Disconnect the cable between the power outlet and

the position C

13. Connect back the connector of the motor steering

(pos. C) .

–UN–22AUG01
14. After making the adjustment, fit the solenoid into the
valve and tighten the lockscrew hand tight

24V—Current

T138248
Y41—Solenoid

24V Current –UN–20MAR02

T152801
EL62757,00001A0 –19–21APR02–3/3

7-5-3 101702

PN=164
 Work Hydraulic System: Check and Adjust
Adjustment of Pressure Difference

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

to measuring points (111) and (117) (pump main
pressure and signal lines).

–UN–01OCT02
2. Engage the working rpm and boom

3. Lift the loader free of the load area.

T159884
4. Rotate the rotator freely and simultaneously check the
pressure at measuring points (111) and (117). The
pressure at (117) must be lower than that of (111) by
2.5...2.7 MPa (362...391 psi). 111—Measure point, work pump’s pressure
117—Measure point, work pump’s signal pressure

NOTE: When checking at measuring point (111) the

pressure should not rise over 15 MPa (2175 psi).

5. If necessary, adjust the pressure with adjusting screw

(102).

NOTE: Turning the screw clockwise will increase the

pressure difference

EL62757,00001A1 –19–21APR02–1/1

Adjusting the Maximum Pressure

1. The sensors are still connected to measuring points

(111) and (117).

2. The working rpm is engaged.

3. Increase the pressure to maximum. For example by

–UN–02OCT02

using the ’extension in’ movement.

• The pressure at measuring point (111) must be

24±0,5 MPa (3480±72 psi).
T160061

4. If necessary, adjust from adjusting screw (101).

Turning the screw clockwise will increase the pressure.
101—Max-pressure adjustment
102—Pressure difference adjustment

EL62757,00001A2 –19–21APR02–1/1

7-6-1 101702

PN=165
 Work Hydraulic System: Check and Adjust

Adjusting the Boom Pressure

What can be measured at the loader valve is the pilot

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

–UN–13OCT02
Measuring the pressures for each function

The pressures of each movement can be measured

through measuring point (116)

T159883
• First, connect a (0...30 MPa) (0...4351 psi) pressure
transducer to quick coupler (116).
• Engage the working rpm and boom

1. Grapple close
a. Operate the grapple close function.
The pressure must rise up to 18.3 MPa (2654 psi)
as the movement is operated to extreme.
b. If necessary, adjust from adjusting screw (135)

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

–UN–01OCT02
3. Other functions

Operate the function you want to check.

T159881
• The pressure must rise up to the maximum level (21.5
MPa) (3118 psi) as the movement is operated to
extreme
116—Measure point, pilot pressure
Steering:
129—Adjusting screw, reduced pressure, boom
a. Operate steering function to right / left slew
b. The pressure must rise up to 20.4 MPa (2959 psi) as 130—Adjusting screw, reduced pressure, boom
the movement is operated to extreme slew
c. If necessary, adjust from adjusting screw (139) / 135—Adjusting screw, reduced pressure, grapple
closed
(140)
136—Adjusting screw, reduced pressure, grapple
open
Boom Slew: 139—Adjusting screw, reduced pressure, steering
140—Adjusting screw, reduced pressure, steering
a. Operate slewing function to right / left
b. The pressure must rise up to 20.4 MPa (2959 psi)
MPa as the movement is operated to extreme

Continued on next page EL62757,00001A3 –19–21APR02–1/3

7-6-2 101702

PN=166
 Work Hydraulic System: Check and Adjust

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

(130)

EL62757,00001A3 –19–21APR02–2/3

Checking the pilot pressure

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

to measuring point (123).
2. Next, engage the loader and working RPMs (1500 ...
1700 rpm).
3. Increase the pressure up to the maximum level by
means of the ’extension in’ function, for instance
• At measuring point (123), the pressure should be 3.5
±0.5 MPa (507 ±72 psi).

The pressure relief valve cannot be adjusted.

123—Pressure measure point

–UN–13OCT02
A—Bleed screws

T159882
EL62757,00001A3 –19–21APR02–3/3

7-6-3 101702

PN=167
 Work Hydraulic System: Check and Adjust

Adjusting Auxiliary Functions

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

–UN–13OCT02
The functions listed above operate with a reduced
pressure of 3.0 MPa (435 psi). The pressure is measured
at measuring point (114).

T159880
If necessary, the pressure is adjusted from adjusting
screw (113). This can be done while the engine is idling.

NOTE: Though the pressure is lower than the delta 113—Adjusting screw
114—Pressure measuring point
pressure of the pump, the adjustment should be (409)—Adjusting screw for frame brake.
checked by increasing the pressure up to the
maximum by engaging the ’extension in’
movement, for instance. The pressure at quick
coupler (114) must remain the same.

Stairs operate with a reduced pressure of 3.0 MPa (435

psi).

EL62757,00001A4 –19–21APR02–1/1

Adjusting Frame Brake

The pressure used for the same frame brake is provided

by the lift cylinder, not directly from the pump.

1. The boom and working rpm are engaged

–UN–15APR02

2. Grap for instance a stake with the grapple.

3. Use the main lift and keep it engaged.
4. Check the pressure at measuring point (411).
The pressure should be 21.0 MPa (3045 psi).
T152779

5. If necessary, adjust the pressure from adjusting screw

(409)

(411)—Pressure measure point

409—Adjusting screw
–UN–20SEP02
T159616

EL62757,00001A5 –19–21APR02–1/1

7-6-4 101702

PN=168
 Work Hydraulic System: Check and Adjust

Adjusting Proportional Decking Blade

The pressure for the proportional decking blade can be

measured from measuring point (116).

1. Operate cylinder function to in / out

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

–UN–14OCT02
T160364
EL62757,0000061 –67–16OCT02–1/1

Adjusting Optional Equipment

• Headboard movement
• Decking blade
• Preparedness for clambunk

All optional equipment (as installed at the factory) operate

with the maximum pressure. There are no separate
pressure adjustments.

EL62757,00001A6 –19–21APR02–1/1

7-6-5 101702

PN=169
 Brake System: Check and Adjust
Checking the brakes

IMPORTANT: Before you start the servicing work, the

machine has to be parked on a level
surface.

–UN–04APR02
You can check that the cylinders are correctly adjusted by
taking measurements through the release screw aperture
(8), for example using a slide calliper.

T153524
1. Release the parking brake
2. Insert the calliper (A) through the aperture and take a
measurement at the adjusting screw (B)
3. Make a note of the measurement.
4. Reconnect the parking brake and repeat the
measurement.
The difference between the two measurements must
not exceed 5,25 mm (0.2 inc).
If the difference is greater than this, the cylinder should
be adjusted.

EL62757,00001A7 –19–21APR02–1/1

7-7-1 101702

PN=170
 Brake System: Check and Adjust

Mechanical adjustment of brakes

1. Disconnect electrical contact Y41W, from the work

brake valve.
2. Remove the protective cover (2). Note the loose
release screw (3) under the cover

–UN–08OCT02
3. Open the larger Allen screws (5) (4 screws, key size 8
mm) and remove the cylinder.

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

T159878
mm) should not be loosened

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

position.
5. Fully open the adjusting screw (1). Clean the thread
and the locking nut (4).
6. Turn the locking nut (4) to the end of the adjusting
screw. Lock the adjusting screw thread (1) by applying
locking fluid (Loctite 242).

–UN–04APR02
NOTE: If the locking fluid comes into contact with other
areas than the adjusting screw and the locking
nut, the excess fluid should be cleaned away.

T153523
7. Insert the adjusting screw (1) and turn it clockwise until
a significant resistance is felt (8...15 Nm) (5,9...11
lb-ft). Turn the adjusting screw (1) 3 1/2 turns
counterclockwise while holding the piston (6) in
position.
8. Tighten the locking nut (4) to approx. 40 Nm (29.5 lb-ft)
while holding the piston (6) in position.
9. Reinstall the cylinder. Ensure that the O ring (7) is in
good condition and is correctly positioned. Tighten the
four screws (5).
10. Fit the protective cover (2). Check that the O ring is in
good condition and is correctly positioned
11. Connect the electrical contact Y41W to the brake
valve. Adjust all the cylinders in the same way

EL62757,00001A8 –19–21APR02–1/1

7-7-2 101702

PN=171
 Brake System: Check and Adjust

Brake Charging Pressure

CAUTION: Do not ever disconnect any brake

system hose joints before all pressure has been
eliminated from pressure accumulators.

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

pressure measuring points (307) and (301).

NOTE: The pressure is the same with that of the

pressure accumulators

1. Turn the start key to I position and wait until you hear
the TMC signal. Start the engine.

–UN–01SEP02
2. Disengage the parking brake and wait until the
pressure has risen to 15,0...16,0 MPa (2175...2320
psi).
3. Engage and disengage the parking brake a number of

T152793
times.
The pressure reading measured from measuring points
(307) and (301) should drop 301—Measure point
307—Measure point
The charging system of the pressure accumulators should
be activated as soon as the pressure drops to 13,0 ...
14,5 MPa (1885...2103 psi), and disengaged when the
pressure has risen to 16,0 MPa (2320 psi).

EL62757,00001A9 –19–21APR02–1/1

Checking the Work Brake

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

to measuring points (305) and (304).
2. Start the engine
3. Disengage the parking brake. Symbol ’P’ on the TMC
–UN–13OCT02

display will be replaced by ’S’.

4. Make sure that the maximum pressure reading from
the pressure measuring points (305) and (304) are 9.5
... 10.0 MPa (1377...1450 psi).
T152794

NOTE: The pressures cannot be adjusted.

EL62757,00001AB –19–21APR02–1/1

7-7-3 101702

PN=172
 Brake System: Check and Adjust

Checking the Drive Brake (Brake Pedal)

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

to measuring points (305) and (304)
2. Start the engine and keep engaged the parking brake
3. Press the brake pedal and ensure that the pressure

–UN–13OCT02
reading from the (305) and (304) rises to 9.5 ... 10.0
MPa (1377...1450 psi).

NOTE: The pressures cannot be adjusted.

T152794
EL62757,00001AC –19–21APR02–1/1

7-7-4 101702

PN=173
 Electrical System
Main Switch

The main switch (1) is behind a cover on the left-hand

side of the machine.

The main current coming from the battery is divided

between two 60 A fuses.

–UN–01OCT02
The fuses can be found in a fuse box under the cab.

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

the main switch. If the machine is equipped with an

T159876
automatic fire extinguishing system (opt. eq.) the system
will be switched on to the automatic mode when the main
switch is turned off.
1—Main Switch
2—Triggering handle for fire extinguisher
3—Quick coupler for hydraulic oil filling
4—Tap for decking blade’s floating system
5—Switch, hydraulic oil filling pump
6—Switch, vacuum pump
7—24V Current

EL62757,00001AD –19–21APR02–1/1

8-1-1 101702

PN=174
 Electrical System

Location of ECU and engine sensors

A—Oil pressure sensor
B—Pump control solenoid
C—Engine Control Unit (ECU)
–UN–01OCT02
T159875
D—Crank position sensor G—Manifold air temperature H—Loss of coolant
E—Fuel temperature sensor (MAT) sensor temperature sensor
F—Engine coolant temperature
(ECT) sensor

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

the machine.

EL62757,00001AE –19–21APR02–1/1

8-1-2 101702

PN=175
 Electrical System

Batteries

CAUTION: Gas given off by battery is explosive.

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

–UN–23AUG88
Never check battery charge by placing a metal
object across the posts. Use a voltmeter or
hydrometer.

TS204
Always remove grounded (-) battery clamp first
and replace it last.

CAUTION: Sulfuric acid in battery electrolyte is

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

• The machine has a negative earth electrical system. It

–UN–14DEC88
is equipped with two 12 volt batteries connected in
series to provide 24 volts and a capacity of 140 Ah.
• The batteries are located under the cab on the left-hand
side of the machine.
• When disconnecting the batteries always uncouple the

RG4698
ground wire first. When connecting the batteries couple
the ground wire last.
• When quick charging the batteries disconnect the
ground wire and positive cable. Do not mix up the
battery terminals. An incorrect connection may seriously
damage the alternator. Do not disconnect the battery
cables while the engine is running.

NOTE: Do not ever disengage the electronic system or

display when the power is on.

Using booster batteries:

Continued on next page EL62757,00001AF –19–21APR02–1/2

8-1-3 101702

PN=176
 Electrical System

NOTE: In case you need an outside power source to start

the machine, it is recommended to use a similar
machine as a power source.

NOTE: If you need an outside power source to start the

machine, be careful not to short-circuit the battery
while handling the cables.

NOTE: Power source, stronger than 140 A (like an

auxiliary battery), can be used only as a quick
charger for batteries.

Connecting auxiliary cable:

First, connect the auxiliary positive cable, coming from a

24-volt power source, to the positive cable of the machine
to be started, and then connect the auxiliary negative
cable to the power source and the other end to the
negative cable or frame of the machine to be started.

Bear in mind this order of connection when using auxiliary

batteries because a full battery is more sensitive to
sparks.

Disconnect the cables in reverse order, beginning by

disconnecting the negative cable from the machine to be
started.

IMPORTANT: Make sure, that the polarity is correct

before you make any connections.
Contrarious polarity violates the
electrical system.

CAUTION: The manufacturer shall assume no

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

EL62757,00001AF –19–21APR02–2/2

8-1-4 101702

PN=177
 Electrical System

Welding

Before you start arc welding the machine, do the following

1. The first actions

• turn the master disconnect switch off

–UN–20MAR02
• disconnect the wire (1) between the battery and the
frame.
• disconnect central unit wires of the automatic fire
extinguishing system (A) and the tripping of the

T152800
extinguisher (F).

Ground cable

A
F

–UN–13SEP02
T159364
Cables to be disconnected

Continued on next page EL62757,00001B0 –19–21APR02–1/2

8-1-5 101702

PN=178
 Electrical System

• disconnect ECU’s cable

• disconnect Hub’s cables (5 cables)

2. Grounding
• Connect the ground wire as close to the welding
point as possible.
• The welding current must never pass through
bearings, joints, electrical equipment, or hydraulic
systems.

3. The parts that must never be welded:

–UN–01OCT02
• boom fastening bolts
• control valves
• hydraulic pipes

T159874
4. The parts that must not be welded without the
manufacturer’s instructions: ECU’s cable
• castings
• cylinder loops.

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

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

6. Welding.
Weld inside, if possible, in facilities reserved for this

–UN–13SEP02
purpose where the temperature is at least 10 degrees
centigrade. If welding in other places, pay attention to
local regulations and to circumstances as well as to the
environment before you start welding.

T159362
The welder must possess adequate skills and the
permits required.
7. Assessment of damage. Hub in the cabine
In case a component or structure has been damaged
as a result of an accident, excessive load, or fatigue, it
is first necessary to determine whether the structure
requires reinforcements or is ordinary repair sufficient.
8. Instructions.
Before you start welding you can also contact the
manufacturer who has detailed instructions for each
case.
Possibility of major damage is reduced by regularly
cleaning and checking the machine and the boom.

EL62757,00001B0 –19–21APR02–2/2

8-1-6 101702

PN=179
 Electrical System

Fuses on the Left-Hand Side in the Engine

Compartment
F51 Main fuse (60 A)
F52 Main fuse (60 A)
F41 Preheater (opt. eq.) (20 A)
F42 Preheater (opt. eq.) (15 A)
and Timer (opt. eq.),
Radio and
Radio-telephone
F43 Air conditioner (opt. (25 A)
eq.)
F44 Grid heater signal (7,5 A)
light
F45 Socket 24 V (20 A)
Hydraulic pump
(fill-up) (opt. eq.)
F46 , Socket 24 V Fuel (20 A)
pump (fill-up) (opt.
eq.)

–UN–16OCT02
F47 Fire extinguishing (10 A)
system (opt.eq.
F48 Fire extinguishing (10 A)
system (opt.eq.

T160565
Relay K3, Starting motor

Relay K15, Engine preheater & AC unit

EL62757,00001B1 –19–21APR02–1/1

8-1-7 101702

PN=180
 Electrical System

Instrument Box Fuses and Relays

F1-F13 Work Lights
F14 Head light switch
F15 Ignition
F16 Parking lights
F17 Brake switch
F18 Air conditioner, Seat compressor (opt.
eq.)
F19 Horn
F20 Indicator lights
F21 TMC
F22 Windscreen wipers
F23 Cigarette lighter
F24 Stairs
F25 Vacuum pump
F26 ECU
F27 Rear window wipers
F28 Fuel valve, stopping solenoid, motor
ECU
F29 Air conditioner, valve (opt. eq.)
F30 Hydraulics vacuum pump , (opt. eq.)
F31 Low beam
F32 Voltage transformer
F33 High beam
F34 Parking brakes
F35 Parking brakes
F36 Working pump’s drop
K1 Electricity controlled by ignition switch
K2 Intermittent rear window wiper
K4 Blinker relay
K6 Seat compressor
K9 Hourmeter
K12 Intermittent windshield wiper
K14 Engine starting prevent
K20 Radio
K21 Pressure switch, Air conditioner,
compressor (opt. eq.)
K22 Air conditioner, (opt. eq.)
K23 Seat compressor
–UN–17JUN02
T152823

Continued on next page EL62757,00001B2 –19–21APR02–1/2

8-1-8 101702

PN=181
 Electrical System

Other relays

Relay K3, Starting motor

Relay K4, Blinker relay in the instrument box

Relay K24, Grid heater, Front frame

EL62757,00001B2 –19–21APR02–2/2

The RPM Sensor of the Drive Hydrostatics

Motor

The sensor (A4) is located on the left-hand side of the

drive hydrostatics motor. The sensor has an impact on the
function of the speedometer and odometer as well as on
the coupling of the work brake.

A—RPM Sensor

–UN–01OCT02
T159873
EL62757,00001B5 –19–21APR02–1/1

8-1-9 101702

PN=182
 Electrical System

Hydraulic Tank Sensors

Hydraulic Oil Level Sensor

The sensor (5) trickers the alarm if the hydraulic oil levels
drops below the acceptable limit.

Hydraulic Oil Temperature Sensor

The sensor (6) sets off the alarm if the hydraulic oil
temperature exceeds the acceptable limit.

Hydraulic Oil Return Filter Sensor

The sensor (7) triggers the alarm if the hydraulic oil filter
has clogged.

5—Level Sensor
6—Temperature Sensor
7—Return Filter Sensor

–UN–20MAR02
T152795
EL62757,00001B6 –19–21APR02–1/1

8-1-10 101702

PN=183
 Transmission
Operating Power Transmission

The hydrostatic-mechanical power transmission can be
divided into three main parts: mechanical, hydraulic,
and electrical part.
–UN–11MAR02
T152540
The hydraulic section consists of a hydraulic motor
connected to the high/low transfer case and of a
hydraulic pump connected to the diesel engine.

The mechanical part consists of the high/low transfer

case, drive shafts, differentials, and bogies.

EL62757,00001B7 –19–21APR02–1/1

High/Low Gear

The high/low transfer case is located at the back of the

front frame. The power generated by the hydraulic motor
is distributed by the high/low transfer case (through the
drive shafts) to the front differential and rear differential.

The gear is shifted with the switch on the right-hand-side

control panel (see Section 4). The switch controls a
hydraulic cylinder via an electrical valve.

EL62757,00001C3 –19–22APR02–1/1

9-1-1 101702

PN=184
 Transmission
Hydrostatic System
The main components of the system are a hydraulic
pump and a hydraulic motor. These components make
up a closed loop circuit in which the oil flowing from
the pump to the motor will return to the pump from the
motor. Both the pump and the motor are of the
variable displacement piston type.
The direction of rotation of the pump shaft is always
the same. The displacement of the pump is regulated
by means of two electrically controlled proportional
valves. One of the valves adjusts the pump plate in
one direction and the other valve in the opposite
direction. This system alters the direction and amount
of oil flow generated by the pump, which, in turn,
changes the direction of rotation of the motor (driving
direction and speed) accordingly. In addition to the
control current of the proportional valve, the amount of
flow generated by the pump can also be changed by
adjusting the speed of the diesel engine.
9-1-2
–UN–08MAR02
T152541
The direction of rotation and speed of the motor
depend on the direction and magnitude of the flow
generated by the pump.
The motor displacement is adjusted by turning the
motor shaft while the plate stays in place.
The pump and motor angles are interdependent. If the
machine stands still, the pump angle is zero and the
motor angle at its maximum. When the machine starts
off, the pump angle begins to increase. When the
pump angle reaches its maximum, the motor angle
begins to decrease. If you drive at full speed, the
pump angle is at its maximum and the motor angle at
its minimum.
EL62757,00001C2 –19–22APR02–1/1
101702
PN=185
 Transmission

Control of Transmission

TMC controls electrically hydrostatic transmission:

• To adjust the speed of the diesel engine and the angle

of the hydraulic pump as dictated by the signal coming
from the accelerator pedal
• The electronic control system monitors the speed of the
diesel engine. If the engine speed drops as a result of
additional loading, the pump angle will be reduced by
the electronic system. In other words, the gear ratio of
the power transmission is adjusted by the electronic
system which ensures that the power needed to operate
the machine is always smaller than the power
generated by the engine
• When the machine stops, the work brake is
automatically engaged by the system.

The control of transmission is part of the Total Machine

Control System. (see Instructions for use TMC enclosed).

EL62757,00001C1 –19–22APR02–1/1

9-1-3 101702

PN=186
 Boom, General
A General Description of the Boom

–UN–08MAR02
T152542
1—Base 5—Extension boom 8—Outer boom cylinder 11—Rotator
2—Tower 6—Slewing cylinder 9—Extension boom cylinder 12—Grapple
3—Main boom 7—Main boom cylinder 10—Link 13—Grapple cylinder
4—Outer boom

NOTE: It is important for you to familiarize yourself assist you in getting the most out of the loader
with the contents of this chapter. That will and in doing the work safely.

EL62757,00001C4 –19–22APR02–1/1

10-0-1 101702

PN=187
 Boom, General

Operating Safety Precautions

IMPORTANT: Make sure that you have been provided

enough guidance in the use of the
loader since it is the operator of the
machine who is primarily responsible
for safety in loading.

❒ Adhere strictly to all safety regulations stipulated by law

at the work site pertaining to the operation of this
equipment.

CAUTION: Before starting the engine ensure

that there is nobody within the reach of the
loader.

❒ If you are still learning to operate the loader, adjust the

moving speed of loader functions to a low level.
❒ Make sure that you have good visibility to the working
area.
❒ Keep an eye on machine stability while you are
loading.

CAUTION: During operation no other people are

allowed in the cab or within the danger zone of
twenty meters.

CAUTION: It is forbidden to use the loader for

lifting people.

❒ Observe the lifting ratings given on the loader decal, do

not overload the system.
❒ Do not force the cylinders to their extreme positions at
full speed.

IMPORTANT: Do not use the loader for towing.

❒ Exercise great caution particularly when operating the

loader in front of the cab.
❒ Bear in mind the overall height of the loader and the
load.

Continued on next page EL62757,00001C5 –19–22APR02–1/2

10-0-2 101702

PN=188
 Boom, General

CAUTION: A load that is stacked too high can

cause the machine to overturn, or the topmost
logs may slide over the headboard and cause a
fatal injury to the driver.

❒ Maintain the safety distances required between the

machine or boom and power lines.
❒ For transport, the loader must be properly secured in
the appropriate position.
❒ Do not leave the cab before you have securely placed
the grapple onto the ground or in transport position.

CAUTION: Approach an area where

overhanging electrical powerlines are present
with extreme caution.

Safety distances for powerlines:

Rated voltage Min. distance (m) on the side

kV under
1 2 (6,5 ft) 2 (6,5 ft
1...45 2 (6,5 ft 3 (9,8 ft)
110 3 (9,8 ft) 5 (16 ft)
220 4 (13 ft) 5 (16 ft)
400 5 (16 ft) 5 (16 ft)

IMPORTANT: If you come into contact with a

powerline, stay in the cab.

EL62757,00001C5 –19–22APR02–2/2

10-0-3 101702

PN=189
 Boom, General

General Operating Instructions

First, operate the loader smoothly without load in

order to allow the grease to warm up and a coherent
lubrication film to be formed in loader joints.

During Operation:

1. Observe the lifting ratings given on the loader decal.

The weight of the lifting equipment is included in the
load to be lifted.
2. When handling a maximum load, exercise great
caution.
3. Operate the control sticks smoothly; avoid jerky
movements
4. Exercise extra caution always when a boom or the
booms are in their extreme positions.
5. Keep an eye on machine stability.
a. Constant alertness is required particular when
operating on sloping ground.
b. If necessary, lift small loads only
c. When you notice that the machine is about to fall
over, pull all extensions in, bend the outer boom,
and lower the load smoothly onto the ground.

6. When handling a load proceed as follows

a. Lift the load up
b. Move it closer to the machine.
c. Slew it.
d. Lower the load down.

7. It is possible that you exceed the lifting capacity of the

loader (the booms will sink) if you pick up a load that is
close to the machine and move the load away from the
machine. When this happens you must bring the load
closer to the machine by pulling the outer boom or
extension inwards. This is necessary because
otherwise the power of the main boom cylinder will not
be sufficient to handle the load.

When Loading Is Over:

1. Carry out the last movements unloaded

2. Lower the booms (and also the center of gravity) onto
the load, as down as possible.
3. Close the grapple around the load or frame in order to
prevent the loader from moving sideways.

Continued on next page EL62757,00001C6 –19–22APR02–1/2

10-0-4 101702

PN=190
 Boom, General

4. Do not ever leave the loader unsupported by relying on

the hydraulic system only.
5. When you drive the machine from one place to another
make sure that the loader does not make any sudden
movements.

EL62757,00001C6 –19–22APR02–2/2

10-0-5 101702

PN=191
 Boom Maintenance, General
Assembly Instructions

IMPORTANT: When removing joint pins or other

load-bearing structures bear in mind the
following:

❒ The lifting capacity of the loader or

pulley must be adequate.
❒ The hoisting equipment must be
reliable and in good working order.
❒ The booms must be properly
supported in every direction

EL62757,00001C7 –19–22APR02–1/1

Bleeding the Hydraulic System

If the hydraulic system has been serviced or repaired, air

must be eliminated from the system before the machine is
put to use again (see Section 7-1)

If not eliminated from the system the presence of air will

result in the following problems:

• Sudden, unintended movements

• Damage to gaskets. When compressed, air heats up
quickly and burns the packing material.

EL62757,00001C8 –19–22APR02–1/1

10-1-1 101702

PN=192
 Boom Maintenance, General

Maintenance Schedule
Maintenance daily or every 10 hours
❒ Grease the grapple and link ❒ Check boom structures
Maintenance weekly or every 50 hours
❒ Check the boom slewing housing oil level ❒ Check that the joint pins of the boom are secured
❒ Check the sideways clearance of the extension booms ❒ Check the loader extension boom chains for tightness
❒ Grease the boom ❒ Lubricate the extension boom chains with oil
Maintenance every 250 hours
❒ Clean the boom ❒ Check boom structures
❒ Check the extension booms for vertical clearance ❒ Check the tightness of loader screw joints
Maintenance every 1000 hours
❒ Clean the magnetic plug of rotator ❒ Change the loader slewing system oil
Maintenance as required
❒ Adjusting the rotator link brakes

EL62757,00001C9 –19–22APR02–1/1

10-1-2 101702

PN=193
 Boom, Maintenance every 10 hours
Grease the grapple and link.

The greasing points are shown in the illustration.

–UN–13JUN01
T142860
EL62757,00001B8 –19–21APR02–1/1

Check boom structures

• Check hoses, joints, and cylinders for tightness.

• Check the loading accessories.

Make sure that the booms are not lowered by themselves.

During the first 250 working hours check and tighten the
bolted joints of a new machine daily.

Should you locate a defective component or a

malfunctioning operation, repair it immediately. Check the
hydraulic system for potential damage visible from the
outside in order to make sure that such damage will not
result in a sudden leakage. All oil leaks must be repaired
immediately.

CAUTION: Do not ever attempt to locate or plug

an oil leak with your hand because it only takes
fluid injected at a pressure of 30 bar to
penetrate your skin and possibly cause serious
personal injury, even death.

EL62757,00001CA –19–22APR02–1/1

10-2-1 101702

PN=194
 Boom, Maintenance every 10 hours

The following service and checks are to be

made at the end of each workday

❒ Clean the machine and check it for potential failures or

leaks. It is particularly important to clean the machine
in the winter. Remove all snow, dirt, and slash before it
freezes and gets stuck.
❒ If it is time to change oils or lubricate, do it while the
machine is still warm.

EL62757,00001CB –19–22APR02–1/1

10-2-2 101702

PN=195
 Boom, Maintenance every 50 hours
Check the boom slewing housing oil level

The boom slew system and the lower bearing of the tower
are immersed in oil.

The oil level is checked in the measuring glass.

If the boom stands still for a long period of time, the oil
level must exceed the upper mark on the measuring
glass. This is to ensure that the slewing cylinder pipes will
not corrode.

As necessary fill in oil through the plug (1)

–UN–02OCT02
1—Filling

T160024
Boom slewing housing

EL62757,00001B9 –19–21APR02–1/1

Check that the joint pins of the boom are

secured.

The joint pins must be well lubricated.

–UN–13JUN01
T142876
EL62757,00001D2 –19–22APR02–1/1

10-3-1 101702

PN=196
 Boom, Maintenance every 50 hours

Check the sideways clearance of the

extension booms.

If necessary, make the adjustment by simultaneously

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

–UN–02OCT02
T160063
EL62757,00001D1 –19–22APR02–1/1

Check the boom extension boom chains for

tightness.

Operate the extension booms to their outermost position

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

EL62757,00001D0 –19–22APR02–1/1

10-3-2 101702

PN=197
 Boom, Maintenance every 50 hours

Grease the rocker and cylinder bearings of

the boom and the slewing system bearing.

Apply a layer of grease on the sliding surface of the

extension booms (see the lubrication and maintenance
chart).

When lubricating the sliding surfaces of the extension

booms, use hydraulic oil or grease designed for open
gears. If you use ordinary grease make sure that it does
not contain molybdenum sulphite.

EL62757,00001CC –19–22APR02–1/1

Lubricate the extension boom chains with

oil.

When lubricating, use an oilcan and engine oil, for

instance. Operate the extension booms to their outermost
positions to lubricate the upper chain.

EL62757,00001CD –19–22APR02–1/1

Check the grapple

Rotate the grapple continuously in one direction a

minimum of 10 rotations This is to ensure that all the fluid
in the rotator and hoses is circulated back to the tank.
–UN–12JUL01
T142800

EL62757,00001CE –19–22APR02–1/1

10-3-3 101702

PN=198
 Boom, Maintenance every 50 hours
T160027 –UN–03OCT02

Lubrication and Maintenance Chart

1. Use a grease gun for greasing.
2. Grease or lubricate the extension booms and the
inner surfaces of the outer boom and the first
extension boom.
3. Lubricate the chains
4. Check the chains for tightness.
5. Check the extension boom clearances.
Before you grease lower the boom to the ground in
order to eliminate pressure from the cylinders. This will
also help the grease to be better spread on bearing
–UN–08OCT02
T160040
surfaces. The slider part of the first extension is
greased when the extensions are inside the boom.
The inner surfaces of the outer boom and extension
are easy to lubricate if the end plate of the outer boom
is first removed.
The lower surfaces are lubricated while the outer boom
is in its outmost position and the upper surfaces while
in the innermost position.

EL62757,00001CF –19–22APR02–1/1

10-3-4 101702

PN=199
 Boom, Maintenance every 250 hours
Clean the boom.

NOTE: When washing the machine with a pressure

washer avoid directing the stream of water at the
point where the boom main post and base meet.

EL62757,00001BA –19–21APR02–1/1

Check boom structures

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

You must keep an eye on these components at all times

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

EL62757,00001D3 –19–22APR02–1/1

10-4-1 101702

PN=200
 Boom, Maintenance every 250 hours

Check the extension booms for vertical

clearance.

If necessary, make the adjustment by inserting additional

adjustment plates under the slide pieces

The aggregate thickness of the fitting plates under the

slider parts must not exceed three millimeters. This is to
make sure that the slider parts will stay in place. The top
of the slider part must exceed the edges of the bearing
housing by at least two millimeters.

The condition of the rearmost slider parts can be checked

by opening the hatch at the rear end of the extension

–UN–08MAR02
boom.

T152546
EL62757,00001D4 –19–22APR02–1/1

Check the tightness of boom fastening bolts,

hydraulic cylinder covers, and other screw
joints

For nut and bolt torque values, see Section 6-0.

Item Measurement Specification

Boom bolts Torque 1120 Nm (826 lb-ft)

EL62757,00001D5 –19–22APR02–1/1

10-4-2 101702

PN=201
 Boom, Maintenance every 1000 hours
Clean the magnetic plug of rotator

Position the unit so that the magnetic plug (1) is at the

lowest point.

• Place a container below the plug

–UN–13JUN01
• Unscrew the plug, clean it and drain 2 liters of oil
• Close and tighten the plug to 60 Nm

T142918
1—Magnetic plug

Item Measurement Specification

Magnetic plug Torque 60 Nm (44 lb-ft)

EL62757,00001BC –19–21APR02–1/1

Change the boom slewing system oil

The oil must be changed after every 1000 running hours

or once a year.

Drain the water from the drain hose by opening the drain
plug (1).

1. The drain hose is located under the base of the boom.

Unscrew the plug (1), clean it and drain the oil into an
oil sump.
2. Fill in new oil.

Volume Boom Slewing 9.5 l (2,5 gal) –UN–02OCT02

System
Hypoid oil API GL-5 eller MIL-L-2105 B eller D
Viscocity SAE 90
SAE 85W/90
T160025

SAE 80W/90
SAE 75W/90

1—Draining plug

EL62757,00001D6 –19–22APR02–1/1

10-5-1 101702

PN=202
 Boom, Maintenance every 1000 hours

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

–UN–02OCT02
T160064
• The chains and extensions can be removed by first NOTE: The extension booms and grapple must be
disconnecting the upper chain from its clamp (2). properly supported at every stage.
• Next, remove the sheave (3) and bearing housing.
Pull the chain through its opening and straighten it
on top of the second extension
• After this, disconnect the lower chain from its clamp
(4) and tie a rope to its end. Pull the second
extension out.

EL62757,000005E –67–16OCT02–1/1

10-5-2 101702

PN=203
 Boom, Maintenance as required
Adjusting the rotator link brakes

The bolted joint of the link brake pads is tightened through

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

–UN–11MAR02
secured with locknut c.

When the bolted joint is opened for the replacement or

check of the brake pads, tension washers d must not be

T152582
removed before loosening the bolted joint.

IMPORTANT: For safety reasons the tension washers

must be in place before the bolted joint a—Screw
b—Flanged nut
is tightened. c—Lock nut
d—Washer

EL62757,00001BB –19–21APR02–1/1

10-6-1 101702

PN=204
 Boom, Technical Data
Boom CF7
CF772 CF785 CF10
Gross lifting 125,4 kNm 125,4 kNm 125,4 kNm
moment
Net lifting 90,3 kNm 86,7 kNm 77,6 kNm
moment
Maximum 7200 mm 8500 mm 10 000 mm
reach
Stroke of 1390 mm 2450 mm 4200 mm
extension
boom
Gross slewing 32,6 kNm 32,6 kNm 32,6 kNm
moment of
booms
Slewing angle 380° 380° 380°
of booms
Weight without 1610 kg 1660 kg 1750 kg
oil

EL62757,00001BD –19–21APR02–1/1

Rotator and Grapple

Rotator cv11-2 GV12–2

Slewing angle Unlimited Unlimited
Slewing moment 2,4 kNm (1770 lb-ft) 1,9 kNm (1400 lb-ft)
(21,5 MPa)
Weight 58 kg (128 lbs) 58 kg (128 lbs)

Grapple Loglift FX25 Loglift FX35 Hultdins SG 260 Hultdins SG 360S Hultdins 360
Grip area 0,25 m2 0,35 m2 0,26 m2 0,36 m2 0,36 m2
Grapple closing 12kN 11 kN 13 kN 16,6 kN 16,5 kN
pressure (21,5 MPa)
Weight 230 kg 240 kg 235kg 432 kg 310 kg

Continued on next page EL62757,0000119 –19–06MAR02–1/2

10-7-1 101702

PN=205
Boom, Technical Data

–UN–08OCT02
T160023

EL62757,0000119 –19–06MAR02–2/2

10-7-2 101702

PN=206
 Boom, Technical Data

Boom CF7

–UN–08OCT02
T159871
–UN–02OCT02
T160022

Continued on next page EL62757,000009C –67–05FEB02–1/2

10-7-3 101702

PN=207
Boom, Technical Data

–UN–08OCT02
T159872

EL62757,000009C –67–05FEB02–2/2

10-7-4 101702

PN=208
 Equipment, Air Conditioner
Introduction

IMPORTANT: The air conditioner must be serviced

and repaired by authorized personnel.

Specifications:

Type and Amount of Refrigerant and the Maximum

Pressure Allowed

CAUTION: The air conditioning system has

been charged with R-134a refrigerant. Do not
use any other type of refrigerant!

The specifications of this air conditioning system are the

following:

Refrigerant Charging volume High pressure

R134a 1,5 kg 8-15 bar
5,5 lbs 116-217 psi

If the air conditioning system has been modified to use

another type of refrigerant, write the new specifications
here:

Refrigerant Charging volume High pressure

R____ ____ kg ______bar
____ lbs _____ bar

Date of modification: _______________________

EL62757,00001D8 –19–22APR02–1/1

Main Parts of Air Conditioning System

Compressor

The compressor functions like a pump, drawing in cooled

gas under low pressure from the evaporator. After this,
–UN–06MAR02

the compressor compresses the gas and sends it (in a

gaseous state) to the condenser at a high pressure and
temperature.
T152366

Continued on next page EL62757,00001D9 –19–22APR02–1/5

11-1-1 101702

PN=209
 Equipment, Air Conditioner

Condenser

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

high pressure. The gas is cooled down by cool air flowing
through the condenser coils and, consequently, the gas is
liquefied under a high pressure. Next, the liquefied

–UN–06MAR02
refrigerant flows into the filter-dryer-receiver.

T152367
EL62757,00001D9 –19–22APR02–2/5

Filter-dryer-receiver

The purpose of the filter-dryer-receiver is to receive the

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

1. Sightglass
2. Moisture indicator (by color)
3. Service valve

–UN–06MAR02
4. Filter insert
5. Pressure switch

T152368
Continued on next page EL62757,00001D9 –19–22APR02–3/5

11-1-2 101702

PN=210
 Equipment, Air Conditioner

Expansion valve

The expansion valve controls the amount of refrigerant

allowed to enter the evaporator coil. The expansion valve
is mounted on the inlet pipe of the evaporator. Upon
entering the expansion valve, the refrigerant is under a

–UN–06MAR02
high pressure and it is injected through a nozzle into the
evaporator where the pressure drops sharply.

1—From the condenser

T152369
2—Into the evaporator
3—Into the pipe located next after evaporator

EL62757,00001D9 –19–22APR02–4/5

Evaporator

The evaporator cools down and dries the air before the air
is forced into the cab. A fan draws in warm air through the
evaporator, forcing the air through the lamellas and ducts
of the evaporator. The refrigerant receives the thermal

–UN–06MAR02
energy contained in the air that cools down while passing
through the evaporator. After this, the cooled-down air is
forced into the cab.

T152370
EL62757,00001D9 –19–22APR02–5/5

11-1-3 101702

PN=211
 Equipment, Air Conditioner

Risks and Counter-Measures

CAUTION: The air conditioning system contains

refrigerant that is under pressure.

Do not disconnect the hoses of the system.

Refrigerant released into the air may be

harmful. Charging the air conditioning system
with a refrigerant of the wrong type will result in
serious damage to the system.

CAUTION: Risk of personal injury!

• Liquid that has been released from the

system has a very low temperature, and it
quickly becomes gasified.
• Warming up the filter-dryer-receiver will result
in the build-up of the gas pressure and may
cause a risk of explosion.
• The gas is colorless and heavier than air, and
it spreads on the ground.
• The gas begins to choke without any
premonitory symptoms.
• Splashing refrigerant causes frostbite and
serious damage to eyes. When working on
the air conditioning system, always wear
good, tight-fitting safety glasses because
refrigerant under pressure may start leaking
abruptly. In addition, cover your hands as
well as all other bare spots of skin.
• When refrigerant burns, it disintegrates into
noxious gases.

CAUTION: Danger of Fire and Explosion!

Do not warm up the filter-dryer-receiver beyond

50 degrees centigrade (122°F), because the high
pressure of the liquid may cause an explosion.

What to Do If Fire Breaks Out ?

Cool down the filter-dryer-receiver with a jet of water.

Leak and Clean-Up

Continued on next page EL62757,00001DA –19–22APR02–1/2

11-1-4 101702

PN=212
 Equipment, Air Conditioner

When arranging the refrigerant evacuation equipment,

make sure that no dangerous discharges of refrigerant
pass into the work area with people.

EL62757,00001DA –19–22APR02–2/2

First Aid

Accident First aid

Gas is inhaled Go out to breathe fresh air
Skin contact Frostbitten parts of body are
rinsed with lukewarm water
Splashes into eyes Continuous rinsing with a
two-percent saline solution for 20
minutes
In gestion of refrigerant Seek medical advice

EL62757,00001DB –19–22APR02–1/1

11-1-5 101702

PN=213
 Equipment, Air Conditioner

Air Conditioner, Using

The heating and cooling devices are controlled

automatically through temperature control. This way, the
temperature in the cabin is brought on the level set with
regulator (2).

A) In the summer, when the weather is warm and

humidity normal:

1. Close the recirculating air vent by turning the control

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

–UN–02OCT02
B) In the summer, when the weather is hot and
humidity high:

T152201
IMPORTANT: The internal air circulation of the
cooling system must not be obstructed.
Make sure that the protective mesh is
not clogged. 1—Speed
2—Temperature
3—Air circulation
1. Open the recirculating air vent by turning the control 4—Air flow
(3) counterclockwise as long as it goes. 5—Defrost
2. Select the temperature you wish (2).
3. Adjust the fan to the maximum speed (1).

C) In the fall and early winter, when the humidity is

high; when it is raining; when there is a lot of wet
snow; and when there is steam on the windshield:

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

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

Dehumidification (5) switches the cooling device on and

the fan to the max. speed, and opens the heating valve
fully.

When the right temperature (2) has been achieved, the

fan speed switches over to the speed set with regulator
(1).

The temperature is kept on the desired level by regulating

the cooling device and the heating valve.

Continued on next page EL62757,00001DC –19–22APR02–1/3

11-1-6 101702

PN=214
 Equipment, Air Conditioner

The cooling device must be switched off with switch (5),

when the indoor air is dry enough.

IMPORTANT: The compressor will not start if the

temperature is below 0°C (14 °F).

EL62757,00001DC –19–22APR02–2/3

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

1. Close the recirculating air vent (3).

2. Select the temperature you wish (2)

E) In the winter, when the weather is extremely cold

and the humidity low:

1. Open the recirculating air vent (3)

2. Select the temperature you wish (2)

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

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

–UN–02OCT02
NOTE: The air conditioner should be operated for a few
minutes every week by pressing the ’max. defrost’
switch (5).

T152201
This is enough to ensure that the drive shaft seal of the
compressor, other packing, joints, and rubber hoses are
lubricated.

EL62757,00001DC –19–22APR02–3/3

11-1-7 101702

PN=215
 Equipment, Air Conditioner

Maintenance and Inspections: Check the

refrigerant level.

1. The engine must be running at 1500 RPM.

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

–UN–06JUN01
position.

When the compressor is running no bubbles should be

seen in the sightglass (1), and the refrigerant should not

T139550
appear ’cloudy’. Bubbles and cloudiness indicate that the
charge of refrigerant is insufficient. If this is the case,
immediately contact the nearest authorized dealer to have
1—Inspection sightglass
the problem remedied.

EL62757,00001DD –19–22APR02–1/5

A. CLEARLY INSUFFICIENT AMOUNT OF

REFRIGERANT

–UN–15JUN01
• Continuous flow of bubbles or a flow that appears
foamy
• The difference in temperature between the low and high
T139551
pressure sides is small.
• The pressure of the high-pressure side is unusually low.

STOP THE COMPRESSOR IMMEDIATELY and contact

an authorized mechanic to check the system.

Continued on next page EL62757,00001DD –19–22APR02–2/5

11-1-8 101702

PN=216
 Equipment, Air Conditioner

B. INSUFFICIENT AMOUNT OF REFRIGERANT

–UN–15JUN01
• A few bubbles seen at several second intervals
• The high-pressure side is warm and the low-pressure
side cool.

T139552
Check to see that there are no leaks in the system. If
there are, repair immediately.

New refrigerant must not be added into the system by

anyone else but authorized personnel.

EL62757,00001DD –19–22APR02–3/5

C. CORRECT AMOUNT OF REFRIGERANT

–UN–15JUN01
• The refrigerant is clear and only a few bubbles pass by
when the engine speed is changed.
• The pressure of both the high-pressure side and the

T139553
low-pressure side is normal.
• The high-pressure side is hot and the low-pressure side
cold.

Continued on next page EL62757,00001DD –19–22APR02–4/5

11-1-9 101702

PN=217
 Equipment, Air Conditioner

D. EXCESSIVE AMOUNT OF REFRIGERANT

–UN–15JUN01
• No bubbles at all
• The high-pressure side is very hot
• The pressure of both the low and high-pressure side is

T139554
unusually high

If refrigerant must be removed from the pressure side of

the system, contact authorized personnel.

❒ Control all hoses and connectors for leaks.

NOTE: New refrigerant R134a may appear slightly

’cloudy’ during operation. This may be the case
although the system has been correctly charged.
If in doubt, please contact the nearest authorized
dealer.

IMPORTANT: Do not operate the system, if the

refrigerant charge is insufficient or if
there is a leaking in the system,
because the compressor will be
damaged. Contact your authorized
dealer.

EL62757,00001DD –19–22APR02–5/5

11-1-10 101702

PN=218
 Equipment, Air Conditioner

Check the service moisture indicator of the

dryer every 50 hours

The service indicator should be blue.

The dryer must be replaced, if the indicator area has

–UN–13JUN01
turned to pink.

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

when the hoses are replaced or if the service

T142872
moisture indicator has turned to pink.

IMPORTANT: Do not operate the system, if the

1—Service indicator
refrigerant charge is insufficient or if
there is a leaking in the system,
because the compressor will be
damaged. Contact your authorized
dealer.

EL62757,00001DE –19–22APR02–1/1

Service the compressor V-belt every 250

hours

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

–UN–13JUN01
T142874

EL62757,00001DF –19–22APR02–1/1

Service the compressor every 1000 hours

Mounting

The compressor must be properly mounted and in

alignment, ensuring that the drive belt moves directly on
the belt pulley, without wearing the sides of the belt.

Check that the clutch plate and sprocket are clean.

Continued on next page EL62757,00001E1 –19–22APR02–1/2

11-1-11 101702

PN=219
 Equipment, Air Conditioner

Compressor plate

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

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

–UN–13JUN01
1—Compressor plate

T142890
EL62757,00001E1 –19–22APR02–2/2

Service the evaporator element every 1000

hours

The evaporation element must be clean.

Make sure that the condensation water outlet is open.

–UN–13JUN01
1—Evaporator

T142892
EL62757,00001E2 –19–22APR02–1/1

Service the condenser element every 1000

hours

Ensure that the condenser gets enough air.

The element must be regularly cleaned by blowing lightly

–UN–18JUL01
with compressed air.

Blow through the condenser, in the opposite direction if

compared with the ordinary flow of air.

IMPORTANT: Carefully clean the ends of the T144037

condenser element with compressed
air. Blowing direction: away from the
condenser. If the compressed air used
is too strong, the condenser fins may
be damaged.

EL62757,00001E3 –19–22APR02–1/1

11-1-12 101702

PN=220
 Equipment, Air Conditioner

Service the hoses and connectors every

1000 hours

CAUTION: Do not open hose connections.

There is pressure in the cooling system.
Incorrect procedures may result in personal
injury.

Check the refrigerant hoses and joints regularly. Oily

connectors may result in leaks.

When connecting and fastening hoses, make sure that

nothing will abrade the hoses.

The filter-dryer-receiver must be replaced always

when the hoses are replaced or if the service
moisture indicator has turned to pink.

NOTE: Make sure that the condensation water outlet is

not restricted and that the water can freely flow
out of the system.

Ensure that the power circuit between the

thermostat and the electromagnet switch is in
order.

EL62757,00001E4 –19–22APR02–1/1

11-1-13 101702

PN=221
 Equipment, Engine Preheater
Operation and maintenence

–UN–28MAR02
T153144
Sektionsritning

WE—Water inlet 2—Flame sensor 8—Heat exchanger 14—Fuel branch piece

WA—Water outlet 3—Combustion chamber 9—Overheating switch 15—Cable tree
V—Combustion air 4—Control unit 10—Water pump 16—Fuse bracket
B—Fuel 5—Heater plug 11—Exhaust silencer 17—Relay for switching on the
A—Fumes 6—Temperature sensor 12—Combustion air silencer vechicle’s fan
1—Combustion motor 7—Flame tube 13—Fuel feeder pump 18—Timer

The preheater heats the engine, cabin and hydraulic
system according to preselected times.
The preheater is controlled by a timer. See information
later on.
NOTE: Before starting the heater or before
pre-programming the heating sequence, set
the cabin heating control to its maximum open
position and the fan speed to position 1.
1. Switching on
• The control lamp on the timer will light on starting
• The combustion air fan and the water pump start
to run, and the ignition plug glows (preliminary
glow).
• After a preliminary glow period (about 40
seconds), and regardless of operation, the fuel
dispenser pump starts to supply fuel at rapid
impulse frequency to give full load in the
combustion chamber and the fuel ignites
The ignition plug is switched off when the control
unit receives a signal from the flame sensor that the
fuel is burning.

Continued on next page EL62757,00001FF –19–24APR02–1/9

11-2-1 101702

PN=222
 Equipment, Engine Preheater
2. Heating
• Depending on the heating need the heating
power will be automatically adjusted: 5000 W /
2200 W
• The settings of the control unit dictate the
temperatures at which the power level changes.
• Should there be only a limited need for heat,
enabling the coolant to reach a temperature of 85
°C (185 °F), the heating system will switch over
to an inactive state. This is when the fan will
continue operating for another 130 seconds to
cool down the heater
• The timer warning lamp will still be on and the
water pump will go on operating.
• As soon as the coolant temperature drops to a
level of 7 5°C (167 °F), the heating system will be
automatically engaged again.
IMPORTANT: Do not start the diesel engine while
the preheater is running. Similarly,
wait until the trailer operation (appr.
two minutes) is over before you start
the engine. Otherwise, the preheater
may be damaged.
3. Switching off
The supply of fuel is cut off when the timer switches
the heater off. The indicating lamp goes out.
The combustion air fan and the water pump
continue to run for about 130 seconds and are then
switched off automatically.
4. Safety devices
The flame is monitored by the flame sensor, and
the maximum permitted temperature by the
overheating switch. Both of these affect the control
unit, which switches off the burner in the event of
malfunctioning.
a. The starting sequence will be repeated if the
heater does not ignite within 90 seconds after
the fuel supply is turned on. If the heater still
does not start within the additional 90 seconds,
the malfunction switch-off will take place. The
malfunction switch-off can be cancelled by briefly
switching the heater off and then on again
11-2-2
b. A renewed start will be made if the burner
should go out during operation. The malfunction
switch-off will then be actuated if it does not start
within 90 seconds or if it starts and then goes
out again within 3 minutes
c. If overheated (e.g., due to lack of water, poorly
vented cooling system), the overheating sensor
switches off and consequently the fuel supply
will be cut off, thus actuating the malfunction
switch-off. After rectifying the cause of
overheating, press in the button on the
overheating circuit breaker and also reset the
malfunction switch-off as above, so that the
heater can be started.
d. The malfunction switch-off will be activated if
voltage of the electrical system should fall below
about 20 V or rise above about 28 V.
e. The heater will not start at all if the ignition plug
is defective or if the electric circuit to the
dispenser pump is broken.
f. Functioning of the blower motor is checked on
starting and the malfunction switch-off will be
activated if it is not running.
5. Correction of malfunction
Check the following items if the heater does not start
when being switched on:
❒ Fuses, See section 8. Also check the fuse for the
cab fan. No heated air will enter the cab if this fuse
has blown, although the heater starts and heats the
engine.
❒ Switch the heater OFF and ON, but not more than
twice. Authorized personnel or workshop should be
contacted if the heater still does not start.
Maintenance of the engine preheater
Remember to keep the preheater and its surroundings
clean, especially near the exhaust system of the
preheater.
❒ Check hoses, joints and other components for
overall shape and tightness.
Continued on next page EL62757,00001FF –19–24APR02–2/9
101702
PN=223
 Equipment, Engine Preheater

❒ Start the heater about once a month even during

CAUTION: Risk of fire. the summer and allow it to run for a few minutes to
prevent binding of the fan and water pump.
❒ Always switch off the battery main switch to protect
the control unit before any electric welding on the
machine, also see Section 8, welding.

Continued on next page EL62757,00001FF –19–24APR02–3/9

11-2-3 101702

PN=224
 Equipment, Engine Preheater

Timer for engine and cabin preheater

The preheater is started with the timer, i.e., either directly

or at preset time.

All signals in the display will flash when electric power

supply is connected. The heater cannot be switched on in
this mode, i.e., the heater timer must first be properly set.

1. Setting the timer

• Press and hold down (1) until the time flashes (basic
setting for the first time: press (1) briefly)
• Set the current time using (4) and (5).
When the time display stops flashing, the time has

–UN–03OCT02
been stored.
The weekday begins to flash.
• Set the current weekday using (4) and (5)

T153141
When the display stops flashing, the setting has been
stored. Acceptable setting can also be skipped by
pressing (1). When the ignition switch of the machine
is turned on, the current time is displayed in the timer. 1—Time indication/setting
2—Preselection
3—Heating on
When the ignition switch is turned off the display 4—Adjust backward
disappears after 15 seconds. When there is no display 5—Adjust forward
the current time appears by pressing (1) . 6—Stored memory indication
7—Day of week
8—Symbol for remote control (opt. eq.)
NOTE: Before starting the heater or before 9—Current time / program time
pre-programming the heating sequence, set the 10—Temperature indication (opt. eq.)
cabin heating control to its maximum open 11—Operating display
position and the fan speed to position

NOTE: If a fault occurs when you switch the heater on (or

if the heater is on), the operating display shows
"F" and a fault code (two numbers) in 15 seconds.
See Malfunction codes later on this section.

2. Direct starting of heater without preselection

(ignition of the base machine is off)
• Press (3), start of heating.

Heating symbol (3) and the heating duration is

displayed. The heating duration is factory-preset to 120
min.

3. Changing the heating duration

a. Temporarily:

Continued on next page EL62757,00001FF –19–24APR02–4/9

11-2-4 101702

PN=225
 Equipment, Engine Preheater

Start heating; press (3).

To reduce heating duration: press (4).
To increase heating duration (to max. 120 min):
press (5).
b. Permanently

Do not switch heating on.

Press the (4) key and hold it down (approx. 3 s) until

the display appears and flashes.

Release the key.

Then set the heating duration (10...120 min) using

the(4) or (5) key. The new heating duration is set when
the display disappears.

4. Switching off the heater

Press (3), automatic cooling phase, about 130
seconds.
5. Heating without preselection (ignition of the base
machine is on)
Press (3) .
Heating stays in operation until ignition is switched off.
After ignition is switched off, a residual heating period
of 15 min remains.
This can be changed (1...120 min) by pressing the (4)
or (5) key. Switching off the heater: press (3).
6. Heating operation preselection

Continued on next page EL62757,00001FF –19–24APR02–5/9

11-2-5 101702

PN=226
 Equipment, Engine Preheater

There are three preset times in the memory. Only one

can be activated at a time (the memory number is
displayed).

A) Set the program time and day

Press the key (2)(1...3 times) until the desired memory

display begins to flash.

Briefly press and then release (4) or (5) . The program

time flashes.

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

–UN–03OCT02
When the display stops flashing, the time has been
stored. The program day begins to flash, set the
weekday using (4) or (5).

T153141
The preselected time and weekday are stored as soon
as the display changes over to the current time.

Flashing ’heating on’ key (3) indicates an activated

preselection. The current time disappears and only the
activated memory number is displayed.

When there is no memory number displayed no

memory is activated. This is done by pressing (2)
several times. Neutral setting is after the memory
number 3.

B)Checking activated memory

Press (2) . The activated preselected time and

preselected day are displayed for approx. 5 s.

7. Advice in event of malfunctioning:

❒ In the event of malfunctioning, switch off and then
on again (but not more than twice)
❒ check the main fuse
❒ ensure that the flow of air is unrestricted
❒ contact an authorized service agent.

Continued on next page EL62757,00001FF –19–24APR02–6/9

11-2-6 101702

PN=227
 Equipment, Engine Preheater

NOTE: If you try to switch on the heater without result

five times in a row or if the heater overheats three
times in a row, the operation will be disabled.
(Fault code F50 or F15).

Malfunction codes of the engine preheater

Example: display shows: F33 (current fault) and

heating-on symbol flashes

Continued on next page EL62757,00001FF –19–24APR02–7/9

11-2-7 101702

PN=228
 Equipment, Engine Preheater

F00 No malfunction
F01 Warning about overvoltage
F02 Warning about undervoltage
F09 TRS 003 unplugging
F10 Overvoltage shutoff
F11 Undervoltage shutoff
F12 Overheating
F13 Possible overheating detected
F14 Too big difference between overheating- and water temperature
*F15 Operation disable because perm.number of possible overheatings exceeded
F20 Glow plug break
F21 Glow plug output overload
F33 Malfunction in combustion engine
F37 Waterpump not working
F42 Water pump short-circuit
F43 Other component short-circuit
F47 Fuel pump short-circuit
F48 Fuel pump break
*F50 Operation disable due to excessive start attempts
F51 Flame signal already at start
F52 Safety time exceeded- no start
F53 Flame cutout from POWER control stage
F54 Flame cutout, HIGH-setting
F55 Flame cutout, Medium-setting
F56 Flame cutout, LOW-setting
F59 Too quick rise in water temperature.
F60 Temperature sensor break
F61 Temperature sensor short-circuit
F64 Flame sensor break
F65 Flame sensor short-circuit
F71 Overheating sensor break
F72 Overheating sensor short-circuit
F90 Control unit defective (internal fault / reset)
F93 Control unit defective (RAM-error)
F94 Control unit defective (EPROM-error)
F97 Internal control unit fault

*) Steps to cancel the disabled operation (fault code

F15 or F50)

Continued on next page EL62757,00001FF –19–24APR02–8/9

11-2-8 101702

PN=229
 Equipment, Engine Preheater

A How to empty the fault memory:

• Switch power on.

• Press(3) . Fault code appears.
• Press (1) to the bottom and in 2 seconds
simultaneously press (2).
• Switch power off
• Press (1) and (2) simultaneously and switch the power
on. Display shows: - - : - -
Display flashes, heating-on symbol doesn’t.
After about 3 seconds the heater will go on (the
disabled operation is canceled).

Display, when the heater has started to operate: AF : 00

BIn case of having the error F50, do the following:

• Disconnect the wire coming to the fuel pump of the

preheater.
• Try to start the preheater normally.
This gives the alarm F48 to the display.

After that, it is possible to deactivate the fault code as

described above.

EL62757,00001FF –19–24APR02–9/9

11-2-9 101702

PN=230
 Equipment, Fire Extinguisher System
General

Fire extinguisher system1.

This installation includes a container with extinguishing

medium, connected to a system of pipes/hoses with
nozzles in the protected areas.

Heat detectors are actuated in the event of fire and make

an electric circuit to the fire alarm.

The alarm is given by:

• pulsating light and sound signals

• red light on the cab roof
• horn underneath the cover on the hydraulic reservoir.

1
in certain markets / optional equipment
EL62757,0000200 –19–24APR02–1/1

11-3-1 101702

PN=231
 Equipment, Fire Extinguisher System

Fire Alarm and Actions

Fire alarm during operating the machine

NOTE: Only the fire alarm will be activated when the

main switch is ON

–UN–12SEP02
ACTIONS:

Operator!

T152199
1. Trigger the alarm
2. Take a hand-held extinguisher with you and check that
the fire does not spread.

The fire fighting installation can be triggered in three

ways:

1. Manually from the cab by pressing the triggering

–UN–05MAR02
button (3) on the control unit.

1—Warning light - machine malfunction (yellow)

T152200A
2—Fire alarm light (red)
3—Control unit trigger button

Alarm lights

Continued on next page EL62757,0000202 –19–24APR02–1/3

11-3-2 101702

PN=232
 Equipment, Fire Extinguisher System

2. Breaking the main power supply by turning the main

switch (1) OFF
3. Triggering device, pull the triggering handle.

Fire alarm when the machine is not operated

The fire extinguisher system will be automatically triggered

in the event of fire when the machine is unmanned and
the main switch is OFF.

1—Main Switch
4—Triggering handle

–UN–05MAR02
T152211
–UN–15SEP02
T152355
Continued on next page EL62757,0000202 –19–24APR02–2/3

11-3-3 101702

PN=233
 Equipment, Fire Extinguisher System

–UN–15SEP02
T159363
Fire Extinguisher System in the machine 6. Junction box
a. Central Unit
1. Fire extinguisher b. Fuse box
2. Signal Horn c. Signal horn
3. Support d. Not in use
4. Fuse box e. Thermal sensor
5. Connector housing f. Tripping

EL62757,0000202 –19–24APR02–3/3

11-3-4 101702

PN=234
 Equipment, Fire Extinguisher System

After a fire

The alarm ceases when the fire is put out and detectors
have cooled down. Open the ventilation covers so that
smoke and fumes can be vented.

IMPORTANT: Before opening any covers or engine

hood, wait at least 30 minutes to let the
machine cool down.

IMPORTANT: Be prepared with a hand extinguisher

while airing the machine.

CAUTION: Avoid breathing in fumes from the

fire.

Clean the machine with water as soon as possible after a

fire.

Restoring the machine after a fire: Contact service

personnel to establish the reason for the fire and to
restore the fire extinguisher system.

EL62757,0000201 –19–24APR02–1/1

11-3-5 101702

PN=235
 Equipment, Fire Extinguisher System

Control unit

1. Green light emitting diode, indicating that the system is

operative.
Goes out if the power supply is broken.
2. Yellow light emitting diode, supervising the detector

–UN–06MAR02
circuit.
Lights up if the circuit is broken or if the end resistor is
removed.
3. Yellow light emitting diode, supervising the circuit to

T152354
the gas generator in the mechanical / electrical
triggering unit.
Lights up if the circuit is broken or when the gas Control unit of the fire extinguisher system
generator is triggered 1—Green
4. Yellow light emitting diode. 2—Yellow
Lights up when the system is in the manual mode = 3—Yellow
Battery master switch is ON. 4—Yellow
5. Triggering button for the system. 5—Triggering button for the system
6—Toggle switch for alarm and error testing
Issues a pulsating light when the fire alarm is given
and a steady light when the system is triggered
electrically.
6. Toggle switch for alarm and error testing.
a. Upper position, testing the alarm.
The alarm 5 of the installation shall be activated,
push-button (5) flashes and diode (1) and (3) will
show a steady light.
b. Middle position: Simulating break of the
detector circuit and the detonator loop.
Diodes 1, 2 and 3 should light. Diode 4 should also
light if the battery master switch is ON. The steady
light for the electrically triggered system will also be
reset when the toggle switch is moved to the middle
position.
c. Lower position, operating mode:
Diode 1 should light, and also 4 if the battery
master switch is ON.

Check every day:

❒ That diode 1 lights up, and also 4 if the battery master

switch is ON, when switch 6 is in the operation mode.

Continued on next page EL62757,0000203 –19–24APR02–1/2

11-3-6 101702

PN=236
 Equipment, Fire Extinguisher System

IMPORTANT: Before leaving the machine, remember

to turn the main switch to 0 to set the
automatic monitoring and triggering of
the fire extinguishers.

Check every week:

❒ That diodes 1, 2 and 3 light up when switch 6 is set to

its middle position.
❒ That diode 4 also lights up if the battery master switch
is ON
❒ That the light and sound alarms are activated and that
push-button 5 flashes, diodes 1 and 3 light up when
switch 6 is moved to its upper position.
❒ Ensure that the hand-held extinguishers are in place
and that the indicators show that they are full.

Annual inspection

The system is to be inspected once a year by authorized

service personnel. This inspection is a condition of the
insurance companies.

IMPORTANT: Disconnect the connector of the control

unit before carrying out any of the
following tasks;

• pressure-jet washing
• steam-jet washing
• electric welding
• battery charging

EL62757,0000203 –19–24APR02–2/2

11-3-7 101702

PN=237
 Equipment, Fire Extinguisher System

Hand-held fire extinguishers

The machine is equipped with a hand-held fire

extinguisher.

The hand-held extinguishers are intended for minor fires

–UN–06MAR02
and for final extinguishing after the sprinkler system has
been triggered.

The fire extinguishers must be checked, serviced and

T152353
stamped by an authorized dealer.

NOTE: On certain markets fire insurance terms stipulate

that fire extinguishers must be checked after
every six months. Contact your insurance
company for all the details.

EL62757,0000204 –19–24APR02–1/1

11-3-8 101702

PN=238
 Equipment, Decking Blade
Using the Decking Blade

The decking blade is operated with the push buttons (1

and 2) on the right-hand-side control panel

The decking blade can also be operated with the

right-hand-side boom control lever .

The lever control is engaged by pushing the push buttons,

(1 and 2), simultaneously for 2 seconds. When the lever
control is on the decking blade symbol will appear to TMC
display.

NOTE: Lever control can only be used when the low gear
is on and the boom is off.

When the lever control is engaged the decking blade can

be controlled even if nobody was sitting in the seat. lever
control is disengaged by switching on the boom or by
pressing the decking blade control switches
simultaneously.

IMPORTANT: Do not use the decking blade for

removing tree stumps or large rocks.
During travel, raise the decking blade
high enough to clear all obstacles
1—Blade up, also with boom control lever-Y
2—Blade down, also with boom control lever +Y

–UN–05MAR02
T152209

EL62757,0000205 –19–24APR02–1/1

11-4-1 101702

PN=239
 Equipment, Decking Blade

Lowering the Decking Blade

If the machine dies and the decking blade has stayed in

upper position, the engine hood can not be opened before
the decking blade has been lowered down.

–UN–12SEP02
Operator can lower the decking blade with the help of
cylinders that are used through a tap (3) at the main
switch.

T159330
NOTE: After lowering, close the tap by twisting it.

EL62757,0000206 –19–24APR02–1/1

11-4-2 101702

PN=240
 Equipment, Decking Blade

Decking Blade’s Float

Decking blade’s float position switch (17) is situated on

the front dashboard.

IMPORTANT: Diesel engine must be on, before you

can use the float position.

The switch has 3 positions, 0, 1, 2

• Float position is ON, when you press the switch to

position 2.
After that the switch will stay in position 1.
• Position 0 will stop the float position.

NOTE: Stopping the engine also stops floating.

NOTE: If you start the engine and the switch is in position

1, you can’t use the float position.

Stop the engine, choose position 0 and start

again.

17—Decking blade float position switch

–UN–17OCT02
T152191

EL62757,0000207 –19–24APR02–1/1

11-4-3 101702

PN=241
 1410D Specifications
Dimensions

–UN–03OCT02
T160088

Continued on next page EL62757,0000001 –19–06FEB02–1/2

12-0-1 101702

PN=242
 1410D Specifications

Length min. 9295 mm 30,5 ft

Length max. 10495 mm 34,4 ft
Width min. 2750 mm 9 ft
Width max. 2930 mm 9,6 ft
Weight 6-hjulmin. 14900 kg 32849 lbs
Weight 8-hjulmin. 16500 kg 36376 lbs
Height 3900 mm 12,8 ft
Load rating 14000 kg 30864 lbs
Ground clearance 605 mm 1,98 ft
Wheelbase 6-hjul 5250 mm 17,2 ft
8-hjul 5850 mm 19,2 ft
Log length max. 7m 23 ft

EL62757,0000001 –19–06FEB02–2/2

Decals and Signs

–UN–08OCT02
T160263

A—Serial number B—Behind the front frame, on

On the front frame, on the the left side
right side of the machine
(optional)

EL62757,00001E5 –19–22APR02–1/1

12-0-2 101702

PN=243
 1410D Specifications

Load area

–UN–03OCT02
T160089
Length of load area min. 3400 mm 11 ft
max. 5000 mm 16,4 ft
Width of load area 2740 mm 9 ft
Load area 5 m2 53,8 ft2

EL62757,0000002 –19–06FEB02–1/1

12-0-3 101702

PN=244
 1410D Specifications

Engine

John Deere, 6068HTJ77 water-cooled and turbocharged

6-cylinder diesel engine with intercooler.

–UN–11NOV97
RG7778

–UN–16MAR98
RG9061
Saran Engine Serial Number Plate

A—Serial Number Plate

B—Engine Serial Number
C—Engine Application Data
D—Coefficient of Absorption (Saran Engines
Only)

Item Measurement Specification

Engine John Deere JD6068 HTJ77 Max. output 136kW (182 hp)/ 1900 r/min
Torsional moment 779 Nm (574,6 lbt-ft)/ 1400 r/min

EL62757,0000003 –19–06FEB02–1/1

12-0-4 101702

PN=245
 1410D Specifications

Transmission

❒ Hydrostatic-mechanical.
❒ High/low gear, power distributed between the front and
rear axles.
❒ Off-road driving, smooth no-surge start without
dropping engine speed.
❒ Release of rear-wheel drive.

Item Measurement Specification

Transmission Max. tractive force 175 kN (39341 lbt)

Maximum driving speed 23 km/h (14 miles/h)

EL62757,0000004 –19–06FEB02–1/1

Axles

❒ Patented, balanced gear-driven bogie, portal type

❒ Identical axles front and rear.
❒ Mechanical differential lock front and rear.
❒ Release of rear-wheel drive.

EL62757,0000005 –19–06FEB02–1/1

Steering

Articulated frame steering with two steering cylinders.

Proportional stick steering.

Item Measurement Specification

Frame steering Steering angle ± 42°

EL62757,0000006 –19–06FEB02–1/1

12-0-5 101702

PN=246
 1410D Specifications

Brakes

Hydraulically actuated, oil-immersed multiple disc brakes

front and rear.

Spring actuated parking brakes and emergency brakes on

front and rear bogie.

EL62757,0000007 –19–06FEB02–1/1

Hydraulic system

Load sensing hydraulic system with power control.

Pump capacity
Hydraulics 280 l/min 74 gal/min
Power train 280 l/min 74 gal/min
Working pressure 24 MPa 3481 psi

EL62757,0000008 –19–06FEB02–1/1

Electrical System

Voltage 24 V
Batteries 2 x 140 Ah
Alternator 24 V 140 A

EL62757,0000009 –19–06FEB02–1/1

Boom
Boom CF7
Lift moment 125,4 kNm 92490 lb-ft
Reach. 7,2/8,5/10 m 23,6/27,9/32,8 ft

EL62757,000000A –19–06FEB02–1/1

12-0-6 101702

PN=247
 1410D Specifications

Cab

Sound and thermal insulated single-seater safety cab.

The cab can be raised and shifted to the side for easy
service access.

Noise level in cab

not usable at 04/02

Vibration level

not usable at 04/02

EL62757,000000B –19–06FEB02–1/1

12-0-7 101702

PN=248
 Hydraulic Diagrams, F622627
Hydraulic Diagrams, F622627

1. Boom Hydraulics
2. Transmission Hydraulics
3. Brake Hydraulics
4. Extra Equipment Hydraulics
5. Options Hydraulics

EL62757,0000062 –67–17OCT02–1/1

Hydraulic Diagrams-1 101702

PN=249
 Hydraulic Diagrams, F622627

Boom Hydraulics
Position Meaning Pressure (MPa) Pressure (psi) Placement
100 Work pump Under the cab
101 Adjustment of work pump’s max. pressure 24 3481 Work pump
102 Adjustment of work pump’s pressure difference 2,5 362,5 Work pump
103 Return filter 0,15 22 Front frame
104 Hydraulic tank Front frame
105 Level guard Hydraulic tank
106 Temperature sensor Hydraulic tank
107 Bleeding Hydraulic tank
108 Bleed screw 0,02 3 Hydraulic tank
109 Pressure valve W84 0,13 19 Hydraulic tank
110 Quick coupler , filling of hydraulic oil Main switch
111 Pressure measure point, work pump’s pressure Attachement valve
112 Pressure valve W41A, parking brake 2 290 Attachement valve
113 Adjustment screw, reduced pressure of 3 435 Attachement valve
attachements
114 Pressure measure point, reduced pressure of Attachement valve
attachements
115 Attachement block Attachement valve
116 Pressure measure point, , pressures for each Attachement valve
function of the boom
117 Pressure measure point, work pump’s signal Attachement valve
pressure
118 Differential front Attachement valve
119 Differential rear Attachement valve
120 Rear wheel drive, engagement with high gear on Attachement valve
121 High/low gear Attachement valve
122 Pilot valve for loader valve Loader valve
123 Pressure measure point, pilot pressure for loader 3.5 508 Loader valve
valve
124 Pressure reduce valve 26 3771 Loader valve
125 Orifice for a signal line Loader valve
126 Loader valve Under the cab
127 Pressure reduction for Boom slew Under the cab
128 Cylinders for boom slew Boom
129-130 Reduced pressure for boom slew 21.5 3118 Loader valve

Continued on next page EL62757,00001E8 –19–22APR02–1/4

Hydraulic Diagrams-2 101702

PN=250
Hydraulic Diagrams, F622627

–UN–09OCT02
T160341

Continued on next page EL62757,00001E8 –19–22APR02–2/4

Hydraulic Diagrams-3 101702

PN=251
 Hydraulic Diagrams, F622627

Position Meaning Pressure (MPa) Pressure (psi) Placement

131 Lift cylinder Boom
132 Jib cylinder Boom
133 Rotator Boom
134 Grapple cylinder Boom
135 Reduced pressure for grapple, (closed) 19 2756 Loader valve
136 Reduced Pressure for grapple, (open) 17 2466 Loader valve
137 Telescope cylinder 21.5 3118 Boom
138 Frame steering Rear frame
139-140 Reduced pressure for frame steering Loader valve
141 Pilot valve, frame steering Under the cab

Continued on next page EL62757,00001E8 –19–22APR02–3/4

Hydraulic Diagrams-4 101702

PN=252
Hydraulic Diagrams, F622627

–UN–09OCT02
T160341

EL62757,00001E8 –19–22APR02–4/4

Hydraulic Diagrams-5 101702

PN=253
 Hydraulic Diagrams, F622627

Transmission Hydraulics
Position Meaning Pressure (MPa) Pressure (psi) Placement
200 Pulse sensor, diesel engine Diesel engine
201 Transmission pump Under the cab
202 Oil cooler Front frame
203 Thermostat valve Under the cab
204 Measure point for charge pressure Transmission pump
205 Pressure sensor 1,0 MPa 145 Transmission pump
206 Measure point for drive pressure; drive pressure Transmission pump
backwards
207 Adjustment of hydrostatic charge pressure 3 435 Transmission pump
208 Drive pump pressure cut-off Transmission pump
209 Adjustment of pressure reduce valve: drive 48 6961,8 Transmission pump
pressure backwards
210 Adjustment of hydrostatic drive pressure forward 45 6526,7 Transmission pump
and backwards
211 Adjustment of pressure reduce valve: drive 48 6961,8 Transmission pump
pressure forward
212 Pressure reduce valve, transmission pump Transmission pump
213 Charge pressure filter Transmission pump
214 Measure point for transmission pressure; drive Transmission pump
pressure forward
215 Direction identification valve in drive motor Drive motor
216 Measure point, motor’s control pressure/ motor Drive motor
pressure cut-off
217 Adjustment of drive motor’s pressure cut-off 33 4496 Drive motor
218 Drive motor’s pressure cut-off Drive motor
219 Pulse sensor, drive motor Drive motor
220 Drive motor Under the cab

Continued on next page EL62757,00001E9 –19–22APR02–1/2

Hydraulic Diagrams-6 101702

PN=254
Hydraulic Diagrams, F622627

–UN–09OCT02
T160342

EL62757,00001E9 –19–22APR02–2/2

Hydraulic Diagrams-7 101702

PN=255
 Hydraulic Diagrams, F622627

Brake Hydraulics
Position Meaning Pressure (MPa) Pressure (psi) Placement
300 Brake valve Under the cab
301 Measure point, pressure accumulator Under the cab
302 Pressure accumulator Under the cab
303 Pressure sensor, brake light 0,5 72,5 Brake valve
304 Measure point for brake pressure Brake valve
305 Measure point for brake pressure Brake valve
306 Orifice Brake valve
307 Measure point, pressure accumulator Brake valve
308 Pressure accumulator Under the cab
309 Pressure sensor, brakes’ charge pressure 10 1450 Brake valve
310 Front brake cylinders Front axle
311 Rear brake cylinders Rear axle
312 Brake fluid container Cab, front
313 Front brake pedal Cabin
314 Rear brake pedal Cabin
315 Shuttle valve Under the cab

Continued on next page EL62757,00001EA –19–22APR02–1/2

Hydraulic Diagrams-8 101702

PN=256
Hydraulic Diagrams, F622627

–UN–09OCT02
T160343

EL62757,00001EA –19–22APR02–2/2

Hydraulic Diagrams-9 101702

PN=257
 Hydraulic Diagrams, F622627

Extra Equipment Hydraulics

Position Meaning Pressure (MPa) Pressure (psi) Placement
400 Hydraulic oil pump Under the cab
401 Hydraulic oil tank Front frame
402 Filling pump, hydraulic oil Under the cab
403 Quick coupler Main switch
404 Compressed air valve Hydraulic tank
405 Vacuum pump Under the cab
406 Bleeding valve filter Hydraulic tank
407 Vacuum valve 0.03 4,4 Under the cab
408 Bleeding valve 0.05 7,25 Under the cab
409 Adjustment screw, frame brake pressure 21 3046 Attachement valve
410 Solenoid Y65, frame brake Attachement valve
411 Measure point, frame brake pressure Middle joint
412 Frame brake cylinder Middle joint
413 Loader valve Under the cab
414 Lift cylinder Boom
415 Steering valve Rear frame
416 Manual steering valve, frame steering Cabin
417 Steering valve, frame steering Pilot valve
418 Shuttle valve Front frame
419 Stairs’ steering valve Front frame
420 Stairs’ cylinder Front frame
421 Directional valve Front frame
422 Quick coupler Front frame
423 Shuttle valve Front frame
424 Valve, hand brake (extra equipment)

Continued on next page EL62757,00001EB –19–22APR02–1/2

Hydraulic Diagrams-10 101702

PN=258
Hydraulic Diagrams, F622627

–UN–09OCT02
T160344

EL62757,00001EB –19–22APR02–2/2

Hydraulic Diagrams-11 101702

PN=259
 Hydraulic Diagrams, F622627

Options Hydraulics
Position Meaning Pressure (MPa) Pressure (psi) Placement
500 Work pump Under the cab
501 Hydraulic tank Front frame
502 Valve for load space expansion Boom foot
503 Cylinders for load space expansion Boom foot
504 Cylinders for Headboard expansion (2 pc.) Headboard
505 Headboard lift valve Under the cab
506 Headboard lift cylinder Headboard
507 Hand pump for cab lift Front frame
508 Directional valve Hand pump
509 Pressure reduce valve Under the cab
510 Cabin, Lift cylinder, front Under the cab
511 Cabin, Lift cylinder, rear Under the cab
512 Loader valve Under the cab
513 Plug Loader valve, rear
514 Proportional valve for decking blade Under the cab
515 Proportional pilot valve for decking blade Under the cab
516 Adjustment for decking blade reduced pressure 21 3046 Proportional valve for
clambunk
517 Load reduction valve for decking blade Under the cab
518 Decking blade cylinders Front frame
519 On/Off -valve for decking blade Under the cab
520 Movement valve for decking blade Under the cab
521 Manual reduction valve of decking blade At main switch
522 Decking blade cylinders Front frame
523 Headboard move cylinder Headboard
524 Headboard lift- and move valve Under the cab
525 Headboard lift cylinder Headboard

Continued on next page EL62757,00001EC –19–22APR02–1/2

Hydraulic Diagrams-12 101702

PN=260
Hydraulic Diagrams, F622627

–UN–09OCT02
T160345

EL62757,00001EC –19–22APR02–2/2

Hydraulic Diagrams-13 101702

PN=261
 Wiring Diagrams, 1410D
General

–UN–13AUG01
T144438

Continued on next page EL62757,00001EF –19–24APR02–1/35

Wiring Diagrams-1 101702

PN=262
 Wiring Diagrams, 1410D

Wiring Diagram Explanations

1. Seek column 4. Reference, seek 7. Connector hose X16 10. Single line 13. Operation symbol
column 608 E terminal 9
2. Double lines, conductor 5. Earth terminal, 8. Number of wire 65+ 11. Magnet valve Y65
on circuit card connector X3 terminal 3
3. Relay K7 6. Fuse 25, 10A 9. S9 in the box, not 12. Machine frame
mounted in all machines

Codes for electric wire colors:

BE = blue BL =black BR = brown GN = green GR = gray OR = orange RD = red YL = yellow

EL62757,00001EF –19–24APR02–2/35

Ignition key positions

In the illustration is shown which connectors are in use in

different positions of the ignition switch.

A—Connectors

–UN–15OCT02
T159290

Continued on next page EL62757,00001EF –19–24APR02–3/35

Wiring Diagrams-2 101702

PN=263
 Wiring Diagrams, 1410D

F619759A 1/15

Position Description Scheme Location

F15 Fuse 20A, ignition switch 107 E PC-board
F28 Fuse 10A, fuel valve, Engine ECU 118 G PC-board
F36 Fuse 7,5A, working pump’s drop 113 L PC-board
F41 Fuse 20A, preheater 102 M Fuse box
F42 Fuse 15A, preheater, 24/12V voltage transformer 103 M Fuse box
F43 Fuse 25A, air conditioner 103 M Fuse box
F44 Fuse 7,5A, engine gridheater, signal light 104 M Fuse box
F45 Socket 24V, hydraulic oil fill-up pump, 20A 105 M Fuse box
F46 Fuse 20A, socket 24V, auxiliary fuel pump 106 M Fuse box
F47 Fuse 10A, DAFO 107 M Fuse box
F48 Fuse 10A, DAFO 108 M Fuse box
F51 Main fuse, 60A 107 N Fuse box
F52 Main fuse, 60A 108 N Fuse box
G1 Alternator 106 T Engine
G2 Batteries 102 U Under the cabin
K1 Relay, ignition switch 115 F PC-board
K3 Relay, starting motor 108 S Fuse box
K14 Relay, starting prevent 111 M PC-board
K24 Relay, engine preheater 111 R Under the cabine
M1 Starting motor 104 T Engine
R2 Heater resistor, grid heater 111 V Engine
S1 Main switch 101 R Front frame
S2 Ignition switch 108 H Control panel
S56 Emergency STOP -button 112 D Control panel
X21 16-pin connector 104 J Cabin floor
X22 24-pin connector 103 J Cabin floor
X23 7-pin connectorr 100 G Cabin floor
X49 7-pin connector 109 X Fuse box
X59 3-pin connector 114 N Front frame
XB1 9-pin connector 100 D PC-board
XB3 9-pin connector 107 F PC-board
XB6 9-pin connector 118 I PC-board
XB9 9-pin connector 111 I PC-board
Y1 Fuel valve 118 T Fuel tank
Y44 Magn. valve, working pump’s drop 113 U Front frame

Continued on next page EL62757,00001EF –19–24APR02–5/35

Wiring Diagrams-4 101702

PN=265
 Wiring Diagrams, 1410D

F619759A 2/15

Position Description Scheme Location

A2 Radio 214 R Ceiling
A3 Radio-telephone 218 D Ceiling
B1 Pressure switch, engine oil pressure 203 T Engine
B3 Pressure switch, brakes charge pressure 205 T Brake valve
B4 Pressure switch, hydraulic supply pressure 202 T Hydrostatic pump
B5 Pressure switch, parking brake 201 T Auxiliary valve
B11,B12 Loud speaker 214 V/215 V Ceiling
B29 Voltage transformer 214 K Instrument box
B40, B41 Loud speaker 216 V Ceiling
F8 Fuse 10A, radio 216 C PC-board
F20 Fuse 7,7A, indicator lights 201 C PC-board
F32 Fuse 5A, voltage transformer 214 F PC-board
H1 Warning light, charge 209 K Gauge panel
H2 Warning light, engine gridheater 203 K Gauge panel
H3 Indicator light, parking brake 201 K Gauge panel
H6 Indicator light, blinker 207 K Gauge panel
H10 Indicator light, working lights 208 K Gauge panel
H12 Indicator light, main beam 205 K Gauge panel
H18 Warning light, hydraulic supply pressure 202 K Gauge panel
H19 Warning light, brakes charge pressure 204 K Gauge panel
K9 Relay, hourmeter 212 H PC-board
K20 Relay, radio 216 I PC-board
P1 Hourmeter 212 P Instrument box
R3 Resistor, charge warning light 210 J Gauge panel
X6,X7 8-pin connectors 206 I, 200K Indicator lights
X13 9-pin connector 214 N Cabin
X17 2-pin connector 218 F Cabin, rear
X21 16-pin connector 210 R Cabin floor
X46 9-pin connector 215 N Cabin
X50 8-pin connector 214 P Radio
X51 3-pin connector 214 S Radio
XB2 9-pin connector 216 D PC-board
XB4 9-pin connector 201 E PC-board
XB6 9-pin connector 211 J PC-board
XB8 9-pin connector 216 K PC-board
XB9 9-pin connector 212 J PC-board
XB10 9-pin connector 214 G PC-board
X172 2-pin connector 218 P

Continued on next page EL62757,00001EF –19–24APR02–7/35

Wiring Diagrams-6 101702

PN=267
 Wiring Diagrams, 1410D

F619759A 3/15

Position Description Scheme Location

A1 Control unit, air conditioner 311 M Air conditioner
B6 Potentiometer, fan 309 E Air conditioner
B7 Potentiometer, temperature 310 E Air conditioner
B17 Thermostat, air conditioner 313 P Air conditioner
B33 Pressure switch, air conditioner 314 S Engine comp
B35 Thermostat, outside temperature 310 U Air conditioner
B36 Thermostat, cabin 308 U Air conditioner
B7C 3-pin connector 301 M Ceiling
E1 Preheater, engine 302 T Front frame
E30 Heater, seat 316 P Seat
F18 Fuse, air conditioner, seat compressor 315 D PC-board
F29 Fuse, air conditioner 308 E PC-board
K15 Relay, air conditioner & preheater 306 T Fuse box
K21 Relay, compressor 315 K PC-board
K22 Relay, air conditioner 307 H PC-board
M2 Heater, fan 314 S Cabin
M6, M7 Fan, ceiling 317 T, 318 T Ceiling
P7 Time switch, preheater 300 J Ceiling
P7B 3-pin connector 301 G Ceiling
S25 Switch, defroster 312 D Heater
S83 Switch, fans 318 I Ceiling
X13 9-pin connector 301 E Instrument box
X16 9-pin connector 316 K Instrument box
X21 16-pin connector 307 U Cabin floor
X22 24-pin connector 307 S Cabin floor
X46 318 C
X48 3-pin connector 316 N Seat
X58 3-pin connector 302 V Front frame
XB4 9-pin connector 315 F Front frame
XB5 9-pin connector 308 G Front frame
XB7 9-pin connector 306 I Front frame
XB8 9-pin connector 305 G Front frame
XB9 9-pin connector 306 C Front frame
XK 9-pin connector 307 T Air conditioner
Y23 Directional valve, air conditioner . 311 U Engine comp
Y194 Magn.coupler, compressor 315 U Compressor

Continued on next page EL62757,00001EF –19–24APR02–10/35

Wiring Diagrams-8 101702

PN=270
 Wiring Diagrams, 1410D

F619759A 4/15

Position Description Scheme Location

B15 Pressure switch, brake lights 414 K Brake valve
E8 Headlight 416 U Front frame
E9 Headlight 418 U Front frame
E10 Position light 406 U Front left
E11 Position light 407 U Front right
E12 Tail light 410 U Rear left
E14 Tail light 412 U Rear right
E24 Blinker 405 U Front left
E26 Blinker 407 U Front right
E52 Cigarette lighter 401 O Control panel
F14 Fuse, headlights 411 B PC-board
F16 Fuse, parking lights 410 B PC-board
F23 Fuse, cigarette lighter 400 B PC-board
F31 Fuse, low beam 416 K PC-board
F33 Fuse, main beam 417 K PC-board
F34 Fuse, parking lights left 411 K PC-board
F35 Fuse, parking lights right 413 K PC-board
K4 Blinker relay 402 M Instrument box
S14 Switch, hazard lights 402 E Control panel
S15 Switch, blinker 407 E Control panel
S18 Switch, headlights/parking lights 413 E Control panel
S19 Switch, low-/high beam 416 E Control panel
X1 Socket, 7-pin connector 410 R Cabin
X2 Socket, 7-pin connector 407 R Cabin
X3 Socket,7-pin connector 405 R Cabin
X22 24-pin connector 405 O Cabin floor
X27 7-pin connector 415 R Ceiling
XB3 9-pin connector 410 D PC-board
XB4 9-pin connector 400 D PC-board
XB7 9-pin connector 401 D PC-board
XB9 9-pin connector 410 K PC-board
XB10 9-pin connector 413 M PC-board

Continued on next page EL62757,00001EF –19–24APR02–12/35

Wiring Diagrams-10 101702

PN=272
 Wiring Diagrams, 1410D

F619759A 5/15

Position Description Scheme Location

B16 Horn 500 S Front frame
F19 Fuse, horn 511 F PC-board
F22 Fuse, windscreen wiper 503 B PC-board
F27 Fuse, rear screen wiper 513 B PC-board
K2 Relay, wiper,rear window 513 J PC-board
K12 Relay, windshield 509 J PC-board
M41 Motor, washer, rear 502 T Engine comp
M42 Motor, washer, front 503 T Engine comp.
M5B Motor, rearscreen wiper 511 U Cabin
M5F Motor, windscreen wiper 506 U Cabin
M5L Motor, side screen wiper 519 U Cabin
M5R Motor, side screen wiper 516 U Cabin
S13 Push button, horn 500 I Control panel
S91 Switch, washer, rear 502 J Control panel
S92 Switch, washer, front 504 J Control panel
S101 Switch, rear screen wiper 508 J Control panel
S102 Switch, windscreen wiper 506 J Control panel
S103 Switch, side screen wiper 517 J Control panel
S104 Switch, side screen wiper 515 J Control panel
V11 Diode 506 Q Wiring
V13 Diode 510 Q Cabin
V15 Diode 515 Q Wiring
V16 Diode 518 Q Wiring
X12 9-pin connector 506 N Cabin, rear
X22 24-pin connector 502 Q Instrument box
XB4 9-pin connector 500 D PC-board
XB5 9-pin connector 508 N PC-board
XB6 9-pin connector 514 D PC-board
XB7 9-pin connector 513 N PC-board

Continued on next page EL62757,00001EF –19–24APR02–14/35

Wiring Diagrams-12 101702

PN=274
 Wiring Diagrams, 1410D

F619759A 6/15

Position Description Scheme Location

E37 Indoor light 618 R Ceiling
E38 Service lightn 615 R Under the cab
E40 Work light, forward 600 T Cabin roof
E41 Work light, forward 601 T Cabin roof
E42 Work light, left 603 T Cabin roof
E43 Work light, left 604 T Cabin roof
E44 Work light, right 609 T Cabin roof
E45 Work light, right 610 T Cabin roof
E46 Work light, backward 612 T Cabin roof
E47 Work light, backward 613 T Cabin roof
E58 Work light, Boom 606 T Boom
E59 Work light, Boom 607 T Boom
F1 Fuse, work light 603 D PC-board
F2 Fuse, work light 604 D PC-board
F3 Fuse, work light 609 D PC-board
F4 Fuse, work light 610 D PC-board
F5 Fuse, work light 612 D PC-board
F6 Fuse, work light 613 D PC-board
F9 Fuse, work light 601 D PC-board
F10 Fuse, work light 605 D PC-board
F11 Fuse, work light 602 D PC-board
F12 Fuse, work light 606 D PC-board
F13 Fuse, work light 607 D PC-board
S26 Switch, indoor light 617 K Ceiling
S27 Switch, service light 615 K Control panel
S64 Switch, work light forwards 606 N Ceiling
S66 Switch, work light forwards 600 N Ceiling
S67 Switch, work light left 603 N Ceiling
S68 Switch, work light right 609 N Ceiling
S69 Switch, work light backwards 612 N Ceiling
X11 9-pin connector 602 K Ceiling
X14 9-pin connector 602 J Instrument box
X37 2-pin connector 615 O Cabin
X46 9-pin connector 615 M Cabin
XB2 9-pin connector 604 F PC-board
XB3 9-pin connector 615 F PC-board
XB5 9-pin connector 616 F PC-board

Continued on next page EL62757,00001EF –19–24APR02–16/35

Wiring Diagrams-14 101702

PN=276
 Wiring Diagrams, 1410D

F619759A 7/15

Position Description Scheme Location

A4 Hub-module, CAN-bus 704 M Instrument box
A5 Display, TMC 710 C Seat
B23 Gas-/drivepedal, front 708 V Cabin, front
B24 Gas-/drivepedal, rear 709 V Cabin, rear
F17 Fuse, switches 709 F PC-board
F21 Fuse, TMC 703 C PC-board
H8 Alarm light, TMC 704 U Ceiling
J1 Splice 707 Q Wiring
J4 Splice 708 Q Wiring
S58 Switch, parking brake 714 D Control panel
S59 Switch, all-wheel drive 706 F Control panel
S60 Switch, steering on/off 717 E Control panel
X12 9-pin connector 704 R Instrument box
X18 3-pin connector 707 U Instrument box
X19 3-pin connector 709 U Instrument box
X75 4-pin connector 705 R Instrument box
X80 6-pin connector 711 V Instrument box
XB2 9-pin connector 704 E PC-board
XB3 9-pin connector 703 F PC-board
XB4 9-pin connector 703 F PC-board
XH1 8-pin connector 709 J Hub-module
XH2 8-pin connector 712 J Hub-module
XH3 8-pin connector 710 P Hub-module
XH4 23-pin connector 703 P Hub-module
XH5 8-pin connector 712 P Hub-module
Y41 Magn. valve, parking brake 716 S Front frame

Continued on next page EL62757,00001EF –19–24APR02–18/35

Wiring Diagrams-16 101702

PN=278
 Wiring Diagrams, 1410D

F619759A 8/15

Position Description Scheme Location

A6 Chair module, TMC 814 L Seat
A9 Control panel, left 801 Z Control panel, L
A10 Control panel, right 808 Control panel, R
B8 Buzzer, alarm 812 D Seat
B20 Steering lever, left 805 D Control panel, L
B21 Steering lever, right 815 D Control panel, R
B22 Machine steering, minilever 801 D Control panel, L
F60 Fuse, 12 V, Scales sensor 810 E Seat
S31-S35 Multifunction switches A,B,C,D Control panel, R
S36 Load narrowing 805 T Control panel, L
S37 Load spreading 806 T Control panel, L
S40 Switch, driving direction 817 D Control panel, R
S42 Button, high/low gear 813 F Control panel, R
S43 Button, front differential lock 814 F Control panel, L
S44 Button, rear differential lock 815 F Control panel, L
S45 Button, wiper 808 F Control panel, R
S46 Button, headboard up 806 X Control panel, L
S47 Button, headboard down 807 X Control panel, L
S48 Button, blade down 804 X Control panel, R
S49 Button, blade up 805 X Control panel, R
S50 Limit switch, seat direction 817 U Seat
S51 Limit switch, driver 819 U Seat
S57 Push button, working rpm’s 804 T Control panel, L
S76 Push button, frame brake release 803 T Control panel, L
S78 Push button, seat 813 Z Control panel, R
X16 6-pin connector 810 C Instrument box
X25 9-pin connector 810 P Control panel, R
X26 9-pin connector 802 R Control panel, L
X35 9-pin connector 816 S Seat
X42 9-pin connector 814 H Control panel, R
X43 9-pin connector 803 H Control panel, L
X44 3-pin connector 800 H Control panel, L
X45 3-pin connector 802 H Control panel, L
X74 2-pin connector 810 B Instrument box
X82 2-pin connector 810 F Seat
X90 2-pin connector 818 R Seat
X91 2-pin connector 819 R Seat
XC1,XC2, 23-pin connector 807 H, 813 I, 814 I Chair module
XC3

Continued on next page EL62757,00001EF –19–24APR02–20/35

Wiring Diagrams-18 101702

PN=280
 Wiring Diagrams, 1410D

F619759A 9/15

Position Description Scheme Location

A7 Transmission module, TMC 900 N Front frame
B9 Fuel sensor 913 U Fuel tank
B14 Sensor rpm, driving speed/distance 914 V Hydraulic motor
B18 Pressure switch, return filter 905 U Hydraulic tank
J10 Splice 901 I Wiring
J11 Splice 910 H Wiring
J13 Splice 905 J Wiring
J14 Splice 914 R Wiring
J16 Splice 914 H Wiring
J17 Splice 917 S Wiring
J25 Splice 910 R Wiring
R1 Resistor 902 Z Wiring
S81 Limit switch, low gear 905 E Gear box
S82 Limit switch, high gear 906 E Gear box
X24 4-pin connector 908 R Front frame
X81 4-pin connector 904 H Front frame
XO1 3-pin connector 902 R Front frame
XO5 3-pin connector 902 R Front frame
XT1 23-pin connector 900 L Transmission module
XT2 23-pin connector 904 L Transmission module
XT3 23-pin connector 913 P Transmission module
XT4 8-pin connector 900 P Transmission module
Y33B Magn. valve, rear differential lock 913 E Auxiliary valve
Y33F Magn. valve, front differential lock 915 E Auxiliary valve
Y39 Magn. valve, rear wheel drive 910 E Auxiliary valve
Y41W Magn. valve, work brake 907 E Brake valve
Y45 Magn. valve, low gear 901 E Auxiliary valve
Y46 Magn. valve, high gear 902 E Auxiliary valve
Y48 Magn. valve, hydraulic motor 918 U Hydraulic motor
Y65 Magn. valve, frame brake 911 E Auxiliary valve
Y102 Magn. valve, driving forward 915 U Hydraulic pump
Y103 Magn. valve, driving reverse 916 U Hydraulic pump
Y103B Magn. valve, constant pressure valve, hydrostatic motor 911 U Hydraulic motor
Y208 Magn. valve, working pump’s pressure 918 E Auxiliary valve

Continued on next page EL62757,00001EF –19–24APR02–23/35

Wiring Diagrams-20 101702

PN=283
 Wiring Diagrams, 1410D

F619759A 10/15

Position Description Scheme Location

A7 Transmission module, TMC 1001 N Front frame
B19 Temp. sensor, hydraulics 1003 D Hydraulic tank
B25 Level sensor, hydraulic oil 1002 U Hydraulic tank
B43 Back -up alarm 1006 U Rear frame
B52 Stairs 1003 T Front frame
F24 Fuse, stairs 1015 C PC-board
J15 Splice 1006 H Wiring
J23 Splice 1001 R Wiring
S29 Switch, stairs 1015 J Instrum. panel
X15 3-pin connector (opt. eq.). 1017 F Instrum. panel
X22 24-pin connector 1015 R Instrument box
X24 4-pin connector 1008 R Front frame
X36 2-pin connector, back-up buzzer. 1006 R Front frame
X47 4-pin connector, decking blade. 1008 G Front frame
X67 3-pin connector, limit switch, stairs. 1003 R Front frame
X68 4-pin connector 1014 T Front frame
XB4 9-pin connector 1015 F PC-board
XT1 23-pin connector 1007 D Transmission module
XT2 23-pin connector 1006 K Transmission module
XT3 23-pin connector 1001 L Transmission module
Y120D Magn. valve, stairs down 1016 T Front frame
Y120U Magn. valve, stairs up 1015 T Front frame
Y195D Magn. valve, blade down 1006 D Front frame
Y195U Magn. valve, blade up 1007 D Front frame

Continued on next page EL62757,00001EF –19–24APR02–25/35

Wiring Diagrams-22 101702

PN=285
 Wiring Diagrams, 1410D

F619759A 11/15

Position Description Scheme Location

A8 TMC-Crane module 1103 O Under the cabin
B53 Limit switch, damping of the steering 1103 X Middle joint
X33 4-pin connector 1102 I Front frame
X34 2-pin connector 1105 I Front frame
X61 12-pin connector 1114 R Front frame
X79 3-pin connector 1116 J Front frame
X96 4-pin connector 1116 J Front frame
XE1 23-pin connector 1100 M TMC-Crane module
XE2 23-pin connector 1104 M TMC-Crane module
XE3 23-pin connector. 1102 M TMC-Crane module
XE4 8-pin connector 1100 Q TMC-Crane module
Y66L Magn. valve, steering L 1105 V Crane valve
Y66R Magn. valve, steering R 1106 V Crane valve
Y100D Magn. valve, headboard 1102 G Front frame
Y100L Magn. valve, headboard lock valve 1104 E Front frame
Y100U Magn. valve, headboard 1101 G Front frame
Y211 Clambunk magn. valve 1114 U Front frame
Y212 Clambunk magn. valve 1115 U Front frame
Y221 Clambunk magn. valve 1117 U Front frame
Y222 Clambunk magn. valve 1118 U Front frame
Y408 Magn. valve, rotator clockwise 1110 G Crane valve
Y409 Magn. valve, rotator counterclockwise 1108 G Crane valve
Y416 Magn. valve, grapple open 1111 G Crane valve
Y417 Magn. valve, grapple close 1113 G Crane valve
Y418 Magn. valve, extension out 1114 V Crane valve
Y419 Magn. valve, extension in 1116 V Crane valve
Y420 Magn. valve, main boom up 1105 G Crane valve
Y421 Magn. valve, main boom down 1107 G Crane valve
Y422 Magn. valve, jib boom out 1111 V Crane valve
Y423 Magn. valve, jib boom in 1112 V Crane valve
Y424 Magn. valve, Boom counterclockwise 1108 V Crane valve
Y425 Magn. valve, Boom clockwise 1109 V Crane valve

Continued on next page EL62757,00001EF –19–24APR02–27/35

Wiring Diagrams-24 101702

PN=287
 Wiring Diagrams, 1410D

F619759A 12/15

Position Description Scheme Location

A1 Engine ECU 1204 L Front frame
050 Grounding Point 1207 M Engine, ECU, wiring harness
B01 Oil Pressure Sensor 1214 F Engine
B02 Manifold Air Temperature Sensor 1211 G Engine
B03 Coolant Temperature Sensor 1212 G Engine
B04 Fuel Temperature Sensor 1210 G Engine
B08 Crank Sensor 1210 T Engine
F26 Fuse 10A, Engine ECU 1206 E PC board
R10 Resistor 1205 U Wiring
XB4 4-pin connector 1200 G PC-board
XB5 9-pin connector 1200 D PC-board
X02 9-pin connector 1202 F
X06 30-pin connector 1208 I Engine ECU
X64 6-pin connector 1204 D Front frame
Y01 Magnitic Valve, Fuel Injectors 1216 F Engine

Continued on next page EL62757,00001EF –19–24APR02–29/35

Wiring Diagrams-26 101702

PN=289
 Wiring Diagrams, 1410D

F619759A 13/15

Position Description Scheme Location

E48, E49 Work light, forwards 1305 S, 1306 S Cabin roof
E50, E51 Work light, backwards 1302 S, 1303 S Cabin, middle
E54 Work light, backwards 1304 S Rear frame
E55, E56 Work light, Boom 1300 S, 1301 S Boom
F7 Fuse, work light, Boom 1301 C PC-board
F25 Fuse, vacuum pump 1312 F PC-board
F30 Fuse, compressor, seat 1309 B PC-board
K6 Relay, compressor, seat 1310 H PC-board
K38 Relay, fuel pump 1315 N Front frame
K39 Relay, fuel pump 1317 N Front frame
M10 Compressor, seat 1310 S Seat
M11 Fill-up pump, hydraulic oil 1314 R Under the cabin
M12 Vacuum pump, hydr. tank 1312 R Under the cabin
M16 Fuel pump 1316 R Front frame
S54 Switch, fill-up pump, hydraulic oil 1314 O Beside main switch
S55 Switch, hydraulic vacuum pump 1312 O Beside main switch
S61 Switch, fuel pump 1315 G Beside main switch
S65 Switch, work light forwards 1305 J Ceiling
S70 Switch, work light Boom 1300 J Ceiling
S71 Switch, corner lights 1303 J Control panel
X11 9-pin connector 1302 F Cabin
X12 9-pin connector 1301 G Cabin
X13 9-pin connector 1301 N Cabin
X16 6-pin connector 1309 M Cabin
X21 16-pin connector 1307 P Cabin floor
X22 24-pin connector 1301 N Cabin floor
X28, X29, 2-pin connector 1319 G, 1315 H, 1300 Front frame
X30, X31 V, 1312 V
X40 2-pin connector 1310 P Front frame
X46 9-pin connector 1303 M Cabin
X52 2-pin connector 1305 Q Front frame
X60 2-pin connector 1310 N Instrument box
X86 2-pin connector 1314 V Front frame
X93 2-pin connector 1310 O. Instrument box
XB2 9-pin connector 1301 E PC-board
XB5 9 -pin connector 1312 D PC-board
Y77 Magn. valve, vacuum pump 1301 S Hydraulic tank

Continued on next page EL62757,00001EF –19–24APR02–31/35

Wiring Diagrams-28 101702

PN=291
 Wiring Diagrams, 1410D

F619759A 14/15

Position Description Scheme Location

A30 Control, Dafo-fire extinguisher 1403 C Ceiling
B30.1 Temp. sensor, Dafo. 1404 T Engine comp
B30.6 Temp. sensor, Dafo 1407 T Under the cabin
B31 Horn, Dafo 1408 K Engine comp.
E60 Work lights 1414 Q Jib boom
E61 Work lights 1415 Q Jib boom
F40 Fuse, dozer blade flotation 1416 D Instrument box
H30 Alarm light, Dafo 1408 D Ceiling
K40 Relay, dozer blade flotation 1416 K Instrument box
M17 Seat lock, servomotor 1411 T Seat
R30 Resistor, Dafo fire extinguisher 1416 T Temp.sensor, Dafo
S74 Switch, dozer blade flotation 1414 E Instrument box
S78 Seat lock, switch 1410 F Control panel, R
X16 6-pin connector 1410 F Instrument box
X22 24-pin connector 1413 I Instrument box
X32 9-pin connector 1402 I Fire extinguisher
X38 2-pin connector 1416 J Seat
X60 2-pin connector 1419 O Instrument box
X63 2-pin connector 1407 C Ceiling
X87 3-pin connector 1401 M Fuse box
X95 2-pin connector 1411 K Seat
Y195 Magnetic valve, decking blade float 1416 T Front frame
YS9 Trigger, Dafo-extinguisher 1409 O Front frame, rear

Continued on next page EL62757,00001EF –19–24APR02–33/35

Wiring Diagrams-30 101702

PN=293
 Wiring Diagrams, 1410D

F619759A 15/15

Position Description Scheme Location

GND1 Grounding Instrument box
GND2 Grounding Under the cabin, left
GND3 Grounding Ceiling
GND4 Grounding Under the cabin, right
GND5 Grounding Seat
GND6 Grounding Engine
GND7 Grounding Front frame
GND8 Grounding Front frame
GND9 Grounding Front frame
GND10 Grounding Under cabin floor
GND11 Grounding Under cabin floor

EL62757,00001EF –19–24APR02–35/35

Wiring Diagrams-32 101702

PN=295
 TMC
TMC CONTROL SYSTEM ver 3G+

EL62757,0000051 –54–16SEP02–1/1

TMC-1 101702

PN=296
 Index
Page
A Bearings
Air conditioner
Checking. . . . . . . . . . . . . . . . . . . . . . 6-6-6, 6-10-6
Air Conditioner
Compressor . . . . . . . . . . . . . . . . . . . . . . . .11-1-11
Compressor V-belt . . . . . . . . . . . . . . . . . . .11-1-11
Condenser element. . . . . . . . . . . . . . . . . . .11-1-12
Air conditioner
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-10
Air Conditioner
Dryer service indicator . . . . . . . . . . . . . . . .11-1-11
Evaporator element. . . . . . . . . . . . . . . . . . .11-1-12
First aid. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1-5
Hoses and connectors . . . . . . . . . . . . . . . .11-1-13
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 11-1-1
Main parts. . . . . . . . . . . . . . . . . . . . . . . . . . 11-1-1
Air conditioner
Maintenance every 50 hour or weekly. . . . . . 6-3-2
Air Conditioner
Refrigerant level . . . . . . . . . . . . . . . . . . . . . 11-1-8
Risks and counter-measures. . . . . . . . . . . . 11-1-4
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1-6
Air filter
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-6
Outside and inside air filter . . . . . . . . . . . . . . 6-4-7
Air filter restriction indicator
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2-6
Air intake system
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-4
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-2
Alternator
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-4
Anti slips
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-7
ATF oil
Check the driving brake oil level . . . . . . . . . . 6-2-6
Atomisers
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-5
Axles
Change Bogie Axle Differential Oil . . . . . . . . 6-7-7
Change Bogie Housings Oil . . . . . . . . . . . . . 6-7-8
Change Single Axle Differential Oil . . . . . . . . 6-7-9
Change Single Axle Wheel Ends Oil . . . . . . 6-7-10
Check Bogie Housings Oil Level . . . . . . . . . . 6-4-5
Check Single Axle Wheel Ends Oil Level . . . 6-4-4
Grease Bogie Bearings . . . . . . . . . . . . . . . . . 6-4-6
Tighten bolts . . . . . . . . . . . . . . . . . . . . . . . . 6-7-11
B Pedal Brake. . . . . . . . . . . . . . . . . . . . . . . . 7-7-4
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-3
Index-1
Page
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-3
Grease center hinge . . . . . . . . . . . . . . . . . . . 6-3-1
Grease steering cylinder . . . . . . . . . . . . . . . . 6-3-1
Belt
Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-6
Bleeding
Brake system . . . . . . . . . . . . . . . . . . . . . . . . 7-3-5
Drive hydraulic system . . . . . . . . . . . . . . . . . 7-3-1
Fuel system . . . . . . . . . . . . . . . . . . . . . . . . 6-10-2
Hydraulic system, Boom . . . . . . . . . . . . . . . 10-1-1
Working hydraulic system . . . . . . . . . . . . . . . 7-3-3
Bogie
Change Bogie Housings Oil . . . . . . . . . . . . . 6-7-8
Bogie axle
Change Bogie Axle Differential Oil . . . . . . . . 6-7-7
Bogie tracks
Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-8
Bolts and joints
Axles and frame . . . . . . . . . . . . . . . . . . . . . 6-7-11
Boom
Assembly instructions . . . . . . . . . . . . . . . . . 10-1-1
Check structures . . . . . . . . . . . . . . . . . . . . . 10-2-1
Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Control levers . . . . . . . . . . . . . . . . . . . . . . . . 4-1-7
Description . . . . . . . . . . . . . . . . . . . . . . . . . 10-0-1
Lubrication and maintenance chart . . . . . . . 10-3-4
Maintenance schedule . . . . . . . . . . . . . . . . 10-1-2
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-2
Operating instructions . . . . . . . . . . . . . . . . . 10-0-4
Operating safety precautions. . . . . . . . . . . . 10-0-2
Structures . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-2
Boom CF7
Specifications . . . . . . . . . . . . . . . . . . . . . . . 10-7-1
Boom joint pins
Check for security . . . . . . . . . . . . . . . . . . . . 10-3-1
Boom sleving housing
Oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-1
Boom sleving system
Oil change . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-1
Brake fluid
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-16
Brake system
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-5
Brakes
Charging pressure . . . . . . . . . . . . . . . . . . . . 7-7-3
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7-1
Checking Drive Brake
Mechanical adjustment . . . . . . . . . . . . . . . . . 7-7-2
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-3
101702
PN=1
 Index
Page
Work Brake . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7-3
Breather
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-3
C
Cab lift pump oil
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-17
Cab windows
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-4
Cabine
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3-1
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3-2
Capacities
Fluids and lubricants . . . . . . . . . . . . . . . . . . 6-0-11
Control panels
Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5
Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-6
Control System
TMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-1
Control unit
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-1
Coolant
Checking engine coolant level. . . . . . . . . . . . 6-2-3
Pressure test system . . . . . . . . . . . . . . . . . 6-11-3
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-14
Replenishing supplemental additives. . . . . . 6-11-1
Coolant additives
Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-9
Coolant, changing. . . . . . . . . . . . . . . . . . . . . . . 6-7-4
Cooling system
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-8
Pressure control . . . . . . . . . . . . . . . . . . . . . 6-5-10
Crankcase vent tube
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-4
D Engine coolant
Daily maintenance
Maintenence after the workshift . . . . . . . . . . 6-2-8
Dashboard
Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-2
Decking Blade
Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4-3
Decking blade
Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3-2
Decking Blade
Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4-2
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4-1
Index-2
Page
Diferential lock-up
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-7
Differential oil
Check the level . . . . . . . . . . . . . . . . . . . . . . . 6-4-3
Drive belt
Check belt wear . . . . . . . . . . . . . . . . . . . . . . 6-5-4
Drive motor
Hydrostatic flushing valve . . . . . . . . . . . . . . . 7-5-1
Pressure cut-off. . . . . . . . . . . . . . . . . . . . . . . 7-5-2
Drive Pump
Charge pressure . . . . . . . . . . . . . . . . . . . . . . 7-4-1
Drive pump
Cut off valve setting . . . . . . . . . . . . . . . . . . . 7-4-2
Driveshafts
Geasing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-10
Driving
Driving off-road . . . . . . . . . . . . . . . . . . . . . . . 5-6-1
Driving on road . . . . . . . . . . . . . . . . . . . . . . . 5-6-2
E
ECU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-2
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1-1
Electrical
Check Batteries Electrolyte Specific
Gravity. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-7
Emergency Stopper
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-1
Engine
A normal operation . . . . . . . . . . . . . . . . . . . . 5-5-5
Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1
Coolant level check. . . . . . . . . . . . . . . . . . . . 6-2-3
Oil level check . . . . . . . . . . . . . . . . . . . . . . . 6-2-2
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-2
Turning off . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-6
Valve clearance, check (200,000- ) . . . . . . . . 6-7-1
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-9
Engine grounding
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-6
Engine Oil
Check the oil level. . . . . . . . . . . . . . . . . . . . . 6-2-2
Engine oil
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-13
Engine Preheater . . . . . . . . . . . . . . . . . . . . . . 11-2-1
Empty fault memory . . . . . . . . . . . . . . . . . . 11-2-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 11-2-2
Malfunction codes . . . . . . . . . . . . . . . . . . . . 11-2-7
Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2-4
101702
PN=2
 Index

Page Page

Engine speeds Grease

Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-6 Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-17
Exhaust manifold
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-6
Extension boom
Sideway clearance . . . . . . . . . . . . . . . . . . . 10-3-2 H
Vertical clearance . . . . . . . . . . . . . . . . . . . . 10-4-2
Extension boom chains High /low gear oil
Lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-3 Check the oil level. . . . . . . . . . . . . . . . . . . . . 6-4-2
Tightness . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-2 High-low gear
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-6
High/low gear
Changing oil . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-4
F
Hub gears
Check oil level . . . . . . . . . . . . . . . . . . . . . . . 6-4-4
Fire Extinguisher System . . . . . . . . . . . . . . . . 11-3-1
Hydraulic oil
After a fire. . . . . . . . . . . . . . . . . . . . . . . . . . 11-3-5
Changing . . . . . . . . . . . . . . . . . . . . . . 6-6-1, 7-1-2
Control unit . . . . . . . . . . . . . . . . . . . . . . . . . 11-3-6
Check oil level . . . . . . . . . . . . . . . . . . . . . . . 7-1-1
Fire Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3-2
Checking oil level . . . . . . . . . . . . . . . . . . . . . 6-2-1
Hand held fire extinguishers . . . . . . . . . . . . 11-3-8
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-15
Fire extinguisher system
Hydraulic oil change
Have checked . . . . . . . . . . . . . . . . . . . . . . . . 6-9-1
Using vacuum pump . . . . . . . . . . . . . . . . . . . 7-1-1
Fire sxtinguisher
Hydraulic return filter
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8-1
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-2
Fluids and lubricants
Hydraulic system
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-11
Bleeding drive hydraulic system . . . . . . . . . . 7-3-1
Frame Brake
Hydraostatic system . . . . . . . . . . . . . . . . . . . 7-2-1
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-4
Workin hydraulic system . . . . . . . . . . . . . . . . 7-2-1
Fuel
Hydraulic system, working hydraulic
Filling the fuel tank . . . . . . . . . . . . . . . . . . . . 6-2-7
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3-3
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-12
Hydraulic tank
Fuel filler filter
Change oil . . . . . . . . . . . . . . . . . . . . . 6-6-1, 7-1-2
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-5
Check oil level . . . . . . . . . . . . . . . . . . . . . . . 7-1-1
Fuel filter
Replace breather . . . . . . . . . . . . . . . . . . . . . 6-6-3
Changing fitters. . . . . . . . . . . . . . . . . . . . . . . 6-5-3
Replace return filter. . . . . . . . . . . . . . . . . . . . 6-6-2
Fuel system
Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-2
Fuel tank
Cleaning the filler filter . . . . . . . . . . . . . . . . 6-10-5 I
Remove sediment and water. . . . . . . . . . . . . 6-5-6
Fuses
Inside air filter
Engine compartment . . . . . . . . . . . . . . . . . . . 8-1-7
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-7
Instrument box fuses . . . . . . . . . . . . . . . . . . . . 8-1-8

Gear oil L
Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-16
Grapple Lubricants and Fluids
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-3 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-10
Grapple and link Lubrication system
Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-1 Change oil . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1

Index-3 101702

PN=3
 Index

Page Page

M S

Main Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1-1 Safety

Maintenance Safety Features. . . . . . . . . . . . . . . . . . . . . . . 3-1-1
Check Bogie Housings Oil Level . . . . . . . . . . 6-4-5 Safety, maintain safety cabin . . . . . . . . . . . . . . 3-2-2
Check Differential Oil Level . . . . . . . . . . . . . . 6-4-3 Screw and bolt connections
Check Single Axle Wheel Ends Oil Level . . . 6-4-4 Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6-5
Check Wheel Nut Torque . . . . . . . . . . . . . . . 6-4-7 Seat Safety Switch
Check Windscreen Washer Fluid Level. . . . . 6-2-4 Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-1
General maintenance instructions . . . . . . . . . 6-0-3 Sensors
Grease Bogie Bearings . . . . . . . . . . . . . . . . . 6-4-6 Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . 8-1-10
Servicing safety precautions . . . . . . . . . . . . . 6-0-2 Hydraulic Oil Return Filter . . . . . . . . . . . . . . 8-1-10
Minilevers Hydraulic Oil Temperature . . . . . . . . . . . . . 8-1-10
During transportation. . . . . . . . . . . . . . . . . . . 5-4-1 RPM of Drive Motor . . . . . . . . . . . . . . . . . . . 8-1-9
Service
Intervaller . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1-1
Signal lights . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-5
O Single axle
Change Single Axle Differential Oil . . . . . . . . 6-7-9
Oil Single axle wheel ends
Hydraulic oil level checking . . . . . . . . . . . . . . 6-2-1 Change Single Axle Wheel Ends Oil . . . . . . 6-7-10
Oil, engine Start Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-3
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5-1 Starter motor
Operator’s station . . . . . . . . . . . . . . . . . . . . . . . 4-1-1 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-4
Outside air filter Starting the Engine
Checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4-7 After starting . . . . . . . . . . . . . . . . . . . . . . . . . 5-5-4
Overhead panel Starting the engine
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-8 Before starting . . . . . . . . . . . . . . . . . . . . . . . 5-5-1
Steering
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-5
Stowing a disabled boom . . . . . . . . . . . . . . . . . 5-7-4
Supplemental coolant additives
P
Replenishing . . . . . . . . . . . . . . . . . . . . . . . . 6-11-1

Pressure filter
Renew filter of drive hydraulic system . . . . . . 6-5-7
T

Telephone
R Prepardness . . . . . . . . . . . . . . . . . . . . . . . . . 4-1-9
Tires
Radiator grille Checking air pressure . . . . . . . . . . . . . . . . . . 6-2-7
Check cleaness. . . . . . . . . . . . . . . . . . . . . . . 6-2-5 Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-5
Rear Wheel Drive TMC
Using . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2-6 Control System . . . . . . . . . . . . . . . . . . . . . . . 5-1-1
Return filter Towing the machine . . . . . . . . . . . . . . . . . . . . . 5-7-1
Replace hydraulic return filter . . . . . . . . . . . . 6-6-2 Transfer case
Rotator Look high/low gear . . . . . . . . . . . . . . . . . . . . 6-6-4
Link brakes . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-1 Transmission
Magnetic plug . . . . . . . . . . . . . . . . . . . . . . . 10-5-1 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-3
Rotator and Grapple High(Low Gear . . . . . . . . . . . . . . . . . . . . . . . 9-1-1
Specifications . . . . . . . . . . . . . . . . . . . . . . . 10-7-1 Hydrostatic System . . . . . . . . . . . . . . . . . . . . 9-1-2

Index-4 101702

PN=4
 Index

Page

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1-1
Turbocharger
Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10-4

Vacuum pump
How to use . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1-1
Valve clearance,
Check - Engines (200,000- ) . . . . . . . . . . . . . 6-7-1
Vibrations damper
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7-3

Warning signals
Lights and buzzer . . . . . . . . . . . . . . . . . . . . . 4-1-9
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . 1-1-3, 2-1-1
Wheels
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-0-6
Wheels and Tires
Check Wheel Nut Torque . . . . . . . . . . . . . . . 6-4-7
Windows
Washers and wipers . . . . . . . . . . . . . . . . . . . 4-1-4
Windscreen washer
Check Windscreen Washer Fluid Level. . . . . 6-2-4
Working Hydraulic System
Auxiliary functions . . . . . . . . . . . . . . . . . . . . . 7-6-4
Boom pressures . . . . . . . . . . . . . . . . . . . . . . 7-6-2
Frame Brake . . . . . . . . . . . . . . . . . . . . . . . . . 7-6-4
Max. pressure . . . . . . . . . . . . . . . . . . . . . . . . 7-6-1
Optional Equipment. . . . . . . . . . . . . . . . . . . . 7-6-5
Pressure Difference . . . . . . . . . . . . . . . . . . . 7-6-1
Worklamp (Xenon)
Safety instructions. . . . . . . . . . . . . . . . . . . . . 3-4-2
1710D
Specifications . . . . . . . . . . . . . . . . . . . . . . . 12-0-1

Index-5 101702

PN=5
 Index

Index-6 101702

PN=6