Ajustes 622B PDF

HTH622B Harvester Head
CTM10002 06JULY09 (English)
COPYRIGHT® 2009 WARATAH NZ LIMITED

Tokoroa, New Zealand All Rights Reserved
LITHO IN NEW ZEALAND
Introduction
Foreword
This manual is written for an experienced technician. Information is organized in groups for the various
Essential tools required in performing certain service components requiring service instruction. At the
work are identified in this manual and are beginning of each group are summary listings of all
recommended for use. applicable essential tools, service equipment and tools,
other materials needed to do the job, service parts kits,
Live with safety: Read the safety messages in the specifications, wear tolerances, and torque values.
introduction of this manual and the cautions presented
throughout the text of the manual. Technical Manuals are concise guides for specific
machines. They are on-the-job guides containing only
This is the safety-alert symbol. When you see this the vital information needed for diagnosis, analysis,
symbol on the machine or in this manual, be alert to testing, and repair.
the potential for personal injury.
Fundamental service information is available from
Technical manuals are divided in two parts: repair and other sources covering basic theory of operation,
operation and tests. Repair sections tell how to repair fundamentals of troubleshooting, general maintenance,
the components. Operation and tests sections help you and basic type of failures and their causes.
identify the majority of routine failures quickly.
OUO1065,0000650 –19–11JAN08–1/1
CTM10002 (06JUL09) HTH622B Component Technical Manual

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Introduction
Technical Information Feedback Form
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OUO1065,0000651 –19–16JUL08–1/1

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Introduction

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Contents
01
01General Information
Group 1—Safety
Group 2—General Precautions
Group 3—Operating Precautions
Group 4—Maintenance Precautions
02
Group 5—General Maintenance
Group 6—Miscellaneous Machine
02Hydraulic System
Group 1—Hydraulic Test Point Locations
Group 2—Settings 03
Group 3—Schematics
03Repair and Adjustment

Group 1—Cylinder
Group 2—Retained Pins
INDX
Group 3—Feed Roller
Group 4—Knives
Group 5—Measuring Unit
Group 6—Accumulator Service
Group 7—Accumulator Charging
Group 8—Photocell Sensor
Group 9—Rotator
Group 10—Top Saw
Group 11—Main Saw—Supercut Option
Group 12—Main Saw—3/4 in. Option
Group 13—Saw Chain and Saw Bar
Group 14—Control Valve
Group 15—Diagnostics
Group 16—Color Marking System Maintenance
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  2009
DEERE & COMPANY
Moline, Illinois
All rights reserved
A John Deere ILLUSTRUCTION Manual
Previous Editions
Copyright  2008
CTM10002 (06JUL09) i HTH622B Component Technical Manual

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Contents
01
02
03
INDX
CTM10002 (06JUL09) ii HTH622B Component Technical Manual

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01
01
General Information
Contents
Page
Group 1—Safety . . . . . . . . . . . . . . . . . . . . . . . 01-1-1
Group 2—General Precautions

Recognize Safety Information . . . . . . . . . . . . . . 01-2-1
Stay Clear of Moving Parts . . . . . . . . . . . . . . . . 01-2-1
Avoid High-Pressure Oils . . . . . . . . . . . . . . . . . 01-2-2
Operate Machine Safely . . . . . . . . . . . . . . . . . . 01-2-2
Keep Riders Off Machine . . . . . . . . . . . . . . . . . 01-2-3
Warning Labels . . . . . . . . . . . . . . . . . . . . . . . . . 01-2-3
Group 3—Operating Precautions

Key Ring Label . . . . . . . . . . . . . . . . . . . . . . . . . 01-3-1
Never Operate Warning . . . . . . . . . . . . . . . . . . 01-3-1
Key Switch Label . . . . . . . . . . . . . . . . . . . . . . . 01-3-1
Never Operate Warning . . . . . . . . . . . . . . . . . . 01-3-1
Do Not Operate—Unless Seated. . . . . . . . . . . . 01-3-2
Do Not Operate—With Window Open . . . . . . . . 01-3-2
Never Stand On Harvester . . . . . . . . . . . . . . . . 01-3-2
Keep Clear of Saw . . . . . . . . . . . . . . . . . . . . . . 01-3-3
Lock Tilt Bracket . . . . . . . . . . . . . . . . . . . . . . . . 01-3-3
Never Stand On Harvester . . . . . . . . . . . . . . . . 01-3-4
Never Operate Without Reading Manuals . . . . . 01-3-4
Pinch Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-3-5
Head Label Positions . . . . . . . . . . . . . . . . . . . . 01-3-6
Group 4—Maintenance Precautions

Servicing and Maintenance Safety . . . . . . . . . . 01-4-1
Group 5—General Maintenance

Unified Inch Bolt and Cap Screw Torque
Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5-1
Metric Bolt and Cap Screw Torque Values . . . . 01-5-3
Additional Metric Cap Screw Torque Values . . . 01-5-4
Group 6—Miscellaneous Machine

Prevent Fires. . . . . . . . . . . . . . . . . . . . . . . . . . . 01-6-1
In Case of Machine Fire . . . . . . . . . . . . . . . . . . 01-6-1
Welding on Machine . . . . . . . . . . . . . . . . . . . . . 01-6-2
CTM10002 (06JUL09) 01-1 HTH622B Component Technical Manual

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Contents
01

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Group 1
Safety
01
Safety First 1
1
Waratah Forestry Attachments’ policy is to produce

products that are safe and reliable. However, even when
using well engineered equipment, there will always be an
element of risk in heavy-duty equipment operation. CAUTION
–19–16APR07
While acknowledging the need and enthusiasm to start
using this machine in a productive capacity as quickly as
possible, we strongly recommend time be taken to read
TX1019680
both your National and Local Safety Regulations as well
as the additional safety precautions listed below.
These safety rules highlight both general and specific

measures the operator should be familiar with and adhere
to. Factory fitted safety stickers are attached to indicate
dangerous areas. Pay particular attention to these warning
signs.
• Study all the safety messages in this manual and on the

grapple harvester carefully.
• Keep safety signs in good condition. Repair or replace
damaged signs.
DH10862,0000001 –19–19JUN08–1/1
Follow Safety Instructions
Read the safety messages in this manual and on the
–UN–24AUG00
machine. Follow these warnings and instructions carefully.
Review them frequently.
Be sure all operators of this machine understand every

T133556
safety message. Replace operator’s manual and safety

labels immediately if missing or damaged.
DH10862,0000002 –19–19JUN08–1/1
CTM10002 (06JUL09) 01-1-1 HTH622B Component Technical Manual

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Safety
01
1 Operate Only If Qualified
2
Do not operate this machine unless you have read the machine functions with the machine in an open area
operator’s manual carefully and you have been before starting to work.
qualified by supervised training and instruction.
Know and observe all safety rules that may apply to
Familiarize yourself with the job site and your your work situation and your work site.
surroundings before operating. Try all controls and
DH10862,0000003 –19–23JUL08–1/1
Inspect Machine
Inspect machine carefully each day by walking around it

before starting.
Keep all guards and shields in good condition and
–UN–18OCT88
properly installed. Fix damage and replace worn or broken
parts immediately. Pay special attention to hydraulic
hoses and electrical wiring.
T6607AQ
DH10862,0000004 –19–19JUN08–1/1
Avoid Unauthorized Machine Modifications
Waratah recommends using only genuine Waratah machine stability or reliability, and may create a hazard
replacement parts to ensure machine performance. for the operator or others near the machine. The
Never substitute genuine Waratah parts with alternate installer of any modification which may affect the
parts not intended for the application as these can electronic controls of this machine is responsible for
create hazardous situations or hazardous performance. establishing that the modification does not adversely
Non-Waratah Parts, or any damage or failures affect the machine or its performance.
resulting from their use are not covered by any
Waratah warranty. Always contact an authorized dealer before making
machine modifications that change the intended use,
Modifications of this machine, or addition of weight or balance of the machine, or that alter
unapproved products or attachments, may affect machine controls, performance or reliability.
DH10862,0000005 –19–19JUN08–1/1

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Safety
01
Wear Protective Equipment 1
3
Guard against injury from flying pieces of metal or debris;

wear goggles or safety glasses.
Wear close fitting clothing and safety equipment

appropriate to the job.
–UN–23AUG88
Prolonged exposure to loud noise can cause impairment
or loss of hearing. Wear suitable hearing protection such
as earmuffs or earplugs to protect against objectionable or
TS206
uncomfortable loud noises.
DH10862,0000006 –19–19JUN08–1/1
Prepare for Emergencies
Be prepared if an emergency occurs or 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
DH10862,0000007 –19–19JUN08–1/1

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Safety
01
1 Operational Safety
4
When starting an operation in a new location When working in a restricted area check for
determine a work zone around the harvester. interference with cylinder rods, hydraulic hoses,
electrical cables, etc.
Choose an agreed working procedure amongst the
team working with the harvester and do not change it Leaving a load suspended could result in injury or
without further discussion. death.
Before each period of operation ensure the correct Passing a load over another vehicle, even if it appears
function of all safety equipment, instruments and empty, could cause injury or death to someone out of
controls have been tested as operational and are the operator’s line of sight.
working correctly.
Always allow enough distance between the stem and
Keep windows and doors securely shut when the harvester cab.
operating.
When freeing a log from a stack, avoid making sudden
Safely stop the harvester immediately when someone moves or giving sharp raps with the harvester head.
enters the safety zone. Such moves may damage the harvester head and can
be costly in terms of parts and down time. It may also
Even outside the safety zone ensure that no one constitute a potential source of injury.
stands in the cutting direction of the saw chain. When
the harvester head is running, a broken saw chain will When working at night, ensure that the work area has
leave the machine at high speed. The estimated safe adequate lighting. Use a recognized safety light with a
distance without protective clothing is 90 meters (295 wire cage protected bulb. (The filament of a broken
ft.). bulb is a dangerous source of fire.)
Before felling a tree or processing a stem make sure Inspect the grapple harvester head daily for signs of
the work zone is clear. damage, unusual wear, fatigue cracks or faulty
operation.
While local safety regulations may vary, a check
should be made with the local authorities. Anticipate a Inspect the saw condition for excessive wear or
safety zone of at least 5 meters (16 ft.) between power damage daily and also immediately after hitting a rock
lines and the nearest point of contact of the harvester. or other foreign material.
DH10862,0000008 –19–08AUG08–1/1

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Group 2
General Precautions
01
Recognize Safety Information 2
1
This is the safety alert symbol. When you see this
–UN–28AUG00
symbol on your harvester or in this manual, be alert
for the potential of personal injury.
Follow the precautions and safe operating practices
T133555
highlighted by this symbol.
A signal word — DANGER, WARNING, or CAUTION — is

used with the safety alert symbol. DANGER identifies the
most serious hazards.
–19–28AUG00
On your machine, DANGER signs are red in color,
WARNING signs are orange, and CAUTION signs are
yellow. DANGER and WARNING signs are located near
specific hazards. General precautions are on CAUTION
T133588
labels.
DH10862,0000009 –19–19JUN08–1/1
Stay Clear of Moving Parts
Entanglements in moving parts can cause serious injury.
Stop engine before examining, adjusting or maintaining

any part of machine with moving parts.
–UN–08JUN90
Keep guards and shields in place. Replace any guard or
shield that has been removed for access as soon as
service or repair is complete.
T7273AS
DH10862,000000A –19–19JUN08–1/1

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General Precautions
01
2 Avoid High-Pressure Oils
2
This machine uses a high-pressure hydraulic system.

Escaping oil under pressure can penetrate the skin
causing serious injury.
–UN–17MAR06
Never search for leaks with your hands. Protect hands.
Use a piece of cardboard to find location of escaping oil.
Stop engine and relieve pressure before disconnecting
lines or working on hydraulic system.
T133509
If hydraulic oil penetrates your skin, see a doctor
immediately. Injected oil must be removed surgically
within hours or gangrene may result. Contact a
knowledgeable medical source or the Deere & Company
Medical Department in Moline, Illinois, U.S.A.
–UN–20SEP00
T133840
DH10862,000000B –19–19JUN08–1/1
Operate Machine Safely
Keep bystanders clear of machine, especially before

operating knives, feed rollers or activate saws. Always be
alert for bystanders in or near the work area.
Avoid contact between machine and overhead obstacles

when you operate, move, or haul machine.
–UN–25AUG03
T193771
DH10862,000000C –19–19JUN08–1/1

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General Precautions
01
Keep Riders Off Machine 2
3
Only allow the operator on the machine. Keep riders off.
Riders on machine are subject to injury such as being

struck by foreign objects and being thrown off of the
machine. Riders also obstruct the operator’s view resulting
in the machine being operated in an unsafe manner.
Never use the harvester head for a work platform or

personnel carrier.
–UN–25AUG03
Never move loads over the heads of other persons.
T193771
DH10862,000000D –19–19JUN08–1/1
Warning Labels
All labels should be periodically inspected and cleaned as

necessary to maintain their legibility for safe viewing. They
should be replaced when they no longer meet legibility
requirements.
When an operator does not follow the instructions of a

warning label, they expose themselves and anyone inside
the safe working zone to unnecessary risk.
DH10862,000000E –19–19JUN08–1/1

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General Precautions
01
2
4

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Group 3
Operating Precautions
01
Key Ring Label 3
1
The option of operating the harvester in manual is

available for servicing. Extreme care is required when
operating the harvester head in manual and this label is
CAUTION
printed on the key ring tag to remind the operator.
–19–16APR07
Extreme care when operating manually.
The reverse side of the key ring holds information Saw bar, arms, harvester bracket, &
regarding model and serial number of the head. rollers can suddenly move.
Information that is required when ordering parts. Personal injury or death may occur.
TX1019681
DH10862,000000F –19–19JUN08–1/1
Never Operate Warning
This never operate warning label is attached to the lid of

the cabin module box.
WARNING
Operating, servicing or adjusting a setting without fully NEVER operate, service or adjust
–19–16APR07
understanding how the harvester head works can have this machine without reading and
understanding the operation and
very serious implications on safety.
maintenance manual.
TX1019687
Personal injury or death may occur.
DH10862,0000010 –19–19JUN08–1/1
Key Switch Label
The Harvester Head Module contains sensitive electronic

components. If welding is to occur on the harvester, the
electronic components must be isolated first. To isolate
Key switch must be in
the electronic components, turn the Key Switch to the off
–19–16APR07
off position before
position. commencing welding
WARNING
These labels are positioned inside the harvester cab in full
view of the operator.
TX1019685
DH10862,0000011 –19–19JUN08–1/1
Never Operate Warning
This never operate warning label is attached to the cabin

window.
WARNING
–19–16APR07
understanding the operation and
very serious implications on safety.
maintenance manual.
TX1019687
DH10862,0000012 –19–19JUN08–1/1

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01
3 Do Not Operate—Unless Seated
2
It is most important that the operator is aware of their

surroundings and of the safe working zone. It is also
WARNING
important that the operator is in total control of the
harvester and is focused on operating it safely. To DO NOT start and/or operate the machine unless
–19–16APR07
seated.
achieve this the operator must be seated. NEVER operate unless ALL personnel and
equipment are clear of agreed work zone.
Servicing the harvester head with the harvester’s engine Turn engine OFF when servicing harvester.
running is extremely hazardous. The hydraulic valve on
TX1019688
the harvester head controlling the functions, operates
when it receives electrical signals. It is imperative that the
harvester engine is turned off. Turning off the harvester
engine removes the hydraulic power to the harvester head
and makes it safe for servicing.
DH10862,0000013 –19–19JUN08–1/1
Do Not Operate—With Window Open
In the event that a chain link breaks, the chain can fly off
the saw at extreme speed. This label is positioned next to
WARNING
any forward facing window that can be opened. It warns
of the potential hazard and alerts the operator of the DO NOT operate harvester with this
–19–16APR07
consequences from opening that window. window open.
Breaking saw chain could enter cab.
TX1019690
DH10862,0000014 –19–19JUN08–1/1
Never Stand On Harvester
When servicing or carrying out maintenance, work from a

safe platform. Never stand on the harvester, the surfaces
WARNING
of the harvester are not designed to be stood on. There is
no tread grip pattern embossed onto any plates and the NEVER stand on harvester.
–19–16APR07
Remain on ground or on safe platform.

surfaces of a harvester can become very slippery. Never
EXTREME CARE required around knives,
stand on the harvester, it is not stable. The link from the chain saw and pinch areas.
arm/stick to the head has freedom of movement in four DO NOT stand under harvester.
directions. Altering the balance can cause the head to
TX1019691

move unpredictably.
DH10862,0000015 –19–19JUN08–1/1

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01
Keep Clear of Saw 3
3
Do not stand or work in the cutting direction of the chain

saw while the machine is running. In the event of a chain
DANGER
link breaking, the chain can fly off the saw bar at high
speed. The safety distance without protective clothing KEEP CLEAR of chain saw.
–19–16APR07
when sawing is 90 meters (295 ft.). Service only when engine is stopped.
Servicing the harvester head with the harvester’s engine Personal injury or death may occur.
running is extremely hazardous. Turning off the harvester
TX1019692
DH10862,0000016 –19–02JUL09–1/1
Lock Tilt Bracket
Servicing the harvester head is extremely hazardous.

Always use the locking pin provided to prevent the
DANGER
harvester head falling over.
LOCK crossover bracket with pin
–19–16APR07
supplied when servicing or carrying
out maintenance.
TX1019693
DH10862,0000017 –19–19JUN08–1/1

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01
3 Never Stand On Harvester
4
When servicing or carrying out maintenance, work from a

safe platform. Never stand on the harvester head, the
WARNING
surfaces of the harvester head are not designed to be
stood on. There is no tread grip pattern embossed onto NEVER stand on harvester.
–19–16APR07
Remain on ground or on safe platform.
any plates and the surfaces of a harvester head can
EXTREME CARE required around knives,
become very slippery. Never stand on the harvester head, chain saw and pinch areas.
it is not stable. The link from the arm/stick to the harvester
DO NOT stand under harverster.
head has freedom of movement in four directions. Altering
TX1019694
the balance can cause the head to move unpredictably.
The knife edges and saw chain are razor sharp. Grabbing
hold of them, handling them without protective gloves or
knocking into them can cause personal injury. Extreme
care is required around the upper and lower knives to
avoid being inside the ‘pinch’ areas. The hydraulic
cylinders creep and move unpredictably if a fault occurs.
Servicing the harvester head with the harvester’s engine
running is extremely hazardous. Turning off the harvester
Never rely on the boom cylinders or the arm/stick cylinder

to keep the harvester head suspended. Should
circumstance prove it necessary to work on a raised boom
harvester head, they must be supported and secured to
prevent the boom from lowering.
DH10862,0000018 –19–19JUN08–1/1
Never Operate Without Reading Manuals
This never operate warning label is attached to the lid of

the head module box.
WARNING
–19–16APR07
very serious implications on safety. understanding the operation and
maintenance manual.
TX1019695
DH10862,0000019 –19–19JUN08–1/1

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01
Pinch Area 3
5
Keep away from pinch area. The harvester can shift or

move unpredictably. WARNING
–19–30AUG07
PINCH
AREA
TX1028887
DH10862,000001A –19–19JUN08–1/1

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01
3 Head Label Positions
6
–19–17JUL08
TX1045795
DH10862,00000A1 –19–18JUL08–1/1

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Group 4
Maintenance Precautions
01
Servicing and Maintenance Safety 4
1
NOTE: The Locking pin is retained in the tool box.
Understand all the control levers and their functions, note

all safety devices on the harvesting head and insure that
they are working properly.
Modifying, moving, or removing safety devices fitted to the

equipment could result in injury or death.
Where possible, lower all equipment to the ground so the

harvesting head is resting on level blocking, stop engine
–UN–17JUL08
and remove the key. Turn off power to control unit and
isolate. Hang a “DO NOT USE” sign in cab window and if
possible lock cab door.
TX1045785A
When servicing or carrying out maintenance on the
harvester head always ensure that the tilt bracket is in the
upright position and the locking pin is installed to prevent
movement.
Should circumstance prove it necessary to work on a

raised boom or harvester head, they must be supported
and secured to prevent the boom from lowering. The
harvester head locking pin must be fitted in the lock
position.
Working in the “Pinch Area” or the “Saw Area” of the

harvester head while the hydraulic system is “Active”
could result in injury or death. Always turn off the
harvester before service begins.
Always remain on the ground or on a safe platform to
–UN–17JUL08
carry out repairs or maintenance. Standing on equipment
is a safety hazard and could result in injury or death.
Standing under a suspended harvester head could result
TX1045787A
in injury or death.
Attempting to alter or change the physical, mechanical, or

hydraulic operation of the head during the warranty period
1—Harvesting Locking Pin Location
without first consulting Waratah Forestry Attachments,
2—Processing Locking Pin Location
voids the machine warranty.
Continued on next page DH10862,000001B –19–17JUL08–1/3

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01
4 Because of the size of some of the product components,
2
service personnel must always use proper lifting
procedures when removing any items.
Ensure that the harvester head adjustments are correct

and the delimb knives and saw chain are sharp. Take
extreme care when moving around these areas. If
necessary, wrap all sharp items in a protective blanket, or
similar. Failure to do so could result in personal injury.
Be aware of exposed parts such as cylinder rods, hoses,

and so on. Replace immediately when they are damaged.
When removing the main valve guard for any reason,

always stop the engine and lock the tilt bracket. If the
harvester head suddenly stands up, serious bodily injury
may result.
Should it prove necessary to work on the hydraulic system

while it is under pressure (searching for leaks etc), always
wear gloves, full protective clothing and search for leaks
using a piece of cardboard.
Always wear approved eye protection while visually

checking hydraulic leaks. Failure to follow this procedure
could result in injury or death.
Hydraulic oil under pressure can easily penetrate bare

skin. Should this happen, the fluid must be removed
immediately by a physician.
Always reduce hydraulic system pressure to zero before

attempting to work on any hydraulic component. Hydraulic
oil becomes hot during operation. Do not allow hydraulic
oil to come in contact with the skin as it will cause severe
burns.
Care must be taken when handling valves. The electrical

controls and solenoids are not intended for carrying.
Check the hydraulic oil regularly and add oil when

required.
Improper disposal of fluids can cause irreversible harm to

the environment. Find out the proper way to dispose of
waste from an environmental agency.

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01
Always replace securely all guards and safety devices 4
3
before attempting a restart after maintenance.
Always make sure all service personnel and equipment

are clear of the agreed work zone. Failure to follow this
practice could result in injury or death.
DH10862,000001B –19–17JUL08–3/3

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01
4
4

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Group 5
General Maintenance
01
Unified Inch Bolt and Cap Screw Torque Values 5
1
–UN–27SEP99
TORQ1A
Top—SAE Grade and Head Markings; Bottom—SAE Grade and Nut Markings
UNIFIED INCH BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
The following data is intended to assist in the general maintenance of the machine. It is recommended that only grade 8 hardware
or better be used.
Grade 1 (No Mark) Grade 2a (No Mark) Grade 5, 5.1 or 5.2 Grade 8 or 8.2
b c b c b c
Thread Lubricated Dry Lubricated Dry Lubricated Dry Lubricatedb Dryc
Size N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft)
1/4 3.8 (2.8) 4.7 (3.5) 6 (4.4) 7.5 (5.5) 9.5 (7) 12 (9) 13.5 (10) 17 (12.5)
5/16 7.7 (5.7) 9.8 (7.2) 12 (9) 15.5 (11.5) 19.5 (14.5) 25 (18.5) 28 (20.5) 35 (26)
3/8 13.5 (10) 17.5 (13) 22 (16) 27.5 (20) 35 (26) 44 (32.5) 49 (36) 63 (46)
7/16 22 (16) 28 (20.5) 35 (26) 44 (32.5) 56 (41) 70 (52) 80 (59) 100 (74)
1/2 34 (25) 42 (31) 53 (39) 67 (49) 85 (63) 110 (80) 120 (88) 155 (115)
9/16 48 (35.5) 60 (45) 76 (56) 95 (70) 125 (92) 155 (115) 175 (130) 220 (165)
5/8 67 (49) 85 (63) 105 (77) 135 (100) 170 (125) 215 (160) 240 (175) 305 (225)
3/4 120 (88) 150 (110) 190 (140) 240 (175) 300 (220) 380 (280) 425 (315) 540 (400)
7/8 190 (140) 240 (175) 190 (140) 240 (175) 490 (360) 615 (455) 690 (510) 870 (640)
1 285 (210) 360 (265) 285 (210) 360 (265) 730 (540) 920 (680) 1030 (760) 1300 (960)
1-1/8 400 (300) 510 (375) 400 (300) 510 (375) 910 (670) 1150 (850) 1450 (1075) 1850 (1350)
1-1/4 570 (420) 725 (535) 570 (420) 725 (535) 1280 (945) 1630 (1200) 2050 (1500) 2600 (1920)
1-3/8 750 (550) 950 (700) 750 (550) 950 (700) 1700 (1250) 2140 (1580) 2700 (2000) 3400 (2500)
1-1/2 990 (730) 1250 (930) 990 (730) 1250 (930) 2250 (1650) 2850 (2100) 3600 (2650) 4550 (3350)
a
Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hex cap screws over 6 in. (152 mm) long,
and for all other types of bolts and screws of any length.
b
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
c
"Dry" means plain or zinc plated without any lubrication.
Continued on next page DH10862,000001C –19–19JUN08–1/2

070909
PN=27
General Maintenance
01
5 DO NOT use these values if a different torque value or tightening Make sure fastener threads are clean and that you properly start
2 procedure is given for a specific application. Torque values listed are thread engagement. This will prevent them from failing when
for general use only. Check tightness of fasteners periodically. tightening.
Shear bolts are designed to fail under predetermined loads. Always Tighten plastic insert or crimped steel-type lock nuts to approximately
replace shear bolts with identical grade. 50 percent of the dry torque shown in the chart, applied to the nut,
not to the bolt head. Tighten toothed or serrated-type lock nuts to the
Fasteners should be replaced with the same or higher grade. If full torque value.
higher grade fasteners are used, these should only be tightened to
the strength of the original.
DH10862,000001C –19–19JUN08–2/2

070909
PN=28
General Maintenance
01
Metric Bolt and Cap Screw Torque Values 5
3
–UN–07SEP99
TORQ2
Top—Property Class and Head Markings; Bottom—Property Class and Nut Markings
METRIC BOLT AND CAP SCREW TORQUE VALUES—Tolerance is ±10% unless otherwise specified
The following data is intended to assist in the general maintenance of the machine. It is recommended that only grade 10.9
hardware or better be used.
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
a b a b a b
Thread Lubricated Dry Lubricated Dry Lubricated Dry Lubricateda Dryb
Size N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft) N•m (lb-ft)
M6 4.7 (3.5) 6 (4.4) 9 (6.6) 11.5 (8.5) 13 (9.5) 16.5 (12.2) 15.5 (11.5) 19.5 (14.5)
M8 11.5 (8.5) 14.5 (10.7) 22 (16) 28 (20.5) 32 (23.5) 40 (29.5) 37 (27.5) 47 (35)
M10 23 (17) 29 (21) 43 (32) 55 (40) 63 (46) 80 (59) 75 (55) 95 (70)
M12 40 (29.5) 50 (37) 75 (55) 95 (70) 110 (80) 140 (105) 130 (95) 165 (120)
M14 63 (46) 80 (59) 120 (88) 150 (110) 175 (130) 220 (165) 205 (150) 260 (190)
M16 100 (74) 125 (92) 190 (140) 240 (175) 275 (200) 350 (255) 320 (235) 400 (300)
M18 135 (100) 170 (125) 265 (195) 330 (245) 375 (275) 475 (350) 440 (325) 560 (410)
M20 190 (140) 245 (180) 375 (275) 475 (350) 530 (390) 675 (500) 625 (460) 790 (580)
M22 265 (195) 330 (245) 510 (375) 650 (480) 725 (535) 920 (680) 850 (625) 1080 (800)
M24 330 (245) 425 (315) 650 (480) 820 (600) 920 (680) 1150 (850) 1080 (800) 1350 (1000)
M27 490 (360) 625 (460) 950 (700) 1200 (885) 1350 (1000) 1700 (1250) 1580 (1160) 2000 (1475)
M30 660 (490) 850 (625) 1290 (950) 1630 (1200) 1850 (1350) 2300 (1700) 2140 (1580) 2700 (2000)
M33 900 (665) 1150 (850) 1750 (1300) 2200 (1625) 2500 (1850) 3150 (2325) 2900 (2150) 3700 (2730)
M36 1150 (850) 1450 (1075) 2250 (1650) 2850 (2100) 3200 (2350) 4050 (3000) 3750 (2770) 4750 (3500)
a
"Lubricated" means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings.
b
"Dry" means plain or zinc plated without any lubrication.
Continued on next page DH10862,000001D –19–19JUN08–1/2

070909
PN=29
General Maintenance
01
5 Fasteners should be replaced with the same or higher property class.
4 CAUTION: Use only metric tools on metric hardware. If higher property class fasteners are used, these should only be
Other tools may not fit properly. Tool may slip and tightened to the strength of the original.
cause injury.
Make sure fastener threads are clean and that you properly start
thread engagement. This will prevent them from failing when
DO NOT use these values if a different torque value or tightening tightening.
procedure is given for a specific application. Torque values listed are
for general use only. Check tightness of fasteners periodically. Tighten plastic insert or crimped steel-type lock nuts to approximately
50 percent of the dry torque shown in the chart, applied to the nut,
Shear bolts are designed to fail under predetermined loads. Always not to the bolt head. Tighten toothed or serrated-type lock nuts to the
replace shear bolts with identical property class. full torque value.
DH10862,000001D –19–19JUN08–2/2
Additional Metric Cap Screw Torque Values
–UN–18OCT88
CAUTION: Use only metric tools on metric
hardware. Other tools may not fit properly. They
may slip and cause injury.
T6873AA
Check tightness of cap screws periodically. Torque values
listed are for general use only. Do not use these values if
a different torque value or tightening procedure is listed
for a specific application.
–UN–18OCT88
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same or higher
T6873AB
grade. If higher grade fasteners are used, these should
only be tightened to the strength of the original.
Make sure fastener threads are clean and you properly

start thread engagement. This will prevent them from
failing when tightening.
–UN–18OCT88
Tighten cap screws having lock nuts to approximately 50
percent of amount shown in chart.
T6873AC
Continued on next page DH10862,000001E –19–16JUL08–1/2

070909
PN=30
General Maintenance
01
METRIC CAP SCREW TORQUE VALUESa 5
5
T-Bolt H-Bolt M-Bolt
Nominal
Diameter N•m lb-ft N•m lb-ft N•m lb-ft
8 29 21 20 15 10 7
10 63 46 45 33 20 15
12 108 80 88 65 34 25
14 176 130 137 101 54 40
16 265 195 206 152 78 58
18 392 289 294 217 118 87
20 539 398 392 289 167 125
22 735 542 539 398 216 159
24 931 687 686 506 274 202
27 1372 1012 1029 759 392 289
30 1911 1410 1421 1049 539 398
33 2548 1890 1911 1410 735 542
36 3136 2314 2401 1772 931 687
a
Torque tolerance is ±10%.
DH10862,000001E –19–16JUL08–2/2

070909
PN=31
General Maintenance
01
5
6

070909
PN=32
Group 6
Miscellaneous Machine
01
Prevent Fires 6
1
–UN–14SEP00
Handle Fuel Safely: Store flammable fluids away from
fire hazards. Never refuel machine while smoking or when
near sparks or flame.
T133552
Clean Machine Regularly: Keep trash, debris, grease
and oil from accumulating in engine compartment, around
fuel lines, hydraulic lines and electrical wiring. Never store
oily rags or flammable materials inside a machine
compartment.
–UN–07SEP00
Maintain Hoses and Wiring: Replace hydraulic hoses
immediately if they begin to leak, and clean up any oil
T133553
spills. Examine electrical wiring and connectors frequently
for damage.
Keep A Fire Extinguisher Available: Always keep a

multipurpose fire extinguisher on or near the machine.
–UN–07SEP00
Know how to use extinguisher properly.
T133554
DH10862,000001F –19–19JUN08–1/1
In Case of Machine Fire
• Turn engine off.

• Turn the master disconnect switch off.
• If possible, fight the fire using the portable fire
extinguisher or other fire suppression equipment.
• Ensure that the fire does not spread to the surrounding
–UN–23AUG88
area.
• Call for help!
TS227
DH10862,0000020 –19–19JUN08–1/1

070909
PN=33
Miscellaneous Machine
01
6 Welding on Machine
2
IMPORTANT: Electrical system damage can occur by

electrical welder current. When welding,
electrical equipment must be isolated.
Failure to isolate electrical equipment
can damage the electrical system and
require component replacement.
1. Disconnect carrier battery.
–UN–17MAY07
2. The attachment is manufactured from high tensile
steel. Use only E11018-M (low hydrogen) welding rods.
TX1022193
NOTE: Contaminants in the weld makes the steel brittle.
3. Clean area of oil, paint, and rust contaminants.
4. The welding earth must be attached directly to the item

being welded.
NOTE: Measure temperature 75 mm (3.0 in.) from weld in

each direction for a good heat soak.
5. Preheat weld area according to table.
Metal Thickness Preheat Temperature

6—20 mm (0.2—0.8 in.) 500— 750°C (930—1380°F)
20—50 mm (0.8—2.0 in.) 750—1400°C (1380—2550°F).
6. When welding multiple runs, allow temperature to drop
–UN–14DEC07
down to specification before starting the next run.
Specification
Weld—Temperature ............................................................ 1750—2200°C
TX1033494A
3179—3989°F
7. Allow weld to cool slowly. Rapid cooling causes

cracking.
DH10862,0000021 –19–19AUG08–1/1

070909
PN=34
02
Hydraulic System
Contents 02
Page
Group 1—Hydraulic Test Point Locations

Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-1-1
Group 2—Settings
Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-2-1
Saw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-2-3
Left Feed Motor. . . . . . . . . . . . . . . . . . . . . . . . . 02-2-6
Right Feed Motor . . . . . . . . . . . . . . . . . . . . . . . 02-2-9
Feed Roller Arm Cylinder . . . . . . . . . . . . . . . . .02-2-12
Harvester Tilt Cylinder. . . . . . . . . . . . . . . . . . . .02-2-14
Harvester Cylinder Flow Control . . . . . . . . . . . .02-2-17
Delimb Cylinder. . . . . . . . . . . . . . . . . . . . . . . . .02-2-17
Measuring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-2-20
Top Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .02-2-23
Main Saw Supercut—(Option) . . . . . . . . . . . . . .02-2-28
Main Saw (3/4-in. Option) . . . . . . . . . . . . . . . . .02-2-32
Color Marking . . . . . . . . . . . . . . . . . . . . . . . . . .02-2-37
Group 3—Schematics
Supercut (Option) . . . . . . . . . . . . . . . . . . . . . . . 02-3-1
3/4 in. (Option) . . . . . . . . . . . . . . . . . . . . . . . . . 02-3-5

070909
PN=1
Contents
02

070909
PN=2
Group 1
Hydraulic Test Point Locations
Test Points
SPECIFICATIONS SERVICE EQUIPMENT AND TOOLS

Main Supply Pressure 32 000 kPa JT05473 Gauge 34 474 kPa (345 bar) (5000 psi)
320 bar JT05471 Gauge 7000 kPa (70 bar) (1000 psi)
4640 psi 02
1
1
Continued on next page DH10862,0000022 –19–01JUL09–1/4

070909
PN=37
CAUTION: Prevent possible injury from high

pressurized oil. Keep to rear of head when
making hydraulic measurements. Pressurized
oil can cause serious burns or penetrating
02 injury.
1
2
1. Measure main supply pressure at main supply test
point (1) using JT05473 gauge.
Specification
–UN–01JUL09
Main Supply—Pressure ............................................................ 32 000 kPa
320 bar
4640 psi
TX1061238
2. Measure load sense pressure at load sense (LS) test
point (2) using JT05473 gauge.
NOTE: Only available with LogRite control unit option.
3. Measure electronic main supply pressure at harvester

control panel.
NOTE: Only available with LogRite control unit option.
4. Measure electronic load sense (LS) pressure at

harvester control panel.
1—Main Supply Test Point
–UN–01JUL09
2—Load Sense (LS) Test Point
3—Electronic Main Supply Test Point
4—Electronic Load Sense (LS) Test Point
TX1061230A
Late Design Shown
–UN–29MAR07
TX1019728

070909
PN=38
5. Measure delimb knife soft clamp pressure at delimb

knife soft clamp test point (5) using JT05473 gauge.
6. Measure feed arm soft clamp pressure at feed arm soft

clamp test point (6) using JT05473 gauge.
02
1
7. Measure pilot pressure at pilot pressure test point (7) 3
using JT04471 gauge.
8. Measure top saw cylinder close (saw bar out) pressure

at top saw cylinder close (saw bar out) test point (8)
using JT05473 gauge.
–UN–29MAR07
5—Delimb Knife Soft Clamp Test Point
6—Feed Arm Soft Clamp Test Point
7—Pilot Pressure Test Point
8—Top Saw Cylinder Close (Saw Bar Out) Test Point
TX1019729
Early Design
–UN–01JUL09
TX1061239A
Late Design

070909
PN=39
9. Measure saw system and measuring pressure at saw

system and measuring test point (9) using JT05473
gauge.
NOTE: Main saw can be a 3/4 cut or a supercut saw.

02
1
4 10. Measure main saw pressure at main saw test point
(10) using JT05471 gauge.
9—Saw System and Measuring Test Point
–UN–29MAR07
10—Main Saw Test Point
TX1019730
DH10862,0000022 –19–01JUL09–4/4

070909
PN=40
Group 2
Settings
Supply
SPECIFICATIONS
Supply From Carrier Relief 32 000 kPa
Pressure 320 bar
4640 psi 02
2
1

070909
PN=41
Settings
NOTE: 320 bar is recommended. Set pressure higher

than carrier pressure but not more than 350 bar
1. Supply pressure is measured at main supply test point.

Pressure is applied only when a function is operated.
02
2
2
CAUTION: Prevent possible injury with engine
running and hydraulics powered. Ensure that
personnel are clear of arm capture zones and
saw bar openings. Failure to follow these safety
–UN–01JUL09
precautions can lead to risk of serious injury.
CAUTION: Prevent possible injury from
TX1061241A
unexpected machine movement. Always service
from the side or the rear. Failure to follow these
safety precautions can lead to risk of serious
Late Design Shown
injury.
1—Pressure Adjusting Set Screw
2. Attach JT05473 gauge to the main supply test point.
3. Start carrier engine.
4. Operate throttle to provide maximum working pressure

to the head.
5. Switch control unit to manual.
6. Remove pressure adjusting set screw plug.
7. Adjust pressure adjusting set screw (1) to specification

with a 4 mm Hex Key.
Specification
Supply From Carrier Relief—
Pressure ................................................................................... 32 000 kPa
320 bar
4640 psi
• Increase pressure - clockwise.

• Decrease pressure - counter clockwise.
8. Install pressure adjusting set screw plug.
DH10862,0000023 –19–01JUL09–2/2

070909
PN=42
Settings
Saw

Top Saw Cut Pressure 23 000 kPa JT05473 Gauge 40 000 kPa (400 bar) (5800 psi)
230 bar
3335 psi 02
2
Top Saw Cut Relief Pressure 26 500 kPa 3
265 bar
3843 psi
Main Saw Cut Pressure 23 000 kPa
230 bar
3335 psi
Main Saw Cut Relief Pressure 26 500 kPa
265 bar
3843 psi
DH10862,0000024 –19–01JUL09–1/4

injury.
–UN–29MAR07
TX1019737
1. Valve can be operated using the handle fitted to the 1—Top Saw Cut Function
manual actuator. If handle is not available a 9 mm
spanner can be used.
• Handle movement up operates port nearest manual

actuator.
• Handle movement down operates port nearest
electrical actuator.
2. Saw motor pressure is measured at the LS test point

(4) on the head valve. Pressure is applied only when
the top saw cut function is operated.

070909
PN=43
Settings
3. Attach JT05473 gauge to LS test point (4).
4. Start carrier engine. Operate throttle to provide

maximum working pressure to the head.
02
2 5. Switch control unit to manual.
4
–UN–01JUL09
TX1061242A
Late Design Shown

070909
PN=44
Settings
6. Remove rubber stoppers protecting pressure adjusting

set screws.
NOTE: Saw motor must be stalled for the LS test point to

register maximum value.
02
–UN–05APR07
2
NOTE: If several functions are operated simultaneously 5
the LS test point registers the highest value.
NOTE: Do not limit flow.
TX1019738
7. Activate valve with manual actuator lever, full travel up
(or down).
2—Pressure Adjusting Set Screw Top Saw Cut
• Increase pressure - clockwise. 3—Pressure Adjusting Set Screw Main Saw Cut
8. Adjust corresponding pressure to specification at set

screw (2 or 3) with a 4 mm hex key.
Specification
Top Saw Cut—Pressure........................................................... 23 000 kPa
230 bar
3335 psi
Top Saw Cut Relief—Pressure ................................................ 26 500 kPa
265 bar
3843 psi
Main Saw Cut—Pressure ......................................................... 23 000 kPa
230 bar
3335 psi
Main Saw Cut Relief—Pressure............................................... 26 500 kPa
265 bar
3843 psi
DH10862,0000024 –19–01JUL09–4/4

070909
PN=45
Settings
Left Feed Motor
SPECIFICATIONS
Left Feed Motor Forward 30 000 kPa
Pressure 300 bar
02 4350 psi
2
6 Left Feed Motor Forward Relief 32 000 kPa
Pressure 320 bar
4640 psi
Left Feed Motor Reverse 30 000 kPa
Pressure 300 bar
4350 psi
Left Feed Motor Reverse Relief 32 000 kPa
Pressure 320 bar
4640 psi
DH10862,0000025 –19–01JUL09–1/4

injury.
–UN–29MAR07
1. Valve can be operated using the handle fitted to the
TX1019743
actuator.
• Handle movement down operates port nearest 4—Left Feed Motor Function

070909
PN=46
Settings
2. Feed motor pressure is measured at the LS test point

the left feed motor function (4) is operated.
3. Attach JT05473 gauge to the LS test point (3).

02
2
7
–UN–01JUL09
TX1061244A
to the head.
Late Design Shown
6. Position harvester with closed feed arms on log.

070909
PN=47
Settings

set screws.
9. Activate feed arm valve manual actuator up to close

feed arms on log.
02
2
8 NOTE: Feed motors must be stalled for the LS test point
to register maximum value.
10. Activate one feed motor valve with manual actuator
–UN–29MAR07
lever, full travel up (or down).

TX1019745
Specification 5—Pressure Adjusting Set Screw Reverse

Left Feed Motor Forward— 6—Pressure Adjusting Set Screw Forward
Pressure ................................................................................... 30 000 kPa
300 bar
4350 psi
Left Feed Motor Forward Relief—
Pressure ................................................................................... 32 000 kPa
320 bar
4640 psi
Left Feed Motor Reverse—
Pressure ................................................................................... 30 000 kPa
300 bar
4350 psi
Left Feed Motor Reverse Relief—
Pressure ................................................................................... 32 000 kPa
320 bar
4640 psi
DH10862,0000025 –19–01JUL09–4/4

070909
PN=48
Settings
Right Feed Motor
SPECIFICATIONS
Right Feed Motor Forward 30 000 kPa
Pressure 300 bar
4350 psi 02
2
Right Feed Motor Forward Relief 32 000 kPa 9
Pressure 320 bar
4640 psi
Right Feed Motor Reverse 30 000 kPa
Pressure 300 bar
4350 psi
Right Feed Motor Reverse Relief 32 000 kPa
Pressure 320 bar
4640 psi
DH10862,0000026 –19–01JUL09–1/4

injury.
–UN–29MAR07
TX1019748
actuator.
• Handle movement down operates port nearest 7—Right Feed Motor Function

070909
PN=49
Settings
2. Feed motor pressure is measured at the LS test point

the function is operated.

02
2
10
–UN–01JUL09
TX1061242A
to the head.
Late Design Shown
6. Position harvester with closed feed arms on log.

070909
PN=50
Settings

set screws.
9. Activate feed arm valve manual actuator up to close

feed arms on log.
02
–UN–29MAR07
2
NOTE: Feed motors must be stalled for the LS test point 11
to register maximum value.
10. Activate one feed motor valve with manual actuator
TX1019749
lever, full travel up (or down).

• Decrease pressure - counter clockwise. 8—Pressure Adjusting Set Screw Reverse
9—Pressure Adjusting Set Screw Forward
Specification
Right Feed Motor Forward—
Pressure ................................................................................... 30 000 kPa
300 bar
4350 psi
Right Feed Motor Forward
Relief—Pressure....................................................................... 32 000 kPa
320 bar
4640 psi
Right Feed Motor Reverse—
Pressure ................................................................................... 30 000 kPa
300 bar
4350 psi
Right Feed Motor Reverse
320 bar
4640 psi
DH10862,0000026 –19–01JUL09–4/4

070909
PN=51
Settings
Feed Roller Arm Cylinder
SPECIFICATIONS
Feed Roller Arm Cylinder Arms 12 000 kPa
Close Pressure 120 bar
02 1740 psi
2
12 Feed Roller Arm Cylinder Arms 15 000 kPa
Close Relief Pressure 150 bar
2175 psi
Open Pressure 110 bar
1595 psi
Open Relief Pressure 150 bar
2175 psi
DH10862,0000027 –19–01JUL09–1/4

injury.
–UN–29MAR07
TX1019750
actuator.
• Handle movement down operates port nearest 10—Feed Roller Arm Cylinder Function

070909
PN=52
Settings
NOTE: Arms must be fully open or fully closed for the LS

test point to register maximum value.
NOTE: If several functions are operated simultaneously

02
2
2. Feed roller arm cylinder pressure is measured at the 13
LS test point (4) on the head valve. Pressure is applied
only when the function is operated.
–UN–01JUL09
TX1061242A
precautions can lead to risk of serious injury. Late Design Shown
4. Start carrier engine. Operate throttle to provide 4—Load Sense (LS) Test Point

070909
PN=53
Settings

set screws.
7. Activate valve with manual actuator lever, full travel up

(or down).
02
–UN–29MAR07
2
14 • Increase pressure - clockwise.
8. Adjust corresponding pressure to specification at
TX1019752
pressure adjusting set screw (11 or 12) with a 4 mm
Hex Key.
Specification 11—Pressure Adjusting Set Screw Arms Open

Feed Roller Arm Cylinder Arms 12—Pressure Adjusting Set Screw Arms Close
Close—Pressure....................................................................... 12 000 kPa
120 bar
1740 psi
Feed Roller Arm Cylinder Arms
Close Relief—Pressure ............................................................ 15 000 kPa
150 bar
2175 psi
Open—Pressure ....................................................................... 11 000 kPa
110 bar
1595 psi
Open Relief—Pressure............................................................. 15 000 kPa
150 bar
2175 psi
DH10862,0000027 –19–01JUL09–4/4
Harvester Tilt Cylinder

SPECIFICATIONS
Harvester Cylinder Tilt Up 18 000 kPa
Pressure 180 bar
2610 psi
Harvester Cylinder Tilt Up Relief 21 000 kPa
Pressure 210 bar
3045 psi
Harvester Cylinder Tilt Down 12 000 kPa
Pressure 120 bar
1740 psi
Harvester Cylinder Tilt Down 15 000 kPa
Relief Pressure 150 bar
2175 psi

070909
PN=54
Settings

injury. 02
–UN–29MAR07
2
15
1. Valve cannot be operated using a handle fitted to the
manual actuator. The actuator shaft is cut back to
prevent manual actuation.
TX1019755
13—Harvester Cylinder Function
DH10862,0000028 –19–01JUL09–2/4
2. Harvester cylinder pressure is measured at the LS test

point (4) on the head valve. Pressure is applied only
when the function is operated.

–UN–01JUL09
TX1061242A
to the head.
Late Design Shown
6. Switch control unit to Auto and activate harvester
function using control unit joystick. 4—Load Sense (LS) Test Point
7. If adjustment is required; switch control unit to manual.

070909
PN=55
Settings

set screws.
NOTE: Harvester function must be fully up or fully down

for the LS test point to register maximum value.
02
–UN–29MAR07
2
16 NOTE: If several functions are operated simultaneously
9.• Increase pressure - clockwise.
TX1019756
Adjust corresponding set screw (14 or 15) to

specification 14—Pressure Adjusting Set Screw Tilt Down
15—Pressure Adjusting Set Screw Tilt Up
Specification
Harvester Cylinder Tilt Up—
Pressure ................................................................................... 18 000 kPa
180 bar
2610 psi
Harvester Cylinder Tilt Up
210 bar
3045 psi
Harvester Cylinder Tilt Down—
Pressure ................................................................................... 12 000 kPa
120 bar
1740 psi
Harvester Cylinder Tilt Down
150 bar
2175 psi
with a 4 mm hex key.
DH10862,0000028 –19–01JUL09–4/4

070909
PN=56
Settings
Harvester Cylinder Flow Control
1. Adjust oil flow to harvester up and down functions for

smooth operation by limiting spool movement at the
head valve
02
2
17
harvester or actuator being replaced. Ensure
that the actuator shaft is cut back to prevent
manual actuation of the valve. Failure to follow
–UN–29MAR07
this warning can result in personal injury or
death.
TX1019757
3. Loosen 10 mm nut.
16—Spool Travel Adjustment Tilt Down
4. Adjust spool travel with 3 mm hex key. 17—Spool Travel Adjustment Tilt Up
5. Operate harvester function and adjust spool until

desired speed is achieved.
• Slower - clockwise.
• Faster - counter clockwise.
DH10862,0000029 –19–06AUG08–1/1
Delimb Cylinder
SPECIFICATIONS
Delimb Cylinder Knives Close 1800 kPa
Pressure 180 bar
2610 psi
Delimb Cylinder Knives Close 21 000 kPa
3045 psi
Delimb Knife Open Pressure 12 000 kPa
120 bar
1740 psi
Delimb Cylinder Knives Open 15 000 kPa
2175 psi

070909
PN=57
Settings


02
actuator.
–UN–29MAR07
2
18 • Handle movement down operates port nearest
TX1019763
18—Delimb Cylinder Function
DH10862,000002B –19–01JUL09–2/4
2. Delimb knife cylinder pressures is measured at the LS

test point (4) on the head valve. Pressure is applied
only when the function is operated.

personnel are clear of knife capture zones and
–UN–01JUL09
TX1061242A
injury.
Late Design Shown

to the head.

070909
PN=58
Settings

set screws.
NOTE: Knives must be fully open or fully closed for the

LS test point to register maximum value.
02
–UN–29MAR07
2
NOTE: If several functions are operated simultaneously 19
8.• Increase pressure - clockwise.
TX1019767
Activate valve with manual actuator lever, full travel up

(or down). 19—Pressure Actuating Set Screw Knives Open
20—Pressure Actuating Set Screw Knives Close
9. Adjust corresponding pressure actuating set screw (19
or 20) to specification
Specification
Delimb Cylinder Knives Close—
Pressure ..................................................................................... 1 800 kPa
180 bar
2610 psi
Delimb Cylinder Knives Close
210 bar
3045 psi
Delimb Knife Open—Pressure ................................................. 12 000 kPa
120 bar
1740 psi
Delimb Cylinder Knives Open
150 bar
2175 psi
with a 4 mm hex key.
DH10862,000002B –19–01JUL09–4/4

070909
PN=59
Settings
Measuring
SPECIFICATIONS
Measuring Cylinder Pressure 5 000—6 000 kPa
50—60 bar
02 725—870 psi
2
20 Accumulator Pressure 90% Measuring Cylinder
Pressure
Measuring and Saw System 13 000—15 000 kPa
Pressure 130—150 bar
1885—2175 psi
DH10862,000002C –19–01JUL09–1/5
–UN–23MAY07
TX1019778
Continued on next page DH10862,000002C –19–01JUL09–2/5

070909
PN=60
Settings

injury. 02
–UN–29MAR07
2
21
1. Measuring and saw system pressure control (1) is
measured at the measuring and saw system test point
(9).
TX1019777
NOTE: Pressure is preset and does not require adjusting,
2. Remove protective cap.
3. Loosen 3/4 in. nut and adjust with 5/16-in. hex key.

4. Set to specifications.
Specification
Measuring Cylinder—Pressure........................................ 5000—6000 kPa
–UN–29MAR07
50—60 bar
725—870 psi
1—Measuring and Saw System Pressure Control
TX1019730
2—Cylinder Close (Arm Out) Pressure Control
3—Measuring Cylinder Activation Control
9—Measuring and Saw System Test Point
10—Main Saw Test Point

070909
PN=61
Settings
5. Measuring cylinder close (arm out) pressure control (2)

is measured at the LS test point (13).
6. Loosen 3/4-in. nut and adjust with 5/16-in. hex key.

02
2 • Increase pressure - clockwise.
22 • Decrease pressure - counter clockwise.
7. Set to specifications.
Specification
–UN–01JUL09
Measuring and Saw System—
Pressure .................................................................... 13 000—15 000 kPa
130—150 bar
1885—2175 psi
TX1061245
8. Measuring cylinder activation control (3) is measured at
the LS test point.
2—Cylinder Close (Arm Out) Pressure Control

3—Measuring Cylinder Activation Control
–UN–01JUL09
TX1061247A
Late Design Shown

070909
PN=62
Settings
9. Cylinder can be manually activated by pressing

cylinder manual activation (4), in the middle of the cap.
10. Attach JT05473 gauge to the LS test point.

02
11. Start carrier engine. 2
23
12. Operate throttle to provide maximum working
pressure to the head.
–UN–17JUL08
13. Operate measuring arm and adjust as required.
NOTE: Pressure set too low and measuring wheel

bounces. Pressure set too high and the
TX1045802A
measuring wheel penetrates too deeply into log.
14. Charge accumulator to 90% of measuring cylinder

pressure.
4—Cylinder Manual Activation
Specification
Accumulator—Pressure ....................................... 90% Measuring Cylinder
Pressure
DH10862,000002C –19–01JUL09–5/5
Top Saw

Top Saw Cylinder Saw Bar 5000—6000 kPa JT05473 Gauge 40 000 kPa (400 bar) (5800 psi)
Return Pressure 50—60 bar
725—870 psi
Top Saw Cylinder Saw Bar Out 6000—7500 kPa
870—1088 psi
Measuring and Saw System 13 000—15 000 kPa
1885—2175 psi
Continued on next page DH10862,000002D –19–01JUL09–1/5

070909
PN=63
Settings
02
2
24
–UN–23MAY07
TX1019768
1—Measuring and Saw System 3—Top Saw Cylinder 5—Top Saw Bar Out Speed 6—Lube Oil Pressure Control
Pressure Control Activation Control 7—Lube Oil Flow Control
2—Top Saw Cylinder Open 4—Top Saw Bar Return Speed
(Arm Return) Pressure Control
Control
1.
unexpected machine movement. Always
service from the side or the rear. Failure to
follow these safety precautions can lead to
risk of serious injury.

070909
PN=64
Settings
Measuring and saw system pressure are controlled at

item (1) and set to specification. Pressure is measured at
the measuring and saw system test point.
Specification
Top Saw Cylinder Saw Bar 02
–UN–29MAR07
Return—Pressure ............................................................ 5000—6000 kPa 2
50—60 bar 25
725—870 psi
Top Saw Cylinder Saw Bar Out—
Pressure .......................................................................... 6000—7500 kPa
TX1019774
60—75 bar
870—1088 psi
Specification
Measuring and Saw System— 1—Measuring and Saw System Pressure Control
Pressure .................................................................... 13 000—15 000 kPa
130—150 bar
1885—2175 psi
NOTE: Pressure is preset and does not require adjusting.
3. Loosen 3/4-in. nut and adjust with 5/16-in. hex key


070909
PN=65
Settings
4. Top saw cylinder open (arm return) pressures

controlled by item (2) and is measured at the LS test
point.
5. Pressure is adjusted at control unit.

02
2
26 6. Top saw cylinder activation controlled by item (3). The
cylinder can be manually activated by pressing the
button in the center of the cap.
7. Attach a suitable gauge to the LS test point.

–UN–29MAR07
9. Operate top saw arm and adjust as required. Top saw
bar return speed controlled by item (4).
TX1019775
10. Loosen 3/4 in. nut and adjust with 5/32 in. Hex Key.
11. Adjust top saw bar out speed control (5).

2—Top Saw Cylinder Open (Arm Return) Pressure
• Increase speed - counter clockwise. Control
3—Top Saw Cylinder Activation
• Decrease speed - clockwise. 4—Top Saw Bar Return Speed Control

070909
PN=66
Settings
NOTE: Pressure must be set higher than tank pressure

and lower than top saw bar out pressure.
02
13. Loosen 3/4-in. lock nut and adjust 3/4 in. nut with five 2
5/32-in. hex key. 27
• Increase speed - counter clockwise.

• Decrease speed - clockwise.
–UN–03APR07
14. Adjust Lube oil pressure controlled by item (6).
TX1019776
15. Lube oil flow controlled by item (7)

Early Design
16. Loosen three quarter in. nut and adjust with one
quarter in. Hex Key.
• Increase flow - counter clockwise.

• Decrease flow - clockwise.
5—Top Saw Bar Out Speed Control

6—Lube Oil Pressure Control
7—Lube Oil Flow Control
–UN–01JUL09
TX1061249A
Late Design
DH10862,000002D –19–01JUL09–5/5

070909
PN=67
Settings
Main Saw Supercut—(Option)
SPECIFICATIONS
Main Saw (Supercut Option) 13 000—15 000 kPa
Measuring and Saw System 130—150 bar
02 Pressure 1885—2175 psi
2
28 Main Saw (Supercut Option) 5000—6000 kPa
Cylinder Saw Bar Return 50—60 bar
Pressure 725—870 psi
Main Saw (Supercut Option) 6000—7500 kPa
Cylinder Saw Bar Out Pressure 60—75 bar
870—1088 psi
Main Saw (Supercut Option) 2000—2500 kPa
Saw Bar Clamp Pressure 20—25 bar
290—363 psi

070909
PN=68
Settings
02
2
29
–UN–23MAY07
TX1019781
1—Measuring and Saw System 3—Main Saw Cylinder 5—Saw Bar Clamp and Chain 6—Reservoir
Pressure Control Activation Control Tension Pressure Control
2—Main Saw Cylinder Open 4—Main Saw Bar Speed
(Arm Return) Pressure Control
Control
1. Chain lube is gravity fed from the reservoir (6) to

the saw unit.
unexpected machine movement. Always
service from the side or the rear. Failure to
follow these safety precautions can lead to
risk of serious injury.

070909
PN=69
Settings

measured at the measuring and saw system test point
.
Specification
02 Main Saw (Supercut Option)
–UN–29MAR07
2 Measuring and Saw System—
30 Pressure .................................................................... 13 000—15 000 kPa
130—150 bar
1885—2175 psi
TX1019777
DH10862,000002E –19–01JUL09–3/5
4. Loosen three 3/4-in. nut and adjust with 5/16-in. hex

key

2—Main Saw Cylinder Open (Arm Return) Pressure

Control
3—Main Saw Cylinder Activation Control
4—Main Saw Bar Speed Control
5—Saw Bar Clamp and Chain Tension Pressure
Control
–UN–31JUL08
TX1019782

070909
PN=70
Settings
5. Main saw cylinder open (arm return) pressure control

(2) is measured at the load sense (LS) test point (13).
02
6. Pressure is adjusted at the control unit. 2
31
7. Main saw cylinder activation control (3) can be
manually activated by pressing the button in the middle
of the cap.
–UN–01JUL09
8. Attach a suitable gauge to the LS test point.
TX1061247A
10. Operate measuring arm and adjust as required.

Late Design Shown
11. Main saw bar return speed control (4) adjustment. 13—Load Sense (LS) Test Point
12. Loosen 3/4 in. nut and adjust with 5/16-in. hex key.

13. Saw bar clamp and chain tension pressure control (5)
adjustment.

Specification
Main Saw (Supercut Option)
Cylinder Bar Return—Pressure ....................................... 5000—6000 kPa
50—60 bar
725—870 psi
Main Saw (Supercut Option)
Cylinder Bar Out—Pressure ............................................ 6000—7500 kPa
60—75 bar
870—1088 psi
Main Saw (Supercut Option) Bar
Clamp—Pressure ............................................................ 2000—2500 kPa
20—25 bar
290—363 psi
DH10862,000002E –19–01JUL09–5/5

070909
PN=71
Settings
Main Saw (3/4-in. Option)
SPECIFICATIONS
Main Saw (3/4-in. Option) 13 000—15 000 kPa
Measuring and Saw System 130—150 bar
02 Pressure 1885—2175 psi
2
32 Main Saw (3/4-in. Option) 5000—6000 kPa
Cylinder Bar Return Pressure 50—60 bar
725—870 psi
Main Saw (3/4-in. Option) 6000—7500 kPa
Cylinder Bar Out Pressure 60—75 bar
870—1088 psi
Continued on next page DH10862,000002F –19–01JUL09–1/6

070909
PN=72
Settings
02
2
33
–UN–23MAY07
TX1019784
1—Measuring and Saw System 3—Main Saw Cylinder Manual 5—Provides Oil Pressure that 6—Reservoir
Pressure Control Activation Activates the Piston of the
2—Main Saw Cylinder Open 4—Main Saw Bar Return Chain Lube Pump
(Arm Return) Pressure Speed Control
Control

070909
PN=73
Settings

02 injury.
–UN–29MAR07
2
34
measured at the measuring and saw system test point.
TX1019777
Specification
Main Saw (3/4-in. Option)
Measuring and Saw System—
Pressure .................................................................... 13 000—15 000 kPa
130—150 bar
1885—2175 psi
DH10862,000002F –19–01JUL09–3/6
2—Main Saw Cylinder Open (Arm Return) Pressure

Control
4—Main Saw Bar Return Speed Control
5—Chain Lube Pump Oil Pressure Control
–UN–31JUL08
TX1019782

070909
PN=74
Settings
4. Main saw cylinder open (arm return) pressure control

(2) is measured at the load sense (LS) test point (13).
02
5. Pressure is adjusted at carrier. 2
35
–UN–01JUL09
13—Load sense (LS) Test Point
TX1061247A
Late Design Shown

070909
PN=75
Settings
6. Main saw cylinder manual activation control (3) can be

manually activated by pressing the button (7) in the
center of the cap.
7. Attach JT05473 gauge to the LS test point.

02
2
36 8. Start carrier engine.

to the head.
–UN–31JUL08
10. Operate measuring arm and adjust pressure to
specification.
TX1046345A
Specification
Main Saw (3/4 in. Option)
Cylinder Bar Out—Pressure ............................................ 6000—7500 kPa
60—75 bar
870—1088 psi
12. Adjust main saw bar return speed control (4) to

specification.
Specification
Main Saw (3/4 in. Option)
Cylinder Bar Return—Pressure ....................................... 5000—6000 kPa
50—60 bar
–UN–31JUL08
725—870 psi

TX1046347A
13. Chain lube pump oil pressure control (5) opens and
closes chain lube reservoir.
14. Chain lube is pumped from the reservoir to the saw 3—Main Saw Cylinder Manual Activation
unit. 7—Manual Activation Button
DH10862,000002F –19–01JUL09–6/6

070909
PN=76
Settings
Color Marking
SPECIFICATIONS
Color Marking Pump Piston 9900—19 900 kPa
1436—2886 psi 02
2
37
SERVICE EQUIPMENT AND TOOLS
JT05473 Gauge 40 000 kPa (400 bar) (5800 psi)
Continued on next page DH10862,0000030 –19–26AUG08–1/2

070909
PN=77
Settings
CAUTION: Prevent possible injury from high

pressurized system. Keep to rear of head when
making hydraulic measurements. Pressurized
system can cause serious burns or penetrating
02 injury.
2
38
1. Pressure is applied only when color marking is
operated.
2. Attach JT05473 gauge to piston pump pressure test
–UN–30MAR07
point (1).
TX1019785
personnel are clear of the arm capture zones
and the saw bar openings. Failure to follow
these safety precautions can lead to risk of
1—Piston Pump Pressure Test Point
serious injury.
2—Piston Pump Pressure Control

to the head.
5. Loosen 3/4-in. lock nut and adjust 3/4 in. nut with
5/32-in. hex key.

6. Adjust piston pump pressure control (2) to

specification.
Specification
Color Marking Pump Piston—
Pressure ....................................................................... 9900—19 900 kPa
90—199 bar
1436—2886 psi
DH10862,0000030 –19–26AUG08–2/2

070909
PN=78
Group 3
Schematics
Supercut (Option)
TX1040543 –19–17JUN09
SUPERCUT OPTION
3 PILOT LINE
DRAIN LINE
5 6
WORKING MAIN LINE
110 111
600 HIGH PRESSURE OIL
10
603 LUBRICATION OIL
604 RETURN OIL

36 1
606 TRAPPED OIL
34 35 609 PILOT OIL
11 12
2
614 LOAD SENSE OIL
4 7 8
B A A B A B B A B A B A
9
59
63
33
37 42 47 52 57 67 72
77
43 48 53 58 68 73 62
61
60 41 51 56 66 71
46
83 76
87 14
40 13
82 84 15
18 88
16
17
80
MAIN AND TOP SAW FEED MOTORS VALVE FEED MOTORS VALVE TILT CYLINDER UPPER DELIMB CYLINDER
19 VALVE SECTION 20 SECTION 21 SECTION 22 FEED ROLLER ARM CYLINDER 23 VALVE SECTION 24 VALVE SECTION 108 109 25 PUMP SIDE MODULE
VALVE SECTION
TX1040543
HTH622B (Supercut Option)
OUO1065,00000EC –19–02JUL09–1/4

070909
PN=79
Schematics
TX1040961 –19–21APR08
THIS PAGE
INTENTIONALLY
LEFT BLANK
OUO1065,00000EC –19–02JUL09–2/4

070909
PN=80
Schematics
1—Main Saw Cylinder 24—Upper Delimb Cylinder 53—Right Feed Roller Arm 72—Upper Delimb Cylinder
2—Main Saw Motor Valve Section Motor Reverse Relief Rod Relief Valve
3—Left Fixed Feed Motor 25—Pump Side Module Valve 73—Upper Delimb Cylinder
4—Left Feed Roller Arm Motor 33—Main Saw Chain 56—Feed Roller Arm Valve Head Relief Valve
5—Fixed Feed Roller Tensioner Spool 76—Pilot Pressure Reducing
6—Right Fixed Feed Motor 34—Main Saw Chain Oiler 57—Feed Roller Arm Cylinder Valve
02
7—Right Feed Roller Arm 35—Main Saw Chain Oiler Rod Relief Valve 77—Pilot Pressure Relief Valve
3
Motor Reservoir 58—Feed Roller Arm Cylinder 80—Top Saw Oiler
3
8—Measuring Cylinder 36—Main Saw Chain Oiler Head Relief Valve 82—Lube Oil Flow Control
9—Measuring Cylinder Pump 59—Measuring Pressure 83—Lube Oil Pressure Control
Accumulator 37—Main Saw Chain Tensioner Control 84—Top Saw Bar Out Speed
10—Feed Roller Arm Cylinder Pressure Reducing Valve 60—Main Saw Cylinder Open Control
11—Tilt Cylinder 40—Main Saw and Top Saw (Arm Return) Pressure 87—Inlet Compensator
12—Upper Delimb Cylinder Pressure Reducing Valve Control 88—Main Relief
13—Top Saw Cylinder 41—Main and Top Saw Valve 61—Main Saw and Top Saw 108—Upper Delimb Knife Soft
14—Top Saw Motor Spool Return and Main Saw Clamp Test Point
15—Load Sense 42—Main Saw Motor Relief Control Solenoid Valve 109—Feed Arm Soft Clamp
16—Main Supply Valve 62—Measuring Cylinder Test Point
17—Return 43—Top Saw Motor Relief Solenoid Valve 110—Left Fixed Feed Motor
18—Case Drain Valve 63—Main Saw and Top Saw Manifold
19—Main and Top Saw Valve 46—Feed Motors Valve Spool Bar Return Speed Control 111—Right Fixed Feed Motor
Section 47—Left Fixed Feed Motor 66—Tilt Cylinder Valve Spool Manifold
20—Feed Motors Valve Forward Relief Valve 67—Tilt Cylinder Rod Relief 600—High Pressure Oil
Section 48—Left Feed Roller Arm Valve 603—Lubrication Oil
21—Feed Motors Valve Motor Reverse Relief 68—Tilt Cylinder Head Relief 604—Return Oil
Section Valve Valve 606—Trapped Oil
22—Feed Roller Arm Valve 51—Feed Motors Valve Spool 71—Upper Delimb Cylinder 609—Pilot Oil
Section 52—Right Fixed Feed Motor Valve Spool 614—Load Sense Oil
23—Tilt Cylinder Valve Section Forward Relief Valve
Continued on next page OUO1065,00000EC –19–02JUL09–3/4

070909
PN=81
Schematics
02
3
4
–19–15MAY02
T154796
OUO1065,00000EC –19–02JUL09–4/4

070909
PN=82
Schematics
3/4 in. (Option)

TX1040544 –19–17JUN09
3/4 IN. OPTION

3 PILOT LINE
DRAIN LINE
5 6
WORKING MAIN LINE
110 111
600 HIGH PRESSURE OIL
10
603 LUBRICATION OIL
604 RETURN OIL
606 TRAPPED OIL

1
35 609 PILOT OIL
11 12
2
34 614 LOAD SENSE OIL
4 7 8
36 B A A B A B B A B A B A
9
59
63
38
61
42 47 52 57 67 72
77
43 48 53 58 68 73 62
60 41 51 56 66 71
46
83 76
87 14
40 13
82 84 15
18 88
16
17
80
MAIN AND TOP SAW FEED MOTORS VALVE FEED MOTORS VALVE TILT CYLINDER UPPER DELIMB CYLINDER
19 VALVE SECTION 20 SECTION 21 SECTION 22 FEED ROLLER ARM 23 VALVE SECTION 24 VALVE SECTION 108 25 PUMP SIDE MODULE
109
VALVE SECTION
TX1040544
OUO1065,00000ED –19–17JUN09–1/4

070909
PN=83
Schematics
TX1040961 –19–21APR08
THIS PAGE
INTENTIONALLY
LEFT BLANK
OUO1065,00000ED –19–17JUN09–2/4

070909
PN=84
Schematics
1—Main Saw Cylinder 24—Upper Delimb Cylinder 56—Feed Roller Arm Valve 76—Pilot Pressure Reducing
2—Main Saw Motor Valve Section Spool Valve
3—Left Fixed Feed Motor 25—Pump Side Module 57—Feed Roller Arm Rod 77—Pilot Pressure Relief Valve
4—Left Feed Roller Arm Motor 34—Main Saw Chain Oiler Relief Valve 80—Top Saw Oiler
5—Fixed Feed Roller 35—Main Saw Chain Oiler 58—Feed Roller Arm Head 82—Top Saw Lube Oil Flow
6—Right Fixed Feed Motor Reservoir Relief Valve Control
02
7—Right Feed Roller Arm 36—Main Saw Chain Oiler 59—Measuring Pressure 83—Top Saw Lube Oil
3
Motor Pump Control Pressure Control
7
8—Measuring Cylinder 38—Main Saw Chain Oiler 60—Main Saw Cylinder Open 84—Top Saw Bar Out Speed
9—Measuring Cylinder Solenoid Valve (Arm Return) Pressure Control
Accumulator 40—Main Saw and Top Saw Control 87—Inlet Compensator
10—Feed Roller Arm Cylinders Pressure Cylinder Open 61—Main Saw and Top Saw 88—Main Relief
11—Tilt Cylinder (Arm Return) Pressure Return and Main Saw 108—Upper Delimb Knife Soft
12—Upper Delimb Cylinder Control Valve Solenoid Valve Clamp Test Point
13—Top Saw Cylinder 41—Main and Top Saw Valve 62—Measuring Cylinder 109—Feed Arm Soft Clamp
14—Top Saw Motor Spool Solenoid Valve Test Point
15—Load Sense 42—Main Saw Motor Relief 63—Main Saw and Top Saw 110—Left Fixed Feed Motor
16—Main Supply Valve Bar Speed Control Manifold
17—Return 43—Top Saw Motor Relief 66—Tilt Cylinder Valve Spool 111—Right Fixed Feed Motor
18—Case Drain Valve 67—Tilt Cylinder Rod Relief Manifold
19—Main and Top Saw Valve 46—Feed Motors Valve Spool Valve 600—High Pressure Oil
Section 47—Left Fixed Feed Motor 68—Tilt Cylinder Head Relief 603—Lubrication Oil
20—Feed Motors Valve Forward Relief Valve Valve 604—Return Oil
Section 48—Left Feed Arm Motor 71—Upper Delimb Cylinder 606—Trapped Oil
21—Feed Motors Valve Reverse Relief Valve Valve Spool 609—Pilot Oil
Section 51—Feed Motors Valve Spool 72—Upper Delimb Cylinder 614—Load Sense Oil
22—Feed Roller Arm Valve 52—Right Fixed Feed Motor Rod Relief Valve
Section Forward Relief Valve 73—Upper Delimb Cylinder
23—Tilt Cylinder Valve Section 53—Right Feed Arm Motor Head Relief Valve
Reverse Relief Valve
Continued on next page OUO1065,00000ED –19–17JUN09–3/4

070909
PN=85
Schematics
02
3
8
–19–15MAY02
T154796
OUO1065,00000ED –19–17JUN09–4/4

070909
PN=86
03
Repair and Adjustment
Contents
Page Page
Group 1—Cylinder Replace Saw Chain and Saw Bar . . . . . . . . . . .03-11-2

Piston Replacement . . . . . . . . . . . . . . . . . . . . . 03-1-1 Replace Sprocket . . . . . . . . . . . . . . . . . . . . . . .03-11-3 03
Sensor Adjustments . . . . . . . . . . . . . . . . . . . . .03-11-3
Group 2—Retained Pins Sensor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . .03-11-5
Type 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-2-1 Saw Limiting Switches. . . . . . . . . . . . . . . . . . . .03-11-6
Type 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-2-2 Saw Chain Shot Guard Installation . . . . . . . . . .03-11-7
Retained Pins . . . . . . . . . . . . . . . . . . . . . . . . . . 03-2-2
Group 12—Main Saw—3/4 in. Option
Group 3—Feed Roller Replace Saw Chain and Saw Bar . . . . . . . . . . .03-12-1
Fixed Feed Roller Adjustment . . . . . . . . . . . . . . 03-3-1 Proximity Switch Testing . . . . . . . . . . . . . . . . . .03-12-2
Feed Roller Adjustment. . . . . . . . . . . . . . . . . . . 03-3-4 Proximity Switch Replacement . . . . . . . . . . . . .03-12-2
Sprocket Replacement . . . . . . . . . . . . . . . . . . .03-12-4
Group 4—Knives Saw Chain Shot Guard Installation . . . . . . . . . .03-12-5
Knife Edge Sharpening . . . . . . . . . . . . . . . . . . . 03-4-1
Knife Cutting Edge Replacement. . . . . . . . . . . . 03-4-3 Group 13—Saw Chain and Saw Bar
Saw Bar Trouble Shooting . . . . . . . . . . . . . . . .03-13-1
Group 5—Measuring Unit Sprocket Trouble Shooting . . . . . . . . . . . . . . . .03-13-5
Length Measuring Unit . . . . . . . . . . . . . . . . . . . 03-5-1 Saw Chain Trouble Shooting. . . . . . . . . . . . . . .03-13-5
Measuring Wheel Replacement. . . . . . . . . . . . . 03-5-5 11H Saw Chain Sharpening . . . . . . . . . . . . . .03-13-14
Encoder Testing . . . . . . . . . . . . . . . . . . . . . . . . 03-5-7
Potentiometer Testing . . . . . . . . . . . . . . . . . . . . 03-5-8 Group 14—Control Valve
Length Measuring Encoder Replacement . . . . .03-5-10 Harvester Manual Activation . . . . . . . . . . . . . . .03-14-1
Diameter Measuring Encoder Replacement . . .03-5-12 Manual Actuator Replacement . . . . . . . . . . . . .03-14-2
Spool Replacement . . . . . . . . . . . . . . . . . . . . . .03-14-3
Group 6—Accumulator Service
Accumulator Bladder Replacement . . . . . . . . . . 03-6-1 Group 15—Diagnostics
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-15-1
Group 7—Accumulator Charging Control Valve Diagnostics . . . . . . . . . . . . . . . . .03-15-2
Accumulator—Bladder Type . . . . . . . . . . . . . . . 03-7-1 Control Valve Fault Code Solutions. . . . . . . . . .03-15-5
Procedure for Pre-Charging . . . . . . . . . . . . . . . 03-7-3
Group 16—Color Marking System Maintenance
Group 8—Photocell Sensor General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-16-1
Sensor Testing . . . . . . . . . . . . . . . . . . . . . . . . . 03-8-1 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . .03-16-2
Sensor Replacement . . . . . . . . . . . . . . . . . . . . . 03-8-2 Filling System . . . . . . . . . . . . . . . . . . . . . . . . . .03-16-3
Sensor Sensitivity Setting . . . . . . . . . . . . . . . . . 03-8-3 Bleeding System . . . . . . . . . . . . . . . . . . . . . . . .03-16-4
Nozzles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .03-16-5
Group 9—Rotator When Not In Use . . . . . . . . . . . . . . . . . . . . . . .03-16-5
Pinion Replacement . . . . . . . . . . . . . . . . . . . . . 03-9-1
Group 10—Top Saw

Replace Saw Chain and Saw Bar . . . . . . . . . . .03-10-1
Proximity Switch—Test and Replace . . . . . . . . .03-10-2
Sprocket Replacement . . . . . . . . . . . . . . . . . . .03-10-4
Group 11—Main Saw—Supercut Option

Bleeding Chain Tension System . . . . . . . . . . . .03-11-1

070909
PN=1
Contents
03

070909
PN=2
Group 1
Cylinder
Piston Replacement
1. Check seals, rod and bore of tube for damage.
2. Clean and dry all parts.
NOTE: Clamping or griping any tool on the chrome plated

surface of the rod will damage the rod and require
replacement.
3. Clamp rod in a solid vice by the pin eye on the end 03

using soft jaws and place a stand under the shaft near 1
1
the piston end.
Continued on next page DH10862,000006D –19–11AUG08–1/2

070909
PN=89
Cylinder
4. Fit seal (1) on to shaft.
5. Lightly coat all surfaces with oil.
6. Position piston (2) on rod.
7. Lightly oil socket head cap screw (3).
8. Initially torque to 25 N•m (18 lb-ft) (4) to obtain the

starting point for torque by angle.
03
1 NOTE: Tightening cap screw may require a 1.4 m long
2
extension handle on the larger size cylinders.
–UN–29MAR07
9. Mark the rod (5) with a maker pen (reference point for
hex key) and tighten the socket head cap screw a
further 60° from this mark.
TX1019820
1—Seal
2—Piston
3—Socket Head Cap Screw
4—Torque Setting
5—Mark Rod for Hex Key
–UN–18FEB08
TX1036215A
–UN–18FEB08
TX1036213A
DH10862,000006D –19–11AUG08–2/2

070909
PN=90
Group 2
Retained Pins
Type 1
1. Remove cap screw (12).
2. Remove retainer (10).
–UN–12FEB08
3. Remove Pin (11).
4. Clean, inspect, and replace as necessary.
TX1036257A
5. Apply anti-seize copper compound to pin. 03
2
1
6. Install pin.
7. Install retainer.
8. Install cap screw and torque to specification.
–UN–12FEB08
Specification
Cap Screw—Torque ..................................................................... 440 N•m
325 lb-ft
TX1036258A
10—Retainer
11—Pin
12—Cap Screw
DH10862,0000004 –19–13AUG08–1/1

070909
PN=91
Retained Pins
Type 2
1. Remove nylon locking nut (8).
2. Remove cap screw.
–UN–19FEB08
3. Remove pin (9).
TX1036254A
03 5. Apply anti-seize copper compound to pin.
2
2
6. Install pin.
8—Nylon Locking Nut
7. Install cap screw. 9—Pin
8. Install nylon locking nut and torque to specification.
Specification
Nylon Locking Nut—Torque ......................................................... 440 N•m
325 lb-ft
DH10862,0000005 –19–13AUG08–1/1
Retained Pins
2. Remove pin.
–UN–12FEB08
5—Cap Screw
TX1036252A
6—Oil
–UN–18FEB08
TX1036585A
Continued on next page DH10862,000006E –19–04AUG08–1/2

070909
PN=92
Retained Pins
4. Apply oil to pin to ease installation.
5. Apply anti seize copper compound (7) to pin during

final installation.
–UN–18FEB08
6. Install cap screw and torque to specification.
Specification
325 lb-ft
TX1036256A
03
7—Anti Seize Copper Compound 2
3
–UN–18FEB08
TX1036255A
DH10862,000006E –19–04AUG08–2/2

070909
PN=93
Retained Pins
03
2
4

070909
PN=94
Group 3
Feed Roller
Fixed Feed Roller Adjustment
SPECIFICATIONS
Fixed Feed Roller End Play 0.05 mm
Maximum Clearance 0.002 in.
M16 Fixed Feed Roller Mounting 320 N•m
Cap Screw Torque 236 lb-ft
Fixed Feed Roller End Play 0—0.127 mm
Preload Clearance 0—0.005 in.
IMPORTANT: Excessive end play results in premature 03

spline wear. End play is adjustable on 3
1
Harvesters with synchronized fixed feed
motors. Check end play periodically or
machine damage can occur.
1. Fixed feed roller end play (sideways movement) must

not exceed specification.
Specification
Fixed Feed Roller End Play
Maximum—Clearance .................................................................. 0.05 mm
0.002 in.
2. Determine the quantity of shims required to eliminate

excessive end play:
3. Reduce hydraulic system pressure to zero and remove

hoses from fixed feed motors.
Continued on next page DH10862,000006F –19–26AUG08–1/3

070909
PN=95
Feed Roller
4. Remove both feed motors.
NOTE: Fixed feed motor plastic shims must be replaced

with mild steel shims.
5. Remove both nylon spacers (1).
6. Install fixed feed roller with excess shims (2).
7. Apply LOCTITE to fixed feed roller mounting cap
–UN–26JUL07
03 screws.
3
2
8. Torque fixed feed roller mounting cap screws to
specification.
TX1023603
Specification
M16 Fixed Feed Roller Mounting
236 lb-ft
1—Nylon Spacer
2—Shim
–UN–14FEB08
TX1036208A
LOCTITE is a trademark of Henkel Corporation Continued on next page DH10862,000006F –19–26AUG08–2/3

070909
PN=96
Feed Roller
9. Move roller sideways as far as possible and set gauge

to zero (8).
10. Move feed roller as far as possible in other direction

and read gauge (9).
11. Calculate quantity of shims being removed so that

end play is between fixed feed roller end play preload
specification.
Specification 03
Fixed Feed Roller End Play 3
Preload—Clearance ............................................................. 0—0.127 mm 3
0—0.005 in.
–UN–18FEB08
12. Remove feed motors,
13. Install nylon spacers,
TX1036218A
14. Grease motor shaft splines,
NOTE: When fitting new roller, check the fixed feed roller
end play after 8 hours of operation.
15. Install calculated quantity of shims and torque fixed

feed roller mounting cap screws to specification.
Specification
M16 Fixed Feed Roller Mounting
236 lb-ft
Shims are available in:
• 0.005 in. purple

• 0.010 in. blue
–UN–18FEB08
• 0.020 in. black
16. Reconnect hoses to fixed feed motors.
TX1036217A
8—Zero Setting on Gauge
9—Feed Roller Sideways Movement
DH10862,000006F –19–26AUG08–3/3

070909
PN=97
Feed Roller
Feed Roller Adjustment
SPECIFICATIONS
Feed Roller Cap Screw Torque 540 N•m
398 lb-ft
03
3
4 DH10862,0000070 –19–08AUG08–1/2
NOTE: To extend the life of feed arm rollers, it is

recommended to turn the roller over and switch
them from arm to arm.
1. Clean feed rollers with a wire brush.
2. Check for excessive wear using Waratah guide tool

(4).
3. Remove feed roller cap screws (3).
–UN–24JUL07
4. Remove feed rollers.
5. Turn over feed rollers and install on opposite feed
TX1019836
arms.
6. Install feed roller cap screws and torque to

specification.
Specification
Feed Roller Cap Screw—Torque ................................................. 540 N•m
398 lb-ft
3—Fed Roller Cap Screw (6 used)

4—Guide Tool
–UN–18FEB08
TX1036216A
DH10862,0000070 –19–08AUG08–2/2

070909
PN=98
Group 4
Knives
Knife Edge Sharpening
SPECIFICATIONS
Delimb Knife Finished Edge 30°
Angle
03
4
Continued on next page DH10862,0000071 –19–14AUG08–1/3 1

070909
PN=99
Knives
CAUTION: Prevent possible injury working in

the knife capture zones or the saw bar opening.
Stop the engine. Failure to follow the safety
precaution can lead to risk of serious injury.
–UN–24JUL07
1. Tap the cutting edge with a ball peen hammer to
change knife edge angle.
IMPORTANT: Disc grinders heat up and soften the
TX1019840
delimb knife cutting edge. Always use a
03
4 file to sharpen the cutting edge. Delimb
2 knives must be replaced if edge is over
heated.
4
2. File delimb knife cutting edge and finish by honing the
cutting edge with an oil stone.
NOTE: Always keep front knife cutting edge (1) and

upper delimb knife cutting edges (2 and 3) sharp
at all times.
3. Finish edge to specification (4).
–UN–13APR07
Specification
Delimb Knife Finished Edge—
Angle ..................................................................................................... 30°
TX1019841
4. Check finished edge angle with Waratah finished angle
guide tool (5).
1—Front Knife Cutting Edge

2—Delimb Knife Cutting Edge
3—Delimb Knife Cutting Edge
4—Finished Edge Angle
5—Finished Angle Guide Tool
–UN–18FEB08
TX1036221A

070909
PN=100
Knives
IMPORTANT: Freshly sharpened knives will damage

log. Always file back edge of knives
after sharpening. Machine damage and
product loss can occur.
5. File back edge of the delimb knife .
6—File
–UN–06AUG08
03
4
3
TX1046572A
DH10862,0000071 –19–14AUG08–3/3
Knife Cutting Edge Replacement

SPECIFICATIONS
Cutting Edge Angle 5°
Cutting Edge Dimension of Edge 10 mm
Middle to Edge End Height 0.394 in.

070909
PN=101
Knives
1. Remove worn cutting edge and grind clean.
2. Tack-weld new cutting edge ensuring it fits on the arm.
3. Weld cutting edge to specification (6).
Specification
Cutting Edge—Angle ............................................................................... 5°
4. Weld cutting edge to specification higher in the center

03 than on the ends (7).
4
4 Specification
Edge Middle to Edge End—
–UN–29MAR07
Height .............................................................................................. 10 mm
0.394 in.
5. Preheat area to specification before welding .
TX1019843
Specification
Weld Area—Temperature.......................................................... 75—100°C
167—212°F
6—5° Angle
6. Weld using welding stick electrodes AWSA 7—Edge Middle to Edge End
5.5-E11018-M or AS1586-E7618M or equivalent.
7. Allow to cool slowly.
8. Remove any high spots.
9. Sharpen knife edge.
DH10862,0000072 –19–20AUG08–2/2

070909
PN=102
Group 5
Measuring Unit
Length Measuring Unit
CAUTION: Prevent possible injury while

working in the arm capture zones or the saw
bar opening. Stop the engine. Failure to follow
the safety precaution can lead to risk of serious
injury.
–UN–19JUN09
1. Excess sideways movement of measuring units hub
arrangement is a good indication that the hub bearings
03
need replacing. 5
TX1046360A
1
2. Remove set screw (1), cap screws (2).
NOTE: If end cap is hard to remove, use 3/8 in. UNC

jacking threads (3).
3. Remove end cap from hub arrangement.
4. Remove lock nut (4) and lock washer (5).
5. Remove hub arrangement from measuring arm.
–UN–19JUN09
1—Set Screw
2—Cap Screw (8 used)
3—Jacking Threads
TX1046361A
4—Lock Nut
5—Lock Washer

070909
PN=103
Measuring Unit
6. Remove bearings (7 and 8).
7. Remove seal ring (9).
–UN–19JUN09
7—Bearing
8—Bearing
9—Seal Ring
TX1046364A
03
5
2
–UN–19JUN09
TX1046365A

070909
PN=104
Measuring Unit
9. Install hub seal (6) into hub as illustrated so that

grease can extrude past seal.
6—Hub Seal
–UN–09JAN08
TX1019846A
03
5
3
–UN–24JUL07
TX1019847

070909
PN=105
Measuring Unit
NOTE: The new matched bearings must be installed as

the cutaway shows.
10. Install a new matched set of bearings and pack each

one with grease.
03
5
4
–UN–18FEB08
TX1036861
Measuring Wheel Bearing Cutaway

070909
PN=106
Measuring Unit
11. Spread grease onto seal ring (9) and gently push hub
onto measuring arm.
12. Install lock washer (10) and lock nut (11).
13. Tighten lock nut to specification while aligning a

groove with a lock washer tab.
–UN–19JUN09
Specification
Lock Nut—Torque ........................................................................ 300 N•m
221 lb-ft
TX1046366A
03
5
14. Bend one tab (12) over to prevent lock nut from 5
loosening.
15. Apply LOCTITE 243 (blue) to cap screws (13).
16. Install end cap and cap screws.
17. Apply LOCTITE 243 (blue) to screw (14).
–UN–19JUN09
18. Install screw.
10—Lock Washer
TX1046367A
11—Lock Nut
12—Tab
13—Cap Screw (8 used)
14—Screw
15—Shaft
LOCTITE is a trademark of Henkel Corporation DH10862,000007D –19–18JUN09–5/5
Measuring Wheel Replacement

the knife capture zones or the saw bar opening.
precaution can lead to risk of serious injury.
1. Inspect measuring wheel using gauge shown.
2. Replace wheel if measuring wheel teeth (1) are worn.

070909
PN=107
Measuring Unit
3. Remove cap screws and nylon locking nuts (2).
4. Remove measuring wheel.
5. Install new measuring wheel.
6. Install cap screws and nylon locking nuts.
7. Torque to specification.
–UN–13FEB08
03 Specification
5 Measuring Wheel Cap Screw and
6 Nylon Locking Nut—Torque ......................................................... 155 N•m
115 lb-ft
TX1036604A
1—Measuring Wheel Teeth
2—Nylon Locking Nut (6 used)
–UN–13FEB08
TX1036695A
DH10862,0000001 –19–11AUG08–2/2

070909
PN=108
Measuring Unit
Encoder Testing
CAUTION: Harvester can shift or move

unpredictably. Shut carrier off before service
begins. Failure to do so will result in injury or
death.
1. Encoders are used to determine length and diameter.

They convert rotation to a series of pulses. Two sets of
pulses are generated and are 90 degrees out of phase.
03
TimberRite uses potentiometer as encoder and LogRite 5
uses digital signal as encoder. 7
NOTE: Control unit needs both signals to be working to

tell direction. Reversing A and B wires reverses
direction.
2. Check the operations of the potentiometer encoder
–UN–31JAN08
(TimbeRite):
NOTE: An analog meter is recommended, as it is easier

to observe the pulses than on a digital display.
TX1033053A
3. Test supply voltage (DC) at head module box.
Encoder
4. Switch harvester so that engine is not operating, but 24
V is supplied to the head control box. Switch control 3—Encoder
unit system to auto. 4—Encoder Connector
5. Disconnect encoder blue wire (negative) and test for

24 V between blue and brown wires.
If there is 24 V, test pulse signals at head module box.
1. Connect voltmeter between encoder brown (24 V) wire

and black wire (A pulse).
2. Rotate encoder slowly at (1 rpm). Observe pulse of 0 V

to 24 V every 1.2 degrees of rotation.
3. Connect voltmeter between encoder brown wire and

white wire (B pulse).
4. Rotate encoder slowly at (1 rpm). Observe pulse of 0 V

to 24 V every 1.2 degrees of rotation.
Continued on next page DH10862,000009D –19–26AUG08–1/3

070909
PN=109
Measuring Unit
5. At head module box, connect voltmeter between

encoder brown wire and orange wire (Z pulse).
DH10862,000009D –19–26AUG08–2/3
6. Rotate encoder.
7. Observe one pulse of 0 V to 24 V every revolution

03 when encoder shaft flat (1) is lined up with encoder
5
mounting face notch (2).
8
–UN–09JAN08
1—Encoder Shaft Flat
2—Encoder Mounting Face Notch 1
TX1033103
2
DH10862,000009D –19–26AUG08–3/3
Potentiometer Testing

death.
NOTE: The sensor values are values scaled from 0 to

1023. When the harvester head is closed, the
sensor value must be in the range 0—100 ohms
(approximately 0 V) and with the harvester head
fully open, the sensor value must be close to
1023 ohms (approximately 5 V).
1. With the harvester head closed.
Continued on next page DH10862,000009E –19–05AUG08–1/2

070909
PN=110
Measuring Unit
Test for 4.5 V between the black and blue wire (+/- 0.5 1
V).
3
2. Test for 0.5 V between the black and red wire (+/- 0.5
V).
–UN–29JAN08
With the harvester head open.
1. Test for 0 V between the black and blue wire (+/- 0.5
V)
TX1035674
2 03
2. Test for 5 V between the black and red wire (+/- 0.5 5
9
V).
1—Harvester Head Open (0 V, 5 V)
If there is no change in voltage on all the testing pairs 2—Potentiometer Motion
3—Harvester Head Closed (4.5 V, 0.5 V)
with the harvester head opened or closed, the
potentiometer is malfunctioning.
DH10862,000009E –19–05AUG08–2/2

070909
PN=111
Measuring Unit
Length Measuring Encoder Replacement
NOTE: When replacing a diameter measure encoder,

ensure that the "Z" pulse occurs within the arm 3
movement range. The Z pulse can be found by
lining up the encoder shaft flat (1) on the encoder
shaft with the mounting face notch (2) in the
mounting face of the encoder.
1. Assemble coupling components and mount onto
–UN–04FEB08
03 encoder shaft flat (1) with set screw (16).
5
10
2. Apply LOCTITE 243 (Blue) to screw.
TX1035628
3. Bushings must be installed with the large diameter end
positioned against the shaft.
4. Set end play to specification.
Specification
Encoder—End Play ........................................................................... 3 mm
0.118 in.
1—Encoder Shaft Flat
–UN–09JAN08
2—Mounting Face Notch
3—3 mm End Play 1
16—Set Screw
TX1033103
2
–UN–13FEB08
TX1036282A
LOCTITE is a trademark of Henkel Corporation Continued on next page DH10862,000009F –19–08AUG08–1/2

070909
PN=112
Measuring Unit
5. Assemble mount (17) onto housing with clamp (18).
6. Push encoder into mount so that it engages in the feed

coupling.
–UN–18FEB08
7. Secure loose wires away from encoder.
17—Assemble Mount
18—Clamp
TX1036283A
03
5
DH10862,000009F –19–08AUG08–2/2 11

070909
PN=113
Measuring Unit
Diameter Measuring Encoder Replacement
1. Install encoder into mount and clamp flush (25).
2. Install mount with second clamp (26).
–UN–14DEC07
3. Install crank onto encoder shaft aligning screw with flat
on shaft.
4. Turn down set screw without tightening.
TX1019861
03
5 5. Ensure the adjustable rod (27) is set at specification
12
(24) between the rod eye centers.
Specification
Measuring Encoder Adjustable
Rod—Length.................................................................................. 116 mm
4.567 in.
–UN–31JAN08
6. Install onto feed arm and encoder crank.
NOTE: When replacing a diameter measure encoder

ensure that the "Z" pulse occurs within the arm
TX1035636
movement range.
7. Align rod with crank as straight as possible.
8. Check that the rod eye does not interfere with the
crank when the feed arms are fully closed (28).
9. Apply LOCTITE 243 (blue) to screw and tighten in

position.
–UN–18FEB08
24—116 mm Adjusted Rod Length
25—Encoder into Mount
26—Second Clamp
TX1036413A
27—Adjustable Rod
28—Rod Alignment
LOCTITE is a trademark of Henkel Corporation DH10862,00000A0 –19–08AUG08–1/1

070909
PN=114
Group 6
Accumulator Service
Accumulator Bladder Replacement
CAUTION: The accumulator is pressurized.

Always release the pressure in the accumulator
before service begins. If pressure is not
released serious injury or death may occur.
NOTE: Accumulator bladder failure can effect length

measuring accuracy.
–UN–10DEC07
03
1. Harvester should be completely shut off to perform this 6
operation. 1
TX1033142A
2. Make sure that all valves are in the neutral position. No
pressure should remain at the fluid side of the
accumulator.
3. Release accumulator pressure by depressing the gas

valve.
4. Remove accumulator hydraulic pressure line.
5. Remove accumulator from its mounting bracket and

place the charge port cover end (2) in a vice.
6. Separate charge port cover (2) from the accumulator

body (1).
–UN–10DEC07
7. Remove failed bladder.
8. Clean inside of the accumulator with compressed air.
TX1033143A
NOTE: Failure to apply a light coating of oil to new
bladder may result in premature bladder failure.
9. Apply a light coating of hydraulic oil to both sides of

the new bladder and also to the inside of the charge
port cover (2).
10. Place new bladder (4) on the charge port cover

making sure that the bladder lip fits into the groove
(3) on the charge port cover.
1—Accumulator Body
2—Charge Port Cover
3—Charge Port Cover Groove
–UN–10DEC07
4—Bladder
TX1033144A
Properly Assembled Bladder

070909
PN=115
Accumulator Service
11. Reassemble the charge port cover to the accumulator

body.
12. Torque accumulator body to specification.
Specification
Accumulator Body—Torque ........................................................... 70 N•m
52 lb-ft
13. Install accumulator into the accumulator mounting

bracket.
03
6
2 14. Install accumulator hydraulic pressure line.
15. Charge accumulator. (See Accumulator Charging)
DH10862,0000073 –19–25AUG08–2/2

070909
PN=116
Group 7
Accumulator Charging
Accumulator—Bladder Type
03
7
1
–UN–23MAY07
TX1019863
1—Nitrogen Pressure 4—Accumulator Gas Valve 7—Gas Bleed Valve 11—Left Hand Gauge
Regulator Valve Assembly 8—Hand Wheel 12—Gauge
2—Nitrogen Cylinder 5—Charging Hose 9—Key 13—Poppet Valve
3—Charging Set 6—Handle 10—Right Hand Gauge
Set up for accumulators having a shell working The accumulator can now be pre-charged, however we
pressure less than the nitrogen source. recommend that a regulator be fitted at the Nitrogen
cylinder prior to the hose connection. This regulator
The charging of an accumulator with nitrogen gas from should be completely backed off prior to opening the
a cylinder requires a set procedure and care by the gas cylinder valve. With the cylinder valve open, adjust
fitter to ensure that the bladder is not damaged. Even the regulator until the gas JUST flows. This setting
experienced hydraulic fitters can occasionally destroy a should be maintained until the poppet valve at the fluid
bladder by introducing the gas too quickly. After a new port is fully depressed. With the closure of the poppet
bladder has been fitted, the preferred procedure is as valve it is then possible to enter the gas at a higher
follows: rate. The gas should be allowed to flow until the
pressure is slightly above the desired gas pre-charge
A small quantity of oil from the system, approximately pressure, and then allow time for the temperature to
10% of the accumulator capacity, should be entered normalize. Check the pressure and adjust as
into the accumulator fluid port and the accumulator necessary to the exact requirement. Remove the
rotated to ensure that both the bladder and the inner charging assembly and check the core for leaks. If no
surface of the shell have a film of oil over their leaks are found then refit the sealing cap and
respective surfaces. protective cover.

070909
PN=117
The lubricating oil is intended to ensure that the forward very rapidly. Since only a minor part of the
bladder extends evenly and will slide when the bladder bladder is expanding, the thickness is greatly reduced
and the shell make contact. If lubricating oil is not and this combined with the rapid forward motion can
introduced prior to pre-charging and if the gas is not cause the bladder to be damaged before the poppet
introduced slowly through the gas regulator, then there valve closes.
is a strong possibility that the bladder will be damaged
during the first few moments of pre-charging. Under It is our experience that the correct procedure is
these conditions the bladder slams against the shell necessary to obtain the long and trouble free life
wall and holds there while the end expands and moves normally associated with bladder type accumulators.
03
7
2 DH10862,0000074 –19–10JUL08–2/2

070909
PN=118
Procedure for Pre-Charging
03
7
3
–UN–23MAY07
TX1019863
1—Nitrogen Pressure 4—Accumulator Gas Valve 7—Gas Bleed Valve 11—Left Hand Gauge
Regulator Valve Assembly 8—Hand Wheel 12—Gauge
2—Nitrogen Cylinder 5—Charging Hose 9—Key 13—Poppet Valve
3—Charging Set 6—Handle 10—Right Hand Gauge
NOTE: Test accumulator gas valve for leak with charging set and screw hand wheel (8) clockwise to
detection spray or a soapy water solution. open gas valve.
Set up for accumulators having a shell working 5. Open nitrogen cylinder valve by turning key (9),
pressure less than the nitrogen source. cylinder pressure will register on the right hand
gauge (10).
1. Remove protective cap if fitted, and sealing cap
(Not illustrated). 6. Turn handle (6) clockwise until outlet pressure on
the left hand gauge (11) registers 10% higher than
2. Attach Nitrogen Pressure Regulator Valve N.P.R.V. the required pre-charged pressure. When the
(1) to nitrogen cylinder (2). pressure on the charged set and the outlet gauges
are equal, close the nitrogen cylinder valve.
3. Attach charging set (3) to accumulator valve gas
assembly (4) and connect charging hoses (5) 7. Turn hand wheel (8) counter clockwise to seal gas
between N.P.R.V. (1) and charging set connection. valve.
4. Back off handle (6) counter clockwise until loose.

Be sure that gas bleed valve (7) is closed on

070909
PN=119
8. Crack gas bleed valve (7) to exhaust gas from valve (7) to vent down to required pre-charge
charging hose. Remove hose from charging set and pressure. Close gas bleed valve.
replace hose connection sealing cap.
10. Turn hand wheel (8) counter clockwise to reseal
9. Close gas bleed valve. Turn hand wheel (8) gas valve, crack gas bleed valve and remove
clockwise to open gas valve and crack gas bleed charging set from accumulator.
03
7
4 DH10862,0000075 –19–16JUL08–2/2

070909
PN=120
Group 8
Photocell Sensor
Sensor Testing
2 3
1
4
death.
volts
1. Switch harvester so that engine is not running, but 24

V is supplied to the head control box.
6
03
2. Switch control unit system to auto. 8
5
7 1
3. Hold object in front of sensor. 8
1
4. Disconnect sensor black wire (signal wire) at control 4
box, and test with analog meter for 24 V.
volts
5. Meter must read 24 V.
6. Remove object in front of sensor and repeat test.
–UN–12FEB08
Meter must read 0 V.
6
9
1—Plus 24 V
TX1033505
2—Photocell (infrared beam sent but not reflected
back) 10
3—LogRrite Indicator Off
4—Ground
5—Analog Voltmeter 0 V
6—Signal Wire
7—Photocell (beam reflected back off object)
8—LogRite Indicator On
10—Object
DH10862,0000076 –19–25AUG08–1/1

070909
PN=121
Photocell Sensor
Sensor Replacement
CAUTION: Prevent possible injury performing

any maintenance or service work. Lower the
harvester head to the ground and stop the
–UN–17DEC07
engine. Turn off any master shutoffs and do not
allow personnel in the cab. Failure to follow the
injury.
TX1033060
03
8 IMPORTANT: Keep the lens of the sensor free from
2 obstruction. When cleaning, do not use
solvents or cleaning agents that could
damage the plastic lens. If lens damage
occurs it must be replaced.
1. Remove nuts and cap screws (1).
2. Remove cap screws from sensor (2).
3. Remove wiring terminals at head module box.
4. Install sensor and connect wiring terminals.
5. Set switch (3) to PNP for LogRrite control unit and

TimberRite control unit.
–UN–11FEB08
6. Set switch (4) to L-On for LogRite control unit and for
TimberRite control unit.
TX1036384A
7. Install housing to harvester head cap screws.
8. Apply anti-seize copper compound on cap screw

thread and protect exposed cap screw thread with nut. 1—Cap Screw (4 used)
2—Sensor
3—Switch
4—Switch
DH10862,0000077 –19–06AUG08–1/1

070909
PN=122
Photocell Sensor
Sensor Sensitivity Setting

2 3
IMPORTANT: This procedure requires hydraulic oil 1
supply to be isolated. Stop the engine. 4
NOTE: Red LED can be on while the green LED is off.

volts
1. When an object is detected the red light emitting diode
(LED) (11) turns on.
6
2. Object is in optimum sensitivity range when green LED 03
(12) is on. 8
5
7 3
8
3. Switch harvester so that engine is not operating, but 24 1
V is supplied to the harvester head module. 4
4. Switch harvester head key switch to auto.

volts
5. Place object in line with sensor at detection distance.
–UN–12FEB08
6. With sensitivity switch (13) at minimum, turn clockwise
until object is detected (red LED turns on).
6
9
7. Note this position.
TX1033505
10
8. Set sensitivity to halfway between detected and
maximum.
9. Sensitivity range must be set at approximately 2/3.

1—Plus 24 V
2—Sensor (object not detected)
3—LogRrite Indicator Off
4—Ground
6—Signal Wire
7—Sensor (object detected)
8—LogRite Indicator On
10—Object
11—Red Light Emitting Diode
12—Green Light Emitting Diode
13—Sensitivity Switch
–UN–11FEB08
TX1036385A
DH10862,0000078 –19–06AUG08–1/1

070909
PN=123
Photocell Sensor
03
8
4

070909
PN=124
Group 9
Rotator
Pinion Replacement
SPECIFICATIONS
Pinion Mounting Cap Screws 153 N•m
Torque 113 lb-ft
03
9
Continued on next page DH10862,0000080 –19–13AUG08–1/2 1

070909
PN=125
Rotator

performing any maintenance or service work.
Lower the attachment to the ground and stop
the engine. Turn off any master shutoffs and do
not allow personnel in the cab. Failure to follow
the safety precautions can lead to risk of
serious injury.
1. Clean the area of debris and dirt.

03
9 2. Remove hoses and plug ports.
2
3. Remove mounting cap screws (1).
–UN–14DEC07
4. Remove motor from housing (2).
5. Remove pinion from splined motor shaft.
TX1019870
6. Remove bearing from pinion.
7. Press bearing into new pinion.
8. With grease on splined motor shaft, install new pinion.
9. Apply anti-seize copper compound between rotator

body and housing (4), housing and motor (5), and
housing and bearing (6).
10. Install motor and pinion into housing.
11. Remove cover cap screws (3) and inspect rotator ring
for damage.
12. Clear away debris that could cause further damage.
–UN–14DEC07
13. Install mounting cap screws using anti-seize copper
compound on thread and torque.
14. Torque mounting cap screws (1/2 in. UNC) to TX1019871

specification.
Specification
Pinion Mounting Cap Screws— 1—Mounting Cap Screws (4 used)
Torque .......................................................................................... 153 N•m 2—Housing
113 lb-ft 3—Cover Cap Screws (6 used)
4—Housing
5—Motor
15. Install cover. 6—Bearing
DH10862,0000080 –19–13AUG08–2/2

070909
PN=126
Group 10
Top Saw
Replace Saw Chain and Saw Bar

serious injury.
1. Soak new chain overnight in chain oil.

03
2. Loosen nut (1). 10
1
NOTE: Because saw bar is slotted at mounting end and
–UN–30MAR07
can slide out of the clamp loosen instead of
remove nuts.
3. Loosen the saw chain by adjusting cap screw (2).
TX1019875
• Increase tension—clockwise.
• Decrease tension—counter clockwise.
1—Nut
4. Remove saw chain. 2—Cap Screw
3—Nut
5. Loosen nut (3) and slide saw bar out of clamp plate (4) 4—Clamp Plate
and slider (5). 5—Slider
6. Install saw bar and tighten nut.
7. Install new saw chain.
8. Check to see that the chain properly engages the saw

bar and sprocket before tensioning.
NOTE: After 5 minutes of running time allow saw chain to

cool, then set tension again.
9. Adjust chain tension and tighten cap screws.
DH10862,0000081 –19–08AUG08–1/1

070909
PN=127
Top Saw
Proximity Switch—Test and Replace
SPECIFICATIONS
Proximity Switch Sensing Zone 5 mm
Clearance 0.197 in.

03
10 not allow personnel in the cab. Failure to follow
2 the safety precautions can lead to risk of
serious injury.
1. Switch carrier so that engine is not operating, but 24 V

is supplied to the head control box.
2. Switch control unit system to Auto.
3. When saw bar is in ’home’ position the proximity switch

is on.
4. Proximity switch light is on. (Light is LED on side of

switch).
5. At control box, disconnect proximity switch black wire

and test for 24 V between blue and black wires for
Harvesters with LogRite control unit systems and
brown and black for Harvesters with TimberRite control
unit systems.
6. Install proximity switch.
7. Move saw bar from ’home’ position and repeat test.
8. No light or 0 V between wires.
9. Clean area around the proximity switch of all debris

and dirt.
10. Remove guard.
11. Disconnect proximity switch wires at head module

box.
12. Remove switch lock nuts.
13. Remove switch.

070909
PN=128
Top Saw
14. Install switch.
DH10862,0000082 –19–26AUG08–2/3
15. Adjust sensing zone to specification.
Specification
Proximity Switch Sensing Zone— 03
Clearance .......................................................................................... 5 mm 10
0.197 in. 3
16. Apply LOCTITE 243 (blue) to lock nuts and guard

threads.
17. Tighten lock nuts.
–UN–29MAR07
18. Test for proper operation.
TX1019876A
LOCTITE is a trademark of Henkel Corporation DH10862,0000082 –19–26AUG08–3/3

070909
PN=129
Top Saw
Sprocket Replacement

–UN–08JAN08
serious injury.
TX1019877A
NOTE: A worn drive sprocket damages and weakens the
saw chain. If the sprocket looks worn, replace it
03
10 immediately.
4
1. Remove saw chain.
3. Remove chain shot guard (7).
–UN–29MAR07
4. Remove drive sprocket (8).
5. Install the new drive sprocket.
TX1019880A
NOTE: Applying a small amount of grease to the back of
the sprocket helps to remove unnecessary shims.
6. Shim sprocket as required (9). 6—Cap Screw

7—Chain Shot Guard
7. Check sprocket and saw bar alignment. 8—Drive Sprocket
9—Shim
8. Clean cap screw thread and saw motor shaft thread.
9. Install chain shot guard.
10. Apply anti-seize copper compound to cap screw.
11. Tighten cap screw.
12. Install saw chain.
DH10862,0000083 –19–18JUN09–1/1

070909
PN=130
Group 11
Main Saw—Supercut Option
Bleeding Chain Tension System

serious injury.
1. Bleed saw chain tightening system.
–UN–19AUG08
03
2. Tilt unit so that the bleeder valve (1) is as high as 11
possible in relation to the tension pistons. 1
TX1047198
CAUTION: Prevent possible injury when
working on the saw chain. Always shut off the
engine and wear safety gloves to prevent
injuries. Remove the saw chain when making
1—Bleeder Valve
any adjustments or servicing the saw unit.
Failure to follow the safety precautions can lead
to risk of serious injury.
4. Open bleeder valve 1 - 2 turns.
NOTE: As there is no saw chain installed the saw bar

holder moves to the outer position and stay there.
5. Start the machine and operate saw several times until

oil coming from the bleeder valve is free from air.
6. Close the bleeder valve.
8. Repeat process after 30 minutes of operation.
DH10862,0000084 –19–20AUG08–1/1

070909
PN=131

serious injury.
–UN–30MAR07
03
11 1. Depressurize saw chain tensioner by pressing button
2 (3).
NOTE: Hydraulic system pressure must be removed
TX1019884
before button can be pressed.
2. Compress Saw bar holder (4) into tensioning device

(5). 3—Button
4—Saw Bar Holder
3. Pull saw chain from saw bar 5—Tensioning Device
6—Mechanical Locking Device
7—Guide Screws
4. Lock the tensioning device by pressing in the
mechanical locking device (6).
5. Remove old saw chain and saw bar.
6. When quick fit saw bar is used, guide screws (7) do

not require removal.
7. Install new saw bar and saw chain.
NOTE: Operate the saw carefully a few times to secure

the pressure in the saw chain tensioning device.
8. Compress saw bar holder into tensioning device to

release mechanical locking device.
9. Pull out saw bar to engage saw chain.
DH10862,0000085 –19–11AUG08–1/1

070909
PN=132
Replace Sprocket

serious injury.

03
immediately. 11
3
–UN–30MAR07
2. Loosen cap screw (8).
3. Remove the saw chain shot guard (9)
TX1019885
4. Remove drive sprocket (10).
5. Install new drive sprocket. 8—Cap Screw

9—Saw Chain Shot Guard
6. Check sprocket and saw bar alignment. 10—Drive Sprocket
7. Clean cap screw thread and saw motor shaft thread.
8. Apply LOCTITE 243 (blue) to cap screw.
9. Install the saw chain shot guard.
10. Tighten cap screw.
LOCTITE is a trademark of Henkel Corporation DH10862,0000086 –19–11AUG08–1/1
Sensor Adjustments
SPECIFICATIONS
Cut-Control Device and Saw 0.75 mm
Home Detector Clearance 0.03 in.

070909
PN=133

Lower the attachment to the ground and shut
off the engine. Turn off any master shutoffs and
do not allow personnel in the cab. Failure to
follow the safety precautions can lead to risk or
serious injury.
1. Loosen the fasteners (11).

03
11 2. Remove housing (12).
4
3. Thread sensor (13) by hand through plate (14) until it
reaches the sensor wheel or the rod.
NOTE: Only use your fingers when assembling and

disassembling the sensors. do not use any tools.
4. Unscrew the sensor three quarter turn.
–UN–30MAR07
5. Sensor is set to specification.
Specification
Cut-Control Device and Saw
TX1020061
Home Detector—Clearance ......................................................... 0.75 mm
0.03 in.
NOTE: Do not use thread lock when locking the sensor.
6. Lock sensor with nut (15).

11—Fasteners
12—Housing
13—Sensor
14—Plate
15—Nut
–UN–30MAR07
TX1019886
DH10862,0000087 –19–11AUG08–2/2

070909
PN=134
Sensor Test

–UN–20AUG08
do not allow personnel in the cab. Failure to
serious injury.
TX1019887
03
1. Proximity switch (16) testing 11
5
NOTE: This procedure requires hydraulic supply to be 16—Proximity Switch
isolated. Turn off carrier engine.

3. Switch control unit system to auto.

is on.

(switching wire) and test for 24 V between blue and
black wires for Harvesters with LogRite control unit
systems and brown and black for Harvesters with
TimberRite control unit systems.
6. Move saw bar away from ’home’ position and repeat

tests. No voltage between wires.
DH10862,0000088 –19–26AUG08–1/1

070909
PN=135
Saw Limiting Switches

off the engine. Turn off any master shutoffs and 17
do not allow personnel in the cab. Failure to 17
serious injury.
–UN–20AUG08
03
11 1. Saw limiting switches (17) are proximity switches
6 detecting notches on a sensor wheel (18).
NOTE: This procedure requires hydraulic supply to be
TX1047555
isolated. Stop the engine.

4. Adjust saw bar position so that the proximity switch is

in an "on" position.

(switching wire) and test for 24 V between brown and
black wires.
–UN–24JUL07
6. Move saw bar and repeat tests. No voltage between
wires.
TX1019888
17—Saw Limiting Switches
18—Sensor Wheel
DH10862,0000089 –19–26AUG08–1/1

070909
PN=136
Saw Chain Shot Guard Installation
SPECIFICATIONS
Saw Chain Shot Guard Cap 32 N•m
Screw Torque 24 lb-ft

03
do not allow personnel in the cab. Failure to 11
follow the safety precautions can lead to risk or 7
serious injury.
1. Saw chain shot is when a saw chain breaks during

sawing and shoots links at high velocity.
2. Saw chain shot occurs around the sprocket area. The

last 1-3 links are whipped outward toward the back of
a harvester head making that area the saw chain shot
danger zone.
3. To reduce chance of saw chain shot to a minimum,

maintain saw bars and saw chains well and ensure
that tensioning & lubrication functions correctly.
4. To reduce the risk of harm (to an operator) to a

minimum, install a saw chain shot guard in the saw
chain shot danger zone.
Continued on next page DH10862,000008A –19–26AUG08–1/2

070909
PN=137
5. Remove cap screws (19).
6. Install saw chain shot guard (20) near saw sprocket as

illustrated.
7. Apply LOCTITE 243 (blue) to cap screw thread.
8. Install cap screws.
9. Torque cap screws to specification.

03
11 Specification
8 Saw Chain Shot Guard Cap
Screw—Torque ............................................................................... 32 N•m
–UN–30MAR07
24 lb-ft
19—Cap Screws (3 used)

20—Saw Chain Shot Guard
TX1019889
LOCTITE is a trademark of Henkel Corporation DH10862,000008A –19–26AUG08–2/2

070909
PN=138
Group 12
Main Saw—3/4 in. Option

these safety precautions can lead to risk of
serious injury.
03
1. Soak new saw chain overnight in chain oil. 12
1
2. Loosen nut (1).
NOTE: Because saw bar is slotted at mounting end and

can slide out of the clamp loosen instead of
remove nuts.
–UN–30MAR07
3. Loosen the saw chain by adjusting cap screw (2).
• Increase tension—clockwise.
• Decrease tension—counter clockwise.
TX1019890
5. Loosen nut (3) and slide saw bar out of clamp plate (4) 1—Nut
and slider (5). 2—Cap Screw
3—Nut
6. Install saw bar and tighten nut. 4—Clamp Plate
5—Slider
7. Install new saw chain.
8. Check to see that the saw chain properly engages the

saw bar and sprocket before tensioning.
NOTE: After 5 minutes of running time allow saw chain to

cool, then set tension again.
9. Adjust saw chain tension and tighten cap screws.
DH10862,000008B –19–26AUG08–1/1

070909
PN=139
Proximity Switch Testing
SPECIFICATIONS
Clearance 0.197 in.
03
12
2 DH10862,000008C –19–20AUG08–1/2
IMPORTANT: This procedure requires hydraulic

supply to be isolated. Turn off carrier
engine.

–UN–27JUL07
is on.
4. Proximity switch light is on. (Light is LED on side of

switch).
TX1019892
(switching wire) and test for 24 V between blue and
black wires for Harvesters with LogRite control unit
1—Sensing Zone
systems and brown and black for Harvesters with
TimberRite control unit systems.
6. Move saw bar away from ’home’ position and repeat

tests. No light or 0 V between wires.
DH10862,000008C –19–20AUG08–2/2
Proximity Switch Replacement

SPECIFICATIONS
Clearance 0.197 in.
Continued on next page DH10862,000008F –19–20AUG08–1/2

070909
PN=140
IMPORTANT: This procedure requires hydraulic

supply to be isolated. Turn off carrier
engine.
1. Clean the area around the proximity switch of all debris

and dirt.
2. Remove guard.
3. Disconnect proximity switch wires at head module box.
–UN–27JUL07
03
4. Remove switch lock nuts 12
3
5. Remove switch.
TX1019892
6. Install switch
7. Adjust sensing zone (1) to specification.

1—Sensing Zone
Specification
Proximity Switch Sensing Zone—
Clearance .......................................................................................... 5 mm
0.197 in.
8. Apply LOCTITE 243 (blue) to lock nuts, and guard

threads.
9. Tighten lock nuts.
10. Test for proper operation.
LOCTITE is a trademark of Henkel Corporation DH10862,000008F –19–20AUG08–2/2

070909
PN=141
Sprocket Replacement

the arm capture zones or the saw bar opening.
2. Straighten tab on tab washer (7).

03
12
4 3. Remove cap screw (6).
4. Remove retainer (8).
5. Remove dowel pins (9).

–UN–29MAR07
immediately.
6. Remove the drive sprocket (10).
TX1019896
7. Install new drive sprocket.
8. Shim (11) sprocket as required.
9. Check sprocket and saw bar alignment. 6—Cap Screw

7—Tab Washer
8—Retainer
10. Clean cap screw thread and saw motor shaft thread. 9—Dowel Pin
10—Drive Sprocket
11. Install dowels 11—Shim
12. Install retainer.
13. Apply anti-seize copper compound to cap screw.
14. Install cap screw.
15. Install tab washer and bend against cap screw.
DH10862,000008D –19–26AUG08–1/1

070909
PN=142
Saw Chain Shot Guard Installation
SPECIFICATIONS
Saw Chain Shot Guard Cap 35 N•m
Screws Torque 26 lb-ft
03
12
Continued on next page DH10862,000008E –19–26AUG08–1/2 5

070909
PN=143
CAUTION: Prevent possible injury performing

any maintenance or service work. Lower the
attachment to the ground and stop the engine.
Turn off any master shutoffs and do not allow
personnel in the cab. Failure to follow the
injury.
1. Saw chain shot is when a saw chain breaks during

sawing and shoots links at high velocity.
03
12
6 2. Saw chain shot occurs around the sprocket area. The
last 1-3 links are whipped outward toward the back of
–UN–30MAR07
a harvester head making that area the saw chain shot
danger zone.
3. To reduce chance of saw chain shot to a minimum,
TX1019898
maintain saw bars and saw chains well and ensure
that tensioning & lubrication functions correctly.
4. To reduce the risk of harm (to an operator) to a 12—Cap Screws (3 used)

minimum, install a saw chain shot guard in the saw 13—Saw Chain Shot Guard
chain shot danger zone.
5. Remove cap screws (12).
6. Install saw chain shot guard (13) near main saw

sprocket as illustrated.
7. ApplyLOCTITE 243 (blue) to cap screw thread.
8. Install cap screws.
9. Torque cap screws to specification.
Specification
Saw Chain Shot Guard Cap
Screws—Torque ............................................................................. 35 N•m
26 lb-ft
LOCTITE is a trademark of Henkel Corporation DH10862,000008E –19–26AUG08–2/2

070909
PN=144
Group 13
Saw Chain and Saw Bar
Saw Bar Trouble Shooting
The saw bar on your saw requires maintenance just like

your saw chain. Keep your saw bar rails square and flat.
The saw bar should set on the rails on a flat surface, or
you may check with a square. Check for inside groove
–UN–25JUN08
wear. Here’s how:
• If saw chain leans and there is no clearance between

saw bar and a straight edge, the saw bar rails are worn.
TX1019899
Saw bar needs replacement. 03
• Place a straight edge against side of saw bar and one 13
1
cutter. If there is clearance between saw bar and
straight edge, the saw bar rails are good.
–UN–25JUN08
TX1019900
DH10862,0000079 –19–13AUG08–1/11
Worn saw bar rails.
Cause. Worn saw bar rails are normal for a saw bar that
has been in service for a period of time.
Result. Shallow groove.
–UN–25JUN08
Remedy. Replace saw bar.
TX1019901

070909
PN=145
Thin rail and low rail.
Cause. Saw chain leaning over, cutting crooked. Forcing

dull saw chain to cut. Damage to cutters on one side of
saw chain.
–UN–25JUN08
Result. Thin rail on one or both sides of saw bar. Rail
could be blue color in thin area. Thin rails are usually low.
Remedy. Saw bar cannot be repaired if rail is thin and
TX1019902
03 uneven. Replace it. Make sure saw chain doesn’t continue
13 to lean. If it does, replace it with a new saw chain.
2
DH10862,0000079 –19–13AUG08–3/11
Wire edged saw bar rails.
Cause. Normal wear caused by pressure of saw chain on

edge of saw bar rails.
Result. Rail edges may chip if wire edge not removed.
–UN–25JUN08
Remedy. Use flat file on edge of saw bar rail to remove
wire edge.
TX1019907
DH10862,0000079 –19–13AUG08–4/11
Blue spots on rails.
Cause. Rails were pinched partially closed. The friction of

the drive links passing through pinched rails cause them
to turn blue.
–UN–25JUN08
Result. Small or large blue area on one or both rails.

Could be entire saw chain if cut crooked.
Remedy. Blue spot is now soft and will wear fast.

TX1019908
Replace saw bar.

070909
PN=146
Sections broken out of hard tip material.
Cause. Irregular operating condition that forced drive links

sideways. Pinched in cutting operation.
Result. Short section broken out of hard tip material or
–UN–24JUN08
section broken out or many little cracks. Nose area of saw
bar is sometimes bent.
TX1019909
Remedy. Can be welded by qualified repair shop, or
replace saw bar. 03
13
3
DH10862,0000079 –19–13AUG08–6/11
Split nose rail.
Cause. Operating accident that caused excessive side

pressure on nose rail. This is a very common problem.
Result. Rail split at bottom of groove. Saw bar could be
–UN–24JUN08
bent in nose area or entire body bent. Rail opposite break
is bent.
TX1019910
Remedy. Can be welded by qualified repair shop, or
replace saw bar.

070909
PN=147
Chipped rail.
CCause. Chipping of rails behind tip. Continual pressure

of saw bar in one area. Dull saw chain. Loose saw chain
tension.
–UN–24JUN08
Result. Material chip out of one or both rails behind the
hard tip.
TX1019911
Remedy. Reverse saw bar to reduce wear. Weld saw bar
03 at a qualified repair shop. Replace saw bar. (This chipping
13 can cause saw chain damage.)
4
DH10862,0000079 –19–13AUG08–8/11
Nose area is blue.
Cause. Nose was pinched. Friction from revolving

sprocket caused heat and area turned blue. Could be lack
of lubrication.
–UN–24JUN08
Result. Entire rail edge turns blue, or only in one or two
spots.
TX1019912
Remedy. If this happens in nose bearing area the saw
bar is no longer serviceable. Replace nose if replaceable
sprocket-nose. Replace saw bar if laminated saw bar.
DH10862,0000079 –19–13AUG08–9/11
Chipped at nose connection. (Replaceable noses)
Cause. Loose saw chain tension. Continual pressure in

this area. Heavy delimbing at this point.
Result. Chipping at connection of both body and nose

–UN–24JUN08
assembly.
Remedy. Replace nose assembly and dress rail of saw

TX1019913
bar and nose to match.

070909
PN=148
Spread nose rails and loss of bearings.
Cause.Saw chain jumped off saw bar. Limb caught nose.

Twisting nose. Any operating accident.
Result. Spread nose rails and loss of bearings.
–UN–27JUN08
Remedy. Replace saw bar.
TX1019914
03
13
DH10862,0000079 –19–13AUG08–11/11 5
Sprocket Trouble Shooting
A worn drive sprocket will damage and weaken a saw

chain beyond repair. If your sprocket looks worn, replace
it immediately. The only cure for a worn sprocket is a new
one. To avoid sprocket problems, check the old sprocket
when you install new saw chain. Replace sprocket if worn.
Keep saw chain properly tensioned.
DH10862,000007A –19–08AUG08–1/2
Worn Spur.
Cause. Normal wear.
Result. Saw chain breakage. Drive link wear.
–UN–27JUN08
Remedy. Replace spur sprocket.
TX1019915
DH10862,000007A –19–08AUG08–2/2
Saw Chain Trouble Shooting
Three things cause most saw chain problems: incorrect

filing, lack of lubrication, and loose saw chain tension.
Here are some of the most common signs to look for if
your saw chain is not performing right.
Continued on next page DH10862,000007B –19–13AUG08–1/29

070909
PN=149
Drive Link Problems.
Sharpening drive link tang.
Keep drive link tangs sharp. Use a round file to sharpen

the tang.
–UN–27JUN08
03
13
6
TX1019917
DH10862,000007B –19–13AUG08–2/29
Drive link tang; cleaning saw bar groove.
Keep drive link tangs sharp so it cleans the saw bar

groove of sawdust.
–UN–27JUN08
TX1019918
DH10862,000007B –19–13AUG08–3/29
Straight bottoms.
Cause. Shallow saw bar groove in body of saw bar.
Result. Drive link tangs worn straight. Drive links cannot

clean saw bar.
–UN–27JUN08
Remedy. Replace saw bar. File toe of drive link to clean

saw bar groove.
TX1019924

070909
PN=150
Concave bottoms.
Cause. Shallow saw bar groove in nose of saw bar. Worn

tip.
Result. Drive link tangs are worn in concave shape.
–UN–27JUN08
Remedy. Replace saw bar or have noses welded.
TX1019925
03
13
DH10862,000007B –19–13AUG08–5/29 7
Battered and broken bottoms.
Cause. Saw chain jumped off revolving spur sprocket.
Result. Drive links batter. Nicks in drive links. Will not fit
in saw bar groove.
–UN–25JUN08
Remedy. File off burrs so drive links fit in saw bar groove.
Replace drive link if bottom is chewed off.
TX1019926
DH10862,000007B –19–13AUG08–6/29
Sides worn round at bottoms.
Cause. Drive links worn thin at bottoms.
Result. Worn saw bar groove allows saw chain to lean

over sideways.
–UN–25JUN08
Remedy. Close groove in saw bar if serviceable or
replace saw bar. Replace saw chain if problem still exists.
TX1019927
DH10862,000007B –19–13AUG08–7/29
Front or back peened.
Cause. Worn sprocket.
Result. Improper sprocket fit causes change in drive link

shape.
–UN–25JUN08
Remedy. Replace sprocket. Service life of saw chain is

shortened.
TX1019934

070909
PN=151
Wear pattern on drive links.
Cause. Worn saw bar groove - worn nose rail.
Result. If the saw bar rails are not kept square, the drive
links wear to match the rail condition.
–UN–25JUN08
Remedy. Replace or have it fixed by a repair shop.
TX1019935
03
13
8 DH10862,000007B –19–13AUG08–9/29
Cause. Thin rails - nose area.
Result. If the rails are not kept square, the drive links
wear to match the rail condition.
–UN–25JUN08
TX1019936
DH10862,000007B –19–13AUG08–10/29
Cause. rails not flat.
–UN–25JUN08
TX1019937
DH10862,000007B –19–13AUG08–11/29
Cause. Wide rails and worn rails.
–UN–25JUN08

TX1019941

070909
PN=152
Cause. One rail worn down.
–UN–25JUN08
TX1019942
03
13
DH10862,000007B –19–13AUG08–13/29 9
Cutter Depth Gauge Problems.
High depth gauges.
Cause. Depth gauge never fitted.
–UN–24JUN08
Result. Slow cutting. Have to force saw chain to cut.
Remedy. Lower gauges to recommended setting.
TX1019943
DH10862,000007B –19–13AUG08–14/29
Low depth gauges.
Cause. Wrong gauge setting or no gauge used.
Result. Rough cutting. Saw chain grabs.
–UN–24JUN08
Remedy. If the depth gauges are too low, the saw chain
is no longer serviceable.
TX1019944
DH10862,000007B –19–13AUG08–15/29
Uneven depth gauge height.
Cause. Uneven depth gauge setting.
Result. Saw chain does not cut straight. Leads off in cut.
–UN–24JUN08
Remedy. Use correct gauge and setting. Keep all depth

gauges same height. Repair .
TX1019946

070909
PN=153
Tight Joint Problems.
Peening on bottom of cutters and tie straps.
Cause. Loose saw chain tension. Dull cutters. Improper

filed cutters. Saw chain chatter. Forcing dull saw chain to
–UN–24JUN08
cut.
Result. Bottoms of all parts, and/or heel of cutter are
TX1019948
burred and peened. Joints are tight and do not flex freely.
03
13 Remedy. A saw chain with severe tight joints is no longer
10
serviceable. Keep proper tension and sharpness.
DH10862,000007B –19–13AUG08–17/29
Peening on front corner of cutters and tie straps.
Cause. Loose saw chain tension allows saw chain parts

to pound on the motor - mount end of the .
Result. Burring and peening on front corner of tie straps
–UN–24JUN08
and cutters. Prevents parts from flexing.
Remedy. Keep proper saw chain tension.
TX1019949
DH10862,000007B –19–13AUG08–18/29
Peened notch in tie strap.
Cause. Peen in notch from worn spur sprocket.
Result. Burring and peening in notch area. Tie strap is

forced against drive link, preventing drive link from flexing.
–UN–24JUN08
Remedy. Saw chain is no longer serviceable. Replace

sprocket and saw chain.
TX1019950
Cutter Problems.
When your saw chain is not cutting, cuts slowly, does not
hold edge, or cuts crooked, your problem must be caused
by one or more of the following condition.

070909
PN=154
Severe damage on either side of top and/or side

plates.
Cause. Cutter hit or cut material other than wood.

(Possibly dirt, rock, or sand.)
–UN–24JUN08
Result. Saw chain does not cut. Saw chain cuts crooked
if only one side has damage to the cutters.
Remedy. Grind damage area out of all cutters. If only one
TX1019951
side is damaged, grind it first. Grind other side to the 03
same length. Reset depth gauges. 13
11
DH10862,000007B –19–13AUG08–20/29
Light damage on cutting edges of top and/or side

plates.
Cause. Cutters came in contact with light abrasive

material.
–UN–24JUN08
Result. Very slow cutting - if at all. Have to force saw
chain to cut.
Remedy. Grind damaged area out of all cutters.
TX1019952
DH10862,000007B –19–13AUG08–21/29
Feathered top plate cutting edge.
Cause. Grind angle too low or the wheel was too small.
Result. Poor stay-sharp. Rapid dulling. Will cut fast for

short time, then becomes dull.
–UN–24JUN08
Remedy. Use proper size wheel. Check grinding method

with grinding instructions.
TX1019953

070909
PN=155
Backslope on side plate cutting edge.
Cause. Grind angle too high, or wheel was too large.
Result. Cutters does not feed into wood. Slow cutting.

Have to force saw chain to cut. Will cause excessive
–UN–24JUN08
bottom wear.
Remedy. Grind cutters to recommended angle. Check

grinding method with grinding instructions. Check wheel
TX1019954
03 size.
13
12
DH10862,000007B –19–13AUG08–23/29
Hook in side plate cutting edge.
Cause. Grind angle too low or the wheel was too small.
Result. Rough cutting. Saw chain grabs.
–UN–24JUN08
size.
TX1019955
DH10862,000007B –19–13AUG08–24/29
Blunt top plate cutting angle.
Cause. Grind angle too high or the wheel was too large.
Result. Cutters cut slow. Requires extra pressure to cut.

Will cause excessive wear on bottom of saw chain parts.
–UN–24JUN08

size.
TX1019956

070909
PN=156
Top plate angle less than recommended.
Cause. Grind angle less than recommended.
Result. Slow cutting. Requires extra pressure to cut.
–UN–24JUN08
grinding method with grinding instructions.
TX1019958
20º
03
13
DH10862,000007B –19–13AUG08–26/29 13
Excessive heel wear on cutters and tie straps.
Cause. One or a combination of the following: blunt top

plate grinding; forcing dull saw chain to cut frozen wood;
low depth gauges; lack of lubrication.
–UN–24JUN08
Result. Heel of cutter wears off rapidly. In cold-weather
cracks appear.
Remedy. Sharpen cutters properly. Use plenty of
TX1019959
lubrication. Do not force saw chain to cut. Keep cutters
sharp.
DH10862,000007B –19–13AUG08–27/29
Blunt top plate cutting angle.
Cause. Grinding angle more than recommended.
Result. Cutting angle is sharp, but will dull fast. Cutting

action rough and erratic.
–UN–05JUN07

grinding method with grinding instructions.
TX1019960

070909
PN=157
Concave wear on bottom of cutters and connecting tie

straps.
Cause. Tight saw chain tension on hard - nose saw.
Result. Concave wear on bottom of all parts.
–UN–05JUN07
Remedy. Use sprocket - nose saw.
TX1019961
03
13
14 DH10862,000007B –19–13AUG08–29/29
11H Saw Chain Sharpening

Cutter Maintenance Terminology
The following table shows some suggested modifications Depth-gauge Top-plate Top-plate
that are often made for wood type and weather conditions. Setting Filing Angle Cutting
Angle
–19–05JUN07
File-guide
Side-plate
Angle
TX1019962
Angle
10˚
Filing suggestions for 11H saw chain to Side Plate Angle Top Plate Cutting Top Plate Filing Depth Gauge Setting
optimize life and cutting speed Angle
Harvesters In Softwood 75 60 35 0.060
Harvesters in Hardwood 85 60 25 0.060
Harvesters in Frozen wood 90 60 25 Reduce to 0.050 by
putting off filing the
depth gauge.
DH10862,000007C –19–08AUG08–1/1

070909
PN=158
Group 14
Control Valve
Harvester Manual Activation

harvester or actuator being replaced. Ensure
that the actuator shaft is cut back to prevent
manual actuation of the valve. Failure to follow
this warning can result in personal injury or
death.
1. Valve must not be able to operate by using a handle
–UN–31JUL08
03
fitted to the manual actuator. 14
1
2. The actuator shaft must be cut back to prevent manual
TX1046379A
actuation.
3. When valve or the actuator being replaced.
4. Lower equipment to the ground.
5. Stop engine.
6. Install locking pins in place.
7. Ensure that the manual actuator shaft on the harvester

section of the valve has been removed to prevent the
head from standing up. Refer to Servicing and
Maintenance Safety Section.
DH10862,0000003 –19–15AUG08–1/1

070909
PN=159
Control Valve
Manual Actuator Replacement
1. Remove manual actuator cap screws.
2. Remove manual actuator (3).
4. Apply grease in O-ring groove (3) to hold the O-ring in

place.
–UN–18JUN09
03
14 5. Install manual actuator.
2
6. Check that the spool is properly engaged by using the
TX1046375A
manual activator.
3—O-Ring Groove
–UN–18JUN09
TX1046377A
DH10862,0000091 –19–20AUG08–1/1

070909
PN=160
Control Valve
Spool Replacement
NOTE: When replacing a spool, take care not to damage

the surface finish.
1. Remove manual actuator (3).
2. Remove spool (1).
–UN–01JUL09
03
4. Apply oil to lubricate the spool as it is inserted into the 14
3
valve slab.
TX1061250A
5. Install spool tension rod (2).
1—Spool Late Design Shown

2—Spool Tension Rod
3—Manual Actuator
–UN–18JUN09
TX1046373A
–UN–18JUN09
TX1046374A
DH10862,0000090 –19–01JUL09–1/1

070909
PN=161
Control Valve
03
14
4

070909
PN=162
Group 15
Diagnostics
General
With any fault-finding, the first step is to decide where diagnostic indicators before digging into the
to investigate. Sometimes the problem is obvious, but wiring.
on other occasions a little detective work is necessary. 3. Cure the disease, not the symptom.
The maintenance operator who makes half a dozen
haphazard adjustments or replacements can be • Replacing a shaft seal can stop the immediate
successful in curing a fault (or its symptoms), but is leak, but the cause may be too much back
none the wiser when the fault occurs again and has pressure.
spent more time and money than was necessary.
4. Do not take anything for granted. 03
A calm and logical approach is more satisfactory in the 15
1
end. • Be aware a ’new’ component may itself be
defective (especially if it’s been rattling round in
Always take into consideration any warning signs or the tool box for months), and do not leave
abnormalities that have been noticed in the period components out of a fault diagnosis sequence
preceding the fault, that is, power loss, high or low just because they are new or recently fitted.
gauge readings, unusual noises, and remember that When you do finally diagnose a difficult fault, you
failure of a component such as a circuit breaker or will probably realize that all the evidence was
shaft seal may only be a pointer to some underlying there from the start.
fault. Whatever the fault, certain basic principles apply.
Verify the following: 5. For manual checks undertake the following.
1. Verify the fault. • Turn the key in the relay panel to the manual
position. This activates the ‘oil-all’ solenoid, but
• It is simply a matter of being sure that you know isolates the rest of the electrical system.
what the symptoms are before starting work. It is • The servo isolating lever also needs to be put in
important if you are investigating a fault for the down position (the same position as required
someone else who has not described it when you use the excavator controls). The valve
accurately. can now be checked manually.
• Use extreme care when operating the machine
2. Do not overlook the obvious. manually. Understand all the control levers and
their functions, note all safety devices on the
• For example, if a function does not operate, is it machine and insure that they are working
the solenoid, wiring or no hydraulic pressure? If properly.
an electrical fault is indicated, check the
DH10862,0000094 –19–07AUG08–1/1

070909
PN=163
Diagnostics
Control Valve Diagnostics
The following pages detail the fault finding procedures for

the control valve fitted to the Harvester.
Problem Cause Solution

No cylinder/motor response to remote control Verify if fault is mechanical, hydraulic, or Check movement of lever manually. (If
unit actuation. Electronic Load Sense (LS) electrical faulty-see fault code solutions 1.2).
Test Point
Check movement of manual lever when
03 electrical control unit operated. (If faulty see
15 solution 1.3).
2 Check movement of manual lever when
hydraulic remote control unit operated. (If
faulty see fault code solutions 1.4).
If none of above, see fault code solutions 1.1
or fault code solutions 1.5.
Cylinder/motor responds in one direction only Verify if fault is mechanical, Hydraulic, or Check movement of lever manually. (If
electrical. faulty-see fault code solutions 1.2).
electrical
electrical remote control unit operated. (If
faulty see Refer to fault code solutions 1.3).
electrical remote control unit operated. (If
faulty see fault code solutions 1.4).
Faulty shock valves. Refer to fault code solutions 1.2.6 or 1.2.7.
Faulty solenoid actuation. Refer to fault code solutions 1.3.6.
Faulty remote electrical control unit. Refer to fault code solutions 1.3.
Faulty remote hydraulic control unit. Refer to fault code solutions 1.4.
Main spool travel restricted. Refer to fault code solutions 1.2.1.
Incorrect setting on EHF flow adjustment Refer to fault code solutions 1.3.12.
module.
Incorrect PVE/PVEO connections. Refer to fault code solutions 1.3.10.
Faulty remote hydraulic control unit PVRH. Refer to fault code solutions 1.4.

070909
PN=164
Diagnostics

Main valve spool moves without oil passing to Insufficient oil supply to valve. Refer to fault code solutions 1.1.
cylinder / motor.
Insufficient load pressure at compensator spring Refer to fault code solutions 1.1.14.
chamber.
Pressure compensator in valve section (if fitted) not Refer solutions 1.2.5.
functioning.
Cylinder/motor load too high for pressure setting of Refer to fault code solutions 1.1.15.
system.
Blocked LS galleries. Refer to fault code solutions 1.1.12.
Blocked LS lines to pump control unit. Refer to fault code solutions 1.1.13. 03
15
Oil bypassing at shock valve / anti-cavitation check Refer to fault code solutions 1.2.6. 3
valve. and 1.2.7.
Internal leakage in cylinder or motor. Refer to fault code solutions 1.5.
Cylinders/motors operate without remote Spool control yoke loose. Refer to fault code solutions 1.2.6.
control unit being operated.
Electrical feedback transducer not in neutral. Refer to fault code solutions 1.1.11.
Remote electrical control unit neutral position switch Refer to fault code solutions 1.3.2.
faulty.
Presence of contamination in hydraulic fluid. Refer to fault code solutions 1.3.9.
Sticking pressure control valve in remote hydraulic Refer to fault code solutions 1.4.6.
control unit.
Sticking main spool in valve section. Refer to fault code solutions 1.2.2.
Internal fault in PVE / PVEH / PVEM / PVEO. Refer to fault code solutions 1.3.6.
Cylinders/motors respond slowly to remote Insufficient system pressure. Refer to fault code solutions 1.1.
control unit actuation.
Main spool travel limited. Refer to fault code solutions 1.2.1.
Incorrect signal voltage. Refer to fault code solutions 1.3.3.
EHF flow control module fitted to circuit. Refer to fault code solutions 1.3.12.
EHR ramp generator module fitted to circuit. Refer to fault code solutions 1.3.13.
Insufficient pilot oil supply. Refer to fault code solutions 1.1.11.
Insufficient LS pump standby pressure. Refer to fault code solutions 1.1.
Dampened compensator spool (PVG 32 only).

070909
PN=165
Diagnostics

Cylinders/motors do not move load. Load too high for system. Refer solutions 1.1.17.
Interval slippage in cylinder / motor. Refer to fault code solutions 1.5.
Faulty shock valve or anti-cavitation check Refer to fault code solutions 1.2.6. or 1.2.7.
valve.
System relief valve faulty. Refer to fault code solutions 1.1.4. or 1.1.9.
Erratic cylinders/motors response to remote Electrical actuator faulty. Refer to fault code solutions 1.3.6.
control unit operation.
Main spool centering spring faulty. Refer to fault code solutions 1.2.4.
03 Main spool position feedback transducer Refer to fault code solutions 1.3.8.
15 signal incorrect.
4 Contamination in hydraulic fluid. Refer to fault code solutions 1.3.9.
Air in hydraulic pilot lines. Refer to fault code solutions 1.4.3.
Hydraulic actuator faulty. Refer to fault code solutions 1.4.
DH10862,0000095 –19–07AUG08–3/3

070909
PN=166
Diagnostics
Control Valve Fault Code Solutions

Hydraulic Oil Supply
1.1.1 Pump not running. Check prime mover for operation.
Check condition of feed coupling.
1.1.2. Insufficient oil in reservoir Fill reservoir with correct hydraulic fluid to required level.
1.1.3. Leaking or burst supply hose. Check and/or replace damaged hose.
1.1.4. Relief valve malfunction. Check operation of relief valve.
1.1.5. Isolating valves closed. Check that all isolating valves are open and clear. 03
15
1.1.6. Pump control faulty. Check pump compensator correct operation and setting.
5
1.1.7. Low standby pressure in PVP Check idle standby pressure of PVP
Open Center PVP.
PVG 32 : 8 bar minimum
PVG 120 : 12 bar minimum*
*Unless fitted with PVPH extra relief
Check operation of extra relief. Check condition of compensator
spool spring.
1.1.8. Low standby pressure in pump Closed Center PVP.
control. Check pump LS control for operation and setting.
1.1.9 PVP Pressure relief valve faulty. Check pressure relief valve spool and spring for freedom of
operation.
1.1.14. PVP orifices blocked. Test load pressure at LS port in PVP module. Check PVP
1.1.10. orifices are clear of foreign particles.
1.1.11. Internal filters blocked. Check and clean pilot oil filters.
1.1.12. Internal hydraulic pilot pressure Inspect pilot oil pressure reducing valve for operation.
insufficient
1.1.13. Supply lines blocked. Check supply line for blockages and clean as necessary.
1.1.14. Insufficient load pressure at Test load pressure at LS port in PVP module.
compensation spring chamber.
Check adjustment at integral LS pressure controls.
Check adjustment of external LS pressure controls to LS ports of
PVB.

070909
PN=167
Diagnostics

1.1.15. Cylinder / motor load too high for Check load pressure at PVB-LS port.
pressure settings of system
Check maximum system settings: Maximum system pressure
must be approximately 20-30 bar higher than the highest load
pressure.
Adjust maximum system pressure if necessary.
Reduce load if load pressure exceeds maximum limits of
system.
1.1.16. Blocked LS galleries. Check pressure at LS port of valve.
03 1.1.17. Faulty shuttle valves. Check and clean LS galleries of blockages.
15
6 1.2. PVG Mechanical Fault
1.2.1. Main spool travel limited. Check and / or adjust main spool limit stops.
1.2.2. No main spool travel. Main spool seized or jammed. Test spool operation with
1.2.5. manual lever control.
Remove main spool to determine cause of seizure.
Carefully polish spool if necessary.
Refit spool and test manually for freedom of movement.
1.2.3. Main spool unserviceable. Replace PVB/PVBS if beyond repair.
1.2.4. Main spool centering spring broken or Check spring and replace if necessary.
1.2.6. damaged.
1.2.5. Pressure compensator in valve section Check compensator spool for correct operation.
not functioning.
Remove, inspect, and repair as necessary.
Check condition of compensator spring
Replace as necessary.
1.2.6. Faulty shock valves. Check condition of shock valves to ensure that they are not
leaking or bypassing.
1.2.7. Faulty anti-cavitation check valves. Check condition of shock valves to ensure that they are not
leaking or bypassing.
1.2.8. Spool control yoke. Check and tighten spool control yoke.
1.2.9. Dampened compensator spool (PVG Check dampening of compensator spool. If fitted with
32 only). dampening screw, remove and replace with plug. Dampening
screw plug 15526092.

070909
PN=168
Diagnostics

1.3. Electrical Supply
1.3.1. No electrical power. Check electrical circuit and rectify as necessary.
Check that emergency stop switch is in the operating
position.
1.3.2. Faulty neutral position switch. Check operation of neutral position switch in remote control
unit (if connected in circuit) PVRE / PVRES / PVREL.
1.3.3. Incorrect signal voltage. Check voltage level at solenoid plug
Proportional operation
Pin 1 : Supply voltage (100%).
Pin 2 : Variable signal voltage (25-50-75%) 03
15
On-Off operation. 7
Pin 1 : Supply voltage if selected.
Pin 2 : Supply voltage if selected.
1.3.4. Faulty remote control unit. Check signal voltage levels at remote control unit.
PVRE / PVRES / PVREL.
PVRE : terminals 1, 2 or 3.
PVRES : terminals S1 and S2. PVREL : terminals S.
PVREL : terminals S.
Supply voltage : 100%.
Signal voltage : Neutral 50%
P to A 25-50%.
P to B 50-75%.
Replace as necessary.
1.3.5. Faulty wiring. Check wiring and / or connections.
1.3.6. Faulty solenoid. Replace PVE / PVEM / PVEH if necessary.
Replace PVE / PVEO if necessary.
1.3.7. Insufficient pilot. Refer solutions 1.1.11.
1.3.8. Main spool position feedback transducer Test oil for contamination and / or water content.
signal incorrect.
If oil contamination to high, flush hydraulic system or
replace oil if necessary.
If problem persists, change PVE.

070909
PN=169
Diagnostics

1.3.9. Insufficient oil filtration. Check condition of system oil filters.
Fit high-pressure filter without bypass and with visual
condition indicator in PVE pilot oil supply line or in main
pressure line (if not already fitted).
1.3.10. Incorrect PVE / PVEO connections. Check that proportional remote electrical control unit has
not been connected to an on-off PVE (0) solenoid.
1.3.11. Electrical feedback transducer not in Check and adjust transducer neutral position.
neutral.
1.3.12. Flow control module fitted to circuit Check setting adjustment on EHF flow control module or
03 PVRES remote control unit.
15 1.3.13. Ramp generator module fitted to circuit. Check function of EHR ramp generator. Replace as
8 necessary.
1.4. Hydraulic (Remote) Pilot Supply
1.4.1. Insufficient pilot oil supply. Check pilot oil pressure.
PVG 32 : 5—15 bar.
PVG 120 : 5—15 bar
1.4.2. Insufficient pilot oil supply. Check that pilot oil flow rate is adequate.
Pilot flow must be 1.5 L per minute per function.
Check pilot lines for breakage or blockage.
1.4.3. Air in pilot line. Ensure that all air is bled from pilot lines.
1.4.4. Pilot lines incorrectly sized. Check and reduce length of pilot lines.
Increase diameter of pilot lines.
Use steel tube for long pilot line runs.
1.4.4. Pilot lines incorrectly sized. Check and reduce length of pilot lines.
Increase diameter of pilot lines.
Use steel tube for long pilot line runs.
1.4.5. Faulty remote pilot operator. Check operation of remote pilot operator.
Check supply pressure to operator.
Check and inspect movement of pressure control valve in
control unit
1.4.6. Sticking pressure control valve in remote Check operation of remote hydraulic control unit PVPH.
hydraulic control unit.
Clean and repair as necessary.
1.5 Mechanical Fault
1.5.1. Cylinder seals bypassing. Check and replace cylinder seals
1.5.2. Motor bypassing internally. Check and replace motor as required.
1.5.3. Motor coupling damaged. Inspect and replace coupling.
1.5.4. Connecting hoses blocked or crimped Check all lines and hoses for blockage or crimping.
1.5.5. Flow control valves closed. Check setting of any control valves.
DH10862,0000096 –19–08AUG08–4/4

070909
PN=170
Group 16
Color Marking System Maintenance
General
CAUTION: Prevent possible injury when filling

color base. Ensure that no skin contact is made
with color base when filling. Spillage onto
machine requires cleaning immediately. Failure
to follow the safety precautions can lead to risk
of serious injury.
1. The Waratah Color Marking System (C M S) sprays

03
color either onto the saw bar that then wipes the color 16
to the log falling away from the processor, or, onto the 1
log end held in the processor.
2. The system is equipped with three individual reservoirs

of color, capable of seven combinations, to identify log
grades at a later stage.
3. Check the pressure supply (1), return (2) and delivery

lines periodically.
4. Check for leaks or wear.
5. Tighten or replace fittings and hoses as necessary.
6. A good performance depends on a clean system.
–UN–29MAR07
7. Keep nozzle assembly (3) clear of debris.
8. Fill reservoirs (4) regularly.
TX1019977
9. Do not run system empty or system requires bleeding
of air.
1—Pressure Supply
2—Return
3—Nozzle Assembly
4—Reservoirs
5—Pump Assembly
DH10862,0000097 –19–07AUG08–1/1

070909
PN=171
Troubleshooting
NOTE: Most problems occur because of foreign matter in

the system.
1. Check all strainers and nozzle units for cleanliness.
2. Bleed system of air.
3. Intermittent operation usually occurs when the filler cap

03 air vent has become clogged.
16
2
4. Clean with solvent and a fine needle.
5. The pump does not work efficiently when the piston

gets stuck and the spring is unable to return it.
6. Check pump assembly (5) piston pressure and adjust

as required.
7. Open pump assembly and check piston and chamber

condition.
8. Clean thoroughly, replace seals as required,

re-assemble, and bleed system of air.
5—Pump Assembly
–UN–12AUG08
TX1046902
DH10862,0000098 –19–14AUG08–1/1

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PN=172
Filling System
1. Identify the correct color.
2. Each reservoir has a strainer (6) and vented filler cap

(7).
3. Ensure that foreign matter is removed around filler

caps before removing.
4. Clean strainers when necessary. 03

16
3
5. Use clean color base only.
–UN–29MAR07
6—Strainer
7—Vented Filler Cap
TX1019978
DH10862,0000099 –19–07AUG08–1/1

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Bleeding System
CAUTION: Prevent possible injury testing color

“shot”. Always wear gloves and protective
clothing when testing for color shot. Failure to
–UN–29MAR07
follow the safety precautions can lead to risk of
serious injury.
1. With a properly bled system, the color “shot” looks like
TX1019980
a cloud. If the color shot instead looks like a jet, bleed
03
16 the system of air.
4
IMPORTANT: Do not activate pump with pump bleed
screws open.
2. Loosen bleed screws (8) and allow color to flow from

reservoir.
–UN–29MAR07
3. When color is present, tighten bleed screw.
4. Bleeding of hoses between reservoir and pump

assemblies is achieved by loosening pump assembly
TX1019981
bleed screws and allowing color to flow freely.
5. Bleeding of hoses between pump and nozzle

assemblies is achieved by loosening nozzle assembly 8—Bleed Screw Between Reservoir and Pump
bleed screws and pumping color. 9—Bleed Screw Between Pump and Nozzle
6. Loosen bleed screws (9) and activate color system.
7. When color is present, tighten bleed screw.
DH10862,000009A –19–07AUG08–1/1

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Nozzles
2. Use an Allen key to remove the blocked nozzle.

the arm capture zones or the saw bar
3. If a nozzle is leaking when the color marking
opening of the harvester. Stop the engine.
function is not activated it indicates that the check
Failure to follow the safety precautions can
valve is jammed.
lead to risk of serious injury.
4. The nozzle must be cleaned and replaced.
1. Should nozzles require cleaning, first ensure that
Harvester is in the upright position, and locking pin
5. Clean nozzle by leaving it in a solvent overnight. 03
installed. 16
5
NOTE: Nozzles are equipped with a check valve
assembly. They contain a spring and ball
which can be easily lost.
DH10862,000009B –19–07AUG08–1/1
When Not In Use
1. When color marking is to be idle for long periods of

time it is advisable to flush the system of dye.
2. Fill reservoirs with a diesel fuel or paraffin.
3. Run through the system and flush out the dye.
DH10862,000009C –19–31JUL08–1/1

070909
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03
16
6

070909
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Index
Page Page
A Keep riders off machine . . . . . . . . . . . . . . . 01-2-3

Operate machine safely . . . . . . . . . . . . . . . 01-2-2
Accumulator charging Recognize safety information . . . . . . . . . . . 01-2-1
Accumulator—bladder type . . . . . . . . . . . . . 03-7-1 Stay clear of moving parts . . . . . . . . . . . . . 01-2-1
Procedure for pre-charging . . . . . . . . . . . . . 03-7-3 Warning labels . . . . . . . . . . . . . . . . . . . . . . 01-2-3
Accumulator service
Accumulator bladder replacement . . . . . . . . 03-6-1
H
C Hydraulic test point locations

Electronic main supply . . . . . . . . . . . . . . . . 02-1-1
Color marking system maintenance Load sense (LS) . . . . . . . . . . . . . . . . . . . . . 02-1-1
Bleeding system . . . . . . . . . . . . . . . . . . . . .03-16-4 Main supply . . . . . . . . . . . . . . . . . . . . . . . . 02-1-1
Filling system . . . . . . . . . . . . . . . . . . . . . . .03-16-3 Pilot valve . . . . . . . . . . . . . . . . . . . . . . . . . . 02-1-1
General. . . . . . . . . . . . . . . . . . . . . . . . . . . .03-16-1 Indx
Saw and measuring . . . . . . . . . . . . . . . . . . 02-1-1
1
Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . .03-16-5 Soft clamp. . . . . . . . . . . . . . . . . . . . . . . . . . 02-1-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . .03-16-2
When not in use . . . . . . . . . . . . . . . . . . . . .03-16-5
Control valve
Harvester manual activation . . . . . . . . . . . .03-14-1 K
Manual actuator replacement . . . . . . . . . . .03-14-2
Spool replacement . . . . . . . . . . . . . . . . . . .03-14-3 Knives
Cylinder Knife cutting edge replacement . . . . . . . . . . 03-4-3
Piston replacement . . . . . . . . . . . . . . . . . . . 03-1-1 Knife edge sharpening . . . . . . . . . . . . . . . . 03-4-1
D M
Diagnostics Main saw—supercut option

Control valve diagnostics . . . . . . . . . . . . . .03-15-2 Bleeding chain tension system . . . . . . . . . .03-11-1
Control valve fault code solutions . . . . . . . .03-15-5 Replace saw chain and saw bar . . . . . . . . .03-11-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . .03-15-1 Replace sprocket . . . . . . . . . . . . . . . . . . . .03-11-3
Saw chain shot guard installation . . . . . . . .03-11-7
Saw limiting switches . . . . . . . . . . . . . . . . .03-11-6
Sensor adjustments . . . . . . . . . . . . . . . . . .03-11-3
F
Sensor test . . . . . . . . . . . . . . . . . . . . . . . . .03-11-5
Main saw—3/4 in. option
Feed roller
Proximity switch replacement . . . . . . . . . . .03-12-2
Feed roller adjustment . . . . . . . . . . . . . . . . 03-3-4
Proximity switch testing. . . . . . . . . . . . . . . .03-12-2
Fixed feed roller adjustment . . . . . . . . . . . . 03-3-1
Replace saw chain and saw bar . . . . . . . . .03-12-1
Saw chain shot guard installation . . . . . . . .03-12-5
Sprocket replacement . . . . . . . . . . . . . . . . .03-12-4
G Maintenance precautions
Servicing and maintenance safety. . . . . . . . 01-4-1
General maintenance Measuring unit
Additional metric cap screw torque Diameter measuring encoder
values . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5-4 replacement. . . . . . . . . . . . . . . . . . . . . . .03-5-12
Metric bolt and cap screw torque values . . . 01-5-3 Encoder testing . . . . . . . . . . . . . . . . . . . . . . 03-5-7
Unified inch bolt and cap screw torque Length measuring encoder replacement . . .03-5-10
values . . . . . . . . . . . . . . . . . . . . . . . . . . . 01-5-1 Length measuring unit. . . . . . . . . . . . . . . . . 03-5-1
General precautions Measuring wheel replacement. . . . . . . . . . . 03-5-5
Avoid high pressure oils . . . . . . . . . . . . . . . 01-2-2 Potentiometer testing . . . . . . . . . . . . . . . . . 03-5-8
CTM10002 (06JUL09) Index-1 HTH622B Component Technical Manual

070909
PN=1
Index
Page Page
Miscellaneous—machine Saw chain trouble shooting . . . . . . . . . . . . .03-13-5

In case of machine fire . . . . . . . . . . . . . . . . 01-6-1 Sprocket trouble shooting . . . . . . . . . . . . . .03-13-5
Prevent fires . . . . . . . . . . . . . . . . . . . . . . . . 01-6-1 11H saw chain sharpening . . . . . . . . . . . .03-13-14
Welding on machine . . . . . . . . . . . . . . . . . . 01-6-2 Schematics
Supercut (option) . . . . . . . . . . . . . . . . . . . . 02-3-1
3/4 in. (option). . . . . . . . . . . . . . . . . . . . . . . 02-3-5
Settings
P Color marking . . . . . . . . . . . . . . . . . . . . . . .02-2-37
Delimb cylinder . . . . . . . . . . . . . . . . . . . . . .02-2-17
Photocell sensor Feed roller arm cylinder . . . . . . . . . . . . . . .02-2-12
Sensor replacement . . . . . . . . . . . . . . . . . . 03-8-2 Harvester cylinder flow control . . . . . . . . . .02-2-17
Sensor sensitivity setting. . . . . . . . . . . . . . . 03-8-3 Harvester tilt cylinder . . . . . . . . . . . . . . . . .02-2-14
Sensor testing. . . . . . . . . . . . . . . . . . . . . . . 03-8-1 Left feed motor . . . . . . . . . . . . . . . . . . . . . . 02-2-6
Pins Main saw (supercut—option). . . . . . . . . . . .02-2-28
Retained pins . . . . . . . . . . . . . . . . . . . . . . . 03-2-2 Main saw (3/4 in. option). . . . . . . . . . . . . . .02-2-32
Indx
2 Measuring . . . . . . . . . . . . . . . . . . . . . . . . . .02-2-20
Right feed motor . . . . . . . . . . . . . . . . . . . . . 02-2-9
R Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-2-3
Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02-2-1
Retained pins Top saw . . . . . . . . . . . . . . . . . . . . . . . . . . .02-2-23
Type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-2-1
Type 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03-2-2
Rotator T
Pinion replacement . . . . . . . . . . . . . . . . . . . 03-9-1
Top saw
Proximity switch—test and replace . . . . . . .03-10-2
Replace saw chain and saw bar . . . . . . . . .03-10-1
S
Sprocket replacement . . . . . . . . . . . . . . . . .03-10-4
Safety
Avoid unauthorized machine
modifications . . . . . . . . . . . . . . . . . . . . . . 01-1-2
Follow safety instructions . . . . . . . . . . . . . . 01-1-1
Inspect machine . . . . . . . . . . . . . . . . . . . . . 01-1-2
Operate only if qualified . . . . . . . . . . . . . . . 01-1-2
Operational safety . . . . . . . . . . . . . . . . . . . . 01-1-4
Prepare for emergencies. . . . . . . . . . . . . . . 01-1-3
Safety first. . . . . . . . . . . . . . . . . . . . . . . . . . 01-1-1
Wear protective equipment . . . . . . . . . . . . . 01-1-3
Safety operating precautions
Do not operate unless seated . . . . . . . . . . . 01-3-2
Do not operate with window open . . . . . . . . 01-3-2
Head label positions . . . . . . . . . . . . . . . . . . 01-3-6
Keep clear of saw . . . . . . . . . . . . . . . . . . . . 01-3-3
Key ring label . . . . . . . . . . . . . . . . . . . . . . . 01-3-1
Key switch label . . . . . . . . . . . . . . . . . . . . . 01-3-1
Lock crossover bracket . . . . . . . . . . . . . . . . 01-3-3
Never operate warning . . . . . . . . . . . . . . . . 01-3-1
Never operate without reading manuals . . . 01-3-4
Never stand on harvester . . . . . . . . 01-3-2, 01-3-4
Pinch area . . . . . . . . . . . . . . . . . . . . . . . . . 01-3-5
Saw chain and saw bar
Saw bar trouble shooting . . . . . . . . . . . . . .03-13-1
CTM10002 (06JUL09) Index-2 HTH622B Component Technical Manual

070909
PN=2

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HTH622B Harvester Head

CTM10002 06JULY09 (English)

COPYRIGHT® 2009 WARATAH NZ LIMITED

CTM10002 (06JUL09) HTH622B Component Technical Manual

Technical Information Feedback Form

We need your help to continually improve our technical

SEND TO: Waratah New Zealand Limited

FAX NUMBER: +647 886 0054

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CTM10002 (06JUL09) HTH622B Component Technical Manual

CTM10002 (06JUL09) HTH622B Component Technical Manual

03Repair and Adjustment

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

CTM10002 (06JUL09) i HTH622B Component Technical Manual

CTM10002 (06JUL09) ii HTH622B Component Technical Manual

Group 1—Safety . . . . . . . . . . . . . . . . . . . . . . . 01-1-1

Group 2—General Precautions

Group 3—Operating Precautions

Group 4—Maintenance Precautions

Group 5—General Maintenance

Group 6—Miscellaneous Machine

CTM10002 (06JUL09) 01-1 HTH622B Component Technical Manual

CTM10002 (06JUL09) 01-2 HTH622B Component Technical Manual

Waratah Forestry Attachments’ policy is to produce

These safety rules highlight both general and specific

• Study all the safety messages in this manual and on the

Follow Safety Instructions

Read the safety messages in this manual and on the

Be sure all operators of this machine understand every

safety message. Replace operator’s manual and safety

CTM10002 (06JUL09) 01-1-1 HTH622B Component Technical Manual

Inspect machine carefully each day by walking around it

Keep all guards and shields in good condition and

Avoid Unauthorized Machine Modifications

CTM10002 (06JUL09) 01-1-2 HTH622B Component Technical Manual

Guard against injury from flying pieces of metal or debris;

Wear close fitting clothing and safety equipment

Prepare for Emergencies

Be prepared if an emergency occurs or a fire starts.

Keep a first aid kit and fire extinguisher handy.

Keep emergency numbers for doctors, ambulance service,

CTM10002 (06JUL09) 01-1-3 HTH622B Component Technical Manual

CTM10002 (06JUL09) 01-1-4 HTH622B Component Technical Manual

This is the safety alert symbol. When you see this

Follow the precautions and safe operating practices

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

Stay Clear of Moving Parts

Entanglements in moving parts can cause serious injury.

Stop engine before examining, adjusting or maintaining

CTM10002 (06JUL09) 01-2-1 HTH622B Component Technical Manual

This machine uses a high-pressure hydraulic system.

Operate Machine Safely

Keep bystanders clear of machine, especially before

Avoid contact between machine and overhead obstacles

CTM10002 (06JUL09) 01-2-2 HTH622B Component Technical Manual

Only allow the operator on the machine. Keep riders off.

Riders on machine are subject to injury such as being