Procedure to Install a SAT420 Felling Head on a Caterpillar® 522B Track Feller Buncher with Harvester Arrangement Excavator{1408, 5051, 5057, 6319, 6320, 6501, 6502, 6543, 7490, 7610, 7620} Caterpillar

Track Feller Buncher:

522B (S/N: F7C1-UP)

Introduction

This Special Instruction provides information to install a SAT420 Felling Head on a Caterpillar^® 522B Track Feller Buncher. Read and understand the entire Special Instruction before installing the head assembly.

Chassis Install

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Stand away from the cab when the cab is being tilted for transportation or for repair. There is no clearance for a person in this area. Severe injury or death from crushing could occur.

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DO NOT TILT CAB WHEN OCCUPIED. BEFORE TILTING CAB REMOVE ALL LOOSE ARTICLES FROM CAB, SECURE ALL WINDOWS AND EXITS, AND THEN CLOSE CAB AND CAB RISER DOORS. FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR DAMAGE TO THE MACHINE.

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the attachments have been lowered, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

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No clearance for person in this area when machine turns. Severe injury or death from crushing could occur.

Table 1

Required Tools
Tool	Item	Qty	Part No	Description
A		1	-	LocktiteTM 242
B		1	6V-9833	Cap As

Table 2

Required Parts
Item	Qty	Part Number	Description
25	1	5P-7467	Clip
	1	5P-7466	Clip
	1	5P-8112	Grommet
34	1	456-9293	Plate
36	1	438-0427	Hydraulic Manifold Gp
37	1	3K-0360	O-Ring Seal
	1	6V-8639	Connector
	1	6V-8398	O-Ring Seal
38	1	7M-8485	O-Ring Seal
	1	6V-9005	Elbow
	1	5K-9090	O-Ring Seal
39	1	9U-6999	Elbow Fitting Gp
40	1	146-7453	Hose
41	2	5P-2230	Hose Clamps
42	1	5P-4362	Connector
	1	7M-8485	O-Ring Seal
43	1	7X-2470	Adapter
	1	2S-4078	O-Ring Seal
47	1	6V-9851	Elbow
	1	6V-8398	O-Ring Seal
48	1	6V-8398	O-Ring Seal
	1	6V-8556	Nut
	1	6V-8942	O-Ring Reducer
	1	6V-9746	O-Ring Seal
49	4	8T-4198	Bolts
50	4	8T-4121	Hard Washers
51	1	135-3993	Flange
	1	1P-3703	Rectangular Seal
52	1	6V-8400	O-Ring Seal
	1	6V-8741	Union
	1	5K-9090	O-Ring Seal
55	1	460-9091	Spool
59	1	460-9092	Spool
60	1	436-4177	Spool
65	1	460-9094	Hose
67	1	5P-7468	Clip
	1	5P-7469	Clip
	1	5P-8444	Grommet
69	1	5P-7464	Clip
	1	5P-7465	Clip
	1	6V-1249	Grommet
70	1	460-9094	Hose
77	1	291-5636	Harness as.

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Illustration 1	g03681533

1. Unlock access door (1) on the right side of the machine. Open the access door to the battery disconnect compartment.

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Illustration 2	g03681536

2. Move rear battery disconnect switch (2) and front battery disconnect switch (3) to the ON position.

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Illustration 3	g03681538

3. Inside the cab, move key switch (4) to ON position.

   Note: Do not start the engine.

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Stand away from the cab when the cab is being tilted for transportation or for repair. There is no clearance for a person in this area. Severe injury or death from crushing could occur.

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DO NOT TILT CAB WHEN OCCUPIED. BEFORE TILTING CAB REMOVE ALL LOOSE ARTICLES FROM CAB, SECURE ALL WINDOWS AND EXITS, AND THEN CLOSE CAB AND CAB RISER DOORS. FAILURE TO DO SO CAN RESULT IN PERSONAL INJURY OR DAMAGE TO THE MACHINE.

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Illustration 4	g03681540

4. Move engine hood raise switch (5) to OPEN position.

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Illustration 5	g03681542

5. Remove tank breather (6) .

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Illustration 6	g03681544

6. Install suction assembly (7) as illustrated.

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Illustration 7	g03681818

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Illustration 8	g03681825

7. Remove four bolts (9), eight washers and four nuts. Remove top boom cover (8) .

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Illustration 9	g03681830

8. Loosen the fittings and move saw pressure hose assembly (10) and tee (11) in order to allow access to the return hose assemblies.

   Note: Do not tighten hose assembly (10) and tee (11) .

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Illustration 10	g03681846

9. Disconnect left return hose assembly (13) and right return hose assembly (14) from the boom tube assemblies. Remove tee (12) .

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Illustration 11	g03681916

10. Cap the boom tube assembly for saw pressure as illustrated. Cap return hose assembly (13) and hose assembly (14) .

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Illustration 12	g03681924

11. Remove two bolts (15), four washers and two nuts. Remove hose clamp (16) .

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Illustration 13	g03681949

12. Disconnect return hose assembly (13) and return hose assembly (14). Remove the return hose assemblies.

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Illustration 14	g03681958

13. Cap the open fittings as illustrated.

14. Remove tee (17) .

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Illustration 15	g03681986

15. Disconnect hose assembly (18) from fitting (19). Lay the hose assembly to the side. Cap the fitting.

    Note: Hose assembly (18) in order to access the return hose assemblies.

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Illustration 16	g03682016

16. Remove tee (20). Install a plug in the machine manifold.

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Illustration 17	g03682024

17. Remove the cap from fitting (19). Connect hose assembly (18) removed in Step 15.

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Illustration 18	g03682038

18. Disconnect hose assembly with elbow (10) from tee (11). Install Tool (B) on the tee.

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Illustration 19	g03682058

19. Loosen the fittings on tee (11). Move the tee as illustrated. Tighten the fittings.

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Illustration 20	g03682068

20. Remove two bolts (22), four washers and two nuts. Remove hose clamp (21).

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Illustration 21	g03682076

21. Remove four bolts (23), four washers and split clamp (24). Remove hose (10).

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Illustration 22	g03682111

22. Install hose clamp assembly (25) as illustrated to hold hose assembly (26).

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Illustration 23	g03682127

23. If necessary, loosen four bolts (28) and reposition hose assembly (27). The hose assembly should nearly contact the rear grab handle.

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Illustration 24	g03682147
Typical Example

24. Remove bolt (29) and hose clamp (30) .

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Illustration 25	g03682150

25. Position hose clamp (31). Secure with one bolt, two washers and one nut.

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Illustration 26	g03682156

26. Located threaded holes (33) in pump manifold plate (32) .

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Illustration 27	g03682170

27. Position bracket (34) to pump manifold plate (32). Secure the bracket with two bolts (35) and washers.

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Illustration 28	g03682208

28. Assemble saw tilt valve. Connector connector group (37) to hydraulic manifold group (36). Connector elbow group (38) to hydraulic manifold group (36). Connector elbow fitting group (39) to hydraulic manifold group (36) .

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Illustration 29	g03682219

29. Install the saw tilt valve on bracket (34) .

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Illustration 30	g03682274

30. Assemble the hose assembly. Connect connector group (42) to hose (40). Attach hose clamps (41). Secure the connector group to the hose with one of the hose clamps. Connect adapter group (43) to connector group (42) .

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Illustration 31	g03682233

31. Install hose assembly (45) to saw tilt valve (44) and port "T3" (46) in machine manifold (47) .

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Illustration 32	g03682316

32. Assemble the flange assembly (63). Connect elbow group (48) to reducer group (49). Connect reducer group (49) to flange group (52). Install bolts (50) hard washers (51) in the flange group.

    Note: Three flange assemblies (63) are needed during installation.

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Illustration 33	g03682331

33. Remove the cap from the boom tube assembly for saw pressure. Install union group (53).

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Illustration 34	g03682332

34. Connect hose assembly (54) to saw tilt valve (44). Install the other end of the hose assembly to union group (53) in boom tube assembly for saw pressure .

    Note: The hose assembly is routed below the bracket.

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Illustration 35	g03682333

35. Install spool (55) for the saw tilt in the first location on the left manifold.
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    Illustration 36	g03682480

    1. Remove two bolts (57). Remove spool cap (56). Remove the spool.
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    Illustration 37	g03682489

    2. Remove spool spring assembly from spool. Clean spool spring threads (58). Apply Tool (A) to the spool spring threads. Install spool spring on new spool.

    3. Position the spool into the valve body. Position spool cap (56). Install two bolts (57) in order to secure the spool cap.

       Note: The procedure is the same for all new spools (55), (59) and (60) .

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Illustration 38	g03683021

36. Install spool (59) for rotate in the first location on the right manifold. Repeat Step 35.a through Step 35.c to install the spool.

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Illustration 39	g03683022

37. Install spool (60) for grapple in the second location on the right manifold. Repeat Step 35.a through Step 35.c to install the spool.

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Illustration 40	g03682500

38. Remove four bolts (62) and four washers for flange assemblies (61). Remove the flange assemblies and cap. Remove the bolts and flange assemblies for each flange assembly.

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Illustration 41	g03682512

39. Install flange assemblies (63). Secure the flange assemblies with four bolts (64) and four washers.

    Note: Flange assemblies (63) may be easier to install as component parts. In this instance, elbow (48 is removed to facilitate flange assembly install.)

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Illustration 42	g03682525

40. Install elbow (48) and hose assembly (65) to the front flange fitting of right manifold (66) .

    Note: Hose assembly (65) will be routed down the boom as the left hose of the set. Hose assembly (65) runs to the base of the boom.

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Illustration 43	g03682548

41. Assemble hose clamp (69) on to hose assembly (54). Assemble hose clamp (67) on to hose assembly (65). Secure the hose clamps with one bolt (68), two washers and one nut. Mount the hose clamps as illustrated.

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Illustration 44	g03682563

42. Install elbow (71) and hose assembly (70) to the rear flange fitting of right manifold (66) .

    Note: Hose assembly (70) will run down the boom as the right hose of the set of hose assembly (65) and hose assembly (70). Hose assembly (70) runs to the base of the boom.

43. Assemble hose clamp on hose assembly (70). Using one bolt, two washers and one nut.

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Illustration 45	g03682584

44. Lay the rotate hose assembly (65) and hose assembly (70) on the boom. The hoses will be connected in the ""Boom Install" ".

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Illustration 46	g03682638

45. Remove four bolts (72) and four washers for flange assembly (73). Remove the flange assembly and cap from the manifold.

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Illustration 47	g03682668

46. Install flange fitting assembly (74) in the manifold.

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Illustration 48	g03682675

47. Connect hose assembly (75) from flange fitting (74) to saw tilt valve (44) .

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Illustration 49	g03682697

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Illustration 50	g03781465

48. Connect one end of harness (77) to saw tilt valve solenoid (76) .

49. Connect one end of harness (77) to connector "INTERMITTENT SAW MAN RET SOL XA" (78) .

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Illustration 51	g03682714

50. Remove rear line relief valve (79) from the third down valve assembly on the right manifold.

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Illustration 52	g03682723

51. Remove front line relief valve (80) from the first valve section of left manifold. Install the relief valve in this location.

52. Install line relief valve (80) in the third down on the right manifold location.

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Illustration 53	g03682729

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Illustration 54	g03682740

53. Purge the air from port (81) and port (82) before restarting the system to move the boom or the stick.

Boom Install

Table 3

Required Parts
Item	Qty	Part Number	Description
1	8	6V-8398	O-Ring Seals
	4	6V-8731	Union
2	1	460-9093	Hose
3	1	460-9093	Hose
5	16	5P-7464	Clips
	16	5P-7465	Clips
	16	6V-1249	Grommets
6	8	187-9851	Plates
7	16	8T-4223	Hard Washers
8	16	8T-4648	Bolts
13	1	456-9302	Hose
14	1	460-9153	Hose
15	1	3G-8047	Grommet
	1	3G-8054	Clip
32	1	206-2723	Hose Guard
35	1	456-9286	Rod Assembly
36	2	160-2074	Bosses
37	2	8T-4139	Bolts
38	2	8T-4223	Hard Washers
45		6V-8557	Face Seal Nut
		6V-8944	O-Ring Reducer
		6V-8398	O-Ring Seal
		6V-8556	Nut
		6V-8942	O-Ring Reducer
		6V-8398	O-Ring Seal

Boom Hose Install

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Illustration 55	g03682767

1. Remove caps from rotate hose assemblies. Refer to ""Chassis Install" ", Step 44.

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Illustration 56	g03682774

2. Install unions (1) in the rotate hose assemblies.

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Illustration 57	g03682785

3. Connect boom hose assembly (2) and boom hose assembly (3) to unions (1).

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Illustration 58	g03682802

4. Remove two bolts (4) and washers from the left hydraulic boom clamp.

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Illustration 59	g03682810

5. Install hose clamps (5) on hose assembly (2) and hose assembly (3). Position plate (6) on the original line clamp. Use one bolt (8) and one hard washer (7) to secure each hose clamp to the plate.

   Note: The right hose assembly is bolted to the rear of the boom and the left hose assembly is bolted to the front of the boom.

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Illustration 60	g03682820

6. Repeat the above Step 5 three more times, four locations total.

   Note: Use the saw drain hard line mounts.

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Illustration 61	g03682825

7. Remove six bolts (9) and six washers. Remove steel plate (10) .

8. Remove caps from rotate hose assembly (2) and hose assembly (3) .

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Illustration 62	g03682847

9. Install unions (1) in hose assembly (2) and hose assembly (3) .

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Illustration 63	g03682856

10. Lay the two stick hose assembly on the ground. Make a mark (11) one end of each hose assembly. Place another mark (12) on each hose assembly 1955 mm (77 inch) from the marked end.

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Illustration 64	g03682866

11. Connect marked end of stick hose assembly (13) and stick hose assembly (14) to unions (1).

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Illustration 65	g03682873

12. Route stick hose assembly (13) and hose assembly (14) under boom bracket (15) .

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Illustration 66	g03682881

13. Remove one bolt (16) and washer from the forward side of the left hydraulic boom clamp.

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Illustration 67	g03682890

14. Install hose clamp (17) on hose assembly (13) and hose assembly (14). Position plate (6) on the original line clamp. Use one bolt (18) and one washer fasten the hose clamp.

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Illustration 68	g03682901

15. Install grommet (19) on right rotate hose assembly (13). Slide the grommet on the hose assembly under bracket (15) as illustrated.

16. Route hose assembly (13) and hose assembly (14) through the boom to the stick joint.

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Illustration 69	g03682825

17. Position plate (10) on the boom. Secure with six bolts (9) and six washers.

Stick Hose Install

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Illustration 70	g03682919

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Illustration 71	g03682923

1. Remove four bolts (21) and four washers. Remove stick shield (20) .

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Illustration 72	g03682924

2. Remove two bolts (23) and two washers. Remove access plate (22) .

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Illustration 73	g03682943

3. Remove two bolts (25) and two washers. Remove electrical junction box (24) .

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Illustration 74	g03682953

4. Route hose assembly (13) and hose assembly (14) to the stick. Remove two bolts (26) and washers from left hydraulic boom clamp (27).

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Illustration 75	g03682960

5. Install hose clamps (5) on the hose assemblies. Position plate (6) on original line clamp. Use one bolt (8) and one hard washer (7) to secure each hose clamp.

   Note: The right hose assembly (13) is bolted to the rear and the left hose assembly (14) is bolted to the front.

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Illustration 76	g03682970

6. Route the right hose assembly (13) through stick mount for the hydraulic cylinder. Route the left hose assembly (14) to the left side of the hydraulic mount.

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Illustration 77	g03682977

7. Remove two bolts (29) and washers from left hydraulic boom clamp (28) .

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Illustration 78	g03682981

8. Install hose clamps (5) on hose assemblies. Position block spacer (6) on the original line clamp. Use one bolt (8) and one hard washer (7) to secure each hose clamp.

   Note: The the right hose assembly (13) is bolted to the rear and the left hose assembly (14) is bolted to the front.

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Illustration 79	g03683432

9. Remove two bolts (30) and washers from center hydraulic boom clamp (31).

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Illustration 80	g03683439

10. Install hose clamps (5) on hose assemblies. Position block spacer (6) on the original line clamp. Use one bolt (8) and one hard washer (7) to secure each hose clamp.

    Note: The the right hose assembly is bolted to the rear and the left hose assembly is bolted to the front.

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Illustration 81	g03683447

11. Install 915 mm (ft) of hose guard (32) on rotate hose assembly (14) .

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Illustration 82	g03683452

12. Install 1 foot of hose guard (32) on left rotate hose assembly (14) fitted through the boom to the stick joint.

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

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NOTICE
Before carrying out arc welding on the machine or on any equipment attached to the machine, disconnect all power and ground leads from the batteries in order to avoid possible damage to electronic components.

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Illustration 83	g03683460

13. Move rear battery disconnect switch (33) and front battery disconnect switch (34) to the ON position.

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Illustration 84	g03683486

14. Measure 567 mm (22 inch) from stick weld. Place a centerline across the face of the stick.

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Illustration 85	g03683504

15. Secure bosses (36) to hose U (35) with bolts (37) and washers (38). Position hose U (35) on the centerline. Mark the placement of the bosses on the stick. Remove the bolts, washers and hose U. Weld bosses (36) in place on the face of the stick.

16. Position hose U (35). Install two bolts (37) and two hard washers (38). Clean, prep and paint the weld area.

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Illustration 86	g03683534

17. Radius grease nipple blocks (39). Paint grind area. Remove three grease nipples (40). Install three 90 degree nipples.

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Illustration 87	g03683551

18. Install coupler adapter (45) to rotate hose assemblies (13) and hose assembly (14) .

19. Install coupler adapter (45) to grapple hydraulic hard lines (43) .

20. Install coupler adapter (46) to case drain tube assembly (41), saw pressure supply tube assembly (43) and saw pressure return tube assembly (44) .

21. Install caps on all adapters and tube assemblies on stick.

22. Before proceeding to ""Head Install" ", go to ""Setup Validation - Pressure level" ".

Head Install

Table 4

Required Parts
Item	Qty	Part Number	Description
35	-	206-2727	Hose Guard

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Illustration 88	g03683581

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Illustration 89	g03683583

1. Remove stick triangle block (1). Grind to finish, paint to protect.

2. Clean stick end pin holes (2) .

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Illustration 90	g03683587

3. Install manufacture supplied bushings (3) into stick end pin holes (2). Use a suitable tool to install and set the bushings flush with outside of the stick.

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Illustration 91	g03683588

4. Remove one bolt (4) and one washer from lock plate (5). Remove the lock plate and bore pin (6). Remove both sets of lock plates and bore pins.

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Personal injury or death can result from lifting a heavy component. The heavy component can fall if using an incorrect hoist and/or sling or fastener to lift the load. Be sure the hoist and other devices have the correct lifting capacity to lift a heavy component. The approximate weight of the heavy component is given below.

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Illustration 92	g03683591

5. Use a suitable lifting device in order to position stick to head coupler (8) to stick (7). The weight of the stick to head coupler is approximately 131 kg (290 lb).

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Illustration 93	g03683592

6. Install manufacturer shims (9) between the stick and the head coupler as required.

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Illustration 94	g03683595

7. Install bore pin (6) in bore on right and left side. Install lock plate (5). Install washer and bolt (4) .

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Illustration 95	g03683596

8. Remove two bolts (10) and two washers. Remove swivel housing access plate (11) .

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Illustration 96	g03683597
(12) Fitting (grapple open) "O" (13) Fitting (tilt up/ saw return) "H" (14) Fitting (grapple close) "C" (15) Fitting (saw) "S"

9. Install and label fittings and caps in swivel connection housing.

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Illustration 97	g03683602

10. Use a suitable lifting device to position the head as illustrated. The weight of the head is approximately 671 kg (1480 lb).

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Illustration 98	g03683603

11. Remove one bolt (16) and one washer. Remove bore pin (17). Repeat this action on the other side of the coupler.

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Illustration 99	g03683604

12. Position the coupler to the head. Install bore pin (17) on each side. Install one bolt (16) and washer to secure the bore pin.

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Illustration 100	g03683607

13. Remove the cap from right fitting (19). Install the right rotate hose assembly to the right fitting. Remove the cap from the left fitting (18). Install the left rotate hose assembly to the left fitting.

14. Lay rotate hose assemblies aside.

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Illustration 101	g03683608

15. Remove the cap from "O" fitting (12). Install the right grapple hose assembly on the "O" fitting.

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Illustration 102	g03683610

16. Route right grapple hose assembly (20) through the hose U bracket. Remove the cap from right grapple stick tube assembly (21). Connect the right grapple hose assembly to the right grapple stick tube assembly.

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Illustration 103	g03683611

17. Remove the cap from "C" fitting (14). Install the left grapple hose assembly on the"C" fitting.

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Illustration 104	g03683612

18. Route left grapple hose assembly (22) through the hose U bracket. Remove the cap from left grapple stick tube assembly (23). Connect the left grapple hose assembly to the left grapple stick tube assembly.

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Illustration 105	g03683800

19. Remove the cap from "H" fitting (13). Install the saw return hose assembly to the"H" fitting.

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Illustration 106	g03683812

20. Route left saw return hose assembly (24) through the hose U bracket. Remove the cap from saw return tube assembly (25). Connect the saw return hose assembly to the saw return tube assembly.

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Illustration 107	g03683821

21. Remove the cap from "S" fitting (15). Install the saw pressure hose assembly on the"S" fitting.

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Illustration 108	g03683833

22. Route left saw pressure hose assembly (26) through the hose U bracket. Remove the cap from saw pressure tube assembly (27). Connect the saw pressure hose assembly to the saw pressure tube assembly.

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Illustration 109	g03683842

23. Remove the cap from case drain fitting (28). Install the case drain hose assembly on the case drain fitting.

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Illustration 110	g03683846

24. Route case drain hose assembly (29) through the hose U bracket. Remove the cap from case drain tube assembly (30). Connect the case drain hose assembly to the case drain tube assembly.

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Illustration 111	g03683852

25. Route right rotate stick hose assembly (31) through the hose U bracket. Remove the cap from right rotate stick hose assembly (32). Connect the right rotate stick hose assembly to the right rotate stick hose assembly.

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Illustration 112	g03683858

26. Route left rotate stick hose assembly (33) through the hose U bracket. Remove the cap from left rotate stick hose assembly (34). Connect the left rotate stick hose assembly to the left rotate stick hose assembly.

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Illustration 113	g03683865

27. Install 610 mm (24 inch) of hose guard (35) to bundle the hose assemblies as illustrated.

28. Ensure that the hydraulic oil tank is filled. Run the machine and check the hose assemblies and tube assemblies for leaks.

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Illustration 114	g03683885

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Illustration 115	g03683895

29. Position top boom cover (36). Secure with four bolts (37), eight washers and four nuts.

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Illustration 116	g03683905

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Illustration 117	g03683908

30. Position stick shield (38). Secure with four bolts (39) and four washers.

Screen Setup

1. Flash software on to Cat^® screen.

   Note: Contact the Caterpillar^® representative to confirm the latest application software for the head to machine installation.

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Illustration 118	g03683927

2. Start screen. Key identification.

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Illustration 119	g03870080

3. From the Home screen select "Menu" button (1) in order to go to the "Menu" screen.

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Illustration 120	g03870250

4. In the "Menu" screen select "F1" button (2) in order to go to the Adjust screen.

   Note: Step 5 through Step 16 cover the screen setup procedure for felling head settings. Step 18 through Step cover the screen setup procedure for operator settings.

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Illustration 121	g03870251

5. In the "Adjust" screen press down button (5) to select "VEHICLE DEFINITION" (3). Press "OK" button (4) in order to go to the "PIN code" screen. When prompted for a password, type "3598", then press the "OK" button.

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Illustration 122	g03870257

6. In the "VEHICLE DEFINITION" screen, press down button (5) in order to select "ENTER 0(FB) 1(IN) 2 (HP)" (6). Press "OK" button (4) .

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Illustration 123	g03870258

7. In the "ENTER 0(FB) 1(IN) 2 (HP)" screen, press up button (8). Change the "Actual value [State]" and "Value" to "2" (7). Press OK button (4). Press back button (11) in order to return to the "VEHICLE DEFINITION" screen.

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Illustration 124	g03870260

8. In the "VEHICLE DEFINITION" screen press down button (5) to select "WORK TOOL ATTACHMENT" (10). Press "OK" button (4) .

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Illustration 125	g03870261

9. In "WORK TOOL ATTACHMENT" press down button (5) to select "SATCO 420/630" (11). Press "OK" button (4). Press back button (9) in order to return to the "Adjust" screen.

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Illustration 126	g03870262

10. In the "Adjust" screen, press down button (5) to select "GRAB AND ACCUMULATE ADJUSTMENT" (12). Press "OK" button (4) in order to go to the "PIN code" screen. When prompted for a password, type "3598", then press the "OK" button.

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Illustration 127	g03870302

11. In the "GRAB AND ACCUMULATE ADJUSTMENT" screen press down button (5) to select "AUTO DUMP" (13). Press "OK" button (4) .

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Illustration 128	g03870301

12. In the "AUTO DUMP" screen press down button (5) to select "Disabled" (14). Press "OK" button (4). Press back button (11) in order to return to the "Adjust" screen.

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Illustration 129	g03870300

13. In the "Adjust" screen press down button (5) to select "JOYSTICK CALIBRATION 1" (15). Press "OK" button (4).

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Illustration 130	g03870299

14. In the "JOYSTICK CALIBRATION 1" screen press down button (5) to select "TOOL DWN/UP FUNCTION 1" (16). Press "OK" button (4) .

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Illustration 131	g03870298

15. In the "TOOL DWN/UP FUNCTION 1" screen press down button (5) to select "EMPTY" (17). Press "OK" button (4). Press back button (11) in order to return to the "Adjust" screen. If "JOYSTICK CALIBRATION 2" has been completed, proceed to Step 17.

16. Repeat Step 13 through Step 15, select "JOYSTICK CALIBRATION 2" instead of "JOYSTICK CALIBRATION 1". Follow the same procedure as "JOYSTICK CALIBRATION 1".

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Illustration 132	g03870300

17. In the "Adjust" screen press down button (5) to select "JOYSTICK CALIBRATION 1" (15). Press "OK" button (4).

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Illustration 133	g03870295

18. In the "JOYSTICK CALIBRATION 1" screen press down button (5) to select "GRAB CLOSE FUNCTION 1" (18). Press "OK" button (4) .

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Illustration 134	g03870294

19. In the "GRAB CLOSE FUNCTION 1" screen scroll using the up button (8) or down button (5) to select the desired joystick button or joystick axis (19) to operate "GRAB CLOSE FUNCTION 1". Press "OK" button (4) .

    Note: The operator may choose a selected operation to function on either the right or left joystick.

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Illustration 135	g03870292

20. In the "JOYSTICK CALIBRATION 1" screen press down button (5) to select "GRAB OPEN FUNCTION 1" (20). Press "OK" button (4) .

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Illustration 136	g03870290

21. In the "GRAB OPEN FUNCTION 1" screen scroll using the up button (8) or down button (5) to select the desired joystick button or joystick axis (19) to operate "GRAB OPEN FUNCTION 1". Press "OK" button (4) .

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Illustration 137	g03870288

22. In the "JOYSTICK CALIBRATION 1" screen press down button (5) to select "INT SAW CUT FUNCTION 1" (21). Press "OK" button (4) .

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Illustration 138	g03870287

23. In the "INT SAW CUT FUNCTION 1" screen scroll using the up button (8) or down button (5) to select the desired joystick button or joystick axis (19) to operate "INT SAW CUT FUNCTION 1". Press "OK" button (4) .

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Illustration 139	g03870285

24. In the "JOYSTICK CALIBRATION 1" screen press down button (5) to select "MAN RETN FUNCTION 1" (22). Press "OK" button (4) .

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Illustration 140	g03870284

25. In the "MAN RETN FUNCTION 1" screen scroll using the up button (8) or down button (5) to select the desired joystick button or joystick axis (19) to operate "MAN RETN FUNCTION 1". Press "OK" button (4) .

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Illustration 141	g03870282

26. In the "JOYSTICK CALIBRATION 1" screen press down button (5) to select "TILT (WRIST) CW FUNCTION 1" (23). Press "OK" button (4) .

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Illustration 142	g03870279

27. In the "TILT (WRIST) CW FUNCTION 1" screen scroll using the up button (8) or down button (5) to select the desired joystick button or joystick axis (19) to operate "TILT (WRIST) CW FUNCTION 1". Press "OK" button (4) .

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Illustration 143	g03870277

28. In the "JOYSTICK CALIBRATION 1" screen press down button (5) to select "TILT (WRIST) CWW FUNCTION 1" (24). Press "OK" button (4) .

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Illustration 144	g03870275

29. In the "TILT (WRIST) CWW FUNCTION 1" screen scroll using the up button (8) or down button (5) to select the desired joystick button or joystick axis (19) to operate "TILT (WRIST) CWW FUNCTION 1". Press "OK" button (4). Select "Menu" button (1) in order to go to the "Menu" screen.

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Illustration 145	g03870274

30. In the "Menu" screen scroll using the down button (5) to select the joystick icon (25) in the right column.

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Illustration 146	g03870271

31. Verify the "FUNCTION INPUT" screen (26) matches the operators desired joystick button and joystick axis locations.

    Note: Verify that each operator function is mapped to a unique button or joystick location.

Setup Validation

Illustration 147	g02571852

Table 5

Required Tools
Tool	Item	Qty	Part No	Description
A			198-4240	Digital Pressure Indicator Gp
	A1	1	198-4234	Digital Indicator
	A2	2	251-9600	Pressure Sensor Gp (0 to 70 000 kPa (0 to 10,000 psi))
	A3	2	198-4236	Adapter Cable As
B		1	351-8635	Tachometer Kit
C			9U-7839	STOPWATCH

Setup Validation - Pressure level

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Illustration 148	g03684082

1. Cap all hydraulic hoses at end of boom.

2. Check the hydraulic oil level and fill to the operation level.

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Illustration 149	g03684111

3. Install Tool (A) on manifold pressure tap (1) .

   Note: This tap location is used for the pressure test of the saw and tilt up functions.

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Illustration 150	g03684092

4. Inside the cab, use key switch (2) to start the engine. Check hydraulic hoses for leaks.

5. Operate the machine until the hydraulic oil temperature reaches 43 ± 6 °C (110 ± 10 °F).

6. Operate the saw with the joystick.

7. Use Tool (A) to read the pressure while the saw is operating. The pressure should be 35000 kPa (5076 psi). Shut off the engine. If the pressure is within the specified value, start the engine and go to Step 9. If the pressure is outside the specified value, go to Step 8.

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Illustration 151	g03684134

8. Remove the cap (3) on saw valve feed reducer on the machine manifold. Loosen the lock nut and adjust the adjustment screw, as required. Hold the adjustment screw in place and tighten the locknut. Start the engine. Go to Step 6.

   Note: The saw feed reducer is located as upper top adjustable nut and screw under a protective red cap.

9. Operate the tilt-up with the joystick.

10. Use Tool (A) to read the pressure while the tilt up is operating. The pressure should be 20000 kPa (2901 psi). Shut off the engine. If the pressure is within the specified value, start the engine and go to Step 15. If the pressure outside the specified value, start machine and go to Step 11.

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Illustration 152	g03684135

11. Remove the cap (4) on tilt valve (low flow) on the machine manifold. Loosen the lock nut and adjust the adjustment screw, as required. Hold the adjustment screw in place and tighten the locknut. Start the engine. Go to Step 10.

    Note: The tilt valve adjustment is located as the lower adjustable nut and screw under a protective red cap.

12. Operate the tilt-up with the joystick.

13. Use Tool (A) to read pressure while tilt up is operating. Shut off machine. If the pressure is within the specified value, go to Step 15.

14. Adjust tilt valve (high flow) on tilt manifold as required. Start the machine. Go to Step 12.

15. Install Tool (A) on manifold pressure tap, as illustrated.

16. Operate rotate clockwise with the joystick.

    Note: This tap location is used for the pressure test of the rotate clockwise / counterclockwise and grapple-open / close functions.

17. Use Tool (A) to read pressure while rotate clockwise is operating. Shut off machine. If the pressure is within the specified value, start machine and go to Step 19.

18. Adjust rotate clockwise valve "B" on machine manifold as required. Start machine. Go to Step 16.

19. Operate rotate counterclockwise with the joystick.

20. Use Tool (A) to read pressure while rotate counterclockwise is operating. Shut off machine. If the pressure is within the specified value, start the machine and, go to Step 22.

21. Adjust rotate counterclockwise valve "A" on machine manifold as required. Start machine. Go to Step 20.

22. Operate grapple open with the joystick.

23. Use Tool (A) to read pressure while grapple open is operating. Shut off the machine. If the pressure is within the specified value, start the machine and go to Step 25.

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Illustration 153	g03706146

24. Loosen lock nut (5). Turn adjustment screw (6) as required, to adjust grapple-open valve "B" on machine manifold. Hold the adjustment screw in place and tighten the lock nut. Start the machine and go to Step 23.

25. Operate grapple close with the joystick.

26. Use Tool (A) to read the pressure while grapple close is operating. Shut off the machine. If the pressure is within the specified value, start the machine and go to Step 28.

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Illustration 154	g03706157

27. Loosen lock nut (7). Turn adjustment screw (8), as required to adjust grapple-close valve "A" on machine manifold. Hold the adjustment screw in place and tighten the lock nut. Start the machine and go to Step 25.

28. Go to ""Head Install" ".

Validation - Time

Table 6

Validation Specifications
Action	Value
Saw Speed	4200 rpm
Tilt Up	1 Second
Rotate	3 - 4 Seconds
Grapple	1 Second

1. Clean saw motor surface. Attach reflective tape.

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Illustration 155	g03684092

2. Inside the cab, use key switch (2) to start the engine. Check hydraulic hoses for leaks.

3. Operate the machine until the hydraulic oil temperature reaches 43 ± 6 °C (110 ± 10 °F).

4. Operate the saw with the joystick.

5. Use Tool (B) to read rpm while saw is operating. If the saw speed is within the specified value, go to Step 7.

6. Adjust saw speed with screen setup procedures. Got to Step 4.

7. Operate the tilt-up with the joystick.

8. Use Tool (C) to read tilt up operation. If the tilt up speed is within the specified value, go to step 10.

9. Adjust tilt up speed with screen setup procedures. Got to Step 7.

   Note: The rotate time test is done with both clockwise and counterclockwise rotation. The steps are identical for both time tests.

10. Operate the rotate with the joystick.

11. Use Tool (C) to read rotate speed. If the rotate speed is within the specified value, go to step 14.

12. Adjust rotate speed with screen setup procedures. Got to Step 11.

    Note: The grapple time test is done with both open and close operation. The steps are identical for both time tests.

13. Operate the grapple with the joystick.

14. Use Tool (C) in order to record the speed of the grapple. If the speed of the grapple is outside the specified value, go to Step 15.

15. Adjust grapple speed with screen setup procedures. Go to Step 13.

16. Installation of the processor head is now complete.