Instructions for Installing HH55/HH65 Harvester Heads on 320B Excavators{6320} Caterpillar

Excavators:

320B (PIN: 5BR; 4XW)

320B L (PIN: 6CR; 1ES; 5GW)

320B LL (PIN: 6LS)

320B FM (PIN: 9JS)

Harvester Heads:

HH55 (PIN: 3MZ)

HH65 (PIN: 4RZ)

Introduction

Illustration 1	g00327383

This Special Instruction provides the necessary guidelines for installation of a HH55 or HH65 Harvester Head onto a 320B Excavator.

Do not perform any procedure that is outlined in this publication until you understand the information that is contained in this document. Perform all steps in the order that they appear in the manual.

Note: The 135-4167 Adapter Arrangement is a recommended optional attachment for the excavator. The arrangement is not part of the kit. The arrangement extends the reach of the boom. The arrangement also increases the visibility from the cab.

Preparation of the Machine

1. Clean the machine. Cleaning the machine will help to prevent dirt from entering the hydraulic system when hydraulic components are being installed.

2. Start the machine. Fully extend the stick. Lower the attachment to the ground.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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At operating temperature, the hydraulic oil is hot and under pressure. Hot oils can cause burns. To prevent possible personal injury, release the pressure in the implement hydraulic circuit (boom, stick, bucket, and swing), travel circuits, and the hydraulic oil tank at the filler cap before any hydraulic lines or components are disconnected or removed. Remove the filler cap only when the engine is stopped and the filler cap is cool enough to touch.

3. If your machine is equipped with an attachment, the attachment must be removed. Start the machine. Lower the attachment to the ground. Remove the attachment.

   Reference: For more information on removing the attachment, refer to the Service Manual module Disassembly and Assembly for the machine that is being serviced.

4. Release the oil pressure in all of the implement circuits (the boom, the stick and the attachment) before any of the hydraulic lines or any of the components are disconnected or removed. Release the pressure as follows:

   1. Shut off the engine and place key in the "ON" position. Put the hydraulic activation control lever in the "UNLOCK" position.

   2. Move the implement joystick controls through the full range of movement. This will release any pressure that might be present in the pilot system.

   3. Return the key to "OFF" position.

   4. Slowly loosen the fill plug on the hydraulic oil tank in order to release the pressure in the tank.

   5. Reinstall the fill plug on the hydraulic tank. Tighten the fill plug to 68 ± 7 N·m (50 ± 5 lb ft).

   6. The pressure in the hydraulic system has been released and the hydraulic oil lines and the components can be removed.

5. Drain the oil from the hydraulic oil tank in a suitable container for storage or disposal. The capacity of the hydraulic oil tank is 130 L (34 US gal).

Installation of 135-4167 Adapter Arrangement

Note: The 135-4167 Adapter Arrangement is a recommended optional attachment for the excavator. The arrangement is not part of the kit for installing the harvester head. The arrangement increases the height of reach of the boom. The arrangement also increases the visibility from the cab.

The 135-4167 Adapter Arrangement consists of a 135-4168 Boom Cylinder Adapter Group and a 135-4179 Front Lines Group .

Table 1

Parts Needed to Install 135-4168 Boom Cylinder Adapter Group
Qty	Part No.	Description
2	4I-4812	Pin Assembly
2	8T-4123	Hard Washer
6	8T-4223	Hard Washer
2	8T-4780	Bolt
6	8T-4956	Bolt
4 (1)	093-0083	Shim
2 (1)	093-0115	Shim
2	093-0349	Washer
2	093-0363	Spacer
2 (1)	133-2425	Shim
1	135-4169	Adapter Assembly
1	135-4170	Adapter Assembly
2	135-4177	Pin
2	135-4178	Plate

( 1 )

Use as required.

Table 2

Parts Needed to Install 135-4179 Front Lines Group
Qty	Part No.	Description
4	4I-3820	Hose Assembly
4	6V-9746	O-Ring Seal

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Illustration 2	g00525485
Right Boom Cylinder (1) Boom cylinder. (2) Retaining bolt. (3) Pin assembly. (4) Hose assemblies .

1. Fasten a lifting sling and a hoist to the right hand boom cylinder (1). Put slight lifting tension on right hand boom cylinder (1) .

2. Disconnect hose assemblies (4) from the right boom cylinder. Oil will drain from the hose assemblies. Drain the oil into a suitable container for disposal.

3. Put plugs in the ends of the hose assemblies to prevent oil loss and to keep contaminants out of the hydraulic system.

4. Remove retaining bolt (2) and the washer. Remove pin assembly (3) and the spacer. Lift right hand boom cylinder (1) away from the frame. The weight of the boom cylinder is 170 kg (375 lb).

   Note: Machines may be equipped with shim(s) between the boom cylinders and the frame at the boom cylinder-to-frame pin joint. For assembly purposes, put identification marks on the shim(s) in order to identify their location.

5. Remove the shim(s) (if so equipped) at the boom cylinder-to-frame pin joint.

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Illustration 3	g00525513
(5) 135-4169 Adapter Assembly (6) 135-4170 Adapter Assembly (7) 135-4177 Pin (8) 093-0349 Washer (9) 8T-4123 Hard Washer (10) 8T-4780 Bolt (11) 4I-4812 Pin Assembly (12) 093-0363 Spacer (13) 135-4178 Plate (14) 8T-4956 Bolt (15) 8T-4223 Hard Washer (16) 093-0083 Shim (17) 093-0115 Shim (18) 133-2425 Shim

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Illustration 4	g00534117
Right Boom Cylinder Adapter (2) Retaining bolt (3) Pin assembly (6) 135-4170 Adapter Assembly (7) 135-4177 Pin (13) 135-4178 Plate

6. Install 135-4170 Adapter Assembly (6) as shown in Illustration 4.

7. Install 135-4177 Pin (7) and 135-4178 Plate (13) with three 8T-4956 Bolts (14) and three 8T-4223 Hard Washers (15) .

   Note: Coat all bores for the pins with 5P-0960 Molybdenum Grease .

8. Install pin assembly (3) and spacer with retaining bolt (2) that was removed in Step 4.

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Illustration 5	g00534118
Right Boom Cylinder Adapter (1) Boom cylinder (10) 8T-4780 Bolt (11) 4I-4812 Pin (12) 093-0363 Spacer

9. Make sure that the pin bores in the boom cylinders, the boom, and the adapter are clean and free of dirt prior to installation of the boom cylinders.

10. Fasten lifting slings and a hoist to right hand boom cylinder (1), and put it in position in the adapter. Make sure that the pin bores in the boom cylinder and the adapter are in alignment with each other.

11. Apply 5P-0960 Molybdenum Grease on 4I-4812 Pin (11) that holds the right boom cylinder to the adapter. Temporarily install 093-0363 Spacer (12) and 4I-4812 Pin (11). Do not remove the hoist from the right boom cylinder at this time.

12. Slide the right boom cylinder to one side until it makes contact with the adapter. Measure the clearance between the right boom cylinder and the adapter at the pin bore. The total clearance must be less than 1 mm (.04 inch).

13. If the total clearance is more than 1 mm (.04 inch), perform Step 14. If total clearance is less than 1 mm (.04 inch), the addition of shim is not necessary. Do not perform Step 14.

14. In order to install the shims, remove 4I-4812 Pin (11). Install the 093-0083, 093-0115, and 133-2425 shims as necessary between the right boom cylinder and the adapter on the same side as bolt (10). Then, reinstall spacer (12) and pin (11). Install 8T-4780 Bolt (10) with 093-0349 Washer (8) and 8T-4123 Hard Washer (9). Tighten bolt (10) to 325 ± 40 N·m (240 ± 30 lb ft).

15. Repeat Steps 1 through 14 to install 135-4169 Adapter Assembly (5) onto the left boom cylinder.

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Illustration 6	g00535582
(19) 4I-3820 Hose Assemblies .

16. Replace the four hose assemblies (4) with four 4I-3820 Hose Assemblies and four 6V-9746 O-Ring Seals . Tighten the hose assemblies to 150 ± 15 N·m (110 ± 11 lb ft).

Installation of 158-7515 Boom Control Arrangement

158-7554 Boom Lines Group (Long Boom)

Table 3

Parts Needed to Install 158-7554 Boom Lines Group
Qty	Part No.	Description
2	1P-3704	Rectangular Seal
2	1P-3705	Rectangular Seal
4	1P-5767	Half Flange
2	5P-0048	Cover
16	7I-8640	Half Clamp
12	7X-2554	Bolt
12	7X-2555	Bolt
8	8T-4184	Bolt
8	8T-4194	Bolt
16	8T-4223	Hard Washer
8	8T-7338	Bolt
32	9X-8257	Washer
1	116-9189	Tube Assembly
6	121-1677	Plate
6	121-1946	Plate
2	127-6816	Plate
1	146-6495	Tube Assembly
1	146-6496	Tube Assembly
1	146-6497	Tube Assembly

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Illustration 7	g00526799
158-7554 Boom Lines Group (1) 146-6497 Tube Assembly (2) 1P-3705 Rectangular Seal (3) 8T-4223 Hard Washer (4) 8T-4184 Bolt (5) 146-6495 Tube Assembly (6) 5P-0048 Cover (7) 1P-3704 Rectangular Seal (8) 8T-4194 Bolt (9) 1P-5767 Half Flange (10) 116-9189 Tube Assembly (11) 146-6496 Tube Assembly (12) 7I-8640 Half Clamp (13) 9X-8257 Washer (14) 7X-2554 Bolt (15) 8T-7338 Bolt (16) 127-6816 Plate (17) 121-1677 Plate (18) 7X-2555 Bolt (19) 121-1946 Plate

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Illustration 8	g00526998
View B-B (12) 7I-8640 Half Clamp . (15) 8T-7338 Bolt . (16) 127-6816 Plate .

1. Install 127-6816 Plates (16) with two 8T-7338 Bolts (15) and two 9X-8257 Washers . Install two 7I-8640 Half Clamps (12) onto plate (16) with two 8T-7338 Bolts and two 9X-8257 Washers .

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Illustration 9	g00527009
View A-A (Near the Stick Cylinder) (12) 7I-8640 Half Clamps . (17) 121-1677 Plate . (19) 121-1946 Plate .

2. Install 121-1946 Plate (19) with two 7X-2554 Bolts and two 9X-8257 Washers . Install 121-1677 Plate (17) and two 7I-8640 Half Clamps (12) onto plate (19) with two 7X-2555 Bolts and two 9X-8257 Washers .

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Illustration 10	g00527037
View A-A (Near the Boom Cylinder Pivot) (12) 7I-8640 Half Clamps . (17) 121-1677 Plate . (19) 121-1946 Plate .

3. Install 121-1946 Plate (19) with two 7X-2554 Bolts and two 9X-8257 Washers . Install 121-1677 Plate (17) and two 7I-8640 Half Clamps (12) onto plate (19) with two 7X-2555 Bolts and two 9X-8257 Washers .

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Illustration 11	g00527079
View A-A (Near End of the Boom) (12) 7I-8640 Half Clamps . (17) 121-1677 Plate . (19) 121-1946 Plate .

4. Install 121-1946 Plate (19) with two 7X-2554 Bolts and two 9X-8257 Washers . Install 121-1677 Plate (17) and two 7I-8640 Half Clamps (12) onto plate (19) with two 7X-2555 Bolts and two 9X-8257 Washers .

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Illustration 12	g00527081
Right Side of the Boom (10) 116-9189 Tube Assembly . (12) 7I-8640 Half Clamps .

5. Position 116-9189 Tube Assembly (10) into 7I-8640 Half Clamps (12) and tighten the bolts.

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Illustration 13	g00527083
Left Side of the Boom (1) 146-6497 Tube Assembly . (12) 7I-8640 Half Clamps .

6. Position 146-6497 Tube Assembly (1) into 7I-8640 Half Clamps (12) and tighten the bolts.

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Illustration 14	g00527088
Right Side of the Boom (9) 1P-5767 Flanges (10) 116-9189 Tube Assembly (11) 146-6496 Tube Assembly (12) 7I-8640 Half Clamps

7. Attach 146-6496 Tube Assembly (11) onto 116-9189 Tube (10) with a 1P-3705 Rectangular Seal , four 8T-4184 Bolts , and four 8T-4223 Hard Washers . Position tube assembly (11) into half clamps (12) and tighten the bolts.

8. Install two 1P-5767 Half Flanges (9) onto tube (11) with a 1P-3704 Rectangular Seal , one 5P-0048 Cover , four 8T-4194 Bolts , and four 8T-4223 Hard Washers .

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Illustration 15	g00527096
Left Side of the Boom (1) 146-6497 Tube Assembly (5) 146-6495 Tube Assembly (9) 1P-5767 Flanges (12) 7I-8640 Half Clamps

9. Attach 146-6495 Tube Assembly (5) onto 146-6497 Tube Assembly (1) with a 1P-3705 Rectangular Seal , four 8T-4184 Bolts , and four 8T-4223 Hard Washers . Position tube assembly (5) into half clamps (12) and tighten the bolts.

10. Install two 1P-5767 Flanges (9) onto tube assembly (5) with one 1P-3704 Rectangular Seal , one 5P-0048 Cover , four 8T-4194 Bolts , and four 8T-4223 Hard Washers .

158-7508 Drain Lines Group

Table 4

Parts Needed to Install 158-7508 Drain Lines Group
Qty	Part No.	Description
10	2V-0216	Half Clip
2	3D-2824	O-Ring Seal
1	6S-5693	Swivel Tee
1	6V-8637	Seal Connector
4	6V-9746	O-Ring Seal
8	7Y-4531	Half Clamp
1	8M-0547	Elbow
4	8T-4121	Hard Washer
2	8T-4136	Bolt
2	8T-4139	Bolt
2	8T-4195	Bolt
22	8T-4223	Hard Washer
18	8T-4956	Bolt
1	030-8189	Flared Connector
1	126-2075	Filter Group
1	130-5279	Hose Assembly
1	132-8572	Hose Assembly
1	159-8081	Tube Assembly
1	159-8082	Tube Assembly
1	159-8083	Tube Assembly
4	159-8084	Plate Assembly
1	159-8086	Angle Assembly
1	160-0191	Bracket

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Illustration 16	g00528308
Top View and Side View of the 158-7508 Drain Lines Group

Note: Do not tighten the half clips that hold the drain lines until Step 12 has been completed.

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Illustration 17	g00394158
View H-H (1) 2V-0216 Half Clips (2) 159-8083 Tube Assembly (3) 159-8084 Plate Assembly (4) 7Y-4531 Half Clamps (5) Tube assembly

1. Install two 7Y-4531 Half Clamps (4) onto tube assembly (5) with one 159-8084 Plate Assembly (3), two 8T-4956 Bolts , and two 8T-4223 Hard Washers .

2. Install 159-8083 Tube Assembly (2) onto plate assembly (3) with two 2V-0216 Half Clips (1), two 8T-4956 Bolts , and two 8T-4223 Hard Washers .

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Illustration 18	g00394638
View G-G (2) 159-8083 Tube Assembly (6) 2V-0216 Half Clips (7) 8T-4956 Bolts (8) 159-8082 Tube Assembly (9) 159-8086 Angle Assembly

3. Install 159-8086 Angle Assembly (9) with two 8T-4956 Bolts (7) and two 8T-4223 Hard Washers on the top and the bottom of 159-8086 Angle Assembly (9) .

4. Connect 159-8082 Tube Assembly (8) to 159-8083 Tube Assembly (2) with two 6V-9746 O-Ring Seals .

5. Attach 159-8082 Tube Assembly (8) onto 159-8086 Angle Assembly (9) with two 2V-0216 Half Clips (6), two 8T-4139 Bolts , and two 8T-4223 Hard Washers .

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Illustration 19	g00398938
View F-F (8) 159-8082 Tube Assembly (10) 159-8081 Tube Assembly (11) 2V-0216 Half Clips (12) 159-8084 Plate Assembly (13) 7Y-4531 Half Clamps (14) Tube assembly

6. Install two 7Y-4531 Half Clamps (13) onto tube assembly (14) with one 159-8084 Plate Assembly (12), two 8T-4956 Bolts , and two 8T-4223 Hard Washers .

7. Install two 2V-0216 Half Clips (11) onto 159-8082 Tube Assembly (8). Then attach the 2V-0216 Half Clips to the 159-8084 Plate Assembly with two 8T-4956 Bolts and two 8T-4223 Hard Washers . Attach 159-8081 Tube Assembly (10) to 159-8082 Tube Assembly (8) .

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Illustration 20	g00399578
View E-E (10) 159-8081 Tube Assembly (14) Tube assembly (15) 2V-0216 Half Clips (16) 159-8084 Plate Assembly (17) 7Y-4531 Half Clamps

8. Install two 7Y-4531 Half Clamps (17) onto tube assembly (14) with one 159-8084 Plate Assembly (16), two 8T-4956 Bolts , and two 8T-4223 Hard Washers .

9. Install two 2V-0216 Half Clips (15) onto 159-8081 Tube Assembly (10). Then attach the 2V-0216 Half Clips to 159-8084 Plate Assembly (16) with two 8T-4956 Bolts and two 8T-4223 Hard Washers .

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Illustration 21	g00399718
View D-D (10) 159-8081 Tube Assembly (14) Tube assembly (18) 132-8572 Hose (19) 2V-0216 Half Clips (20) 159-8084 Plate Assembly (21) 7Y-4531 Half Clamps

10. Install two 7Y-4531 Half Clamps (21) onto tube assembly (14) with one 159-8084 Plate Assembly (20), two 8T-4956 Bolts , and two 8T-4223 Hard Washers .

11. Install two 2V-0216 Half Clips (19) onto 159-8081 Tube Assembly (10). Then attach the 2V-0216 Half Clips to the 159-8084 Plate Assembly with two 8T-4956 Bolts and two 8T-4223 Hard Washers .

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Illustration 22	g00539830
Detail C (10) 159-8081 Tube Assembly (18) 132-8572 Hose (A) 60 ± 3 mm (2.36 ± .12 inch) to end of tube

12. Connect 132-8572 Hose (18) with one 6V-9746 O-Ring Seal to 159-8081 Tube Assembly (10) according to dimension (A) .

13. Tighten the bolts for all of the half clamps.

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Illustration 23	g00399918
View B-B (18) 132-8572 Hose (22) 160-0191 Bracket (23) 8T-4136 Bolt (24) 126-2075 Filter Group (25) 8T-4195 Bolt

14. Install 160-0191 Bracket (22) with two 8T-4195 Bolts (25) and two 8T-4121 Hard Washers . Install 126-2075 Filter Group (24) onto 160-0191 Bracket (22) with two 8T-4136 Bolts (23) and two 8T-4121 Hard Washers .

15. Attach 132-8572 Hose (18) to 126-2075 Filter Group (24) with one 6V-8637 Seal Connector , one 3D-2824 O-Ring Seal , and one 6V-9746 O-Ring Seal .

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Illustration 24	g00400058
View A (24) 126-2075 Hydraulic Filter . (26) 130-5279 Hose .

16. Connect 130-5279 Hose (26) to 126-2075 Filter Group (24) with one 030-8189 Flared Connector and one 3D-2824 O-Ring Seal .

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Illustration 25	g00400067
(26) 130-5279 Hose . (27) 8M-0547 Elbow . (28) 6S-5693 Tee .

17. Connect the other end of 130-5279 Hose (26) to the hydraulic tank with one 8M-0547 Elbow (27) and one 6S-5693 Tee (28) .

158-7506 Stick Lines Group

Table 5

Parts Needed to Install 158-7506 Stick Lines Group
Qty	Part No.	Description
4	1P-3704	Rectangular Seal
8	1P-5767	Half Flange
12	2V-0216	Half Clip
4	6V-8398	O-Ring Seal
2	6V-8556	ORFS Nut
2	6V-8942	O-Ring Reducer
4	6V-9746	O-Ring Seal
8	7Y-4038	Half Clamp
18	8T-4184	Bolt
8	8T-4192	Bolt
42	8T-4223	Hard Washer
16	8T-4956	Bolt
2	158-7513	Hose Assembly
2	158-7531	Tube Assembly
1	158-7532	Tube Assembly
1	158-7533	Tube Assembly
1	158-7534	Tube Assembly
1	158-7536	Bar
2	158-7537	Bar
3	158-7538	Bar
2	158-7539	Bar
1	158-7540	Bar
3	158-7545	Spacer
1	158-7546	Spacer
1	158-7551	Guard
2	161-0533	Hose Assembly
1	161-0534	Hose Assembly

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

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Illustration 26	g00539893
Boom Position for Installing 158-7506 Stick Lines Group

1. The 158-7506 Stick Lines Group is installed on the bottom of the stick. Place the stick into a position that will be easily accessible. Install two jack stands on either side of the stick pivot joint to prevent the boom from lowering. Refer to Illustration 1.

2. Clean the surface of the area to be welded so that it is free from oil, grease, paint, rust, or scale. These materials displace hydrogen gas when in contact with intense heat. The gas causes weld porosity and weld deposit cracking.

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Illustration 27	g00527305
Bottom View of the Stick

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Illustration 28	g00419158
(A) 874.3 ± 2 mm (34.42 ± .08 inch) (B) 236.8 ± 2 mm (9.33 ± .08 inch) (C) 445.2 ± 2 mm (17.5 ± .08 inch) (D) 269 ± 1 mm (10.60 ± .04 inch) (E) 196.6 ± 2 mm (7.74 ± .08 inch) (F) 80 ± 2 mm (3.15 ± .08 inch) (G) 45° (H) 20° (I) 262 ± 2 mm (10.31 ± .08 inch) (J) 48.7 ± 2 mm (1.92 ± .08 inch) (K) 28.6 ± 2 mm (1.13 ± .08 inch) (L) 56.8 ± 2 mm (2.24 ± .08 inch) (M) 180.4 ± 2 mm (7.10 ± .08 inch) (N) 147 ± 2 mm (5.79 ± .08 inch) (O) 16 ± 2 mm (0.63 ± .08 inch) (P) 269 ± 1 mm (10.60 ± .04 inch) (Q) 1485 ± 3 mm (58.46 ± .12 inch) (R) 1602 ± 3 mm (63.07 ± .12 inch)

3. Position the bars onto the stick according to the dimensions specified in Illustration 28. Weld the long sides of each bar with a 6 mm (.24 inch) fillet weld. Refer to Table 6 for suitable welding rods.
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   Table 6

   Suitable Welding Rods
   Rod Diameter	Part Numbers
   3.2 mm (1/8 inch)	1U-5232 or 9U-6645
   4.0 mm (5/32 inch)	1U-5233 or 9U-6646
   4.8 mm (3/16 inch)	1U-5234 or 9U-6647
   5.6 mm (7/32 inch)	1U-5235 or 9U-6648
   6.4 mm (1/4 inch)	1U-5236 or 9U-6649

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Illustration 29	g00534211
Bottom View of the Stick (1) 158-7534 Tube Assembly . (2) 158-7533 Tube Assembly .

4. Position 158-7534 Tube Assembly (1) and 158-7533 Tube Assembly (2) onto the bottom of the stick.

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Illustration 30	g00539938
View A-A (1) 158-7534 Tube Assembly (3) 8T-4223 Hard Washers (4) 8T-4956 Bolts (5) 158-7539 Bar (6) 7Y-4038 Half Clamps

5. Clamp 158-7534 Tube Assembly (1) to 158-7539 Bar (5) with two 7Y-4038 Half Clamps (6), two 8T-4956 Bolts , and two 8T-4223 Hard Washers .

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Illustration 31	g00539939
View B-B (2) 158-7533 Tube Assembly (3) 8T-4223 Hard Washers (4) 8T-4956 Bolts (5) 158-7539 Bar (6) 7Y-4038 Half Clamps

6. Clamp 158-7533 Tube Assembly (2) to 158-7539 Bar (5) with two 7Y-4038 Half Clamps (6), two 8T-4956 Bolts (4), and two 8T-4223 Hard Washers (3) .

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Illustration 32	g00539940
View C-C (1) 158-7534 Tube Assembly (2) 158-7533 Tube Assembly (3) 8T-4223 Hard Washers (4) 8T-4956 Bolts (6) 7Y-4038 Half Clamps (7) 158-7540 Bar

7. Clamp 158-7534 Tube Assembly (1) and 158-7533 Tube Assembly (2) onto 158-7540 Bar (7) with four 7Y-4038 Half Clamps (6), four 8T-4956 Bolts , and four 8T-4223 Washers .

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Illustration 33	g00534212
Side View and Bottom View of the Stick (8) 158-7532 Tube Assembly (9) 158-7531 Tube Assembly

8. Position 158-7532 Tube Assembly (8) and 158-7531 Tube Assembly () on the stick.

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Illustration 34	g00539944
View D-D (3) 8T-4223 Hard Washers (8) 158-7532 Tube Assembly (9) 158-7531 Tube Assembly (10) 158-7537 Bar (11) 2V-0216 Half Clips (12) 158-7545 Spacer (13) 8T-4184 Bolt

9. Attach tube assembly (8) and tube assembly (9) to 158-7537 Bar (10) with one 158-7545 Spacer (12), four 2V-0216 Half Clips (11), four 8T-4184 Bolts (13), and four 8T-4223 Hard Washers (3) .

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Illustration 35	g00539946
(3) 8T-4223 Hard Washers (4) 8T-4956 Bolts (8) 158-7532 Tube Assembly (9) 158-7531 Tube Assembly (11) 2V-0216 Half Clips (14) 158-7536 Bar (15) 158-7546 Spacer

10. Attach tube assembly (8) and tube assembly (9) to 158-7536 Bar (14) with one 158-7546 Spacer (15), four 2V-0216 Half Clips (11), four 8T-4956 Bolts (4), and four 8T-4223 Hard Washers (3) .

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Illustration 36	g00539947
(3) 8T-4223 Hard Washers (4) 8T-4956 Bolts (8) 158-7532 Tube Assembly (9) 158-7531 Tube Assembly (10) 158-7537 Bar (11) 2V-0216 Half Clips (12) 158-7545 Spacer

11. Install 158-7531 Tube Assembly (9). Attach tube assembly (9) to 158-7537 Bar (10) with one 158-7545 Spacer (12), two 2V-0216 Half Clips (11), two 8T-4956 Bolts (4), and two 8T-4223 Hard Washers (3) .

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Illustration 37	g00539948
(3) 8T-4223 Hard Washers (4) 8T-4956 Bolts (9) 158-7531 Tube Assembly (11) 2V-0216 Half Clips (12) 158-7545 Spacer (16) 158-7538 Bar

12. Attach tube assembly (9) to 158-7538 Bar (16) with one 158-7545 Spacer (12), two 2V-0216 Half Clips (11), two 8T-4956 Bolts (4), and two 8T-4223 Hard Washers (3) .

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Illustration 38	g00527349
(3) 8T-4223 Hard Washers (17) 8T-4192 Bolts (18) 158-7551 Guard

13. Install 158-7551 Guard (18) with eight 8T-4192 Bolts (17) and eight 8T-4223 Hard Washers (3) .

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Illustration 39	g00527357
Right Side of the Boom and the Stick (1) 158-7534 Tube Assembly (3) 8T-4223 Hard Washers (8) 158-7532 Tube Assembly (9) 158-7531 Tube Assembly (13) 8T-4184 Bolts (19) 159-8083 Tube Assembly (20) Tube assembly (21) 161-0534 Hose Assembly (22) 158-7513 Hose Assembly (23) 146-6496 Tube (24) 161-0533 Hose Assembly (25) 1P-3704 Rectangular Seal (26) 1P-5767 Half Flanges

14. Install 161-0534 Hose Assembly (21) to 158-7532 Tube Assembly (8) with one 6V-9746 O-Ring Seal . Connect the opposite end of the hose assembly (21) to 159-8083 Tube Assembly (19) with one 6V-9746 O-Ring Seal .

15. Install 161-0533 Hose Assembly (24) to 158-7532 Tube Assembly (9) with one 6V-8398 O-Ring Seal . Connect the opposite end of 161-0533 Hose Assembly (24) to tube assembly (20) with one 6V-8398 O-Ring Seal , one 6V-8942 O-Ring Reducer , one 6V-8556 Nut , and one 6V-9746 O-Ring Seal .

16. Install 158-7513 Hose Assembly (22) to 158-7534 Tube Assembly (1) with one 1P-3704 Rectangular Seal (25), two 1P-5767 Half Flanges (26), four 8T-4184 Bolts (13), and four 8T-4223 Washers (3) .

17. Connect the opposite end of hose assembly (22) to 146-6496 Tube (23) with one 1P-3704 Rectangular Seal (25), two 1P-5767 Half Flanges (26), four 8T-4184 Bolts (13), and four 8T-4223 Washers (3) .

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Illustration 40	g00527367
Left Side of the Boom and the Stick (2) 158-7533 Tube Assembly (3) 8T-4223 Washers (9) 158-7531 Tube Assembly (13) 8T-4184 Bolts (22) 158-7513 Hose Assembly (25) 1P-3704 Rectangular Seal (26) 1P-5767 Half Flanges (27) Tube assembly (28) 146-6495 Tube (29) 161-0533 Hose Assembly

18. Install 161-0533 Hose Assembly (29) to 158-7531 Tube Assembly (9) with one 6V-8398 O-Ring Seal . Connect the opposite end of hose assembly (29) to tube assembly (27) with one 6V-8398 O-Ring Seal , one 6V-8942 O-Ring Reducer , one 6V-8556 Nut , and one 6V-9746 O-Ring Seal .

19. Install 158-7513 Hose Assembly (22) to 158-7533 Tube Assembly (2) with one 1P-3704 Rectangular Seal (25), two 1P-5767 Half Flanges (26), four 8T-4184 Bolts (13), and four 8T-4223 Washers (3) .

20. Connect the opposite end of hose assembly (22) to 146-6495 Tube (28) with one 1P-3704 Rectangular Seal (25), two 1P-5767 Half Flanges (26), four 8T-4184 Bolts (13), and four 8T-4223 Washers (3) .

158-7510 Front Lines Group

Table 7

Parts Needed to Install 158-7510 Front Line Group
Qty	Part No.	Description
1	1P-3703	Rectangular Seal
4	1P-3704	Rectangular Seal
2	1P-4578	Half Flange
6	1P-5767	Half Flange
1	2Q-4560	Adapter
1	3J-1907	O-Ring Seal
1	4J-0522	O-Ring Seal
2	5K-9090	O-Ring Seal
1	6C-6699	Block
4	6V-8200	Bolt
1	6V-8397	O-Ring Seal
2	6V-8400	O-Ring Seal
2	6V-8635	Seal Connector
1	6V-8636	Seal Connector
1	6V-9855	Elbow
4	7M-8485	O-Ring Seal
4	8T-4121	Hard Washer
4	8T-4183	Bolt
4	8T-4184	Bolt
8	8T-4194	Bolt
4	8T-4196	Bolt
20	8T-4223	Hard Washer
4	8T-4956	Bolt
1	8T-7927	Connector
1	9S-4181	Plug
4	9X-6032	Bolt
1	116-3600	Pilot Relief Valve
1	119-2620	Plate
1	119-2621	Plate
1	119-2629	Tube Assembly
1	129-5995	Block
1	146-6499	Hose Assembly
1	158-7513	Hose Assembly
1	158-7514	Hose Assembly

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Illustration 41	g00527508
158-7510 Front Lines Group (1) 6V-8400 O-Ring Seal (2) 6V-9855 Elbow (3) 7M-8485 O-Ring Seal (4) 8T-7927 Connector (5) 158-7514 Hose Assembly (6) 119-2629 Tube Assembly (7) 129-5995 Block (8) 146-6499 Hose Assembly (9) 8T-4194 Bolt (10) 8T-4223 Hard Washer (11) 1P-5767 Half Flange (12) 1P-3704 Rectangular Seal (13) 6V-8397 O-Ring Seal (14) 3J-1907 O-Ring Seal (15) 6V-8636 Connector (16) 6C-6699 Block (17) 8T-4184 Bolt (18) 158-7513 Hose Assembly (19) 116-3600 Pilot Relief Valve (20) 9X-6032 Bolt (21) 1P-3703 Rectangular Seal (22) 8T-4121 Hard Washer (23) 8T-4196 Bolt (24) 1P-4578 Half Flange (25) 6V-8200 Bolt (26) 4J-0522 O-Ring Seal (27) 2Q-4560 Adapter (28) 9S-4181 Straight Thread Plug (29) 119-2621 Plate

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Illustration 42	g00527577
View B-B and View C-C of 158-7510 Front Lines Group (30) 5K-9090 O-Ring Seal (31) 6V-8635 Seal Connector (32) 8T-4956 Bolt (33) 8T-4183 Bolt (34) 119-2620 Plate

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Illustration 43	g00527853
View B-B (7) 129-5995 Block (31) 6V-8635 Seal Connector (32) 8T-4956 Bolt (33) 8T-4183 Bolts (34) 119-2620 Plate

1. Install 119-2620 Plate (34) with two 8T-4183 Bolts (33) and two 8T-4223 Washers .

2. Install 129-5995 Block (7) onto plate (34) with two 8T-4956 Bolts (32) and two 8T-4223 Washers .

3. Install 6V-8635 Seal Connectors (31) onto each end of block (7) with a 7M-8485 O-Ring Seal .

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Illustration 44	g00527854
Left Side of the Boom (8) 146-6499 Hose Assembly (11) 1P-5767 Half Flange (31) 6V-8635 Seal Connector (35) 146-6497 Tube Assembly

4. Attach one end of 146-6499 Hose Assembly (8) with one 5K-9090 O-Ring Seal to 6V-8635 Seal Connector (31). Tighten the hose assembly to 190 ± 20 N·m (140 ± 15 lb ft).

5. Attach the other end of hose assembly (8) to 146-6497 Tube Assembly (35) with a 1P-3704 Rectangular Seal , two 1P-5767 Half Flanges (11), four 8T-4194 Bolts , and four 8T-4223 Hard Washers .

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Illustration 45	g00527856
(6) 119-2629 Tube Assembly (7) 129-5995 Block (20) 9X-6032 Bolts

6. Install 119-2629 Tube Assembly (6) to 129-5995 Block (7) with one 5K-9090 O-Ring Seal . Tighten the tube assembly to a torque of 190 ± 20 N·m (140 ± 15 lb ft).

7. Connect the opposite end of tube assembly (7) to the main control valve with one 1P-3703 Rectangular Seal and four 9X-6032 Bolts (20) .

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Illustration 46	g00527880
(16) 6C-6699 Block (28) 9S-4181 Straight Thread Plug (29) 119-2621 Plate (32) 8T-4956 Bolts (33) 8T-4183 Bolts

8. Install 119-2621 Plate (29) with two 8T-4183 Bolts (33) and two 8T-4223 Washers .

9. Install 6C-6699 Block (16) onto plate (29) with two 8T-4956 Bolts (32) and two 8T-4223 Washers .

10. Install 9S-4181 Straight Thread Plug (28) with one 7M-8485 O-Ring Seal onto block (16) .

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Illustration 47	g00527881
(5) 158-7514 Hose Assembly (11) 1P-5767 Half Flanges (16) 6C-6699 Block (18) 158-7513 Hose Assembly (24) 1P-4578 Half Flanges (27) 2Q-4560 Adapter

11. Install 158-7513 Hose Assembly (18) onto 6C-6699 Block (16) with two 1P-5767 Half Flanges (11), one 1P-3704 Rectangular Seal , four 8T-4184 Bolts , and four 8T-4223 Washers .

12. Install 2Q-4560 Adapter (27) onto block (16) with one 1P-3704 Rectangular Seal and four 6V-8200 Bolts .

13. Install 158-7514 Hose Assembly (5) onto adapter (27) with two 1P-4578 Half Flanges (24), one 4J-0522 O-Ring Seal , four 8T-4196 Bolts , and four 8T-4121 Washers .

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Illustration 48	g00528248
(11) 1P-5767 Half Flanges (18) 158-7513 Hose Assembly (36) 116-9189 Tube Assembly

14. Attach the other end of hose assembly (18) to 116-9189 Tube Assembly (36) with a 1P-3704 Rectangular Seal , two 1P-5767 Half Flanges (11), four 8T-4194 Bolts , and four 8T-4223 Hard Washers .

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Illustration 49	g00527927
Cooler Drain Lines to Tank (2) 6V-9855 Elbow (4) 8T-7927 Adapter (5) 158-7514 Hose Assembly

15. Install the opposite end of 158-7514 Hose Assembly (5) to the cooler lines drain port with one 8T-7927 Adapter (4), one 7M-8485 O-Ring Seal , one 6V-9855 Elbow (2), and two 6V-8400 O-Ring Seals .

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Illustration 50	g00528157
Left Side of the Main Control Valve (37) Pilot oil line. (38) Fitting. (39) Pilot oil line. (40) Stopper.

16. Remove pilot oil lines (37) and (39) from the boom 2 spool on the main control valve. Remove fitting (38). Remove stopper (40) and the two seals.

17. Install the 6V-8636 Connector with a 3J-1907 O-Ring Seal and a 6V-8397 O-Ring Seal in the place of stopper (40) .

18. Reinstall fitting (38) and pilot oil lines (37) and (39) .

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Illustration 51	g00528300
Right Side of the Main Control Valve (View A-A) (19) 116-3600 Pilot Relief Valve .

19. Install 116-3600 Pilot Relief Valve (19) to the bottom of the attachment spool.

161-8424 Front Lines Group , Two Pump Flow

Table 8

Parts Needed to Install 161-8424 Front Line Group
Qty	Part No.	Description
1	1P-3704	Rectangular Seal
1	4I-0890	Check Valve
1	4K-1388	O-Ring Seal
2	5K-9090	O-Ring Seal
1	6V-9008	Elbow
3	6V-9746	O-Ring Seal
1	7M-8485	O-Ring Seal
4	8T-4121	Hard Washer
2	8T-4136	Bolt
4	095-0673	Bolt
2	096-4883	Locknut
1	121-6270	Tube Assembly
1	121-6356	Hose Assemby
1	121-6461	Support Assembly
1	122-8705	U-Bolt
1	129-5865	Tube Assembly
1	131-9798	Hose Assembly

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Illustration 52	g00345507
(1) Bolts. (2) Panel .

1. Remove four bolts (1), the washers, and access panel (2) .

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Illustration 53	g00342714
(3) Support. (4) Bolt. (5) Hose assembly. (6) Hose assembly .

2. Remove two bolts (4), the washers, and support (3) .

3. Disconnect hose assembly (5) and hose assembly (6) .

   Note: Hose assembly (5) is disconnected in order to access hose assembly (6). Hose assembly (5) will be reinstalled.

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Illustration 54	g00383552
(5) Hose assembly. (6) Hose assembly. (7) Clamp .

4. Remove clamp (7) .

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Illustration 55	g00383972
(6) Hose assembly.

5. Disconnect hose assembly (6) from the main pump. Remove hose assembly (6) .

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Illustration 56	g00534274
Top View and Side View of 161-8424 Front Lines Group (7) Clamp (8) 131-9798 Hose Assembly (11) 4I-0890 Check Valve (12) 129-5865 Tube (13) 121-6356 Hose (14) 122-8705 U-Bolt (15) 121-6461 Support

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Illustration 57	g00386853
(8) 131-9798 Hose Assembly (9) 6V-9008 Elbow (10) 121-6270 Tube Assembly

6. Install 121-6270 Tube (10) onto the backside of the main control valve with a 1P-3704 Rectangular Seal and four 095-0673 Bolts . 121-6270 Tube (10) should be installed into the port from which hose assembly (6) was removed.

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Illustration 58	g00534275
View A-A (8) 131-9798 Hose Assembly (9) 6V-9008 Elbow (10) 121-6270 Tube (13) 121-6356 Hose (A) 22.5° ± 3.0°

7. Install 6V-9008 Elbow (9) onto 121-6270 Tube (10) with one 5K-9090 O-Ring Seal and one 7M-8485 O-Ring Seal according to dimension (A) .

8. Install 131-9798 Hose Assembly (8) onto 6V-9008 Elbow (9) .

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Illustration 59	g00386932
(8) 131-9798 Hose Assembly .

9. Connect the opposite end of hose assembly (8) to the main pump with one 5K-9090 O-Ring Seal . Tighten the hose assembly to a torque of 190 ± 20 N·m (140 ± 14 lb ft).

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Illustration 60	g00387012
(5) Hose assembly. (7) Clamp. (8) 131-9798 Hose Assembly .

10. Reinstall hose assembly (5). Then install clamp (7) around hose assembly (5) and 131-9798 Hose Assembly (8) .

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Illustration 61	g00387412
(11) 4I-0890 Check Valve .

11. Install 4I-0890 Check Valve (11) with 4K-1388 O-Ring Seal and 6V-9746 O-Ring Seal . Tighten the check valve to a torque of 150 ± 15 N·m (110 ± 11 lb ft).

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Illustration 62	g00387433
(11) 4I-0890 Check Valve (12) 129-5865 Tube (13) 121-6356 Hose (14) 122-8705 U-Bolt (15) 121-6461 Support

12. Install 121-6461 Support (15) with two 8T-4136 Bolts and two 8T-4121 Washers .

13. Install 129-5865 Tube (12) to 4I-0890 Check Valve (11). Tighten the tube to 150 ± 15 N·m (110 ± 10 lb ft).

14. Clamp tube (12) to support (15) with a 122-8705 U-Bolt (14), two 096-4883 Locknuts and two 8T-4121 Washers . Tighten the locknuts to a torque of 22 ± 3 N·m (16 ± 2 lb ft).

15. Connect 121-6356 Hose Assembly (13) to tube (12) with a 6V-9746 O-Ring Seal . Tighten the hose assembly to 150 ± 15 N·m (110 ± 10 lb ft).

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Illustration 63	g00389532
(10) 121-6270 Tube . (13) 121-6356 Hose .

16. Install the opposite end of 121-6356 Hose Assembly (13) to 121-6270 Tube (10) with a 6V-9746 O-Ring Seal . Tighten hose assembly (13) to 150 ± 15 N·m (110 ± 10 lb ft).

158-7553 Speed Control Lines Group

Table 9

Parts Needed to Install 158-7553 Speed Control Lines Group
Qty.	Part No.	Description
8	3J-1907	O-Ring Seal
1	4I-0821	Hose Assembly
2	5C-7261	Nut
7	6V-8397	O-Ring Seal
1	6V-8636	Connector
1	6V-8781	Face Seal Tee
3	6V-9001	Elbow
6	7K-1181	Cable Strap
2	7X-2538	Bolt
1	7Y-5262	U-Bolt
1	8T-0075	Connector
2	8T-4121	Hard Washer
2	8T-4133	Nut
2	8T-4224	Hard Washer
1	9C-2632	Hose Assembly
1	9Q-9728	Control Valve
2	030-7942	Elbow
1	087-5772	Hose Assembly
1	136-7077	Bracket

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Illustration 64	g00528778
158-7553 Speed Control Lines Group (1) 3J-1907 O-Ring Seal (2) 6V-8397 O-Ring Seal (3) 6V-8636 Connector (4) 4I-0821 Hose Assembly (5) 8T-0075 Connector (6) 6V-9001 Elbow (7) 9C-2632 Hose Assembly (8) 087-5772 Hose Assembly (9) 7K-1181 Cable Strap

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Illustration 65	g00550786
View A-A and Detail B of 158-7553 Speed Control Lines Group (1) 3J-1907 O-Ring Seal (2) 6V-8397 O-Ring Seal (6) 6V-9001 Elbow (10) 8T-4121 Washer (11) 8T-4133 Nut (12) 7Y-5262 U-Bolt (13) 136-7077 Bracket (14) 6V-8781 Face Seal Tee (15) 030-7942 Elbow (16) 9Q-9728 Control Valve (17) 5C-7261 Nut (18) 8T-4224 Hard Washer (19) 7X-2538 Bolt (A) Port from hand control (B) Port from hand control (C) Line from top of bucket stem (D) Line from bottom of bucket stem

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Illustration 66	g00528949
(11) 8T-4133 Nut (12) 7Y-5262 U-Bolt (13) 136-7077 Bracket (16) 9Q-9728 Control Valve (19) 7X-2538 Bolt (20) 119-2629 Tube (E) 176 ± 10 mm (6.92 ± .39 inch)

1. Install 136-7077 Bracket (13) onto 119-2629 Tube (20), according to dimension (E), with one 7Y-5262 U-Bolt (12), two 8T-4133 Nuts (11), and two 8T-4121 Hard Washers .

2. Install 9Q-9728 Control Valve (16) onto bracket (13) with two 7X-2538 Bolts (19), two 5C-7261 Nuts , and two 8T-4224 Washers .

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Illustration 67	g00528981
(21) Hose assembly for the bucket stem.

3. Disconnect the end of hose assembly (21) from the bucket stem of the main control valve.

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Illustration 68	g00528987
(15) 030-7942 Elbow . (16) 9Q-9728 Valve Group . (21) Bucket stem hose assembly .

4. Connect the end of hose assembly (21) to 9Q-9728 Valve Group (16) at location (A) with one 030-7942 Elbow (15) and one 3J-1907 O-Ring Seal .

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Illustration 69	g00528988
Right Side of the Main Control Valve (22) Hose assembly.

5. Disconnect hose assembly (22) from the bottom of the bucket stem.

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Illustration 70	g00528992
(15) 030-7942 Elbow . (16) 9Q-9728 Valve Group . (22) Hose assembly.

6. Connect hose assembly (22) to 9Q-9728 Control Valve (16) at location (B) with one 030-7942 Elbow (15) and one 3J-1907 O-Ring Seal .

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Illustration 71	g00528996
(4) 4I-0821 Hose Assembly .

7. Install 4I-0821 Hose Assembly (4) to the top of the bucket stem with one 6V-8636 Connector , one 6V-8397 O-Ring Seal , and one 3J-1907 O-Ring Seal .

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Illustration 72	g00529020
(4) 4I-0821 Hose Assembly . (16) 9Q-9728 Valve Group .

8. Connect the opposite end of 4I-0821 Hose Assembly (4) to control valve (16) at location (C) with one 6V-9001 Elbow , one 6V-8397 O-Ring Seal , and one 3J-1907 O-Ring Seal .

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Illustration 73	g00529023
(5) 8T-0075 Connector . (8) 087-5772 Hose Assembly . (16) 9Q-9728 Control Valve .

9. Install 087-5772 Hose Assembly (8) to the bottom of the bucket stem with one 8T-0075 Connector (5), one 6V-8397 O-Ring Seal , and one 3J-1907 O-Ring Seal .

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Illustration 74	g00529030
(8) 087-5772 Hose Assembly . (16) 9Q-9728 Control Valve . (D) Line from bottom of the bucket stem.

10. Connect the opposite end of 087-5772 Hose Assembly (8) to control valve (16) at location (D) with one 6V-9001 Elbow , one 6V-8397 O-Ring Seal , and one 3J-1907 O-Ring Seal .

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Illustration 75	g00529062
(7) 9C-2632 Hose Assembly . (14) 6V-8781 Face Seal Tee . (16) 9Q-9728 Control Valve . (23) Hose assembly.

11. Install 9C-2632 Hose (7) onto control valve (16) with one 6V-8781 Face Seal Tee (14), one 3J-1907 O-Ring Seal , and one 6V-8397 O-Ring Seal .

    Note: Hose assembly (23) will be installed as part of the "" 158-7511 Logic Lines Group " ".

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Illustration 76	g00529072
View C-C of the Pilot Manifold (E) Location for 9C-2632 Hose .

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Illustration 77	g00529076
(7) 9C-2632 Hose Assembly . (24) Pilot manifold. (E) Location for 9C-2632 Hose Assembly .

12. Connect the opposite end of 9C-2632 Hose Assembly (7) to pilot manifold (24) at location (E) with one 6V-9001 Elbow , one 6V-8397 O-Ring Seal , and one 3J-1907 O-Ring Seal .

13. Secure the speed control lines with several 7K-1181 Cable Straps as shown in Illustration 64.

158-7511 Logic Lines Group

Table 10

Parts Needed to Install 158-7511 Logic Lines Group
Qty	Part No.	Description
2	3E-9205	Solenoid Valve
45	3J-1907	O-Ring Seal
1	4I-0894	Pilot Valve
3	4I-6287	Coupling Assembly
2	4M-8303	O-Ring Seal
18	5C-7261	Nut
2	5I-8825	Hose Assembly
1	5P-4272	O-Ring Union
1	6V-0484	O-Ring Adapter
58	6V-8397	O-Ring Seal
17	6V-8636	Connector
11	6V-8724	Elbow
2	6V-8774	Face Seal Tee
3	6V-8781	Face Seal Tee
2	6V-9836	Tee
11	6V-9850	Swivel Elbow
6	7K-1181	Cable Strap
4	7X-2538	Bolt
2	7X-2539	Bolt
2	7X-2540	Bolt
2	8C-7310	Adapter
4	8J-6875	Shuttle Valve Assembly
1	8T-0075	Connector
1	8T-1779	Connector
4	8T-4139	Bolt
4	8T-4223	Hard Washer
20	8T-4224	Hard Washer
8	8T-4908	Bolt
2	8T-6912	Bolt
2	9Q-9728	Control Valve
1	9S-4191	Plug
2	9X-9097	Manifold Assembly
1	087-4532	Hose Assembly
3	087-5303	Hose Assembly
1	087-5772	Hose Assembly
1	087-5778	Hose Assembly
2	122-4924	Hose Assembly
1	158-7520	Tube Assembly
1	158-7521	Tube Assembly
1	158-7522	Tube Assembly
1	158-7523	Tube Assembly
1	158-7524	Tube Assembly
1	158-7525	Tube Assembly
1	158-7526	Tube Assembly
1	158-7527	Tube Assembly
2	158-7528	Plate
2	158-7529	Plate
1	158-7530	Plate
1	158-7541	Tube Assembly
1	165-2730	Flow Control Valve

Illustration 78	g00529323
Front View of the 158-7511 Logic Lines Group

Illustration 79	g00529364
Side View of the 158-7511 Logic Lines Group

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Illustration 80	g00529555
(1) 3E-9205 Solenoid Valve (2) 6V-8724 Elbow (3) 9X-9097 Manifold Assembly (4) 9X-9097 Manifold Assembly (5) 158-7529 Plates (6) 8T-0079 Connector (7) 158-7530 Plate (12) 6V-8636 Connector

1. Install two 158-7529 Plates (5) to 158-7530 Plate (7) with four 8T-4908 Bolts , four 8T-4224 Washers , and four 5C-7261 Nuts .

2. Connect 9X-9097 Manifold Assembly (3) and 9X-9097 Manifold Assembly (4) together with two 4M-8303 O-Ring Seals , two 7X-2539 Bolts , two 8T-4224 Washers , and two 5C-7261 Nuts .

3. Then, attach both manifold assemblies to 158-7529 Plates (5) with two 7X-2540 Bolts , two 8T-4224 Washers , and two 5C-7261 Nuts .

4. Install 8T-0075 Connector (6) to manifold assemblies (4) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

5. Install one 3E-9205 Solenoid Valve (1) to each manifold assembly.

6. Install one 6V-8724 Elbow (2) to manifold assembly (3) with one 3J-1907 O-Ring Seal , and one 6V-8397 O-Ring Seal .

7. Install four 6V-8636 Connectors (12) with four 3J-1907 O-Ring Seals and four 6V-8397 O-Ring Seals .

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Illustration 81	g00529406
View B-B (2) 6V-8724 Elbow (3) 9X-9097 Manifold Assembly (8) 158-7520 Tube Assembly (9) 9S-4191 O-Ring Plug (10) 6V-8724 Elbow (11) 6V-9850 Swivel Elbow

8. Connect 6V-9850 Swivel Elbow (11) to elbow (2) with one 6V-8397 O-Ring Seal . Attach 158-7520 Tube Assembly (8) to swivel elbow (11) .

9. Connect the opposite of tube assembly (8) to manifold assembly (3) with one 6V-8724 Elbow (10), one 3J-1907 O-Ring Seal , and one 6V-8397 O-Ring Seal .

10. Install 9S-4191 O-Ring Plug (9) to manifold assembly (3) with one 3J-1907 O-Ring Seal .

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Illustration 82	g00423218
Upper Pressure Reducing Valves (7) 158-7530 Plate (12) 6V-8636 Connectors (13) 6V-9850 Swivel Elbows (14) 6V-8724 Elbow (15) 9Q-9728 Control Valve (16) 6V-8774 Tee (17) 7X-2538 Bolts (18) 8T-4909 Bolts (19) 158-7528 Plate

11. Install 158-7528 Plate (19) to 158-7530 Plate (7) with two 8T-4908 Bolts (18), two 8T-4224 Washers , and two 5C-7261 Nuts .

12. Install 9Q-9728 Control Valve (15) to plate (19) with two 7X-2538 Bolts (17), two 8T-4224 Washers , and two 5C-7261 Nuts .

13. Attach three 6V-8636 Connectors (12) and three 6V-9850 Swivel Elbows (13) to control valve (15) with three 3J-1907 O-Ring Seals and six 6V-8397 O-Ring Seals .

14. Attach one 6V-8724 Elbow (14) to control valve (15) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

15. Attach one 6V-8774 Tee (16) to control valve (15) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

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Illustration 83	g00423239
Lower Pressure Reducing Valves (7) 158-7530 Plate (20) 6V-8636 Connectors (21) 6V-9850 Swivel Elbows (22) 6V-8724 Elbow (23) 9Q-9728 Control Valve (24) 6V-8774 Tee (25) 6V-9836 Tee (26) 7X-2538 Bolts (27) 8T-4909 Bolts (28) 158-7528 Plate

16. Install 158-7528 Plate (28) to 158-7530 Plate (7) with two 8T-4908 Bolts (27), two 8T-4224 Washers , and two 5C-7261 Nuts .

17. Install 9Q-9728 Control Valve (23) to plate (28) with two 7X-2538 Bolts (26), two 8T-4224 Washers , and two 5C-7261 Nuts .

18. Attach three 6V-8636 Connectors (20) and three 6V-9850 Swivel Elbows (21) to control valve (23) with three 3J-1907 O-Ring Seals and six 6V-8397 O-Ring Seals .

19. Attach one 6V-8724 Elbow (22) to control valve (23) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

20. Attach one 6V-8774 Tee (24) to control valve (23) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

21. Connect one 6V-9836 Tee (25) to 6V-8774 Tee (24) with two 6V-8397 O-Ring Seals .

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Illustration 84	g00550790
Detail C (29) 6V-8724 Elbow (30) 4I-0894 Pilot Valve (31) 8T-6912 Bolts (32) 8T-1779 Connector (33) 6V-9850 Swivel Elbow (34) 6V-9850 Swivel Elbow (35) 6V-8781 Tee (36) 6V-9836 Tee (37) 6V-9850 Swivel Elbow (38) 6V-8724 Elbow (A) Drill point

22. Install 4I-0894 Pilot Valve (30) to the 158-7530 Plate with two 8T-6912 Bolts (31), four 8T-4224 Washers , and two 5C-7261 Nuts .

    Note: Ensure that the 4I-0894 Pilot Valve is positioned on the plate with drill point (A) downward.

23. Attach 6V-8724 Elbow (29) to pilot valve (30) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

24. Connect 6V-9850 Swivel Elbow (34) to 6V-8724 Elbow (29) with one 6V-8397 O-Ring Seal .

25. Attach 6V-8781 Tee (35) to pilot valve (30) with one 3J-1907 O-Ring Seal and two 6V-8397 O-Ring Seals .

26. Connect 6V-9836 Tee (36) to tee (35) with two 6V-8397 O-Ring Seals .

27. Connect 6V-9850 Swivel Elbow (37) to tee (36) with one 6V-8397 O-Ring Seal .

28. Attach one 8T-1779 Connector (32) to pilot valve (30) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

29. Connect 6V-9850 Swivel Elbow (33) to connector (32) with one 6V-8397 O-Ring Seal .

30. Attach one 6V-8724 Elbow (38) to pilot valve (30) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

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Illustration 85	g00529473
Front View of the 158-7530 Plate . (13) 6V-9850 Swivel Elbow (14) 6V-8724 Elbow (16) 6V-8774 Tee (21) 6V-9850 Swivel Elbow (22) 6V-8724 Elbow (24) 6V-8774 Tee (25) 6V-9836 Tee (33) 6V-9850 Swivel Elbow (35) 6V-8781 Tee (36) 6V-9836 Tee (38) 6V-8724 Elbow (39) 158-7525 Tube Assembly (40) 158-7524 Tube Assembly (41) 158-7527 Tube Assembly (42) 158-7526 Tube Assembly (43) 158-7541 Tube Assembly (44) 158-7523 Tube Assembly (45) 158-7521 Tube Assembly (46) 158-7522 Tube Assembly

31. Connect 158-7525 Tube Assembly (39) from the 9X-9097 Manifold Assembly to 6V-8724 Elbow (14) .

32. Connect 158-7527 Tube Assembly (41) from the 9X-9097 Manifold Assembly to 6V-8781 Tee (35) .

33. Connect 158-7524 Tube Assembly (40) from from the 9X-9097 Manifold Assembly to swivel elbow (13) .

34. Connect 158-7526 Tube Assembly (42) from the 9X-9097 Manifold Assembly to tee (16) .

35. Connect 158-7541 Tube Assembly (43) from elbow (38) to tee (25) .

36. Connect 158-7523 Tube Assembly (44) from tee (36) to elbow (22) .

37. Connect 158-7521 Tube Assembly (45) from swivel elbow (33) to swivel elbow (21) .

38. Connect 158-7522 Tube Assembly (46) from tee (16) to tee (24) .

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Illustration 86	g00423318
Right Rear of the Machine (48) Plate .

39. Install the assembly in Illustration 85 to plate (48) with four 8T-4139 Bolts and four 8T-4223 Washers .

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Illustration 87	g00424078
Main Pump (58) Hose assembly.

40. Disconnect hose assembly (58) from the lower pump control. Remove the elbow from the end of the hose assembly.

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Illustration 88	g00550791
(51) 4I-6287 Coupling Assembly (52) 6V-8724 Elbow (53) 6V-8636 Connector (54) 6V-8636 Connector (56) 5I-8825 Hose (58) Hose assembly (96) 8J-6875 Shuttle Valve Assembly

41. Install one 6V-8636 Connector (53) to the lower pump controller with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

42. Attach one 4I-6287 Coupling Assembly (51) to connector (53) with one 3J-1907 O-Ring Seal .

43. Attach one 8J-6875 Shuttle Valve Assembly (96) to coupling assembly (51) .

44. Install one 6V-8724 Elbow (52) to shuttle valve (96) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

45. Install one 6V-8636 Connector (54) to shuttle valve (96) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal . Connect hose assembly (58) to connector (54) .

    Note: Hose assembly (56) will be connected in Steps 78 and 79.

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Illustration 89	g00529732
Pilot Oil Lines to Swing Stem (87) Elbow. (88) Pilot oil line. (89) Connector. (90) Pilot oil line.

46. Remove pilot oil lines (88) and (90) from the swing stem of the main control valve. Remove elbow (87) and connector (89) .

47. Remove the pilot oil line that connects from the top of the attachment stem to the bottom of the attachment stem (if equipped).

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Illustration 90	g00529768
Detail F (81) 8J-6875 Shuttle Valve Assembly (82) 6V-8636 Connector (83) 6V-8636 Connector (84) 6V-8781 Tee (85) 4I-6287 Coupling Assembly (86) 8C-7310 Adapter

48. Install one 6V-8781 Tee (84) to the bottom of the swing stem of the main control valve with one 3J-1907 O-Ring Seal and two 6V-8397 O-Ring Seals .

49. Connect one 8C-7310 Adapter (86) to tee (84). Connect one 4I-6287 Coupling Assembly (85) to tee (84) with one 3J-1907 O-Ring Seal .

50. Connect one 8J-6875 Shuttle Valve Assembly (81) to coupling assembly (85). Attach one 6V-8636 Connector (82) to shuttle valve assembly (81) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

51. Attach one 6V-8636 Connector (83) to shuttle valve assembly (81) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

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Illustration 91	g00530037
Detail E (74) 6V-8636 Connector . (75) 4I-6287 Coupling .

52. Install one 6V-8636 Connector (74) to the bottom of the attachment stem with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

53. Attach one 4I-6287 Coupling (75) to connector (74) .

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Illustration 92	g00530043
View D-D (61) 8J-6875 Shuttle Valve Assembly (62) 6V-8724 Elbow (63) 6V-8724 Elbow (64) 5P-4272 O-Ring Union (65) 6V-8724 Elbow (66) 8J-6875 Shuttle Valve Assembly

54. Install one 8J-6875 Shuttle Valve Assembly (61) to coupling (75). Connect one 6V-8724 Elbow (62) to shuttle valve assembly (61) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

55. Connect one 5P-4272 O-Ring Union (64) to shuttle valve assembly (61) with one 3J-1907 O-Ring Seal .

56. Install one 8J-6875 Shuttle Valve Assembly (66) to o-ring union (64) with one 3J-1907 O-Ring Seal .

57. Connect one 6V-8724 Elbow (63) to shuttle valve assembly (66) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

58. Connect one 6V-8724 Elbow (65) to shuttle valve assembly (66) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

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Illustration 93	g00530067
Detail G (79) 6V-0484 O-Ring Adapter (91) 165-2730 Flow Control Valve

59. Attach one 6V-0484 O-Ring Adapter (79) to the side of the boom 2 stem with one 3J-1907 O-Ring Seal .

60. Connect one 165-2730 Flow Control Valve (91) to adapter (79) with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

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Illustration 94	g00530236
View H-H (49) 6V-8636 Connector (50) 6V-9850 Swivel Elbow (60) 6V-8636 Connector

61. Install one 6V-8636 Connector (49) to the pilot manifold with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

62. Attach one 6V-9850 Swivel Elbow (50) to 6V-8636 Connector (49) with one 6V-8397 O-Ring Seal .

63. Install one 6V-8636 Connector (60) to the pilot manifold with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

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Illustration 95	g00530263
Detail A (70) 6V-8781 Face Seal Tee . (71) 8C-7310 Adapter .

64. Install one 6V-8781 Face Seal Tee (70) to the top of the swing stem with one 3J-1907 O-Ring Seal and two 6V-8397 O-Ring Seals .

65. Connect one 8C-7310 Adapter (71) to face seal tee (70) .

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Illustration 96	g00530089
Front View of the Logic Lines Group (6) 8T-0075 Connector (34) 6V-9850 Swivel Elbow (37) 6V-9850 Swivel Elbow (50) 6V-9850 Swivel Elbow (55) 087-5778 Hose Assembly (67) Face seal tee (68) 6V-8724 Elbow (69) 087-5772 Hose Assembly (70) 6V-8781 Tee (71) 8C-7310 Adapter (72) 087-4532 Hose Assembly (73) 122-4924 Hose Assembly (80) 122-4924 Hose Assembly (82) 6V-8636 Connector (83) 6V-8636 Connector (86) 8C-7310 Adapter (88) Pilot oil line (90) Pilot oil line (91) 165-2730 Flow Control Valve

66. Connect 087-5778 Hose Assembly (55) from connector (6) to swivel elbow (50) .

67. Connect 122-4924 Hose Assembly (80) from swivel elbow (34) to connector (83) .

68. Connect 122-4924 Hose Assembly (73) from swivel elbow (37) to flow control valve (91) .

69. Connect pilot oil line (90) (previously attached to the bottom of the swing stem) to adapter (86) .

70. Connect pilot oil line (88) (previously attached to the top of the swing stem) to adapter (71) .

71. Install 6V-8724 Elbow (68) to the top of the attachment spool with one 3J-1907 O-Ring Seal and one 6V-8397 O-Ring Seal .

72. Connect 087-4532 Hose Assembly (72) from elbow (68) to face seal tee (67) .

73. Connect 087-5772 Hose Assembly (69) from tee (70) to connector (82) .

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Illustration 97	g00530274
Side View of the Logic Lines Group (25) 6V-9836 Tee (56) 5I-8825 Hose Assembly (57) 5I-8825 Hose Assembly (60) 6V-8636 Connector (62) 6V-8724 Elbow (63) 6V-8724 Elbow (65) 6V-8724 Elbow (76) 087-5303 Hose Assembly (77) 087-5303 Hose Assembly (78) 087-5303 Hose Assembly (92) 6V-9850 Swivel Elbow (93) 6V-9850 Swivel Elbow (94) 6V-9850 Swivel Elbow (95) 6V-9850 Swivel Elbow

74. Connect 087-5772 Hose Assembly (57) from tee (25) to connector (60) .

75. Connect 087-5303 Hose Assembly (78) from elbow (95) to elbow (63) .

76. Connect 087-5303 Hose Assembly (77) from elbow (92) to elbow (65) .

77. Connect 087-5303 Hose Assembly (76) from elbow (93) to elbow (62) .

78. Connect the elbow end of 5I-8825 Hose Assembly (56) to elbow (94) .

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Illustration 98	g00530329
Lower Pump Control (52) Elbow. (56) 5I-8825 Hose Assembly .

79. Connect the opposite end of 5I-8825 Hose Assembly (56) to elbow (52) .

80. Secure the hose assemblies as necessary with the six 7K-1181 Cable Straps .

158-7512 Wiring Group

Table 11

Parts Needed to Install 158-7512 Wiring Group
Qty	Part No.	Description
4	8T-4220	Bolt
4	8T-4224	Washer
1	106-0179	Pressure Switch
6	106-8704	Arc Suppressor
1	108-7463	Connector
1	158-7518	Wiring Panel
1	158-7519	Harness Assembly

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Illustration 99	g00530520
Front View of the Main Control Valve (1) 106-0179 Pressure Switch . (2) 108-7463 Connector .

1. Install 108-7463 Connector (2) in the port in front of the main control valve as shown in Illustration 99.

2. Install 106-0179 Pressure Switch (1) into connector (2). Tighten the pressure switch to 30 ± 2 N·m (22 ± 1.5 lb ft).

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Illustration 100	g00530519
View Behind the Cab (3) 158-7518 Wiring Panel

3. Install 158-7518 Wiring Panel (3) with four 8T-4220 Bolts and four 8T-4224 Washers .

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Illustration 101	g00530522
(4) 158-7519 Harness . (5) 106-8704 Arc Suppressor .

4. Install six 106-8704 Arc Suppressors (5) in the connections of the 158-7519 Harness (4) .

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Illustration 102	g00530523
Routing of the 158-7519 Harness (1) 106-0179 Pressure Switch . (3) 158-7518 Wiring Panel . (5) 106-8704 Arc Suppressors .

5. Route the 158-7519 Harness through the machine. Refer to Illustration 102.

6. Connect the six-pin connector and the four-pin connector to 158-7518 Wiring Panel (3) at location (A) .

   Note: The connections at locations (B) and (C) will be made in ""Installation of 161-1606 Installation Group " ".

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Illustration 103	g00530658
View Into Side Panel

7. Connect the four-pin connector that has two wires coming from 158-7519 Harness to solenoid (6) at location (D) .

8. Connect the four-pin connector that has four wires coming from 158-7519 Harness to solenoid (7) at location (E) .

9. Connect pressure switch (1) to the 158-7519 Harness at location (F) .

Installation of 161-1606 Installation Group

Table 12

Parts Needed to Install 161-1606 Installation Group
Qty	Part No.	Description
2	4J-0522	O-Ring Seal
4 dm	5P-0755	Tube
1	6E-3091	Relief Valve
16 (1)	6K-6180	Washer
2	6V-8398	O-Ring Seal
1	6V-8943	Reducer Assembly
1	6V-9746	O-Ring Seal
1	7J-9108	O-Ring Seal
8	7X-0562	Hard Washer
6 (1)	7Y-2498	Shim
4	8T-4121	Hard Washer
2	8T-4133	Nut
2	8T-4185	Bolt
30 (2)	8T-8730	Connector Socket
1 (2)	8T-9834	Connector Plug
2	9X-7423	Bonded Seal
8	095-0670	Bolt
1	119-6419	Hose Assembly
2	155-8994	Adapter Assembly
1	155-9547	Nut
1	156-3862	Plug
1	158-7721	Plate Assembly
1	159-4782	Support Group
1	159-4786	Pin Assembly
1	159-4787	Pin Assembly
2	159-5968	Hose Asembly
1	159-7254	Pin Assembly
1	160-6986	Instruction Film
1	160-6987	Instruction Film
2 m	161-5102	Guard
3 m	161-5104	Guard
2	161-5452	Adapter
1	161-5558	Nut
1	162-8711	Adapter Assembly
1	165-0552	Wiring Group
1	165-0553	Harness Assembly
1	166-3435	Nut
2	166-3436	Flange
1	169-7130	Chain

( 1 )	Use as required.
( 2 )	Not needed if the wiring harness from the harvester head has a 40-pin connector.

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Illustration 104	g00530738
View of the End of the Stick (1) 159-4786 Pin Assembly (2) 158-7721 Plate Assembly (3) 159-4787 Pin Assembly (4) 166-3435 Nut (5) 155-9547 Nut

1. Line up the holes of 158-7721 Plate Assembly (2) with the holes in the end of the stick.

   Note: The weight of the plate assembly is 97 kg (213 lb).

2. Install 159-4787 Pin Assembly (3) with one 166-3435 Nut (4) and the required number of 6K-8180 Washers .

3. Install 159-4786 Pin Assembly (1) with one 155-9547 Nut (5) and the required number of 7Y-2498 Shims .

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Illustration 105	g00550794
(2) 158-7721 Plate Assembly . (6) Bar. (7) Notch. (8) Bar.

4. Lower the end of the stick over the damper. Notch (7) must slide into bar (6) .

5. Attach the damper to plate assembly (2) with the 159-7254 Pin Assembly and a 161-5558 Nut .

   Note: Bar (8) prevents the pin assembly from rotating.

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Illustration 106	g00530899
Cover Assembly for the Harvester Head

6. Remove the cover assembly from the harvester head.

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Illustration 107	g00530862
Left Side View of the Harvester Head

7. Remove the pressure tap and adapter (9) from the left side of the harvester head.

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Illustration 108	g00530875
Left Side View of the Harvester Head (10) 156-3862 Plug .

8. Insert 156-3862 Plug (10) where adapter (9) was removed.

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Illustration 109	g00530901
Right Side View of the Harvester Head

9. Remove the hose assembly from signal line (11) (if equipped). Attach adapter and pressure tap (9) to signal line (11) .

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Illustration 110	g00530915
Front View of the Harvester Head (12) Return oil line. (13) Pressure oil line.

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Illustration 111	g00530917
Bottom View of the Stick (12) Return line (13) Pressure line (14) 161-5452 Adapter (15) 166-3436 Flange (16) 159-5968 Hose Assembly (17) 159-5968 Hose Assembly

10. Install a 166-3436 Flange (15) with a 4J-0522 O-Ring Seal to the two tube assemblies. Use four 095-0670 Bolts and four 7X-0562 Washers to attach each flange.

11. Attach one 161-5452 Adapter (14) with one 9X-7423 Bonded Seal to each flange (15) .

12. Attach return line (12) and pressure line (13) to adapters (14) as shown in Illustration 111.

13. Attach 159-5968 Hose Assemblies (16) and (17) to the tube assemblies on the end of the stick.

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Illustration 112	g00530951
View of the Rotator (16) 159-5968 Hose Assembly . (17) 159-5968 Hose Assembly . (18) 155-8994 Adapter Assembly .

14. Install one 155-8994 Adapter Assembly (18) into the two ports on the rotator.

15. Attach the opposite end of hose assembly (17) to adapter (18) with one 6V-8398 O-Ring Seal .

16. Attach the opposite end of hose assembly (16) to adapter (18) with one 6V-8398 O-Ring Seal .

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Illustration 113	g00531357
End View of the Stick (19) 6V-8943 Reducer Assembly . (20) 119-6419 Hose Assembly .

17. Attach one 6V-8943 Reducer Assembly (19) to the drain line tube with one 6V-9746 O-Ring Seal .

18. Install 119-6419 Hose Assembly (20) onto reducer assembly (19) .

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Illustration 114	g00531364
(20) 119-6419 Hose Assembly . (21) 162-8711 Adapter Assembly .

19. Remove the drain line from the harvester head (if equipped).

20. Install 162-8711 Adapter Assembly (21). Install the opposite end of hose assembly (20) to adapter assembly (21) with one 7J-9108 O-Ring Seal .

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Illustration 115	g00531372
(22) 161-5102 Guards . (23) 161-5104 Guards .

21. Wrap 161-5102 Guard (22) around the two hoses for the rotator and the two hoses for the tilt cylinders.

22. Wrap 161-5104 Guard (23) around the two tilt cylinder lines and the three lines from the stick to the harvester head.

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Illustration 116	g00531381
(2) 158-7721 Plate Assembly . (24) 5P-0755 Tube . (25) 169-7130 Chain .

23. Slide 350 mm (13.75 inch) of 5P-0755 Tube (24) onto 169-7130 Chain (25). Install chain (25) onto plate assembly (2) with two 8T-4185 Bolts , four 8T-4121 Washers , and two 8T-4133 Nuts .

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Illustration 117	g00531391
Front View of the Right Side of the Main Control Valve (26) 6E-3091 Relief Valve .

24. Remove the line relief valve from the top of the boom stem (boom DOWN). Install 6E-3091 Relief Valve (26) in the place of the line relief valve.

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Illustration 118	g00531952
View in the Cab of the Machine

25. Remove the two pilot control levers. Disconnect the wires from the levers. Remove the two travel levers.

    The 159-4782 Support Group consists of the parts listed in Table 13.

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    Table 13

    159-4782 Support Group
    Qty	Part No.	Description
    2	5C-9553	Bolt
    3	8T-4200	Bolt
    2	9X-8256	Washer
    1	157-7147	Support Assembly
    1	158-6298	Plate Assembly
    1	159-4779	Support Assembly

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Illustration 119	g00531434
(27) 157-7147 Support Assembly . (28) 8T-4200 Bolt .

26. Install 157-7147 Support Assembly (27) onto the front window frame with the four existing bolts in the window frame. Loosen 8T-4200 Bolt (28) to adjust the width of the support assembly.

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Illustration 120	g00531515
Back View of the DASA (27) 157-7147 Support Assembly . (29) 158-6298 Support Assembly . (30) 8T-4200 Bolt .

27. Install 158-6298 Support Assembly (29) onto the back of the DASA with two 5C-9553 Bolts and two 9X-8256 Washers .

28. Mount the DASA onto support assembly (27) with two 8T-4200 Bolts .

    Note: Do not tighten bolts (30). The DASA will be removed to install wiring harnesses.

Note: Do not perform Steps 29 or 30 if the wiring harness from the harvester head already has a 40-pin connector plug.

29. Install one 8T-8730 Connector Socket to the end of each wire from the harvester head.

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Illustration 121	g00531559
8T-9834 Connector Plug

30. Each wire from the harvester head is numbered. Insert each connector socket for the numbered wire into the corresponding socket number of the 8T-9834 Connector Plug .

165-0552 Wiring Group

Table 14

Parts needed to install 165-0552 Wiring Group
Qty	Part No.	Description
1	3E-5239	Relay Assembly
1	3E-8770	Rocker Switch
1	3K-8782	Fuse
3	7N-6545	Socket Terminal
1	8D-8113	Fuse
1	121-0129	Rocker Actuator
1	161-4165	Harness Assembly
1	161-4166	Harness Assembly
1	161-4167	Harness Assembly
1	161-4168	Harness Assembly
1	163-6131	Joystick Control
1	163-6132	Joystick Control
1	163-7335	Harness Assembly
1	163-7336	Harness Assembly
1	165-0753	Power Supply

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Illustration 122	g00531639
Routing of 163-7336 Harness Assembly (1) 8T-9834 Connector Plug .

1. Connect one end of the 163-7336 Harness Assembly to connector plug (1) from the harvester head wiring harness.

2. Route the harness assembly over the stick and boom as shown in Illustration 122.

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Illustration 123	g00531654
Routing of 163-7336 Harness Assembly

3. Route the opposite end of the harness assembly under the cab.

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Illustration 124	g00531791
View Under the Cab (2) 165-0533 Harness Assembly (3) 161-4167 Harness Assembly (4) 163-7336 Harness Assembly (5) 161-4166 Harness Assembly

4. Tilt the cab up. Connect 161-4167 Harness Assembly (3) to 163-7336 Harness Assembly (4) .

5. Connect the 37-pin connector end of 165-0533 Harness Assembly (2) to 161-4167 Harness Assembly (3) .

6. Connect one end of 161-4166 Harness Assembly (5) to harness assembly (3) .

7. Connect the opposite end of harness assembly (5) to the six-pin connector from the arc suppressors under the 158-7518 Wiring Panel .

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Illustration 125	g00531981
View Behind Cab of the Machine (6) 161-4165 Harness Assembly . (7) 158-7519 Harness Assembly .

8. Connect the end of 161-4165 Harness Assembly (6) with the six-pin connector to 158-7519 Harness Assembly (7) .

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Illustration 126	g00531984
Bottom View of the Cab (2) 165-0533 Harness Assembly . (6) 161-4165 Harness Assembly .

9. Route harness assemblies (2) and (6) through the hole in the cab floor behind the operator's seat. Secure the wires so the wires do not tighten when the cab is tilted up.

10. Route the two two-pin connectors of harness assembly (6) into the back of the left console.

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Illustration 127	g00532041
Back View of the DASA (2) 165-0533 Harness Assembly . (8) Wiring harness for printer. (9) Wiring harness to joysticks. (10) Connector.

11. Connect the 48-pin connector of 165-0533 Harness Assembly (2) to the back of the DASA.

12. Connect the nine-pin connector of wiring harness (8) for the printer to the back of the DASA.

13. Connect the 37-pin connector of wiring harness (9) to the back of the DASA.

14. Connect wiring harness (2) and wiring harness (9) together with connector (10) .

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Illustration 128	g00532056
View Inside the Cab

15. Route wiring harnesses (2), (8), and (9) behind the panel to the back of the seat as shown in Illustration 128.

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Illustration 129	g00532162
View In Front of the Operator's Seat (11) Left hand control keypad (12) 163-6132 Joystick Control (13) Right hand control keypad (14) 163-6131 Joystick Control

16. Install the 163-6132 Joystick Control (12) to the left pilot valve.

    Note: The left joystick control has three wires. The ground wire has one 2K-0613 Bullet Connector on the end of it. The two positive wires are connected together with a 2K-0613 Bullet Connector .

17. Connect the terminal with the black and gray wires to the ground connection for the horn. Connect the terminal with the red wire to the supply connection for the horn.

    Note: Either button on the left joystick control will now activate the horn.

18. Install left hand control keypad (11) to joystick (12) with a threaded rod, a clamp, two bolts, and two washers.

19. Route the wiring harness from the hand control keypad through the left console to the back of the seat.

20. Install the 163-6131 Joystick Control (14) to the right pilot valve. (The right joystick has a three-pin connector on the end of it.)

21. Route the wiring harness from the right joystick control into the right console.

22. Install right hand control keypad (13) to joystick (14) with a threaded rod, a clamp, two bolts, and two washers.

23. Route the wiring harness from the right hand control keypad through the right console and behind the seat.

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Illustration 130	g00532292
Left Joystick (15) Screws. (16) 160-6987 Instruction Film .

24. Laminate 160-6987 Instruction Film (16) between two sheets of clear pressure sensitive adhesive film that is 0.08 to 0.13 mm (.0031 to .0051 inch) thick.

    Note: The instruction film for the left hand control keypad has the label for the "CUT" button.

25. Loosen screws (15). Partially slide instruction film (16) into the left hand control keypad. Tighten the screws.

26. Repeats Steps 24 through 25 for 160-6986 Instruction Film on the right hand control keypad.

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Illustration 131	g00532202
Panel From the Left Console (All Dimension in Millimeters)

27. Drill two 7 mm diameter holes in the panel for the potentiometers. Cut a rectangle into the panel for the rocker switch. Refer to the dimensions in Illustration 131.

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Illustration 132	g00532359
Panel From the Left Console (16) Potentiometers. (17) Cap. (18) 121-0129 Rocker Actuator . (19) 3E-8770 Rocker Switch .

28. Remove cap (17) from each potentiometer (16). Remove the knob from the potentiometer in order to slide the potentiometers through the holes in the panel.

29. Install the potentiometer with the green wire in the REAR position. Install the potentiometer with the white wire in the FRONT position.

30. Tighten the nuts on the potentiometers. Reinstall the knobs. Reinstall the caps.

31. Install 3E-8770 Rocker Switch (19) into the panel. Install 121-0129 Rocker Actuator (18) onto the rocker switch (19) .

32. Cut off the wire connectors for the three wires from potentiometers (17). Install one 7N-6545 Socket Terminal on the end of each wire.

33. Route the wires through the left armrest to the back of the seat.

34. Disassemble the 16-pin connector for the left hand control keypad. Insert each socket terminal from the potentiometers into the back of the 16-pin connector according to Table 15.
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    Table 15

    Potentiometer Wire Color	Keypad Connector Pin Number
    Brown	13
    White	14
    Green	15

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Illustration 133	g00532371
(9) Wiring harness to DASA. (20) Wiring harness from the right hand control keypad. (21) Wiring harness from the left hand control keypad and the potentiometers.

35. Connect the wiring harness from the right hand control keypad (20) to the connector from wiring harness (9) that does not have a pin 13, 14, and 15.

36. Connect the wiring harness from the left hand control keypad (21) to the connector from wiring harness (9) that has a pin 13, 14, and 15.

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Illustration 134	g00532966
161-4168 Harness Assembly (22) Connector to 3E-8770 Rocker Switch (23) Connector to 165-0753 Power Supply (24) 3K-8782 Fuse (25) Three-pin connector to right joystick (26) 16-pin connector to 165-0553 Harness (27) Two-pin connector to 161-4165 Harness (28) Three-pin connector to 163-7335 Harness (29) 8D-8113 Fuse (30) Connector to 3E-5239 Relay Assembly

37. Install one 3K-8782 Fuse (24) and one 8D-8113 Fuse (29) in the 161-4168 Harness Assembly . Install the harness assembly into the left console.

38. Route three-pin connector plug (25) through the left console to the back of the seat. Route the connector into the right console and attach the plug to the wiring harness from the right joystick control.

39. Route the 16-pin connector from 161-0533 Harness Assembly into the left console. Attach connector (26) to the 16-pin connector of 161-0533 Harness Assembly .

40. Attach connector socket (27) to the two-pin connector plug of the 161-4165 Harness Assembly (6) .

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Illustration 135	g00533043
View of 161-4168 Harness Assembly in the Left Console (22) Connector to the rocker switch. (31) 165-0753 Power Supply (32) 3E-5239 Relay Assembly

41. Attach connector (22) of the harness assembly to the 3E-8770 Rocker Switch .

42. Connect 165-0753 Power Supply (31) to the harness assembly at connector (23) .

43. Connect 3E-5239 Relay Assembly (32) to the harness assembly at connector (30) .

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Illustration 136	g00535531
Fuse Panel (33) Horn fuse.

44. Install the 163-7335 Harness Assembly into the left console. Connect the red wire from the harness assembly to the 10A fuse for the horn at the bottom of the fuse panel.

45. Route the black wire from the 163-7335 Harness Assembly under the cab. Ground the wire to the frame under the cab.

46. Connect the two-pin connector plug of the harness assembly to the two-pin connector socket of 161-4165 Harness Assembly (6) .

47. Connect the three-pin connector plug of the harness assembly to connector (28) of the 161-4168 Harness Assembly .

Systems Operation

Illustration 137	g00534628
Schematic of the Attachment System (1) Relay (2) Pilot valve (3) Solenoid (4) Solenoid (5) Relay (6) Relay (7) Pressure reducing valve (8) Pilot pump (9) Solenoid (10) Pressure reducing valve (11) Pressure reducing valve (12) Upper pump (13) Pressure reducing valve (14) Travel pressure switch (15) Flow control valve (16) Lower pump (A) Delimbing knives CLOSE (B) Tilt DOWN (C) Tilt UP (D) Feed roller OPEN (E) Feed roller CLOSE (F) Signal from saw or feed rollers (G) Pilot oil from pilot valve

Illustration 138	g00534820
(2) Pilot valve (3) Solenoid (4) Solenoid (7) Pressure reducing valve (9) Solenoid (10) Pressure reducing valve (11) Pressure reducing valve (13) Pressure reducing valve

Pressure reducing valves (7), (10), (11), and (13) are located on the right rear side of the machine. The flow of pilot oil to the pressure reducing valves is controlled by solenoids (3), (4), and (9) .

The solenoids are activated by relays (1), (5), and (6). The three relays are located in the wiring panel behind the cab.

Travel pressure switch (14) and flow control valve (15) are attached to the main control valve.

The harvester head contains a close stack valve with seven circuits. One pump flow or two pump flow can be provided to the harvester head. Three circuits require two pump flow (the two feed rollers and the saw). Four circuits require one pump flow (delimbing knives, holding arm, tilt, and feed roller arms).

The harvester head receives flow from pumps (12) and (16) through the attachment stem of the main control valve. After setting the pressure reducing valves for the lowest flow requirement (for either one pump flow or two pump flow), the flow control to the circuits on the harvester head must be adjusted. The hydraulic control valve on the harvester head will be used to adjust the pressure and flow to each circuit.

Note: The rotation of the harvester head is controlled by the bucket stem and a flow control valve.

One Pump Flow

When one of the circuits that require one pump flow (A), (B), (C), (D), or (E) is activated, the DASA closes relay (5). Solenoid (4) is activated. The solenoid allows pilot pressure oil from pilot pump (8) to flow through pressure reducing valve (13) to the attachment stem. One pump flow is provided to the harvester head. The amount of flow can be regulated by adjusting pressure reducing valve (13) .

When the operator wants to hold a tree in the harvester head and travel at the same time, travel pressure switch (14) is activated. A signal from the pressure switch closes relay (6). Solenoid (9) energizes. Solenoid (4) de-energizes. Solenoid (9) allows pressure reducing valve (11) to control movement of the attachment spool. The pressure reducing valve reduces the flow of oil from the attachment stem. More oil is then available for traveling.

Two Pump Flow

When the feed rollers or saw (F) are activated, the DASA closes relay (1). Relay (5) remains closed by the signal from the feed roller arms (E). Relay (1) deenergizes solenoid (4) and energizes solenoid (3). Solenoid (3) provides a flow of pilot oil in order to cause the following conditions:

• The attachment stem shifts

• The boom 2 stem shifts upward to provide two pump flow

• An artificial signal is provided to pump (16) in order to upstroke the pump

Pressure reducing valve (7) controls amount of flow to the harvester head by controlling the movement of the attachment stem. Pressure reducing valve (10) controls the amount that pump (16) upstrokes.

When the feed rollers or saw function is stopped, solenoid (3) closes. Pilot oil drains from the system. Flow control valve (15) allows the boom spool to slowly shift back to the NEUTRAL position. This enables smoother operation of the pumps.

The swing function is often used while feeding or sawing. When the swing function is activated pilot oil flow to the swing stem through line (G). The pilot oil shifts pilot valve (2), canceling the pump control signal from pressure reducing valve (10). Control of the pump is returned to the standard negative flow control circuit. This will provide additional flow for the swing circuit.

Testing and Adjusting

The following procedures must be performed after the HH65 Tree Harvester Head has been mounted on the 320B Excavator. The procedures must be performed in sequence to ensure proper adjustment of the machine. Read through each procedure before performing the procedure. All adjustments must be performed with the hydraulic oil at normal operating temperature.

The following procedures will be performed:

• Calibrate the right joystick control.

• Install the pressure gauges.

• Purge the air from the pilot oil lines.

• Adjust the pump output for one pump flow.

• Set the relief valves for the system.

• Adjust the oil pressure to the delimbing knives, feed roller arms, holding arms, and tilt cylinders.

• Adjust the back pressure to the feed roller motors.

• Adjust the pressure on the measuring arm cylinder.

• Adjust the speeds of the delimbing knives, feed roller arms, holding arms, and tilt cylinders.

• Adjust the output to the harvester head when traveling.

• Adjust the pump output for two pump flow.

• Adjust the speed of the feed rollers and saw bar return.

• Adjust the speed of the rotator.

• Adjust the line relief valves for the rotator.

• Adjust the line relief valves for the boom.

• Calibrate the diameter sensor(s).

• Calibrate the length sensor.

Table 16

Tools Required
Part No.	Description	Quantity
1U-5481	Pressure Gauge Group	1
9U-7400	Multitach Group (2)	1
8T-5114	Adapter Assembly	1
8T-2352	Tee	4
6V-3966	Valved Nipple Assembly	4
8T-8730	Socket	2
8T-5115	Hose Assembly	1

( 2 )

A 1U-6602 Phototach Group may be substituted.

Illustration 139	g00423959
Cab Features (1) Left keypad. (2) DASA Measuring and Control System. (3) Right keypad. (4) Left button. (5) Right button. (6) Left joystick control. (7) Right joystick control.

Some procedures require the use of joystick controls and buttons in the cab. In order to use the correct joystick controls and buttons in the procedures, refer to Illustration 139.

Use the following procedure to prepare the machine for each procedure. A tape measure and a stop watch may be necessary to perform some procedures.

1. Permit only one operator on the machine. Keep other personnel away from the machine and harvester head.

2. Park the machine on a smooth, level surface. Move away from other operating machines and away from personnel. Tilt the harvester head into the HORIZONTAL position. Lower the head to the ground.

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Illustration 140	g00413582
Parking Position

3. Stop the engine by turning the engine start switch key to the OFF position. Turn the attachment switch to the OFF position.

4. Place blocks in front of the tracks. Place blocks behind the tracks.

5. Turn the engine start switch key to the ON position. Move the joystick controls through the full range of travel.

6. Turn the engine start switch key to the OFF position. Lower the hydraulic activation control lever.

7. Remove the saw chain.

The following warnings and notice apply to all procedures:

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Personal injury or death can result from a rotating saw chain. Do not operate the saw when personnel are near the harvester head. Remove the saw chain when testing and adjusting the harvester head.

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Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak.

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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, 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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Personal injury or death can result if two persons are not used in the following procedure.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Joystick Controls - Calibrate

The following procedure calibrates the two buttons on the right joystick control that open and close the delimbing knives, holding arm, and feed rollers. You will not be able to calibrate the joystick controls if you did not select "Monsum" type levers in the "Programming Variables" of the DASA. If the "Grapple Setting" does not appear as an option under the "Min/Max Settings" change the lever type in the "Programming Variables".

Reference: For more information on calibrating the joystick controls, refer to the service manual module for Operation and Maintenance Manual, SEBU7182, "Programming Variables".

The procedure calibrates the electrical signals from the two buttons to the DASA. The procedure calibrates the following electrical signals:

• Minimum value for CLOSE

• Maximum value for CLOSE

• Minimum value for OPEN

• Maximum value for OPEN

1. Turn the engine start key to the ON position. Turn the attachment switch to the ON position. Move the toggle switch on the control unit to the right to activate the programming mode.

2. Press 6 for "Setting Module". Press "Enter". Press 4 for "Min/Max Setting". Press "Enter". Press 4 for "Grapple Setting". Press "Enter". The display screen will show the following message:
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   Table 17

   Setting min-value GRAPPLE CLOSE
   Press Grapple Close so that column
   just appears, then press ENTER
   _ _ _ _
   ENTER = save / ESC = Escape

3. Press in the left button on the right joystick control until the line on the screen just appears (refer to Table 17). While the button is in this position, press "ENTER". The minimum value for CLOSE is set.

4. Press the button in completely. Release the button approximately 2 mm (.1 inch). Press "ENTER". The maximum value for CLOSE is set. Release the button.

5. Press in the right button on the right joystick control until the line on the screen just appears. While the button is in this position, press "ENTER". The minimum value for OPEN is set.

6. Press the button in completely. Release the button approximately 2 mm (.1 inch). Press "ENTER". The maximum value for OPEN is set. Release the button.

7. The calibration procedure is complete. Press "ESC" several times to return to the main menu.

Pressure Gauges - Install

The following procedure is used to install the pressure gauges on the machine. The pressure gauges will allow you to measure the pilot pressure from the pilot pump and the pilot pressure to the main control valve on the machine. The pressure gauges will also allow you to measure the pressure in the implement hydraulic system.

1. Turn the engine start switch key to the ON position. Raise the hydraulic activation control lever. Move the left joystick control and the right joystick control through the full range of travel.

2. Lower the hydraulic activation control lever. Turn the engine start switch key to the OFF position.

3. Release the pressure in the hydraulic oil tank by slowly loosening the filler cap.

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Illustration 141	g00415418
Location for Installation of Pressure Gauges (1) Pilot pressure lines.

4. Disconnect pilot pressure lines (1) from the pressure reducing valves.

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Illustration 142	g00415399
Pressure Taps for Pilot Pressure (2) 8T-2352 Tee . (3) 6V-3966 Valved Nipple Assembly .

5. Install four 8T-2352 Tees into the pressure reducing valves. Connect pilot pressure lines (1) to the 8T-2352 Tees for the correct pressure reducing valves.

6. Install a 6V-3966 Valved Nipple Assembly into each tee.

   Note: When you adjust a pressure reducing valve, attach a 0 to 3400 kPa (0 to 500 psi) pressure gauge to the valved nipple assembly for the pressure reducing valve.

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Illustration 143	g00422300
Location for Installation of Pressure Gauges (4) Pressure tap for pilot pump. (5) Pressure tap for main pump.

7. Attach a 0 to 16000 kPa (0 to 2300 psi) pressure gauge to pressure tap (4) for the pilot pump.

8. Attach a 0 to 40000 kPa (0 to 5800 psi) pressure gauge to pressure tap (5) for the main pump.

Pilot Pressure Lines - Purge

The following procedure will purge the air from the pilot lines that control the output of the main pump. Failure to purge the air from the pilot lines may cause erratic operation of machine or harvester head. This procedure also reduces the pressure setting of the four pressure reducing valves to the minimum pressure setting.

Air will be purged from the pilot lines in six locations. The purging locations are identified in Illustration 146. In order to purge a line, the function must be activated.

Note: When a function is activated the function may not move because the pressure setting of the pressure reducing valves has been decreased. The functions do not need to operate in order to purge the air from the pilot pressure lines.

1. Lower the harvester head to the ground. Turn the engine start switch key to the OFF position. Lower the hydraulic activation control lever. Stop the engine.

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Illustration 144	g00413778
View Behind the Right Access Door (1) Pressure reducing valves. (2) Locknuts.

2. Loosen locknuts (2) on the four pressure reducing valves (1) .

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NOTICE
Do not force the adjustment screws in the counterclockwise direction. Forcing the adjustment screws may damage the valve. Turn the adjustment screws by hand to prevent damage to the valve.

3. Turn the adjusting screws for each locknut counterclockwise until resistance is felt. Turn the adjustment screws back clockwise for two turns.

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Illustration 145	g00414878
View in Front of the Main Control Valve (3) Connector plug for swing brake solenoid.

4. Disconnect connector plug (3) in order to activate the swing brake.

5. Start the engine. Turn the engine speed dial to position "8". Raise the hydraulic activation control lever. Turn the attachment switch to the ON position. Press "Enter" on the DASA keypad. Raise the harvester head 1 m (3 ft) above the ground.

6. Press in the left button on the right joystick control to close the delimbing knives, the feed roller arms, and the holding arm. Hold the button in while Steps 7 through 11 are completed.

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Illustration 146	g00535917
Front View of the Pilot Lines (Purging Locations)

7. Carefully loosen the connection at purging location (B). Allow the pilot pressure line to purge until the air has been completely removed. Tighten the connection.

8. Press the "Feed Forward" button on the right keypad. Keep the buttons depressed until Steps 9, 10, and 11 have been completed.

9. Carefully loosen the connection at purging location (C). Allow the pilot pressure line to purge until the air has been completely purged from the line. Tighten the connection.

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Illustration 147	g00536127
Purging Location (Behind the Main Pump)

10. Carefully loosen the connection at purging location (F). Allow the pilot pressure line to purge until the air has been completely removed from the line. Tighten the connection.

11. Carefully loosen the connection at purging location (E). Allow the pilot pressure line to purge until the air has been completely removed from the line. Tighten the connection.

12. Release the "Feed Forward" button. Release the left button on the right joystick control. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

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Illustration 148	g00414686
View in Front of the Main Control Valve (4) Connector plug for travel pressure switch.

13. Disconnect connector plug (4). The connector plug is located in front of the main control valve on the machine.

14. Make a jumper wire. Use two 8T-8730 Connector Sockets and a 130 mm (5 inch) piece of 16 gauge wire.

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Personal injury or death can result from electrocution by the electrical system on the machine. Do not allow the jumper wire to contact the machine. Use care when connecting the jumper wire to the pins of the harness plug.

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Illustration 149	g00414700
Jumper Wire for Travel Pressure Switch

15. Install jumper wire (5) between the pins on the harness plug. Be careful to not ground the jumper wire to the machine.

16. Start the engine. Turn the engine speed dial to position "8". Raise the hydraulic activation control lever. Turn the attachment switch to the ON position. Press "Enter" on the DASA keypad. Raise the harvester head approximately 1 m (3 ft) above the ground.

17. Press in the left button on the right joystick control to close the delimbing knives, the feed roller arms, and the holding arm. Hold the button in completely while Step 18 is completed.

18. Carefully loosen the connection at purging location (D). Allow the pilot pressure line to purge until the air has been completely removed from the line. Tighten the connection.

19. Release the left button on the right joystick control. Move the left joystick control to the SWING LEFT position. The swing brake will prevent the machine from rotating.

20. Carefully loosen the connection at purging location (A). Allow the pilot pressure line to purge until the air has been completely removed from the line. Tighten the connection.

21. Move the left joystick control to the SWING RIGHT position. The swing brake will prevent the machine from rotating.

22. Carefully loosen the connection at purging location (A) again. Allow the pilot pressure line to purge until the air has been completely removed from the line. Tighten the connection.

23. Release the left joystick control. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

24. Remove jumper wire (5) from the connector plug for the travel pressure switch. The jumper wire will be used in another procedure. Reconnect the connection plug for the travel pressure switch. Do not reconnect connection plug (3) for the swing break solenoid.

Pump Output for One Pump Flow

The following procedure will adjust the maximum output from the attachment stem for one pump flow. The output is controlled by the displacement of the attachment spool from the HOLD position when the delimbing knives, feed roller arms, holding arm, or tilt functions are activated. The displacement of the attachment spool is controlled by a pressure reducing valve.

1. Start the engine. Turn the engine speed dial to position "8". Raise the hydraulic activation control lever. Turn the attachment switch to the ON position. Press "Enter" on the DASA keypad. Raise the harvester head approximately 1 m (3 ft) above the ground.

2. Press the right button on the right joystick control to open the feed roller arms, delimbing knives, and holding arm. Press the left button on the right joystick control to close the feed roller arms, delimbing knives, and holding arm. Slowly alternate the activation of the left button and the right button for Step 3.

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Illustration 150	g00415961
Pressure Reducing Valve for One Pump Flow (1) Locknut. (2) Adjusting screw.

3. Turn adjusting screw (2) clockwise until the pressure gauge for the pressure reducing valve shows approximately 1025 kPa (150 psi). The functions will move. Tighten locknut (1) .

   Note: The speed of the functions on the harvester head will be adjusted in another procedure.

4. Stop activating the left button and the right button. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

Attachment System Pressure

The following procedure adjusts the maximum pressure of the oil flow to the harvester head. The line relief valve for the attachment stem will control the maximum system pressure. The main relief valve on the harvester head will be set above the pressure setting of the line relief valve. The procedure consists of the following Steps:

• Raise the setting of the line relief valve to 32500 kPa (4700 psi).

• Adjust the main relief valve to 30000 kPa (4350 psi).

• Lower the setting of the line relief valve to 27500 kPa (4000 psi).

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Illustration 151	g00536183
Right Side of Main Control Valve on Machine (1) Stick (2) Boom (3) Rotator (4) Attachment (5) Right travel (6) Locknut for line relief valve (7) Adjustment screw for line relief valve

1. Loosen locknut (6) on the line relief valve for the attachment stem. Turn adjustment screw (7) completely in the clockwise direction. The line relief valve is set to the maximum pressure setting.

   Note: The pressure setting of the line relief valve must be set above 30000 kPa (4350 psi) to adjust the main relief valve on the harvester head.

2. Remove the valve cover from the harvester head.

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Illustration 152	g00536190
Main Control Valve (Top View) (8) Connector for the left feed roller motor (9) Connector for the right feed roller motor

3. Remove connectors (8) and (9) .

4. Start the engine. Turn the engine speed dial to position "8". Raise the hydraulic activation control lever. Turn the attachment switch to the ON position. Press "Enter" on the DASA keypad.

5. Press and hold the "Feed Forward" button on the right keypad. Keep the button depressed for Steps 6 through 8.

6. Record the oil pressure from the gauge on the main pump. The recorded pressure is the setting of the main relief valve on the harvester head.

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Illustration 153	g00470396
Adjustment Location for the Main Relief Valve (13) Adjustment screw.

7. Adjust the pressure setting of the main relief valve on the harvester head to 30000 kPa (4350 psi). Turn adjustment screw (13) in the clockwise direction in order to increase the pressure. Turn adjustment screw (13) in the counterclockwise direction in order to decrease the pressure.

   Note: The adjustment screw may reach the end of the range of adjustment. Adjust the pressure setting to as close to 30000 kPa (4350 psi) as possible.

8. Turn adjustment screw (7) for the line relief valve counterclockwise until the pressure gauge on the main pump indicates 27500 kPa (4000 psi). Tighten the locknut for the line relief valve.

9. Release the "Feed Forward" button. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

Oil Pressure to One Pump Flow Functions

The following procedure will adjust the maximum oil pressure in the circuits for the delimbing knives, feed roller arms, holding arms, and tilt cylinders. The speed of these functions will be adjusted in another procedure.

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Illustration 154	g00416038
View at the End of the Stick (1) Connector.

1. Disconnect 40-pin connector (1) from the harvester head to the machine.

2. Ensure that the saw chain has been removed. Ensure that the connector to the swing brake solenoid has been disconnected.

Note: If the pressure taps on the harvester head are not Caterpillar pressure taps an adapter must be used. Follow Step 3.

3. Place a 3J-1907 O-Ring Seal on a 6V-3965 Nipple Assembly . The nipple assembly and the seal are part of the 8T-5320 Hydraulic Test Group . Attach the nipple assembly to a 8T-5114 Adapter . Attach a 8T-5115 Hose to the adapter.

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Illustration 155	g00470400
Pressure Tap Location (2) Adapter. (3) Pressure tap.

4. If necessary, attach adapter (2) to pressure tap (3). Attach a 0 to 40000 kPa (0 to 5800 psi) pressure gauge to the pressure tap or the adapter. Move the pressure gauge so the gauge can be observed from the left side of the harvester head.

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Illustration 156	g00422631
Strap for Holding Hydraulic Oil Lines

5. Use a strap to hold the hydraulic oil lines off the hydraulic control valve. Attach the strap around the hydraulic oil lines and through the guard on the rotator. Access to the hydraulic control valve will be easier.

6. Start the engine. Turn the engine speed dial to position "4". Raise the hydraulic activation control lever. Turn the attachment switch to the ON position. Press "Enter" on the DASA keypad. Raise the harvester head approximately 0.3 m (1 ft) above the ground.

7. Move the toggle switch for the DASA to the right in order to activate the programming mode.

8. Press "7" on the keypad for "Test Module". Press "Enter". Press "1" on the keypad for "Test Outputs". Press "Enter".

9. Press any key, except "Esc", in order to continue. Enter "4" in order to activate "Knives Cl". The delimbing knives may not move.

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Illustration 157	g00417118
Position for Adjusting Oil Pressure (4) Strap. (5) Allen wrench. (6) Pressure gauge. (7) 9 mm Wrench.

Note: Do not manually activate the tilt function.

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Illustration 158	g00416718
Hydraulic Control Valve (Top View) (8) Saw (9) Left feed roller (10) Right feed roller (11) Delimbing knives (12) Feed roller arms (13) Holding arm (14) Tilt (15) Pressure limiter valve (CLOSE position) (16) Pressure limiter valve (OPEN position) (17) Pressure limiter valve (CLOSE position) (18) Pressure limiter valve (DOWN position) (19) Pressure limiter valve (OPEN position) (20) Pressure limiter valve (CLOSE position) (21) Pressure limiter valve (OPEN position) (22) Pressure limiter valve (UP position) (23) Stud for manual movement of valve spool (24) Stud for manual movement of valve spool (25) Stud for manual movement of valve spool

10. Place wrench (7) on stud (23). Slowly turn the wrench to the DOWN position. The delimbing knives will close. Adjust pressure limiter valve (15) until the pressure gauge indicates 12500 kPa (1800 psi).

    Note: If the oil pressure does not change when a pressure limiter valve is turned, the valve may contain dirt. Turn the valve in the counterclockwise direction then open and close the function several times in order to allow oil to flow through the valve. Then, turn the valve in the clockwise direction in order to adjust the pressure setting.

11. Slowly turn the wrench to the UP position. The delimbing knives will open. Adjust pressure limiter valve (19) until the pressure gauge indicates 5500 kPa (800 psi).

12. Place the wrench on stud (24). Slowly turn the wrench to the DOWN position. The feed roller arms will open. Adjust pressure limiter valve (16) until the pressure gauge indicates 12500 kPa (1800 psi).

13. Slowly turn the wrench to the UP position. The feed roller arms will close. Adjust pressure limiter valve (20) to the lowest possible pressure while maximizing performance. Do not exceed the pressure of 19000 kPa (2750 psi).

14. Place the wrench on stud (25). Slowly turn the wrench to the DOWN position. The holding arm will close. Adjust pressure limiter valve (17) until the pressure gauge indicates 13500 kPa (1950 psi).

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Illustration 159	g00417229
Bypass Relief Valve (26) Adjusting screw. (27) Locknut.

15. Loosen locknut (27). Turn adjusting screw (26) clockwise until the screw reaches the end of travel.

16. Place the wrench on stud (25). Slowly turn the wrench to the UP position. The holding arm will not open. Adjust pressure limiter valve (21) until the pressure gauge indicates 16500 kPa (2400 psi).

17. While the wrench is in the UP position, slowly turn adjusting screw (26) in the counterclockwise direction until the holding arm begins to open. Tighten locknut (27) .

18. Adjust pressure limiter valve (21) until the pressure gauge indicates 5500 kPa (800 psi). Remove the wrench.

19. Press "Enter" on the DASA keypad. Lower the harvester head to the ground.

20. Reconnect connector (1) to the harvester head. Raise the harvester head approximately 0.3 m (1 ft) above the ground.

21. Move the toggle switch for the DASA to the right in order to activate the programming mode.

22. Press "7" on the keypad for "Test Module". Press "Enter". Press "1" on the keypad for "Test Outputs". Press "Enter".

23. Enter "25" on the DASA in order to activate "Tilt Down". Press "Enter". The harvester head will tilt down. Adjust pressure limiter valve (18) until the pressure gauge indicates 10000 kPa (1450 psi).

24. Remove the strap for the hydraulic hoses.

25. Press "Enter" on the DASA keypad. Enter "6" in order to activate "Tilt Up". Press "Enter". The harvester head will tilt up.

26. Lower the harvester head onto the ground while in the harvester head is in the VERTICAL position. Adjust pressure limiter valve (22) until the pressure gauge indicates 16000 kPa (2300 psi).

27. Raise the harvester head off the ground. Press "Enter" on the DASA keypad. The head will tilt down. Move the toggle switch on the DASA to the left to activate the operation mode.

28. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine. Remove the pressure gauge. Remove the adapter (if installed).

Back Pressure on Feed Roller Motors

The following procedure adjusts the back pressure of the oil to the feed roller motors. The back pressure must be set for the feed rollers to function correctly.

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Illustration 160	g00417440
Left Side of the Harvester Head (1) Adjusting screw. (2) Locknut. (3) Pressure tap.

1. Attach a 0 to 4000 kPa (0 to 580 psi) pressure gauge to pressure tap (3) .

   Note: If the pressure reducing valve does not have a Caterpillar pressure tap, use the adapter from Step 3 of ""Oil Pressure to Low Flow Functions - Adjust" ".

2. Start the engine. Turn the engine speed dial to position "4".

3. Move the toggle switch for the DASA to the right in order to activate the programming mode.

4. Press "7" on the keypad for "Test Module". Press "Enter". Press "1" on the keypad for "Test Outputs". Press "Enter".

5. Press any key, except "Esc", in order to continue. Enter "4" in order to activate "Knives Cl". The delimbing knives may not move.

6. Loosen locknut (2). Turn adjusting screw (1) until 1800 kPa (260 psi) is read on the pressure gauge. Tighten locknut (2) .

7. Remove the pressure gauge. Remove the adapter (if installed).

Pressure of Measuring Arm Cylinder

The following procedure adjusts the pressure of the measuring arm on the log. A pressure reducing valve controls the oil pressure to the measuring arm cylinder. By increasing the oil pressure to the measuring arm cylinder the measuring wheel will press further into the log. The measuring wheel must apply enough pressure to the tree in order to remain in contact with the tree when the tree is processed.

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Illustration 161	g00422828
View in Back of the Harvester Head (1) Pressure tap.

1. Attach a 0 to 10000 kPa (0 to 1450 psi) pressure gauge to pressure tap (1) .

   Note: If the pressure reducing valve does not have a Caterpillar pressure tap, use the adapter from Step 3 of ""Oil Pressure to Low Flow Functions - Adjust" ".

2. Move the toggle switch for the DASA to the right in order to activate the programming mode.

3. Press "7" on the keypad for "Test Module". Press "Enter". Press "1" on the keypad for "Test Outputs". Press "Enter".

4. Press any key, except "Esc", in order to continue. Enter "4" in order to activate "Knives Cl". The delimbing knives may not move.

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Illustration 162	g00417525
Adjusting Screw for the Pressure Reducing Valve

5. Loosen the locknut for the adjusting screw. Turn the adjusting screw until 5000 to 7000 kPa (725 to 1000 psi) is read on the pressure gauge (depending on the type of tree). Tighten the locknut.

   Note: Anytime the pressure setting is adjusted the length sensor must be calibrated.

6. Remove the pressure gauge. Remove the adapter (if installed).

7. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

Speed of One Pump Flow Functions

The following procedure will test and adjust the speed of the delimbing knives, the feed roller arms, the holding arm, and the tilt function. Increasing the oil flow to a function increases the speed of the function. The speed of the engine must be set correctly during the test to ensure proper operation of the functions.

1. Start the engine. Turn the engine speed dial to position "8". Raise the hydraulic activation control lever. Turn the attachment switch to the ON position. Press "Enter" on the DASA keypad. Raise the harvester head approximately 0.3 m (1 ft) above the ground.

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NOTICE
The speed of the functions on the harvester head must be set correctly. If the speeds are set too fast damage to the harvester head may result. Adjust the speeds of the functions according to the following procedure to prevent damage to the harvester head.

2. Press the "Tilt Up" button on the right keypad. Measure the amount of time to tilt the head from the HORIZONTAL position to the VERTICAL position.

3. While the harvester head is in the HORIZONTAL position, press the "Tilt Down" button. The harvester head will rotate down about 15 °. The harvester head should not strike the stops. The "Tilt Down" function should operate smoothly.

4. Press the right button on the right joystick control to open the delimbing knives, feed roller arms, and holding arm. Measure the amount of time to fully open the functions from the FULLY CLOSED position.

5. Press the left button on the right joystick control to close the delimbing knives, feed roller arms, and holding arm. Measure the amount of time to fully close the functions from the FULLY OPEN position.

   If the speeds do not meet the following criteria, the speeds must be adjusted. Perform Steps 6 through 10 to adjust the speed.

   • The measured speeds should be between 0.6 seconds and 1.0 seconds.

   • The opening speed of the delimbing knives, feed roller arms, and holding arm should be slightly slower than the closing speed.

   • The delimbing knives, feed roller arms, and holding arm should open and close at the same speed.

   • The functions must not strike into the stops when the function reaches the end of travel.

6. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

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Illustration 163	g00419001
Left Side of Hydraulic Control Valve (1) Delimbing knives (CLOSE) (2) Feed roller arms (OPEN) (3) Holding arm (CLOSE) (4) Tilt (DOWN) (5) Delimbing knives (OPEN) (6) Feed roller arms (CLOSE) (7) Holding arm (OPEN) (8) Tilt (UP)

7. Select the stroke limitation screw for the function that must be adjusted. Loosen the locknut for the stroke limitation screw.

8. Turn the screw counterclockwise to increase the speed of the function. Turn the screw clockwise to decrease the speed of the function. Tighten the locknut to 7.9 N·m (70 lb in).

9. Start the engine. Turn the engine speed dial to position "8". Raise the hydraulic activation control lever. Turn the attachment switch to the ON position. Press "Enter" on the DASA keypad. Raise the harvester head approximately 0.3 m (1 ft) above the ground.

10. Activate the function again. If the speed of the function is not correct repeat Steps 6 through 10 to readjust the speed.

11. The speed of all one pump flow functions should now be set correctly. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

Pump Output for Holding While Traveling

The following procedure will adjust the maximum output from the attachment stem when the machine is traveling. When the machine travels, the travel pressure switch changes the machine to two pump flow. The travel motors required increased oil flow, therefore the oil flow to the harvester head is decreased by moving the attachment spool closer to the HOLD position. The displacement of the attachment spool when traveling is controlled by a pressure reducing valve.

1. Reconnect the 40-pin connector between the machine and the harvester head.

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Illustration 164	g00463775
Connector Plug for the Travel Pressure Switch

2. Disconnect the connector plug for the travel pressure switch. The connector plug is located in front of the main control valve on the machine.

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Personal injury or death can result from electrocution by the electrical system on the machine. Do not allow the jumper wire to contact the machine. Use care when connecting the jumper wire to the pins of the harness plug.

3. Acquire the jumper wire for the travel pressure switch used in ""Pilot Pressure Lines - Purge" ". Install the jumper wire between the pins on the harness plug. Be careful to not ground the jumper wire to the machine.

4. Start the engine. Turn the engine speed dial to position "8". Raise the hydraulic activation control lever. Turn the attachment switch to the ON position. Press "Enter" on the DASA keypad. Raise the harvester head approximately 0.3 m (1 ft) above the ground.

5. Press the left button on the right joystick control to cause the holding arm to close. The holding arm may not move.

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Illustration 165	g00419199
Pressure Reducing Valve (1) Locknut. (2) Adjusting screw.

6. Turn adjusting screw (2) until the holding arm closes in approximately eight seconds. The pressure gauge for the pressure reducing valve should read approximately 825 kPa (120 psi).

   Note: Turn adjusting screw (2) clockwise to increase the speed of the holding arm. Turn adjusting screw (2) counterclockwise to decrease the speed of the holding arm.

7. Tighten locknut (1) .

8. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

9. Remove the jumper wire from the connector plug of the travel pressure switch. Reconnect the connector plug for the travel pressure switch.

Oil Flow to the Saw and Feed Rollers

The following procedure adjusts the oil flow to the feed roller motors and the saw motor. The oil flow to the saw motor and the feed roller motors will be adjusted for maximum oil flow. The motors will then operate at maximum speed. The correct speed of the feed roller motors will be set in another procedure.

1. Ensure that the harvester head has been lowered to the ground. Ensure that the engine is stopped.

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Illustration 166	g00419326
Left Side of Hydraulic Control Valve (1) Saw (RETURN). (2) Left feed roller (FORWARD). (3) Right feed roller (FORWARD). (4) Saw (CUT). (5) Left feed roller (REVERSE). (6) Right feed roller (REVERSE).

Note: Stroke limitation screw (1) will be adjusted in another procedure.

2. Loosen the locknuts on stroke limitation screws (2), (3), (4), (5), and (6). Turn the screws completely in the counterclockwise direction.

3. Place a wrench on the stud for the left feed roller. Turn the wrench to the DOWN position. While the wrench is in the DOWN position, turn screw (2) clockwise until the wrench just begins to move. Tighten the locknut for screw (2) .

   Note: Tighten all locknuts to a torque of 7.9 N·m (70 lb in).

4. Turn the wrench to the UP position. While the wrench is in the UP position, turn screw (5) clockwise until the wrench just begins to move. Tighten the locknut for screw (5) .

5. Place a wrench on the stud for the right feed roller. Turn the wrench to the DOWN position. While the wrench is in the DOWN position, turn screw (3) clockwise until the wrench just begins to move. Tighten the locknut for screw (3) .

6. Turn the wrench to the UP position. While the wrench is in the UP position, turn screw (6) clockwise until the wrench just begins to move. Tighten the locknut for screw (6) .

7. Place a wrench on the stud for the saw. Turn the wrench to the UP position. While the wrench is in the UP position, turn screw (4) clockwise until the wrench just begins to move. Tighten the locknut for screw (4) .

Pump Output for Two Pump Flow Functions

The following procedure will adjust the maximum output from the attachment stem for two pump flow. The output is controlled by the displacement of the attachment spool from the HOLD position when the saw motor or the feed roller motors are activated. The displacement of the attachment spool is controlled by a pressure reducing valve.

The output of the main pump for the two pump flow functions will be measured by the speed of the feed rollers. The speed of the feed rollers will be adjusted in another procedure.

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Illustration 167	g00419558
Left Feed Roller (1) Photo pickup. (2) Reflective tape.

1. Clean the inside of the rim for the left feed roller. Clean the inside of the rim for the right feed roller.

2. Cut eight pieces of 1U-6605 Reflective Tape approximately two inches long. Attach four pieces reflective tape (2) to the inside of each feed roller rim. Evenly space the four pieces of tape on the rim.

3. Place the 6V-3137 Magnetic Base of 9U-5140 Photo Pickup (1) on top of the left feed roller motor. Direct the photo pickup toward the pieces of reflective tape.

4. Attach the 6V-2198 Extension Cable from the 9U-7401 Multitach to the cable of the photo pickup. Set the multitach for four pulses per revolution.

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Illustration 168	g00540167
Tachometer for Feed Rollers (3) 6V-2198 Extension Cable . (4) 9U-7401 Multitach .

5. Move cable (3) away from the feed rollers. Move multitach (4) onto the machine.

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Illustration 169	g00536298
Connector to the Feed Roller Arms

6. Remove the connector to the feed roller arms. Removing the connector will prevent the feed roller arms from closing and damaging the photo pickup when the feed button is pressed.

7. Start the engine. Turn the engine speed dial to position "8". Raise the hydraulic activation control lever. Turn the attachment switch to the ON position. Press "Enter" on the DASA keypad. Raise the harvester head approximately 0.3 m (1 ft) above the ground.

8. Press and hold the "Feed Forward" button on the right keypad. Keep the buttons depressed until Steps 9, 10, and 11 have been completed.

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Illustration 170	g00419658
Pressure Reducing Valves (5) Locknut. (6) Adjusting screw. (7) Locknut. (8) Adjusting screw.

9. Turn adjusting screw (8) completely in the clockwise direction. The pressure gauge for the pressure reducing valve must read above 2750 kPa (400 psi).

10. Turn adjusting screw (6) clockwise until the pressure gauge for the pressure reducing valve indicates approximately 2250 kPa (325 psi) .

11. Turn adjusting screw (8) counterclockwise until the multitach indicates approximately 200 revolutions per minute. The pressure gauge for the pressure reducing valve should read approximately 2050 kPa (300 psi).

    Note: If you are unable to attain 200 revolutions per minute, ensure that the 6V-8636 Connector was installed in Step 17 as part of the installation of the "" 158-7510 Front Lines Group " ".

12. Tighten locknut (5). Tighten locknut (7) .

13. Release the "Feed Forward" button. Release the right button on the right joystick control. Do not remove the tachometer assembly.

14. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

Feed Roller Speed and Saw Bar Return Speed

The following procedure will adjust the speed of the feed rollers and the saw bar return. The speed of the feed rollers must be adjusted to 170 revolutions per minute. Incorrect speeds will not provide enough feeding force to delimb the tree. The return speed of the saw bar must be set correctly to not damage the harvester head.

1. Ensure that the saw chain has been removed. Ensure that the tachometer assembly from ""Pump Output for Two Pump Flow Functions" " is set to measure the speed of a left feed roller.

2. Start the engine. Turn the engine speed dial to position "8". Raise the hydraulic activation control lever. Turn the attachment switch to the ON position. Press "Enter" on the DASA keypad. Raise the harvester head approximately 0.3 m (1 ft) above the ground.

3. Press and hold the "Feed Forward" button on the right keypad.

4. Record the speed of left feed roller forward and reverse. Release the buttons. Place the photo pickup on the right feed roller motor. Repeat Step 3. Record the speed of the right feed roller forward and reverse. Release the buttons.

5. The speed of the feed rollers in the forward direction and the reverse direction must be adjusted to approximately 170 revolutions per minute. To adjust the speed of the feed rollers perform Steps 6 through 8.

6. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

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Illustration 171	g00420285
Left Side of Hydraulic Control Valve (1) Left feed roller (FORWARD) (2) Right feed roller (FORWARD) (3) Left feed roller (REVERSE) (4) Right feed roller (REVERSE)

7. Loosen the locknut for the function that must be adjusted. Turn the adjusting screw clockwise to decrease the speed of the function. Turn the adjusting screw counterclockwise to increase the speed of the function.

8. Start the engine. Turn the engine speed dial to position "8". Activate the function again to test the new setting of the stroke limitation screw.

   Note: The speed of the left feed roller must be the same as the speed of the right feed roller.

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Personal injury or death can result from a rotating saw chain. Do not operate the saw when personnel are near the harvester head. Remove the saw chain when testing and adjusting the harvester head.

9. Remove the photo pickup from the harvester head. Press in the right button on the right joystick control to open the delimbing knives, the feed roller arms, and the holding arm. While the right button is depressed, press and hold the "Cut" button on the left keypad.

10. Release the "Cut" button when the saw bar has completely rotated to the OUT position.

    Note: The return speed of the saw bar must be set as fast as possible without damaging the saw bar. To adjust the return speed of the saw bar perform Steps 11 through 13.

11. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

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NOTICE
The speed of the functions on the harvester head must be set correctly. If the speeds are set too fast damage to the harvester head may result. Adjust the speeds of the functions according to the following procedure to prevent damage to the harvester head.

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Illustration 172	g00420379
Left Side of Hydraulic Control Valve (5) Saw (RETURN).

12. Loosen the locknut on the stroke limitation screw for saw RETURN (5). Turn the adjusting screw clockwise to decrease the speed of the function. Turn the adjusting screw counterclockwise to increase the speed of the function.

13. Start the engine. Turn the engine speed dial to position "8". Activate the function again to test the new setting of the stroke limitation screw. Tighten the locknut when the speed has been set correctly. The speed should be set so the saw bar fully extends and retracts within 1 to 1.5 seconds.

    Note: The speed at which the saw bar extends is not adjustable. Only the speed at which the saw bar retracts can be adjusted.

14. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

15. Reconnect the connector to the feed roller arms.

Rotator Speed

The following procedure adjusts the speed of rotation of the harvester head. The speed of the rotator should be adjusted to the preference of the operator. If the speed is too fast it will be difficult to control the head.

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Illustration 173	g00420462
Speed Control Valve for the Rotator (1) Adjusting screw (Rotator COUNTERCLOCKWISE) (2) Adjusting screw (Rotator CLOCKWISE) (3) Locknuts

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NOTICE
Do not force the adjustment screws in the counterclockwise direction. Forcing the adjustment screws may damage the valve. Turn the adjustment screws by hand to prevent damage to the valve.

1. Loosen locknuts (3) on adjusting screws (1) and (2). Turn the adjusting screws completely in the counterclockwise direction.

2. Start the engine. Turn the engine speed dial to position "8". Raise the hydraulic activation control lever. Turn the attachment switch to the ON position. Raise the harvester head approximately 0.3 m (1 ft) above the ground.

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NOTICE
The rotator does not have stops that limit the rotation of the harvester head. The hydraulic oil lines between the machine and harvester head can be damaged. Do not allow the harvester head to rotate enough to damage the hydraulic oil lines.

3. Move the right joystick control completely to the left. The harvester head will not rotate. Turn adjusting screw (1) clockwise until the harvester head begins to rotate counter-clockwise.

4. Move the right joystick control completely to the right. The harvester head will not rotate. Turn adjusting screw (2) clockwise until the harvester head begins to rotate clockwise.

   Note: If the harvester head does not rotate, move the joystick control to the left. The pilot oil lines may have been connected backwards.

5. Turn adjusting screws (1) and (2) until the desired speed of the rotator is obtained. Turn the adjusting screws clockwise to increase the speed of the rotator. Turn the adjusting screws counterclockwise to decrease the speed of the rotator.

6. Tighten locknuts (3). Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

Line Relief Valves for the Rotator

The following procedure adjusts the maximum oil pressure in the circuit for the rotator. The oil pressure to the rotator must be set correctly to prevent damage to the harvester head.

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Illustration 174	g00536401
Right Side of the Main Control Valve (1) Stick II (2) Boom (3) Rotator (4) Attachment (5) Right travel (6) Line relief valve (Rotator COUNTERCLOCKWISE) (7) Line relief valve (Rotator CLOCKWISE)

1. Loosen the locknut on line relief valve (6). Turn the adjusting screw for line relief valve (6) in the counterclockwise direction without completely removing the nut.

2. Loosen the locknut on line relief valve (7). Turn the adjusting screw for line relief valve (7) in the counterclockwise direction without completely removing the nut.

3. Start the engine. Turn the engine speed dial to position "8". Raise the hydraulic activation control lever. Turn the attachment switch to the ON position. Lower the harvester head firmly onto the ground.

4. Move the right joystick control completely to the right. Do not allow the harvester head to rotate on the ground.

5. Turn the adjusting screw for line relief valve (6) clockwise until the pressure gauge for the main pump indicates approximately 19000 kPa (2755 psi). Tighten the locknut for line relief valve (6) .

6. Move the right joystick control completely to the left. Do not allow the harvester head to rotate on the ground.

7. Turn the adjusting screw for line relief valve (7) clockwise until the pressure gauge for the main pump indicates approximately 19000 kPa (2755 psi). Tighten the locknut for line relief valve (7) .

8. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

Line Relief Valves for the Boom Cylinders

The following procedure adjusts the lift capacity and lower capacity of the boom. The adjustments must be made to prevent damage to the harvester head.

1. Ensure that the harvester head is on the ground in the HORIZONTAL position with the stick fully extended

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Personal injury or death can result from sudden movement of the boom. The boom can suddenly move when adjusting the line relief valves. Keep all personnel away from the attachment when adjusting the line relief valves.

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Illustration 175	g00420778
Line Relief Valve (Boom DOWN) (1) Locknut. (2) Adjusting screw.

2. Loosen locknut (1). Turn adjusting screw (2) in the counterclockwise direction without completely removing the nut.

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Illustration 176	g00420780
Line Relief Valve (Boom UP). (3) Adjusting screw. (4) Locknut.

3. Loosen locknut (4). Turn adjusting screw (3) in the counterclockwise direction without completely removing the nut.

4. Start the engine. Turn the engine speed dial to position "8". Raise the hydraulic activation control lever.

5. Move the right joystick control fully forward to lower the boom. Turn adjusting screw (2) clockwise until the pressure gauge on the main pump indicates approximately 9000 kPa (1300 psi).

6. Tighten locknut (1). Release the right joystick control.

7. Move the right joystick control fully back to raise the boom. Hold the joystick control in the FULLY BACK position for Steps 8 and 9. The boom should not move.

8. Slowly turn adjusting screw (3) clockwise. The boom will begin to raise. Allow the boom raise completely.

9. Continue turning adjusting screw (3) clockwise until the pressure gauge on the main pump indicates approximately 20700 kPa (3000 psi). Tighten locknut (4) .

10. Lower the harvester head to the ground. Lower the hydraulic activation control lever. Turn the attachment switch to the OFF position. Stop the engine.

11. Reconnect the connection for the swing break solenoid. Reinstall the valve cover on the harvester head. Remove all of the pressure gauges that have been installed.

Lubrication Oil - Check

The following procedure must be performed before the harvester head is used. Proper lubrication is necessary to prevent damage to the saw chain and feed roller arms.

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Illustration 177	g00470450
Lubricating Oil Tank

1. Fill the lubricating oil tank with 7.6 L (8.0 qt) of biodegradable oil.

2. Operate the feed roller arms from the OPEN position to the CLOSE position several times. Lubrication oil should be present on the shafts of the feed roller arms.

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Illustration 178	g00470452
Saw Chain Oil Pump

3. Lubricate the saw manually before operating the saw by pushing on the piston underneath the saw chain oil pump.

4. Operate the saw several times. Lubrication oil should be present on the saw chain.

Default Calibration of the Diameter Sensor(s)

This procedure must be performed for the diameter sensors to accurately process the tree. The following procedure sets the values in the default calibration list.

Note: The following procedure uses plastic tubes to calibrate the diameter sensors. If plastic tubes are not available use a tree. The tree should be straight and circular in cross-section. The tree should have a limited number of branches.

1. Select five to ten tubes of various diameter. The tubes must be between 35 mm (1.4 inch) and 650 mm (25.6 inch). Measure and record the diameter of each tube in millimeters.

2. Tilt the harvester head into the VERTICAL position. Fully open the delimbing knives, feed rollers, and holding arm. Lower the harvester head to the ground. Stop the engine.

3. Turn the engine start key to the ON position. In the operating mode, press in the button on the right joystick control to open the delimbing knives, feed rollers, and holding arm. Hold the button in until the DASA beeps.

4. Chain the frame of the harvester head to the yoke to prevent the head from tilting. Remove the valve cover from the head.

   Note: The delimbing knives, feed rollers, and holding arm must be fully open before performing Step 6.

5. Move the toggle switch on the control unit to the right to activate the programming mode. Press "6" for "Setting Module". Press "ENTER". Press "4" for "Default Setting Diameter Measure". Press "ENTER".

6. Enter "650" after "Write Max. Diameter?". The display screen will show the following message:
   Show/hide table

   Table 18

   No. 0 Address = Max Dia = 650
   Address = 2047
   Set Limbing Knives
   Continue with ENTER / End with ESC
   Move Back with left arrow

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Illustration 179	g00471588
Tube Position for Calibration of Diameter Sensors

7. Place the largest tube in the harvester head. Ensure that the tube is parallel to the head. The top and bottom of the tube must also be touching the guide rollers on the head.

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Illustration 180	g00471534
Stud for Delimbing Knives on a HH55 or HH65

8. Place a wrench on the stud for the delimbing knives. Fully turn the wrench away from the head. While the wrench is in this position, manually close the two delimbing knives onto the tube.

9. Press "ENTER". The display screen will show the following message:
   Show/hide table

   Table 19

   No. 0 Address = Max Dia = 650
   Write Diameter of knives
   Diameter No 1?_
   Address = 2047

10. Enter the diameter of the tube in millimeters. Press "ENTER" to accept the entered value. The entered diameter will be displayed at the top of the screen.

11. Move the wrench on the valve fully toward the head. Manually open the delimbing knives. Repeat Steps 7 through Steps 11 for the remaining tubes. Use the second largest tube and work toward the smallest tube.

12. When all tubes have been calibrated enter "35" for the final diameter value. Press "ENTER" to accept the entered calibration settings. The calibration is complete.

Calibration of the Length Sensor

The length sensor must be calibrated before the length of trees can be measured accurately. Before the length sensor can be calibrated an inspection procedure must be performed. The following procedure should only be used the first time the length sensor is calibrated.

Reference: For more information on the complete inspection procedure, refer to the Operation and Maintenance Manual, SEBU7182, "DASA Measuring and Control System", "Length Sensor - Inspect".

1. In the operating mode, process a tree. Cut one log 500 cm (195 inch) or longer.

2. Press "8" to view the length of the cut log. A printout can be made by pressing "9".

3. Measure the length of the log in centimeters. Subtract the "SHOWED LENGTH" on the DASA screen from the measured length of the log. If the difference is greater than 1 cm (0.40 inch), the length sensor must be calibrated. Go to Step 4.

4. In the programming mode, go into the sub-menu for "Calibration Length Measure". The display screen will show a message similar to Table 20.
   Show/hide table

   Table 20

   	--Calibration of Length measure--
   		Length/Pulse-Relation: 101.08%
   	Continue with ENTER / End with ESC

5. Press "ENTER". Enter the value from the DASA screen after "SHOWED LENGTH". Press "ENTER". The display screen will show the following message.
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   Table 21

   	--Calibration of Length measure--
   		Write SHOWED LENGTH : 500
   	Write MEASURED LENGTH : _

6. After "MEASURED LENGTH", enter the measured length of the log.

7. The "Length/Pulse-Relation" will change. Press "Esc" to end the calibration procedure.

   Note: If "550" is entered for the "SHOWED LENGTH" and "550" is also entered for the "MEASURED LENGTH" the "Length/Pulse Relation" will not change to 100.00%. When values are entered, the DASA changes the "Length/Pulse Relation" an amount proportional to values entered.

Final Pressure Settings

All testing and adjusting procedures are now complete. The following table is a summary of the pressure settings of the HH55 or HH65 Harvester Head and the 320B Excavator.

The pressure settings for the hydraulic functions in Table 22 are the maximum pressure settings. The hydraulic functions of the harvester head should be operated at the lowest pressure setting possible. The pressure settings may need to be adjusted based on the species of tree, weather conditions, and tree quality.

Illustration 181	g00536474
Top View of the Hydraulic Control Valve

Table 22

HH55 and HH65 Harvester Heads
Callout	Function	Oil Pressure
1	Main relief valve	30000 kPa (4350 psi)
2	Delimbing knives CLOSE	12500 kPa (1800 psi)
3	Feed roller arms OPEN	12500 kPa (1800 psi)
4	Holding arm CLOSE	13500 kPa (1950 psi)
5	Tilt DOWN	10000 kPa (1450 psi)
6	Measuring arm	5000 to 7000 kPa (725 to 1000 psi)
7	Bypass relief valve	16500 kPa (2400 psi)
8	Back pressure to feed roller motors	1800 kPa (260 psi)
9	Delimbing knives OPEN	5500 kPa (800 psi)
10	Feed roller arms CLOSE	19000 kPa (2750 psi)
11	Holding arm OPEN	5500 kPa (800 psi)
12	Tilt UP	16000 kPa (2300 psi)

Illustration 182	g00536505
Right Side of the Main Control Valve

Table 23

Main Control Valve
Callout	Function	Oil Pressure
13	Boom DOWN	9000 kPa (1300 psi)
14	Rotator CCW	15900 kPa (2300 psi)
15	Rotator CW	15900 kPa (2300 psi)
16	Attachment	27500 kPa (4000 psi)
17	Boom UP	20700 kPa (3000 psi)

Illustration 183	g00536547
Side View of the Pressure Reducing Valves

Table 24

Pressure Reducing Valves
Callout	Function	Oil Pressure
18	Holding while traveling	825 kPa (120 psi)
19	Low flow	1025 kPa (150 psi)
20	Pump signal	2250 kPa (325 psi)
21	High flow	2050 kPa (300 psi)