OPERATION AND MAINTENANCE MANUAL

PUB NO. 1653 REVISION 0

SERIAL NUMBER 490044

MODEL SV-22-P-H-30 SCALER WITH:

CUMMINS QSB4.5 160HP TIER 3 DIESEL ENGINE
FULL REVERSING POWERSHIFT TRANSMISSION
HEAVY DUTY KESSLER AXLES WITH SAHR EMERGENCY BRAKE
SAE ROPS/FOPS CAB WITH LEXGUARD WINDOW PROTECTION
ANSUL FIRE SUPPRESSION SYSTEM OPTION
ATLAS COPCO HAMMER OPTION
SPRAY WATER SYSTEM
LINCOLN AUTOMATIC LUBRICATOR
PUSH BLADE OPTION
ACCESSORY PICK

© 2012 All rights reserved.

The electronic copy of this manual has been prepared using the software Adobe® Acrobat® (pdf format). The
user is encouraged to become familiar with the features of Adobe Acrobat or Reader to facilitate navigating the
manual electronically. The electronic manual has incorporated such features as bookmarks, hypertext links, text
search capabilities, etc to enable the user to quickly locate the desired information. Hypertext links allow the
reader to click on the text and go to the desired location. Navigating the document is made easier by opening the
bookmarks and thumbnails option. Using text search allows the user to quickly locate instances in the manual for
a word or phrase.

Read and understand

manual and safety
information before
operating!

The Operation and Maintenance Manual provides all the necessary information to safely operate, maintain, and
troubleshoot your Oldenburg Group Incorporated equipment. Safe and efficient operation requires that the
operator be familiar with the equipment, understand its capabilities, and follow the recommended operating
procedures in this manual.

New operators must be thoroughly trained by qualified personnel and must never operate the equipment
unsupervised. Information in this manual must be reviewed and understood before using your equipment.
Failure to comply could result in serious injury or death.

In addition to all safety measure outlined in this manual, personnel shall adhere to all applicable workplace
practices and regulations. To maintain optimum performance from this equipment, any questions concerning this
publication should be directed to the manufacturer.
 OPERATION AND MAINTENANCE MANUAL
TABLE OF CONTENTS

TABLE OF CONTENTS
Section Page

1.0 SAFETY
Safety Signal Words................................................................................................................. 1-2
General Safety Precautions ..................................................................................................... 1-2
Operation Safety Precautions .................................................................................................. 1-3
Maintenance Safety Precautions ............................................................................................. 1-4
Hazardous Atmospheres.......................................................................................................... 1-5

2.0 GENERAL INFORMATION

General Description ................................................................................................................. 2-2
Components............................................................................................................................. 2-4
Specifications ........................................................................................................................... 2-5

3.0 OPERATION
3.1 Controls and Indicators
Fuel System.................................................................................................................... 3-2
Oil System ...................................................................................................................... 3-3
Engine & Transmission................................................................................................... 3-5
Brakes............................................................................................................................. 3-8
Cab ................................................................................................................................. 3-10
Battery Box ..................................................................................................................... 3-23
Fire Suppression ............................................................................................................ 3-24
3.2 Vehicle and Equipment Operation
Pre-Operation Checklist ................................................................................................. 3-26
Vehicle Start-Up ............................................................................................................. 3-27
Driving the Vehicle.......................................................................................................... 3-27
Brake Test ...................................................................................................................... 3-31
Scale Brake Mode .......................................................................................................... 3-32
Vehicle Stopping and Shutdown .................................................................................... 3-32
Boom Operation ............................................................................................................. 3-33
Tool Operation ................................................................................................................ 3-33
Emergency Operation..................................................................................................... 3-34

4.0 MAINTENANCE
4.1 Scheduled Maintenance
Pre-Shift (8hr) ................................................................................................................. 4-2
First 40 Hours ................................................................................................................. 4-13
Every 40 Hours............................................................................................................... 4-15
Every 250 Hours............................................................................................................. 4-16
Every 500 Hours............................................................................................................. 4-21
Every 1000 Hours........................................................................................................... 4-26

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OPERATION AND MAINTENANCE MANUAL
TABLE OF CONTENTS

TABLE OF CONTENTS (CONTINUED)

Section Page

4.2 Adjustments and Alignments

Check System Hydraulic Pressure ................................................................................. 4-29
Adjust System Hydraulic Pressure ................................................................................. 4-29
Check Accumulator Pre-Charge..................................................................................... 4-33
Charge Accumulator....................................................................................................... 4-33
Adjust Boom Rollers ....................................................................................................... 4-36
Adjust Park Brake ........................................................................................................... 4-39

4.3 Lube Chart ...................................................................................................................... 4-40

4.4 Fluid List ......................................................................................................................... 4-50

4.5 Filter List ......................................................................................................................... 4-51

5.0 TROUBLESHOOTING
General Troubleshooting....................................................................................................... 5-2
Troubleshooting Guide.......................................................................................................... 5-3

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 OPERATION AND MAINTENANCE MANUAL
SAFETY

1.0 SAFETY

This Operation and Maintenance Manual contains the information necessary to safely operate, maintain, and
troubleshoot your Oldenburg machine. Safe and efficient operation requires that the operator be familiar with
the vehicle, understand its capabilities and follow the recommended operating procedures in this manual.

New Operators must be thoroughly trained by qualified personnel and must never operate the machine
unsupervised. Information in this manual must be reviewed and understood before using this machine. Failure
to comply could result in serious injury or death.

In addition to all safety measures outlined in this manual, personnel shall adhere to all applicable workplace
practices and regulations. To maintain optimum performance from this equipment, any questions concerning
this publication should be directed to the manufacturer.

Section Page
Safety Signal Words ....................................................................................................................... 1-2
General Safety Precautions............................................................................................................ 1-2
Operation Safety Precautions......................................................................................................... 1-3
Maintenance Safety Precautions.................................................................................................... 1-4
Hazardous Atmospheres ................................................................................................................ 1-5

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OPERATION AND MAINTENANCE MANUAL
SAFETY

Safety Signal Words

This is the safety-alert symbol. When you see this symbol on your machine, you must be alert to the
potential for personal injury. Follow recommended precautions and safe operating practices.

A Danger identifies the most serious hazards that will result in serious injury or death.

A Warning identifies critical hazards that could result in serious injury or death.

A Caution identifies potential hazards that could result in minor injury.

A Notice identifies the potential for major damage to the machine or other equipment.

General Safety Precautions

The machine shall not be used during inclement weather which may affect the safe operation of the
equipment. The machine shall not be used anytime lightning is present.

It is important to keep the equipment clean for safe operation. Dirt and mud can build up on the
equipment causing an unsafe condition. It is also important to keep the equipment clean for proper
operation of the moving components and for serviceability of the equipment.

Do not operate this equipment to remove debris. Do not operate this equipment to lift, lower or
transport personnel or objects. Do not operate this equipment in an explosive hazardous atmosphere.
Do not operate this equipment on or near public roadways.

Carefully read all safety messages in this manual and on your equipment. Keep safety signs or
decals in good condition. Replace any missing or damaged signs. Follow all maintenance
recommendations to keep the equipment in proper working condition.

Wear tight fitting clothing and safety equipment appropriate for the job. This may include, but not be
limited to, the following items: eyewear, gloves, hardhat, steel-toe boots, and hearing protection.
Operating requires full attention. Do not wear music headphones while operating the equipment.

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 OPERATION AND MAINTENANCE MANUAL
SAFETY

Prepare for emergencies. Be prepared if a fire starts and keep a first aid kit and fire extinguisher
handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near
a telephone.
 

Handle fluids safely and avoid fires. Prevent fires by keeping the equipment clean and free of
accumulated grease or debris. Always clean up spilled fluids and oils. Do not leave oily rags on the
equipment as they can ignite and burn spontaneously. Alert mine personnel of any fire hazards.

Avoid hot parts. Drill string parts become very hot during operation. Avoid skin contact with the drill
string. Allow these parts to cool before performing any maintenance. Be alert when working around
the drill string and do not wear loose fit clothing.

Avoid high pressure fluids. Escaping high pressure fluid can penetrate skin, causing serious injury.
Relieve pressure before disconnecting hydraulic or other pressure lines. Tighten all connections
before restoring system pressures. Do not use hands or feel for leaks

ALWAYS chock wheels before performing any maintenance. Whether parked on an incline or flat
surface, always take the necessary precautions to prevent the vehicle from rolling. Do not rely
exclusively on the park brake to hold the vehicle in place. Also place the articulation lock in the
locked position prior to performing any maintenance.

Operation Safety Precautions

 Ensure area around the vehicle is clear and parking brakes are applied.

 NEVER start a machine that has been tagged OUT OF SERVICE.

 Make sure windows are up and cab is ventilated properly if hearing protection is not worn.

 Ensure the transmission directional control switch is in the NEUTRAL position.

 ALWAYS sound the horn before starting the engine, to alert anyone who might be close to the vehicle.

 Ensure all scheduled maintenance has been performed.

 DO NOT operate the vehicle unless all dash gauges display operation in the normal indication range.

 Ensure all accessories are properly stowed.

 DO NOT allow riders except in equipped seats.

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SAFETY

 Do not leave the vehicle unattended with the engine running.

 Remove wheel chocks only when parking brake is applied.

 Keep the haulage or roadways clear of loose rock and debris.

 Know the area of operation (loose or hanging rock, low voltage electrical cables, harmful mined gases, etc.)

 ALWAYS scale with the vehicle under previously scaled or supported roof conditions working toward the un-
scaled area. Scale from the highest point to the lowest.

Maintenance Safety Precautions

 NEVER perform service in hinged area without articulation lock in place.

 Unless otherwise specifically directed all checks listed shall be performing while the Vehicle Engine is off.

 Do not run vehicle if the hydraulic fluid is low, failure to comply will result in vehicle damage.

 Ensure the fuel tank is full. Excessive condensation may occur inside fuel tank if vehicle is low on fuel. This
can damage the engine

 Do not run vehicle with a dirty filter. The filter is bypassed when the dirt alarm indicates a dirty condition. The
hydraulic system can become contaminated, causing serious damage to hydraulic components.

 Do not operate the vehicle with a dirty Hydraulic Tank Filter. Contamination can cause serious damage to
hydraulic system components.

 Do not run the vehicle with a dirty Fuel Filter. Engine damage may occur. Do not run vehicle with a dirty air
element. Dirty Air can cause engine damage.

 ALWAYS chock wheels, install boom cylinder locks, and articulation lock bar during maintenance.

 ALWAYS provide proper ventilation when performing any maintenance with the engine running.

 NEVER work under boom without adequate support. If available, cylinder lock collars are designed to support
elevated booms and should be used.

 NEVER work on inner or outer boom assembly without locking inner boom from moving in or out. Chaining
and blocking boom is MANDATORY.

 Never inflate tire and wheel assemblies without proper safeguards.

 ALWAYS use proper lifting equipment to remove and install tires and wheels.

 NEVER work on hydraulic system without removing pressure from system.

 ONLY remove radiator cap when system is cool.

 Cyberstick pilot controls may allow steering movement, tool rotation, and boom functions after engine has
been shut down. This is due to stored energy in the accumulator circuit. Always block machine from
movement and drain accumulator pressure before performing maintenance.

 Do not run the vehicle with a dirty Transmission Filter. Serious damage to the transmission can occur.

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SAFETY

Hazardous Atmospheres

Evaluating Hazardous Atmospheres:

A hazardous atmosphere means an atmosphere that may expose employees to the risk of death, incapacitation,
impairment of ability to self-rescue (escape unaided from a permit space), injury, or acute illness from one or
more of the following causes:

 Oxygen concentration below 19.5% or above 23.5%

 Flammable gas, vapor, or mist in excess of 10% of its Lower Explosive Limit (LEL)
 Combustible dust at a concentration that meets or exceeds its LEL
 Atmospheric concentration in excess of any substance’s published dose or Permissible Exposure Limit
(PEL) which is capable of causing death, incapacitation, impairment of ability to self-rescue, injury, or acute
illness due to its health effects
 Any other atmospheric condition that is immediately dangerous to life or health

You must do air monitoring to determine if a hazardous atmosphere exists!

Atmospheric conditions in a confined space can change very quickly!

Oxygen Levels:

Is the oxygen level too high or too low? Below are oxygen levels and what is considered too high or low.

 23.5% and above is too HIGH

 20.8% - 21% is NORMAL
 19.5% and below is DEFICIENT

What are some causes or indications of possibly having a deficient oxygen atmosphere inside a space?
Inerting or purging, which means the displacement of the atmosphere in a space by a noncombustible gas
(such as nitrogen) to such an extent that the resulting atmosphere is non-combustible. The following is a list of
dangers of low oxygen levels.

 16-12% oxygen in air generally causes deep breathing, fast heartbest, poor attention, poor
thinking, and poor coordination
 14-10% oxygen in air generally causes faulty judgement, intermittent breathing, rapid fatigue
(possibly causing heart damage), very poor coordination, and lips turning blue
 10% or less oxygen in air generally causes nausea (vomiting), loss of movement, and loss of
conciousness followed by death.
 Less than 6% oxygen in air generally causes spasmodic breathing, convulsive movement, and
death in approximately eight minutes. 4-6% oxygen in air can lead to a coma in 40 seconds.

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OPERATION AND MAINTENANCE MANUAL
SAFETY

Flammable/Explosive Gases, Vapors, or Mists:

At atmosphere is hazardous if it exceeds 10% of its Lower Explosive Limit (LEL). The Lower Explosive Limit
(LEL) is the lowest concentration where a material is flammable in the air. Upper Explosive Limit (UEL) is the
highest concentration where a material is flammable in the air. LEL and UEL can also be referred to as a
Lower Flammable Limit (LFL) and Upper Flammable Limit (UFL). Check your Material Safety Data Sheets
(MSDS) or other resources for the chemical’s LEL and UEL.

The following diagram shows the flammable or explosive range from minimum (LEL) to maximum (UEL)
limits. It also shows where 10% LEL is.

Ignition
Too Rich
UEL
Concentration in Air

Flammable
LEL Oxygen Fuel
Region

10% LEL
Too Lean
Don’t forget airborne
combustible dust.
Flash Point Combustible solids,
when finely dispersed
Temperature and raised, can explode
when its concentration is
between LEL and UEL.

Toxic Substances:

The atmosphere is hazardous if it exceeds the dose or Permissible Exposure Limit (PEL) and capable of
causing death, incapacitation, impairment of ability to self-rescue, injury, or acute illness due to its health
effects. Most chemicals have permissible exposure limits.

Even non-toxic or low-toxic chemicals can replace oxygen if levels are high enough.

The most comon toxic chemicals in confined space fatailities are Hydrogen Sulfide and Carbon Monoxide.

Hydrogen Sulfide (H2S) gas is commonly found in sewers and can be instantly fatal at higher levels in
confined spaces. Disturbing sewage sludge can release hydrogen sulfide gas. Carbon Monoxide (CO)
comes from operating internal combustion and propane-powered engines in or near confined spaces. Fatal
levels of CO are quicly reached in confined spaces.

Other toxic chemicals can include welding fumes, vapors from liquid residues in storage tanks, or chemical
products used in confined spaces. Chemicals can quickly reach toxic levels in the air of a confined space,
especially gases, solvent vapors, or sprayed products.

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 OPERATION AND MAINTENANCE MANUAL
GENERAL INFORMATION

2.0 GENERAL INFORMATION

In this section of your Operation and Maintenance Manual is a general description of the machine, including all
standard equipment and machine options, as well as machine dimensions and specifications. A description of all
the major machine components and systems is provided and includes component dimensions and specifications.
All machine generated levels and machine limitations are listed and the location of the machine data plate is
indicated.

Section Page
General Description ........................................................................................................................... 2-2
Components....................................................................................................................................... 2-4
Specifications..................................................................................................................................... 2-5

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OPERATION AND MAINTENANCE MANUAL
GENERAL INFORMATION

GENERAL DESCRIPTION

The SV-22 Scaler is a single-boom machine designed to scale in large rooms or low narrow entries. On the front
frame of the machine is the heavy duty boom with FOPS rock deflector and Atlas Copco SB452E hammer, and
an optional push blade. On the rear frame of the machine is the ROPS/FOPS certified open operators cab and
the Cummins diesel engine.

The frame is made from high strength steel and inlcudes ball bearing oscillation and tapered roller bearing
articulation. Nylon dividers in the front and rear frames protect the cables and hoses throughout the articulation
joint.

The boom is mounted low for better visibility and extends an additional 9’8” for a maximum scale height of 33 feet.
No adjustments are required for the boom with access to components without removing the inner boom. All
grease points are external and extend and retract boom stops extend the life for the extension cylinder. All roller
assemblies are interchangeable and accessed from outside the boom. The boom rotator has 180 degree rotation
with Rotek bearing designed specifically for scaling.

The open operators cab includes a 1” Lexguard bulletproof windshield and inside the cab are the operator
controls with fluid two handed joystick controls that provide fluid back scaling motion, proportional control, and
synchronous movement.

The hydraulic system includes a high pressure filter on the brake circuit, spin-on filters, load-sensing pumps, and
main control valves that have port relief and pressure settings built in. Auxiliary oil cooler is mounted in a swing-
open design for easy cleaning and all hydraulics include bolt-on end caps for reduced load and improved
geometry.

The electrical system includes point-to-point wiring with Nema 4 stainless steel boxes and hinged dash panels for
easy access. The DIN connectors are waterproof with locking setscrews and LED indicator lights.

The drive train includes a Cummins QSB4.5, 160HP diesel engine, 4-speed power-shift transmission with wet-
disc SAHR parking brake, and new Kessler drive axles. Also included is a heavy-duty external cooling package
with easy access for cleaning.

Extendible Boom ROPS/

& Rock Deflector FOPS
Cab

Cummins Engine

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 OPERATION AND MAINTENANCE MANUAL
GENERAL INFORMATION

Rotary ROPS/FOPS
Actuator Certified Open Cab
Rotation 180 degree with 1” Lexguard
Bearing rotation Windshield

Kessler Axles and Frame Oscillation Dana 32000

12 x 24 tires with Tapered Powershift
Sealed Roller Transmission with
Bearings Wet Disc Brake

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OPERATION AND MAINTENANCE MANUAL
GENERAL INFORMATION

COMPONENTS

Standard:
 Tier 3 Cummins QSB4.5 160HP diesel engine.
 24V, 100A Alternator, sealed point-to-point wiring.
 Full reversing 32000 series, 4-speed powershift
transmission.
 Heavy duty Kessler Drive Axles.
 Four wheel drive with hydraulic axle service braking and
driveline SAHR emergency disc brake.
 Transmission mounted SAHR park brake.
 Heavy-duty articulation with Timken tapered roller
bearings.
 Cyber Stick steering with 30 degrees articulation each side.
 10 micron “spin-on” return filters.
 Pressure compensated pumps with load sensing.
 ROPS/FOPS open cab with bulletproof lexguard
windshield.
 Boom with rock deflector and rotation for the hammer or pick.
 4 front and 2 rear tramming lights.
 4 cab and 4 boom working lights.

Machine Options:
 Water Spray System.
 10 lb. Fire Extinguisher.
 Ansul Fire suppression system.
 Wheels Chocks.
 Push Blade.
 Auto Greasing System.

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 OPERATION AND MAINTENANCE MANUAL
GENERAL INFORMATION

SPECIFICATIONS

Boom
Boom Extension 9'8" (2.9m)
Max Scale Height 33'-1" (10.1m)
Boom Swing Angle 30° by Articulation
Min Pick Height 4'-5" (1.4m)

Hydraulic System
System Type Load Sense System
Pumps 2 x Piston Pumps
Max System Pressure 2500 (172 bar)
Tank Volume 76 gal (287 l)
Hydraulic Oil ISO 068
Pressure Filtration 10 micron
Oil Temp Meter Yes
Oil Filter Plugged Indication Yes
Low Oil Level Indication Yes

Engine & Powertrain

Model QSB 4.5
Number of Cylinders 4
Power 160 (119 kW) hp (@ 2200
Torque (ft-lbf @ rpm) 459 (622 N-m) @ 1500 rpm
Emissions Tier III
Alternator 24V--70 Amp
Engine Air Cleaner Dual Element, Dry Air
Exhaust Muffler, Cataylic Cleaner
Murphy Monitoring System Option
Safety Shutdown Circuits High Temp & Low Oil Press
Transmission Dana 32,000 Powershift
Transmission Speed Range 4 Sped to 13 mph
Axle John Deere Teammate II
Tire Size 12.00 X 24

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OPERATION AND MAINTENANCE MANUAL
GENERAL INFORMATION

Chassis
Steering Articulation +/- 30 degrees
Four Wheel Drive Yes
Service Brakes Wet Disc
Emergency Brakes SAHR Wet Disk
Fuel Tank Volume 75 gal (287 l)
Fuel Gauge Yes
Exhaust Catalyser Optional
Exhaust Muffler Yes
Lighting 12 Front & 2 Rear
Horn/Back-Up Alarm Yes
Fire Extinguisher Yes
Central Lubrication Option
Machine Weight 57,000 lbs (25,855 kg)
Cab Height Options 8' (2.4m), 9' (2.7m), & 10' (3.0m)

Operator Station
Standard Operator Station Enclosed Cab
In-Cab Operating Sound Level 84 dBA
Cab Pressurization Yes
Certified FOPS Yes
Certified ROPS Yes

Options
Fire Suppression
Spare Tire & Rim
Push Blade
Water Spray

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OPERATION

3.0 OPERATION

Only authorized personnel (trained and certified) shall operate this machine. Always review the Safety section of
this manual prior to operating this machine.

Section Page

3.1 Controls and Indicators

Fuel System .......................................................................................................................... 3-2
Oil System............................................................................................................................. 3-3
Engine & Transmission ......................................................................................................... 3-5
Brakes ................................................................................................................................... 3-8
Cab........................................................................................................................................ 3-10
Battery Box............................................................................................................................ 3-23
Fire Suppression ................................................................................................................... 3-24
3.2 Vehicle and Equipment Operation
Pre-Operation Checklist ........................................................................................................ 3-26
Vehicle Start-Up .................................................................................................................... 3-27
Driving the Vehicle ................................................................................................................ 3-27
Brake Test............................................................................................................................. 3-31
Scale Brake Mode................................................................................................................. 3-32
Vehicle Stopping and Shutdown ........................................................................................... 3-32
Boom Operation .................................................................................................................... 3-33
Tool Operation ...................................................................................................................... 3-33
Emergency Operation ........................................................................................................... 3-34

Read and understand

manual and safety
information before
operating!

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OPERATION AND MAINTENANCE MANUAL
OPERATION

3.1 CONTROLS AND INDICATORS

Fuel Tank
The fill cap is located on top of the fuel tank next to the fuel/water separator filter. The cap includes a strainer to
ensure a cleaner fuel supply into the tank when filling. If equipped with the Wiggins Remote Fill Option, the fuel is
added using a ground-level remote fill connector and the tank includes a Wiggins air vent.

A Fuel Supply Shut-Off Valve is mounted at the fuel inlet. Shown in the “open” position, rotate handle 90° to the
“close” position to shut off flow of fuel.

Fuel / Water Fill Cap &

Separator Filter Strainer Fuel Tank
Wiggins Remote Fill
Option (Not Shown)
includes Wiggins air
vent and ground-
level Wiggins fuel fill
connector

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 OPERATION AND MAINTENANCE MANUAL
OPERATION

Hydraulic Tank
The Hydraulic Oil Level and Temperature Gauge is located on the side of the hydraulic tank. Oil level should be
approximately in the middle of the gauge. The gauge is also equipped with a thermometer (oil temperature
gauge) that indicates the temperature of the hydraulic oil. If equipped with the Wiggins Remote Fill Option, the
hydraulic oil is added using a Wiggins remote fill connector with dust cap.

Wiggins Remote Fill Option (Not Shown) includes

Wiggins remote fill connector with dust cap

Hydraulic Oil Level and

Temperature Gauge

Hydraulic Oil Fill Cap

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OPERATION AND MAINTENANCE MANUAL
OPERATION

Hydraulic High Pressure Filter

The hydraulic high pressure filter is located on the front of the engine end frame assembly, near the articulation
joint. It is equipped with a visual dirt indicator that provides an indication of when it is time to change the filter
element. When the filter element clogs and is bypassed, a highly visible orange disk springs or “pops up”. Once
activated, the orange signal continues to indicate a bypass or clogged condition even after equipment shut down.
The signal will not change until it is manually reset.

Hydraulic High Pressure

Filter Dirt Indicator

Engine End Frame Assembly

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 OPERATION AND MAINTENANCE MANUAL
OPERATION

Engine Oil Dipstick

Refer to the Engine Operation and Maintenance Manual for specific Oil Level Dipstick location and information.

Coolant Fill
The Coolant Sight Check is located on the radiator. The face of the Coolant Sight Check has a glass observation
window where engine coolant can be observed. If engine coolant is not visible in the Coolant Sight Check,
coolant should be added at this coolant fill point.

Coolant Fill

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OPERATION AND MAINTENANCE MANUAL
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Transmission Filter
The Transmission Filter is equipped with a Mechanical Dirt Indicator that shows a red visual indicating signal.
The mechanical indicator has a Manual Reset Button. Once activated the red signal continues to indicate a
bypass or clogged condition even after equipment shut down.

Mechanical Dirt Indicator

Transmission Filter

Some machines are

equipped with
ground-level access
to the transmission
filter. Locations may
vary depending on
the option selected.

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Transmission Fluid
The Transmission Fluid Level Dipstick is used to check the transmission fluid level.

Transmission Fluid Level Dipstick

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OPERATION AND MAINTENANCE MANUAL
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Accumulator
The Accumulator Dump Relief Valve relieves the hydraulic pressure in the brake accumulators. The Accumulator
Dump Relief Valve is located below the access panel on the engine end frame. The control cap above
designated port “A1” releases the accumulator pressure for the front brakes and the control cap above the
designated “A2” port releases the accumulator pressure for the rear brakes. Pull up on the control cap to open
the valve and release pressure in the accumulator. Push down on the control cap to retain pressure in the
accumulator.

Control Cap

A1 A2

Accumulator Dump Relief Valve

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Manual Brake Release

The transmission mounted park brake is spring applied (set) and hydraulically released. It takes a minimum 1100
psi of hydraulic pressure in the brake release circuit to overcome the spring to release the brake. If hydraulic
pressure in the brake system drops below 1100 psi, the spring assembly will automatically apply (set) the brake.
The spring will keep the brake applied (set) until sufficient hydraulic pressure is available to release. During
normal operation hydraulic system pressure is directed to release the park brake. If system and accumulator
pressure is not available it is possible to manually pressurize the brake release circuit using the manual brake
release hand pump located on the floor of the cab next to the seat. To do this, close the release valve by turning
it clockwise and pump the handle to build pressure until the brakes release. To apply the brakes, turn the release
valve counterclockwise to release pressure.

Manual Brake Release Hand Pump

Release Valve

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OPERATION AND MAINTENANCE MANUAL
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Brake Pressure
The brake pressure gauge (0 - 2000 psi) registers hydraulic pressure at the brake system accumulator for the
drive axle service brakes. System should maintain 1100 -1500 psi (75.8 – 103.4 bar) at all times during
operation. Reading may fluctuate during operation.
Transmission Pressure
The transmission pressure gauge (0 - 400 psi) registers hydraulic pressure available to shift the transmission.
Gauge should read 240 – 280 psi (16.5 – 19.3 bar) during operation.

Transmission
Pressure Gauge

Inside the Cab

Brake
Pressure
Gauge

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Engine Oil Pressure

The engine oil pressure gauge (0 - 100 psi) registers active engine oil pressure. Oil pressure is normally between
80 and 100 psi.

Converter Temperature
The converter temperature gauge (140-300F) registers the active converter operating temperature. Operating
temperature is normally between 180 and 200F.

Engine Temperature
The engine temperature gauge (100-250F) registers the active engine operating temperature. Operating
temperature is normally between 160 and 200F.

Tachometer
Registers engine Revolutions Per Minute (RPM). Tachometer range is 0-3000 RPM.

System Voltmeter
Registers engine operating voltage. Voltage range is 18-32 Volts.

Hour Meter
Registers hours of operation.

Fuel level gauge

Indicated fuel level in fuel tank (E - ½ - F).

Park Brake/Reset Switch:

Park brake will SET automatically and Park Brake/Reset light will come “on” with Brake Fail
indication. With Brake Fail light extinguished park brake will have to be RESET before normal operation can
resume.

The Park Brake/Reset Switch is a three-position, push-pull (red illuminated) selector switch. The switch has
two maintained positions for normal operation and a third “momentary” position for RESET operation. Push
“IN” to normally set the parking brake. Red cap light will come on. Pull “OUT” to normally release the parking
brake. Red cap light will turn off. With switch in the brake released position (out/maintained), pull “OUT” to
RESET. Switch will spring-return to brake released (out/maintained) position when released.

NOTE: Red cap light will also come “on” whenever the scale brake or park brake is activated.

Engine Ready (to start) Indicator:

Comes on when the engine is ready to be started.

Scale Brake On Indicator Light:

Red warning lamp, which comes on when the scale brake function is activated. The Park Brake/Reset
indicator light will come “on” with “Scale Brake On” indication.

Brake Fail Indicator Light:

Red warning lamp, which comes “on” when hydraulic pressure in either brake accumulator (front or rear)
drops below 1100 psi or the transmission charge pressure drops below 60 psi. Alarm buzzer activated
with warning light.

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OPERATION AND MAINTENANCE MANUAL
OPERATION

Air Filter Blocked Indicator Light:

Red warning lamp, which comes “on” when airflow through the engine air intake filter is restricted to the
maximum recommended limit. The indicator automatically resets itself after the filter is serviced. Alarm
buzzer activated with warning light.

Hydraulic Oil Filter Blocked Indicator Light:

Red warning lamp, which comes “on” when oil flow though either the high pressure (hydraulic) oil filter or
the dual element, return line (hydraulic) filter is restricted to the point where changing the filter element is
required.

Axle Filter Blocked Indicator Light:

Red warning lamp, which comes “on” when oil flow though the axle brake circuit oil filter is restricted to
the point where changing the filter element is required.

Hydraulic Oil High Temperature Indicator Light:

Red warning lamp, which comes “on” when temperature of the oil in the hydraulic tank reaches 180°F.
Alarm buzzer activated with warning light. Automatic engine shut down after 5 minutes.

Engine Switch:

Refer to Vehicle and Equipment Operation, for further instructions on starting the engine.
Improper operation of the starting circuit can lead to serious engine damage.

The OFF/ON/START Engine Switch and an engine heater indicator work together in the starting circuit. The
OFF/ON/START switch is a three position rotary switch with manual selection between OFF and ON
positions. Momentary, manual hold to START position with spring return to ON.

ON: Turn selector to “ON” position to complete starting circuit and enable engine starting operation. The
Engine Ready Indicator indicates that the glow plug preheat timer is energized. The Engine Ready Indicator
light goes “off” when glow plug preheat sequence is complete. Engine is ready for cold weather start.

DO NOT hold on START for more than 20 seconds at one time. If engine does not fire, wait
one minute then try again. If engine does not start after two attempts refer to the Engine Operation and
Maintenance Manual.

START: Turn and hold momentarily to energize the engine starter (turn over the engine). Release as soon
as engine fires. Selector spring returns to ON when manually released.

Letting the engine idle for at least 20 seconds prior shut off will prolong the life of the engine.

OFF: Turn selector to OFF to open the engine starting circuit and shut off engine and/or disable the engine
starting circuit.

Brake Test Pushbutton:

Application of the park brake test button will release the service brakes. This may cause the
vehicle to roll freely and can cause serious injury or death. Prepare for vehicle movement prior to using the
brake test button. DO NOT initiate the brake test with anyone near the vehicle.

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Momentary pushbutton (normally open) switch. To test, press and hold the pushbutton. Release to terminate
test mode.

Hydraulic Oil Low Level Indicator Light:

Continued operation with Hydraulic Oil Low Level indication could result in catastrophic
damage to the hydraulic system.

Red warning lamp, which comes “on” when oil level in the hydraulic tank is below the minimum level
required to properly sustain normal operation. Alarm buzzer activated with warning light. Automatic
engine shut down after 90 seconds. The Hydraulic Oil Low Level warning light comes “on” when
hydraulic oil level is reduced by approximately 40%. The engine will shut down automatically when
hydraulic oil level is reduced by approximately 55 %.

Indicating Lights:
-Brake Fail
Park Brake/Reset
-Engine Oil Low Pressure
-Engine High Temp Engine Oil Pressure
-Air Filter Blocked Axle Filter
-Hydraulic Oil Filter Blocked Blocked
-Hydraulic Oil High Temp Tachometer
-Hydraulic Oil Low Level
Converter Temp
Brake Test

Scale Engine Fuel Engine Engine Hour Meter Voltmeter

Brake On Temperature Gauge Switch Ready
Indicator

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OPERATION

Manual Transmission Selector Switch:

5-Position rotary selector switch. Controls the transmission shifting selection. Select (1), (2), (3) or (4) to set and
maintain operation in an operator selected gear. Operation works the same in forward (FWD) and reverse (REV)
directions of travel.

Scale Lights:
2-Position, toggle switch. Toggle selector to “ON” to illuminate scaling boom and cab mounted spotlights. Toggle
selector to “OFF” to extinguish scaling boom and cab mounted spotlights.

Front Lights:
2-Position, toggle switch. Toggle selector to “ON” to illuminate front facing (clear) spotlights and rear facing (red)
running light. Toggle selector to “OFF” to extinguish front facing spotlights and rear facing running light.

Rear Lights:
2-Position, toggle switch. Toggle to “ON” to illuminate rear facing (clear) spotlights and front facing (red) running
light. Toggle to “OFF” to extinguish rear facing spotlights and front facing running light.

Windshield Wiper Control:

Rotary switch. Controls the windshield wiper. Turn clockwise to energize and increase the speed of the wiper
motor. Turn counter-clockwise to decrease speed and de-energize the wiper motor. Press rotary switch to
energize washer spray. Release to de-energize washer spray.

Audible Alarm:
The audible alarm will sound automatically as an alarm signal when the following conditions exist:

 Hydraulic oil temperature exceeds 180°F.

 Oil level in hydraulic tank below minimum level.

 Engine oil pressure below is below 15 psi (1.03 bar).

 Engine coolant temperature exceeds 235°F (113°C).

 Engine coolant level below minimum level.

Pick Rotate Enabled Indicator Light:

Orange lamp, which comes “on” when Pick Rotate trigger or pushbutton is engaged at either the LH or RH
Control Handle. This is referred to as the Pick Rotate Mode.

Water Spray Switch:

2-Position, toggle switch. Toggle selector to “ON” to energize the water spray system. Toggle selector to “OFF”
to de-energize the water spray system.

Water Spray Indicator Light:

Yellow lamp, which comes “on” when the water spray system is energized and ready for use.

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Circuit Breaker 1:
10 amp circuit breaker. Press to reset. Travel Control Circuit: Transmission Solenoid 1, Transmission Solenoid
2, Transmission Solenoid 3, Park Brake Test Button and Solenoid, Horn, Pick Rotate/Steering, Reverse Solenoid,
Backup Horn, Neutral Relay, Forward Solenoid.

Circuit Breaker 3:
20 amp circuit breaker. Press to reset. Starter motor solenoid circuit: Starter Motor, Dump Solenoid.

Circuit Breaker 2:
10 amp circuit breaker. Press to reset. HVAC circuit: HVAC Controller, HVAC Unit, Binary Switch and AC
Compressor.

Circuit Breaker 4:
10 amp circuit breaker. Press to reset. Micrologic Power Source, R.H. Control Handle: Park Brake, Scale Brake,
Pick Rotate/Steering

Circuit Breaker 5:
10 amp circuit breaker. Press to reset. Hydraulic Oil Level Audible Alarm, Hydraulic Oil Low Level Lamp, Dirty
Air Filter Lamp/Switch, Engine Shutdown, Hydraulic Oil Clogged Filter Pressure Switch, Hydraulic Oil Clogged
Filter Switch (Return Line), Hydraulic Oil Mid-Level Switch, Hydraulic Oil Low-Level Switch.

Circuit Breaker 6:
20 amp circuit breaker. Press to reset. Brake Fail Lamp, Park Brake Relay (Set), Controller, Park Brake Lamp
(Set), Park Brake Relay (Reset), Park Brake (Release), Transmission Converter Temperature Meter,
Transmission Converter Temperature Sender, Fuel Meter, Fuel Level Sensor, Scale Brake, Axle Brake On Lamp,
Pick Rotate (Left), Pick Rotate (Right), Pick Rotate Enabled Indicator, Hydraulic Oil Filter Blocked Lamp, Lamp
Test, Air Filter Blocked Lamp, Hydraulic Oil High Temperature Lamp, Hydraulic Oil Temperature Switch.

Circuit Breaker 7:
20 amp circuit breaker. Press to reset. Starting Circuit: Ignition ON/OFF/START Switch, Park Brake, Neutral,
Ignition ON Relay, Throttle Position Signal, Throttle Return, Intermediate Speed Input.

Circuit Breaker 8:
20 amp circuit breaker. Press to reset. Accessory Circuit: Windshield Wiper Control Switch, Windshield Wiper
Motor, Windshield Washer Motor, Regeneration Pressure Switch and Solenoid.

Circuit Breaker 9:
20 amp circuit breaker. Press to reset. Front lighting circuit: Front Light Switch, Front Lights, Rear Running
Lights, Dome Light, Boom Light Relay.

Circuit Breaker 10:

20 amp circuit breaker. Press to reset. Boom, bar, rear lighting circuit: Rear Light Switch, Rear Lights, Cab Bar
Lights (LH)

Circuit Breaker 13:

60 amp circuit breaker. Press to reset. Circuit Breaker CB1, Circuit Breaker CB2, Circuit Breaker CB4, Circuit
Breaker CB5, Circuit Breaker CB6, Circuit Breaker CB8.

Circuit Breaker 14:

80 amp circuit breaker. Press to reset. Dump Solenoid.

Circuit Breaker 15:

20 amp circuit breaker. Press to reset. Boom Lights Switch, Boom Lights, Cab Bar Lights (RH).

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OPERATION AND MAINTENANCE MANUAL
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HVAC Controller
Scale Lights
Audible Alarm

Manual Transmission Rear Front Pick Rotate Enabled

Windshield
Selector Switch Lights Lights Indicator Light
Wiper Control

CB1 CB3 CB5 CB7 CB9 CB15 CB13

CB2 CB4 CB6 CB8 CB10

Water Spray Pump

Indicator Light

Water Spray Pump Switch

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 OPERATION AND MAINTENANCE MANUAL
OPERATION

Left Hand (LH) and Right Hand (RH) Control Handles are mounted on the arm rests of the operator seat. They
are used to control:
 Directional selection and Steering
 Park brake and scale brake activation
 Boom positioning
 Tool or hammer rotation and actuation
 Horn

There is no need for the operator to switch from one set of controls to another when positioning the Scaler
between scaling operations. Each control consists of a lever actuated hydraulic pilot unit with electric control
switches mounted in the handle. The following paragraphs describe the various controls associated with each
control handle.

Left Hand (LH) Control Handle

The Left Hand Control Handle is a multi-function, 2-axis hydraulic pilot valve with multiple electric function
selection on the handle. Actuation of the hydraulic pilot valve controls the BOOM UP, BOOM DOWN, BOOM
EXTEND and BOOM RETRACT functions. PICK ROTATE (engage/disengage), HAMMER (if equipped), MOVE
FWD / NEUTRAL / MOVE REV, and HORN functions are controlled by the electrical switches.

BOOM UP - Pull the LH control handle back to raise the boom.

BOOM DOWN - Push the LH control handle forward to lower the boom.
BOOM EXTEND - Move the LH control handle left to extend the boom.
BOOM RETRACT - Move the LH control handle right to retract the boom.

With engine running and the travel direction selector switch is set in NEUTRAL, the brakes are
released and the vehicle is free to roll unless the PARK BRAKE is set, the SCALE BRAKE is engaged or the
BRAKE PEDAL is manually actuated.

Shift Travel Direction Switch only when the vehicle is at a complete stop.

TRAVEL DIRECTION SWITCH (MOVE FWD / NEUTRAL / MOVE REV): 3-Position rocker-type toggle switch.
Used to select neutral or the direction of machine travel. Select MOVE FWD to tram in the forward direction.
Select NEUTRAL to shift the transmission into neutral. Select MOVE REV to tram in the reverse direction.

PICK ROTATE: Pushbutton. Press to enable pick rotate mode. Press again to disable pick rotate mode. When
enabled, the PICK ROTATE ENABLED indicator light on the auxiliary control panel is illuminated. In this mode
(pick rotate enabled), the RIGHT HAND (RH) CONTROL HANDLE is used for tool or hammer rotation. When
pick rotate is not enabled, the vehicle is in “Steering Mode” and can be articulated left or right using the RIGHT
HAND (RH) CONTROL HANDLE.

HAMMER AND WATER SPRAY: Trigger switch. Squeeze the trigger on the LH control handle to actuate the
hammer. Trigger is spring return to STOP. Water spray is actuated whenever the hammer is actuated.

HORN: Momentary pushbutton. Press to activate horn. Horn will sound as long as pushbutton is pressed.
Release pushbutton to deactivate horn.

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OPERATION AND MAINTENANCE MANUAL
OPERATION

A
D E
B
C

A) MOVE FWD
B) NEUTRAL
C) MOVE REV
D) PICK ROTATE BOOM DOWN
E) HORN
F) HAMMER (OPTIONAL)
BOOM BOOM
EXTEND RETRACT

BOOM UP

LH CONTROL HANDLE

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Right Hand (RH) Control Handle

The Right Hand Control Handle is a multi-function, 2-axis hydraulic pilot valve with multiple electric function
selection on the handle. Actuation of the hydraulic pilot valve controls the PICK FWD, PICK REV, STEER
LEFT/TOOL ROTATE LEFT (CCW) and STEER RIGHT/TOOL ROTATE RIGHT (CW) functions. SCALE BRAKE
(engage/disengage), PARK BRAKE (engage/disengage), and PICK ROTATE (engage/disengage) functions are
controlled by the electrical switches.

PICK FWD - Push the RH control handle forward to actuate the pick forward.
PICK REV - Pull the RH control handle back to actuate the pick in reverse.

The steering is enabled unless Pick Rotate mode is engaged.

STEER LEFT - Move the RH control handle left to articulate left.

ROTATE CCW - Move the RH control handle left to rotate tool counter-clockwise (CCW).
STEER RIGHT - Move the RH control handle right to articulate right.
ROTATE CW - Move the RH control handle right to rotate tool clockwise (CW).

With engine running and the travel direction selector switch is set in NEUTRAL, the brakes are
released and the vehicle is free to roll unless the PARK BRAKE is set, the SCALE BRAKE is engaged or the
BRAKE PEDAL is manually actuated.

SCALE BRAKE: Pushbutton toggle switch. Press and release to engage the scale brake mode (scale brake
mode will remain engaged). Scale Brake On lamp will come “on”. Press and release again to disengage the
scale brake mode. Scale Brake On lamp will go “off”. Scale brake mode Engaged will automatically set the park
brake, engage the wheel brakes, lock the oscillation cylinders, shifts transmission to “neutral” and set engine
speed at 2400 RPM. Park brake indicator light will come “on”. Scale brake indicator will come “on”.

PARK BRAKE: Pushbutton toggle switch. Press and release to SET the park brake (park brake will remain set).
Park Brake/Reset cap light on the main gage/relay panel will come “on”. Press and release again to release the
park brake. Park Brake/Reset cap light will go “off”. The PARK BRAKE pushbutton duplicates the operation of
the Park Brake/Reset (push/pull) selector switch located on the main gauge/relay panel with the exception that if
the push/pull selector is pushed “in” (maintained park brake SET position) the brake cannot be released or reset
using the momentary pushbutton on the control handle. Park brake indicator light will stay “on”. When resetting
the brake the vehicle will be free to roll as soon as the brake is reset. Always maintain pressure on the wheel
brake pedal when releasing and/or resetting the park Brake.

PICK ROTATE: Trigger switch. Squeeze the trigger on the RH control handle to enable pick rotate mode.
Release to disable pick rotate mode. When enabled, the PICK ROTATE ENABLED indicator light on the auxiliary
control panel is illuminated. In this mode (pick rotate enabled), the RIGHT HAND (RH) CONTROL HANDLE is
used for tool rotation. When pick rotate is not enabled, the vehicle is in “Steering Mode” and can be articulated
left or right using the RIGHT HAND (RH) CONTROL HANDLE.

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OPERATION AND MAINTENANCE MANUAL
OPERATION

BOOM BOOM
EXTEND RETRACT

A
C D
BOOM DOWN

BOOM UP

A) BLADE (OPTIONAL) UP
B) BLADE (OPTIONAL) DOWN
C) SCALE BRAKE
D) PARK BRAKE
E) PICK ROTATE

RH CONTROL HANDLE

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Accelerator Pedal:
The accelerator pedal is the right pedal on the floor of the operators cab. Pressing down on the accelerator pedal
will accelerate the engine and letting off of the accelerator pedal will decelerate the engine. The pedal is spring
return to zero throttle.

Accelerator Pedal

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OPERATION AND MAINTENANCE MANUAL
OPERATION

Brake Pedal (Service Brake):

The brake pedal (or service brake) is the left pedal on the floor of the operators cab. When pressed, it controls a
valve that causes oil to flow to the disc brake assemblies inside of the front and rear drive axles. Press the foot
pedal to apply hydraulic pressure to the brakes causing them to engage or set. Let off of the foot pedal to relieve
pressure and release the brakes. Braking is proportional to the force applied to the brake pedal.

Brake Pedal
(Service Brake)

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 OPERATION AND MAINTENANCE MANUAL
OPERATION

Main Disconnect
2–Position, toggle selector switch. Located inside of the battery box, on engine end frame. Used to disconnect
the batteries from the rest of the vehicle electrical system. Turn selector to ON to connect the batteries to the
system. Turn selector to OFF to disconnect the batteries from the system.
Circuit Breaker
20 amp circuit breaker. Press to reset. Alternator.
Fuse
Inline 150 AMP cartridge fuse (F1) located inside the battery box.

Fuse (F1)
Circuit Breaker
Disconnect Switch

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OPERATION AND MAINTENANCE MANUAL
OPERATION

Fire Suppression System:

The fire suppression system may be actuated from either of two locations. One actuator is dash mounted inside
the cab, to the right side of the main dash panel. A second remote actuator is located on the left side of the
engine end frame chassis. Some suppression systems are equipped with a Checkfire® automatic activation
system, which through the use of detection wires, automatically activates the suppression system if a fire is
detected.

Activation of the fire suppression system will automatically shut off engine and set the parking
brake. Exit vehicle immediately.

To activate the fire suppression system from either actuator location:

a. Shut OFF vehicle power.
b. Pull the ring pin.
c. Strike the actuator button.

If activated, the system must be serviced and recharged before it can be used again.

Actuator Button
Ring Pin

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Actuator Button Ring Pin

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3.2 VEHICLE AND EQUIPMENT OPERATION

The following paragraphs describe how to operate the vehicle, test the brakes, operate in scale brake mode,
operate the boom and tool, and emergency operation. Refer to controls and indicators section for descriptions
and illustrations of each control and indicator.

OPERATOR: DATE: HOUR METER:

BEFORE ENGINE START (Park Brake is set, Main Disconnect is OFF)

O.K. N OT EQUIPMENT PROBLEM

Perform walk-around vehicle inspection…………………..

Inspect tires and lug nuts; check tire pressure...…………
Inspect hydraulic hoses and connections for leaks………
Verify all grease points are full……………………………..
Check fuel level. Inspect fuel strainer & fuel filter……….
Check hydraulic oil level…………………..………………..
Check coolant level……………………………….…………
Check engine oil and air cleaner …..……………………..
Check transmission fluid level……………….…..………...
Check hydraulic pumps for leaks.……………...………….
Check hydraulic high pressure filter indicator…..………...
Check washer fluid level……………………...…..………...
Inspect electrical enclosures…………………….….……...
Inspect tool mounting bolts.………………..………..….….
Inspect boom bolts and retaining pins……………………..
Inspect water level and spray system..……………………..

AFTER ENGINE START (see Vehicle Startup to start engine, let idle for 3-5 minutes)
O.K. N OT

Check hydraulic high pressure filter dirt indicator……..…

Check transmission filter……………………………………
Check hydraulic system return line filter…………………..
Check engine conditions (Dash Assembly)……………….
Check converter temperature……..………………………..
Perform park/service brake test (see Paragraph 1.2.4)……....
Verify operation of warning indicator lights (“on” 3 sec)…
Verify operation of lights (front, rear, scale)…………….…
Verify operation of accessories (horn, wipers)…………….

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VEHICLE START-UP

Always sound the horn and make sure that the area around the vehicle, especially around
the articulation joint, is clear before starting the engine. Never start the engine without first knowing how
to shut it off.

a. Make sure of the following:

 BATTERY DISCONNECT SWITCH is in the “On” position.

 FUEL SUPPLY SHUT-OFF VALVE is in the “Open” position.
 CONTROL HANDLES or ACCELERATOR PEDAL is not actuated.
 PARK BRAKE/RESET SWITCH on gauge/relay panel is pushed “In” (Set position).
 TRAVEL DIRECTION SWITCH on left hand control handle is in the “Neutral” position.

b. Turn the ENGINE SWITCH to the “On” position. Wait for ENGINE READY INDICATOR to indicate that
the engine can be started.

c. When the ENGINE READY INDICATOR illuminates, turn ENGINE SWITCH to the momentary “Start”
position to crank the engine. If the engine fails to start within 20 seconds, release the switch and it will
spring return to the “On” position.

Do not actuate the starter for more than 20 seconds. If engine fails to start, wait two
minutes then try again.

d. When engine starts, immediately verify the following:

 All warning lights come “on” and go “off”.

 There is engine oil pressure.
 The tachometer reads 750 RPM.
 The Park Brake/Reset Switch is in “set” (full in) position.
 Brake accumulator pressure gauges read 1100 to 1500 psi.
 The Voltmeter reads + 24 to + 28 volts.
 All remaining gauges read in the normal ranges.
 No “red light” indications on gauge panels.

DRIVING THE VEHICLE

The vehicle will travel in either forward or reverse. The same gear ratios are used in forward and reverse and the
transmission will provide equal speeds in each range selection; in either direction of travel. Direction of travel is
manually controlled by the TRAVEL DIRECTION SWITCH on the left hand control handle. Gear selection is
manually controlled by the MANUAL TRANSMISSION SELECTOR SWITCH on the auxiliary control panel.

Engine RPM is operator controlled in travel mode with an automotive-type ACCELERATOR PEDAL (RPM is
computer controlled automatically in scale brake mode). Dynamic (axle) braking is operator applied with an
automotive-type BRAKE PEDAL. Articulated steering, in travel mode, is hydraulically actuated and manually
controlled by the operator using the CONTROL HANDLES (steering control becomes boom swing control in scale
mode).

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DRIVING THE VEHICLE (CONTINUED)

When operating the vehicle always remember the following:

 The engine must be at idle speed and the vehicle stopped before shifting the travel direction selector
switch.
 Always start out in first gear and shift into higher ranges as the vehicle accelerates and as conditions
permit.
 NEVER coast in “Neutral”.
 Use the transmission to decelerate the vehicle whenever possible.
 BEFORE proceeding onto a down hill grade, ALWAYS stop and manually select the lowest gear ratio (1).
 DO NOT down shift the transmission unless the vehicle is traveling at a speed suitable for the slower
range.
 NEVER shift the directional control switch to neutral or select the opposite direction of travel unless the
vehicle is completely stopped.
 DO NOT touch hand pump release valve or handle while operating.

1. Releasing the park brake (with engine running).

When activating the park brake (from gauge panel and/or control handle), the vehicle will stop
suddenly upon activation. ALWAYS wear your seat belt to avoid injury.

a. While applying the service brakes (pressing down on the BRAKE PEDAL), release the park brake by
doing one of the following:

Release from the PARK BRAKE/RESET SWITCH on the main gauge/relay panel; pull “out” on
mushroom cap to normally release parking brake. The red cap light will go “off”.

Or

Release from the control handle; press and release the PARK BRAKE pushbutton to release the park
brake. Park brake indicator light (park brake/reset switch) will go “off”.

b. (If Necessary) Reset the park brake by doing one of the following:

With the engine running, the transmission in neutral and while depressing the BRAKE PEDAL, reset the
PARK BRAKE/RESET SWITCH by pulling to “release position”, then pull again for “reset position” and
let go.

Or

With the engine running, the transmission in neutral and while depressing the BRAKE PEDAL, press the
PARK BRAKE pushbutton on the control handle to reset the park brake in the “released” mode.

c. Keep pressure on the BRAKE PEDAL until desired direction and gear are selected.

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DRIVING THE VEHICLE (CONTINUED)

2. Using the TRAVEL DIRECTION SWITCH (FWD / NEUTRAL / REV).

With the engine running and the TRAVEL DIRECTION SWITCH in “Neutral”, the brakes are
released and the vehicle is free to roll unless the PARK BRAKE/RESET SWITCH is in the “set” position (light
“on”) or the brake pedal is manually depressed.

If the transmission should overheat (converter temperature exceeds 200°F), stop the vehicle, put
the transmission in “Neutral”, and run the engine at half-speed until the temperature drops to within normal
operating temperature range. If the temperature does not drop rapidly, trouble is indicated and the problem
should be corrected before resuming operation. Generally, operating in a gear not suitable for conditions causes
overheating.

a. Use the TRAVEL DIRECTION SWITCH to select the direction of machine travel. Select forward (MOVE
FWD), Neutral (NEUTRAL) or reverse (MOVE REV).

MOVE FWD – Engages the transmission to drive the vehicle in the forward direction.

NEUTRAL – Disengages the transmission.

MOVE REV – Engages the transmission to drive the vehicle in the reverse direction.

NEVER attempt to change the TRAVEL DIRECTION SWITCH while the vehicle is in motion. ONLY
select direction after the vehicle is at a complete stop.

3. Using the MANUAL TRANSMISSION SELECTOR SWITCH.

ALWAYS begin travel (from stop) in 1st gear; this applies to forward and reverse.

a. Use the MANUAL TRANSMISSION SELECTOR SWITCH to manually control the transmission gearshift
selection. Select (1), (2), (3) or (4) to engage and maintain operation in a selected gear. The same gear
ratios are used in forward and reverse providing equal speeds in each range selection.

1 – Lowest gear ratio; used for heavy loads and steep grades at low speed.

2 & 3 – Intermediate gear selections for varying loads and grades and also deceleration.

3 – Moderate loads and grades. Also selection used for brake test.

4 – Highest gear ratio for light loads and top speed on level surfaces.

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OPERATION AND MAINTENANCE MANUAL
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DRIVING THE VEHICLE (CONTINUED)

4. Steering the Vehicle.

- NEVER allow anyone to stand in the pivot area near the articulation joint.
- Watch the complete length of the vehicle on both sides, particularly when operating in confined
areas.
- Depending upon direction of travel, extend the leading end, before making a sharp turn,
otherwise, the side of the vehicle may contact the wall or other obstruction.
- Steering is disabled when in pick rotate mode.
- Steering is active in scale brake mode with pick rotate disabled. Watch boom swing.

In scale mode steering is disabled and steering control becomes boom swing control.

The vehicle has an articulated steering arrangement (pivots at the center between the front and rear
frames). It is recommended that the operator experiment and practice with this type of steering arrangement by
driving the vehicle in an open area prior to operating in a confined space.

a. Move the RH CONTROL HANDLE to the right to turn the machine to the right. The control handle will
spring return to the center if released. The angle of articulation will remain unchanged after the control
handle is centered.

b. Move the RH CONTROL HANDLE to the left to turn the machine to the left. The control handle will spring
return to the center if released. The angle of articulation will remain unchanged after the control handle is
centered.

5. Moving the Vehicle.

When the TRAVEL DIRECTION SWITCH is set in “Neutral” and the brakes are released, the
vehicle is free to roll even if the accelerator pedal is not pressed down.

The ACCELERATOR PEDAL electronically controls the fuel governor throttle shaft on the engine. Pressing down
on the accelerator pedal will accelerate the engine and move the vehicle in the desired direction of travel that was
selected. Releasing the accelerator pedal will allow the engine to return to idle and the vehicle will slow down.
DO NOT press down on the ACCELERATOR PEDAL while holding down the BRAKE PEDAL.

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OPERATION

BRAKE TEST

Application of the park brake test button will release the service brakes. This may cause the
vehicle to roll freely and can cause serious injury or death. Prepare for vehicle movement prior to using the brake
test button. DO NOT initiate the brake test while bystanders are near.

DO NOT use the park brake test button while standing outside the operator’s compartment.

Never operate the vehicle if the service or park brakes do not operate properly.

The brake test electrically disables the mechanism that automatically applies the service brakes isolating the park
brake to test for operational integrity. The park brake should be tested prior to operation and again prior to shut
down. Test the park and service brakes for safe operation as follows:

1. Test the Park Brake.

a. “Set” the PARK BRAKE.

b. DO NOT actuate the service BRAKE PEDAL.

c. Manually shift the MANUAL TRANSMISSION SELECTOR SWITCH into 3rd gear.

d. Press and hold the BRAKE TEST pushbutton.

e. Toggle TRAVEL DIRECTION SWITCH to FWD.

f. Slowly depress accelerator to full throttle. Vehicle must not move at full throttle.

g. Repeat operation with TRAVEL DIRECTION SWITCH in REV.

h. Refer to the MAINTENANCE section of this manual and inspect the park brake. Make sure that it is
physically actuating and that the park brake is working properly.

2. Test the Service Brakes.

a. Drive the vehicle forward slowly and apply the service BRAKE PEDAL.

b. Verify the vehicle comes to a full and immediate stop.

c. Repeat test in the opposite direction.

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OPERATION AND MAINTENANCE MANUAL
OPERATION

SCALE BRAKE MODE

Engaging the scale brake mode will set the park brake, engage the wheel brakes, lock the oscillation cylinders,
disable travel and automatically set engine speed. The PARK BRAKE/RESET SWITCH will illuminate “red”. The
SCALE BRAKE ON INDICATOR LIGHT will illuminate.

1. Place the TRAVEL DIRECTION SWITCH in “Neutral”.

2. Press and release the SCALE BRAKE pushbutton on the RH CONTROL HANDLE to engage the scale brake
mode (scale brake mode will remain engaged). The SCALE BRAKE ON INDICATOR LIGHT on the main
gauge/relay panel will come “on”.

3. Actuate the RH CONTROL HANDLE to automatically release the wheel brakes and oscillation cylinder lock.
The park brake will remain set and the PARK BRAKE/RESET SWITCH will remain illuminated. The machine
will now articulate in either direction. The vehicle will not be able to move forward or backward with the park
brake set, however the left and right wheels (front and back) will rotate in opposite directions to allow the
machine to articulate left or right to re-position the vehicle. Wheel brakes and oscillation cylinder lock will re-
engage automatically when control handle is returned to the center position.

4. Press and release the SCALE BRAKE pushbutton on the RH CONTROL HANDLE again to disengage the
scale brake mode. The SCALE BRAKE ON INDICATOR LIGHT on the main gauge/relay panel will go “off”.

VEHICLE STOPPING AND SHUTDOWN

1. Stop the vehicle.

a. Stop the vehicle by pressing and holding down the BRAKE PEDAL until the vehicle comes to a complete
stop. Continue holding down the BRAKE PEDAL.

b. Place the TRAVEL DIRECTION SWITCH in “Neutral”.

c. Push in the PARK BRAKE/RESET SWITCH or press and release the PARK BRAKE pushbutton to set
the park brake. Park brake indicator light (park brake/reset switch) will go “on”, indicating the park brake
is set.

d. Let up on the BRAKE PEDAL.

2. Run engine at low idle for approximately 3 minutes prior to shutting down. This allows internal temperatures
to reduce gradually.

3. Turn the ENGINE SWITCH to “Off”.

4. Turn the BATTERY DISCONNECT SWITCH to “Off”.

3-32
 OPERATION AND MAINTENANCE MANUAL
OPERATION

BOOM OPERATION

Scale brake mode must be engaged prior to boom operation. Moving the control handles to
operate the boom, without being in scale brake mode, may lead to injury or vehicle damage.

The steering is enabled unless Pick Rotate mode is engaged.

1. Boom up/down operation.

a. Refer to Scale Brake Mode paragraph and engage scale brake mode. This enables the control of boom
raising and lowering with the LH CONTROL HANDLE.

b. Pull the LH CONTROL HANDLE back to raise the boom.

c. Push the LH CONTROL HANDLE forward to lower the boom.

2. Boom extend/retract operation.

a. Refer to Scale Brake Mode paragraph and engage scale brake mode. This enables the control of boom
extending and retracting with the LH CONTROL HANDLE.

b. Move the LH CONTROL HANDLE left to extend the boom.

c. Move the LH CONTROL HANDLE right to retract the boom.

TOOL OPERATION

Hammer operation is an option available on this vehicle and when used, it replaces the normal
pick operation. Tool rotate operation will rotate either the pick or the hammer. The water spray system, once
energized, will operate with the use of the hammer trigger switch.

1. Pick or Hammer rotate operation.

a. Press PICK ROTATE pushbutton on the LH CONTROL HANDLE or squeeze PICK ROTATE trigger on
the RH CONTROL HANDLE to enable Pick Rotate mode. Verify the PICK ROTATE ENABLED indicator
light on the auxiliary control panel is illuminated.

b. Move the RH CONTROL HANDLE left to rotate the tool or hammer counter-clockwise (CCW) or right to
rotate the tool or hammer clockwise (CW).

c. Press PICK ROTATE pushbutton on the LH CONTROL HANDLE again or release the PICK ROTATE
trigger on the RH CONTROL HANDLE to disable Pick Rotate mode. Verify the PICK ROTATE ENABLED
indicator light on the auxiliary control panel is no longer illuminated.

2. Pick forward and reverse operation.

a. Push the RH CONTROL HANDLE forward to actuate the pick forward. Release the control handle and it
will spring return to the neutral position.

b. Pull the RH CONTROL HANDLE back to actuate the pick in reverse. Release the control handle and it
will spring return to the neutral position.

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OPERATION AND MAINTENANCE MANUAL
OPERATION

3. Hammer operation.

a. Squeeze the HAMMER trigger on the LH CONTROL HANDLE to actuate the hammer and water spray.

b. Release the HAMMER trigger on the LH CONTROL HANDLE to stop the hammer and stop water spray.

EMERGENCY OPERATION

1. Towing the vehicle.

If the Scaler must be towed, refer to Driving the Vehicle to release the park brake and put the transmission in
neutral. Tow at low (crawl) speed. If possible, start the engine and run at idle while towing to lubricate the
transmission clutches. If the park brake cannot be released, it will be necessary to disconnect the drive lines prior
to towing. If hydraulic power is not available it may be necessary to release the park brake using the MANUAL
BRAKE RELEASE HAND PUMP. Refer to the following to release the park brake using the hand pump:

With parking brakes released the vehicle is free to roll. DO NOT release the parking brakes
without first taking the following safety precautions:

 Block all four wheels of the disabled vehicle.

 Attach a tow bar to the disabled vehicle and to a towing vehicle having sufficient braking capacity to
stop both vehicles. DO NOT use a chain, cable or any other flexible means of towing.

 On the towing vehicle, block all four wheels, set the parking brake and shut off the engine.

a. Make sure the PARK BRAKE/RESET SWITCH is in the “release position”.

b. Remove pump handle from storage mount and install on pump.

c. Close the release valve by turning it clockwise.

d. Pump the handle to build pressure until the brake releases.

NOTE: Turn release valve counter-clockwise to release pressure and set the brakes.

2. Operating the FIRE SUPPRESSION SYSTEM (from either actuator location).

Activation of the fire suppression system will automatically shut off engine and set the parking
brake. Exit vehicle immediately.

If activated, the fire suppression system must be serviced and recharged before it can be used
again.

a. Shut “Off” vehicle power.

b. Pull the RING PIN.

c. Strike the ACTUATOR button

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 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

4.0 MAINTENANCE

Only authorized personnel (trained and certified) shall service this machine. Always review the Safety section of
this manual prior to servicing this machine.

Section Page

4.1 Scheduled Maintenance

Pre-Shift (8hr)........................................................................................................................ 4-2
First 40 Hours........................................................................................................................ 4-13
Every 40 Hours ..................................................................................................................... 4-15
Every 250 Hours ................................................................................................................... 4-16
Every 500 Hours ................................................................................................................... 4-21
Every 1000 Hours ................................................................................................................. 4-26
4.2 Adjustments and Alignments
Check System Hydraulic Pressure ....................................................................................... 4-29
Adjust System Hydraulic Pressure........................................................................................ 4-29
Check Accumulator Pre-Charge ........................................................................................... 4-33
Charge Accumulator ............................................................................................................. 4-33
Adjust Boom Rollers.............................................................................................................. 4-36
Adjust Park Brake ................................................................................................................. 4-39

4.3 Lube Chart ............................................................................................................................ 4-40

4.4 Fluid List................................................................................................................................ 4-50

4.5 Filter List................................................................................................................................ 4-51

Read and understand

manual and safety
information before
servicing!

4-1
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

4.1 SCHEDULED MAINTENANCE

The following table furnishes a complete listing of regularly scheduled maintenance to be performed on the SV-22
Scaler. The first column of the chart denotes the task performance interval. This listing is arranged by Periodicity
and includes Pre-Shift/8 Hours Intervals, First 40 Hour Service, 40 Hour Intervals, 250 Hour Intervals, 500 Hour
Intervals, and 1000 Hour Intervals. The second column contains a brief description of the Task to be performed.
The Criteria column contains detailed descriptive information, notes, and safety data to perform the applicable
task.

As noted below, the vehicle Diesel Engine, Transmission, and Drive Axles have specific manufacturer supplied
maintenance schedules. These manufacturer recommended maintenance schedules should be utilized to ensure
warranty validity.

Unless otherwise specifically directed all checks listed shall be performing while the Vehicle Engine is Off.

Maintenance Schedule
Periodicity Task Criteria
Pre-Shift/8 Visually inspect condition of Walk around entire vehicle; inspect top, side, underneath, front
Hours overall vehicle, correct and rear. This is to check for fluid leaks, broken lights, structure
situation or call for for stability, loose items needing to be removed, prior stowage of
maintenance assist as all equipment/ components and any visually notable problems.
necessary

Pre-Shift/8 Inspect for Leaks at Hoses Walk around entire vehicle; inspect top, side, underneath, front
Hours and Fittings and rear. Specifically check hydraulic hoses and fittings for fluid
leaks, cracks, broken fittings or hoses, or any other signs of
appreciable wear to any hydraulic component.

Pre-Shift/8 Inspect Electrical Inspect enclosures for moisture and signs of corrosion. Inspect
Hours Enclosures terminals and connections for corrosion, discoloration, or signs of
(Junction Boxes, Control overheating. Clean accessible areas of electrical enclosures and
Consoles, etc.) replace any part that does not operate properly.

Pre-Shift/8 Inspect Pick Insert and Visually inspect for damage or wear. Replace as necessary.
Hours Lock

Pick

Lock

4-2
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
Pre-Shift/8 Inspect parking brakes, Inspect parking brake actuator and linkage for damage or wear.
Hours service if required. Inspect pivot points and make sure they are free to move.
Inspect all electrical and hydraulic connections related to the Park
Brake and make sure all valves are operating properly. If
necessary, perform park brake adjustment.

Actuator

Cable

Lever

4-3
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
Pre-Shift/8 Check Tire Pressure, Perform the following:
Hours Wheel Nuts
Do not over torque Wheel Nuts.

Check Wheel Nut torques, for both front and rear wheels. Apply
Locktite and torque bolts in accordance with Section 3 of the
Kessler Axle Service Manual.

Do not inflate tires over 120 PSI.

Check Air Pressure in all tires. Fill Tires with Air as required.

Torque Wheel Nuts

Check Tire Pressure at valve stem

4-4
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
Pre-Shift/8 Check water tank fluid Check water tank water level.
Hours level, service as required
Add water as required.
Pre-Shift/8 Check washer fluid level, Check windshield washer fluid level.
Hours service as required
Add Washer Fluid as required.

Water Tank
with Fill Cap

Windshield

Windshield Washer
Fluid Reservoir

4-5
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
Pre-Shift/8 Check hydraulic oil level Check hydraulic tank fluid level.
Hours
Do not run vehicle if the hydraulic fluid is low, Failure to
comply will result in vehicle damage.

If Hydraulic Tank Fluid level is low, refer to suggested lubricants

for recommended fluid and fill tank.

Wiggins Remote Fill Option (Not Shown) includes

Wiggins remote fill connector with dust cap

Hydraulic Oil Level and

Temperature Gauge

Hydraulic Oil Fill Cap

4-6
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
Pre-Shift/8 Check hydraulic pumps for Check hydraulic pumps for leaks.
Hours leaks, service as required
If leaks are found, replace faulty seals.

Refill pump case with one of the suggested lubricants.

Hydraulic Pumps
Engine End Frame

4-7
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
Pre-Shift/8 Check fuel level, service as Check fuel level
Hours Required (see fuel gauge on gauge/relay panel inside cab)

Ensure the fuel tank is full. Excessive condensation may

occur inside fuel tank if vehicle is low on fuel. This can damage
the engine.

If Fuel Tank Fluid level is low, use recommended fuel and fill the
tank.

Fuel / Water Fill Cap &

Separator Filter Strainer Fuel Tank
Wiggins Remote Fill
Option (Not Shown)
includes Wiggins air
vent and ground-
level Wiggins fuel fill
connector

4-8
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
Pre-Shift/8 Check engine air cleaner,
Hours replace air cleaner filters as Do not run vehicle with a dirty air element. Dirty air can
required. cause engine damage.

Check air cleaner filters.

If dirty, replace air cleaner filters

(Primary – UV401162, Safety – UV401163).

Air Cleaner Filters Inside

4-9
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
Pre-Shift/8 Check engine coolant fluid Check engine coolant fluid level.
Hours level, service as required
NOTE – Using the coolant sight check, ensure coolant level is
visible through the glass. Coolant is added to the vehicle radiator
at the coolant fill point.

Wait for the engine to completely cool before removing the

radiator fill cap at the coolant fill point. Pressurized steam will
escape if the cap is removed while the engine is hot. Burns can
result. Avoid prolonged contact with anti-freeze. Prolonged
contact can cause irritation to skin.

Fill radiator with suggested Coolant.

Coolant Fill

4-10
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
Pre-Shift/8 Check transmission fluid Use dipstick to check transmission fluid level.
Hours level, service as required
To add transmission fluid, refer to the transmission service
information provided in the manufacturers manual for fill location,
and add transmission fluid.

Pre-Shift/8 Inspect Transmission Filter Check mechanical dirt indicator. If necessary, replace
Hours Dirt Indicator transmission filter.

Transmission Fluid Level Dipstick

Mechanical Dirt Indicator

Transmission Filter

4-11
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
Pre-Shift/8 Check hydraulic high Check the hydraulic high pressure filter dirt indicator.
Hours pressure filter dirt indicator,
replace filter element as
required Do not run vehicle with a dirty filter. The Filter is bypassed
when the dirt alarm indicates a dirty condition. The Hydraulic
system can become contaminated, causing serious damage to
hydraulic components.

Replace Filter Element as required (UV402011).

Hydraulic High Pressure

Filter Dirt Indicator

Engine End Frame Assembly

4-12
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
First 40 Hours Replace hydraulic high Replace the hydraulic high pressure filter element
pressure filter element (UV402011)

Do not run vehicle with a dirty filter. The Filter is bypassed

when the dirt alarm indicates a dirty condition. The Hydraulic
system can become contaminated, causing serious damage to
hydraulic components.

First 40 Hours Replace hydraulic system Replace the hydraulic system return line filter element
return line filter element (UV401172)

Do not run vehicle with a dirty filter. The Hydraulic system

can become contaminated, causing serious damage to hydraulic
components.

Dual Spin-On
Return Line
Filters

4-13
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
First 40 Hours Replace transmission filter Change the transmission filter element
element (UV401168)

Do not run the vehicle with a dirty Transmission Filter.

Serious damage to the transmission can occur.

Transmission Filter

4-14
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
Inspect and Lube Inner and With boom fully retracted, remove side wipers at front of boom
Outer Boom Rollers and lower front roller cover. Inspect for proper lubrication or any
damage to the rollers. If necessary, perform roller adjustment.
Inspect and Lube Steering
Cylinder Pivot Joints
Inspect and Lube
Articulation Pivot
Inspect and Lube
Oscillation Lock Cylinder
Pivot Joints
Inspect and Lube Boom Lift
Cylinder Pins
Inspect and Lube Boom
Pivot Pin
Inspect and Lube Front
Driveline Carrier Bearing
Inspect and Lube Boom
Extend Cylinder Pins
Inspect and Lube Rotary
First 40 Hours Actuator
Inspect and Lube Tool Refer to lube chart for illustration of all lubrication points and
- AND -
Extend Cylinder Base End grease fittings.
Pin
40 Hr Interval
Inspect and Lube Tool Refer to fluid list for recommended grease or lubricant.
Extend Cylinder Rod End
Pin
Inspect and Lube Tool Pivot
Pin
Inspect and Lube Tool
Rotation Bearing
Inspect and Lube
Oscillation Bearing
Inspect and Lube Mid Drive
Shaft Slip Joint
Inspect and Lube Rear
Drive Shaft Slip Joint
Inspect and Lube Front
Drive Shaft U-Joint
Inspect and Lube Mid Drive
Shaft U-Joints
Inspect and Lube Rear
Drive Shaft U-Joints
Inspect Driveline Brake for
Leaks (if applicable)

4-15
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
250 Hours Inspect Electrical Inspect enclosures for moisture and signs of corrosion. Inspect
Enclosures terminals and connections for corrosion, discoloration, or signs of
(Junction Boxes, Control overheating. Clean accessible areas of electrical enclosures and
Consoles, etc.) replace any part that does not operate properly.

250 Hours Inspect all pins and Refer to 40 Hour Service Interval for list and location of pins and
bushings bushings.

250 Hours Clean engine fuel strainer Clean engine fuel strainer.
(if equipped)
Remove cap and strainer from fuel tank and clean.
Replace Fuel / Water
Separator Filter Element Coat Strainer with clean Fuel and reinstall in tank.

Fuel / Water Fill Cap &

Separator Filter Strainer Fuel Tank
Wiggins Remote Fill
Option (Not Shown)
includes Wiggins air
vent and ground-
level Wiggins fuel fill
connector

4-16
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
250 Hours Pressure Wash Radiator Pressure Wash the Radiator.

Be careful not to damage the radiator. Pressure wash from

a safe distance and wear appropriate eye protection.

Radiator

4-17
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
250 Hours Inspect engine mounts Inspect engine mounts, retighten if necessary.

Engine Mounts

Engine Mounts

Engine Mounts

4-18
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
250 Hours Inspect Air Intake Tract Clean and Inspect air intake tract rubber boots for any cracks or
excessive wear. Replace any rubber boot that is cracked or
worn.

250 Hours Replace engine air cleaner

filters. Do not run vehicle with a dirty air element. Dirty air can
cause engine damage.
Replace air cleaner filters
Primary – UV401162
Safety – UV401163
250 Hours Fill Driveline Brake Drain and refill the driveline brake with the suggested lubricant.
(if applicable)

Driveline Brake
(Optional)

4-19
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
250 Hours Inspect and clean batteries Inspect and clean batteries.

Ensure the Battery Disconnect Switch is in the OFF

position prior to performing the following procedures!

Place Battery Disconnect Switch in the OFF position.

Inspect battery terminals for corrosion and wipe clean. If

necessary, tighten battery connections.

Place the Battery Disconnect Switch in the ON position.

Batteries Battery Disconnect Switch

Engine End Frame

4-20
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
500 Hours Inspect Electrical Inspect enclosures for moisture and signs of corrosion. Inspect
Enclosures terminals and connections for corrosion, discoloration, or signs of
(Junction Boxes, Control overheating. Clean accessible areas of electrical enclosures and
Consoles, etc.) replace any part that does not operate properly.

500 Hours Replace hydraulic high Replace the hydraulic high pressure filter element
pressure filter element (UV402011)

Do not run vehicle with a dirty filter. The Filter is bypassed

when the dirt alarm indicates a dirty condition. The Hydraulic
system can become contaminated, causing serious damage to
hydraulic components.

Hydraulic High Pressure

Filter Dirt Indicator

Engine End Frame Assembly

4-21
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
500 Hours Replace hydraulic system Replace the hydraulic system return line filter element
return line filter element (UV401172)

Do not run vehicle with a dirty filter. The Hydraulic system

can become contaminated, causing serious damage to hydraulic
components.

Dual Spin-On
Return Line
Filters

4-22
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
500 Hours Inspect hydraulic oil tank Inspect the hydraulic oil tank breather cap/filter. If necessary,
breather cap/filter, replace if replace filter (UV402797).
necessary.
Do not run vehicle with a dirty filter. The Hydraulic system
can become contaminated, causing serious damage to hydraulic
components.

Wiggins Remote Fill Option (Not Shown) includes

Wiggins remote fill connector with dust cap

Hydraulic Oil Level and

Temperature Gauge

Hydraulic Oil Fill Cap

4-23
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
500 Hours Inspect engine mounts Inspect engine mounts, retighten if necessary.

Engine Mounts

Engine Mounts

Engine Mounts

4-24
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
500 Hours Replace transmission filter Change the transmission filter element
element (UV401168)

Do not run the vehicle with a dirty Transmission Filter.

Serious damage to the transmission can occur.

Transmission Filter

4-25
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
1000 Hours Drain/Clean/Refill Hydraulic Drain/Clean/Refill Hydraulic Tank
Tank
Drain oil from hydraulic tank.

Clean the tank and inspect for any signs of corrosion that could
contaminate the hydraulic oil.

Refill with appropriate fluid.

1000 Hours Inspect water spray system Inspect water spray system.

Inspect all hoses/tubing for cracks.

Inspect all connections.

Check nozzles for proper spray direction.

Ensure water tank is free of any cracks or corrosion.

4-26
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Maintenance Schedule
Periodicity Task Criteria
1000 Hours Inspect fire suppression Inspect fire suppression system.
system
Inspect all hoses/tubing for cracks.

Inspect all connections.

Check nozzles for proper spray direction.

Ensure all Tanks, Cartridges and Extinguishers are fully charged

4-27
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

4-28
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

4.2 ADJUSTMENTS AND ALIGNMENTS

CHECK SYSTEM HYDRAULIC PRESSURE

Two people are required to check the system hydraulic pressure. Station one person in the cab to control the
machine operation. Station the other at the test port bulkhead to observe the pressure gauge and to make
pressure adjustments. A test port hose assembly (401846) is supplied with the machine for this procedure. A
5000 PSI pressure gauge, not supplied, is also required. To check/set the system hydraulic pressure, refer to the
following:

The test port hose assembly with 5000 PSI gauge attached may be safely installed or removed
from the test port fitting with the hydraulic system fully pressurized. However, the 5000 PSI
gauge should only be installed or removed from the test port hose with the hydraulic system
depressurized (engine off).

1. Attach the 5000 PSI pressure gauge to the test port hose assembly (401846).

2. Locate the test port bulkhead on the engine end of the machine frame. Unscrew the dust cap for the Pump A
test port, allowing it to hang by its chain.

3. Thread the test port hose assembly with attached gauge by hand onto the test fitting. No tools are required.

4. Start the vehicle in accordance with Operation procedures. Ensure the park and service brakes are engaged.

5. Turn on scale brake mode using the pushbutton on the right hand control handle. This will raise engine
speed to 2000 RPM and disable steering.

6. Retract the boom fully and use the control handle to hold the boom in a retracted position for the duration of
the pressure check.

7. Read the pressure gauge measurement. The correct system pressure is 2500 PSI. If the pressure gauge
shows 2500 PSI, proceed to step 8. If the pressure gauge reading is not 2500 PSI, proceed to step 8 and
adjust the system pressure.

8. Turn off scale brake mode and shut down machine. Remove the test port hose assembly and gauge from the
test port fitting and install the dust cap.

ADJUST SYSTEM HYDRAULIC PRESSURE

Two people are required to adjust the system hydraulic pressure. Station one person in the cab to control the
machine operation. Station the other at the test port bulkhead to observe the pressure gauge and to make
pressure adjustments. A test port hose assembly (401846) is supplied with the machine for this procedure. A
5000 PSI pressure gauge, #16 JIC Plug and Cap, and #6 JIC Plug and Cap; not supplied, are also required. To
adjust the system hydraulic pressure, refer to the following:

The test port hose assembly with 5000 PSI gauge attached may be safely installed or removed
from the test port fitting with the hydraulic system fully pressurized. However, the 5000 PSI
gauge should only be installed or removed from the test port hose with the hydraulic system
depressurized (engine off).

1. Attach the 5000 PSI pressure gauge to the test port hose assembly (401846).

4-29
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

2. Locate the test port bulkhead on the engine end of the machine frame. Unscrew the dust cap for Pump A,
allowing it to hang by its chain.

3. Thread the test port hose assembly with attached gauge by hand onto the test fitting. No tools are required.

4. To isolate the pressure for Pump A, use the #16 JIC Plug and Cap to block the line for Pump A after the
pressure filter. Use the #6 JIC Plug and Cap to block the load sense line, Port X on Pump A.

5. Start the vehicle in accordance with Operation procedures. Ensure the park and service brakes are engaged.

6. Turn on scale brake mode using the pushbutton on the right hand control handle. This will raise engine
speed to 2000 RPM and disable steering.

Use caution to avoid losing the sealing washer between the cap and the lock nut on the pump
control adjustments.

7. At the low pressure standby control (farthest from pump body) on Pump A, remove the cap. Loosen the lock
nut. Retain sealing washer between cap and locknut.

8. Turn the low pressure standby adjustment screw fully clockwise to force Pump A into high pressure stand-by
mode.

9. Read the pressure gauge measurement. The correct system pressure is 2500 PSI. If the pressure gauge
shows 2500 PSI, proceed to step 10 to isolate and adjust Pump B. If the pressure gauge reading is not 2500
PSI, proceed to step 18 to adjust the system pressure.

10. Turn the low pressure standby adjustment screw on Pump A counterclockwise until the gauge reads 300 PSI.

11. Being careful not to move the adjustment point, tighten the lock nut at the pump pressure compensator
control, install the sealing washer, and reattach the cap.

12. Turn off the machine. Remove test hose assembly and gauge from Pump A test port to Pump B test port.

13. Remove the #16 JIC Plug and Cap from the line for Pump A and block the line for Pump B after the pressure
filter. Remove the #6 JIC Plug and Cap from the load sense line, Port X, on Pump A and block the load
sense line, Port X, on Pump B.

14. Start the vehicle in accordance with Operation procedures. Ensure the park and service brakes are engaged.

15. Turn on scale brake mode using the pushbutton on the right hand control handle. This will raise engine
speed to 2000 RPM and disable steering.

Use caution to avoid losing the sealing washer between the cap and the lock nut.

16. At the low pressure standby control (farthest from pump body) on Pump B, remove the cap. Loosen the lock
nut. Retain sealing washer between cap and locknut.

17. Turn the low pressure standby adjustment screw fully clockwise to force Pump B into high pressure stand-by
mode.

Use caution to avoid losing the sealing washer between the cap and the lock nut.

18. At the pump pressure compensator control (closest to pump body) on Pump A or B, remove the cap. Loosen
the lock nut. Retain sealing washer between cap and locknut.

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 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

19. At the pump pressure compensator control adjustment point, use a metric allen key to increase or decrease
pump pressure. To increase pump pressure, turn the key clockwise. To decrease pump pressure turn the
key counterclockwise. Make adjustment as required until the pressure gauge reads 2500 PSI.

20. Being careful not to move the adjustment point, tighten the lock nut at the pump pressure compensator
control, install the sealing washer, and reattach the cap.

21. Observe the pressure gauge one last time to confirm that the system pressure is 2500 PSI.

22. Turn the low pressure standby adjustment screw counterclockwise until the gauge reads 300 PSI for Pump A
or 350 PSI for Pump B.

23. Being careful not to move the adjustment point, tighten the lock nut at the pump control, install the sealing
washer, and reattach the cap.

24. Turn off scale brake mode and shut off machine.

25. Remove the test port hose assembly and gauge from the test port fitting and install the dust cap. Remove the
#16 JIC Plug and Cap and #6 JIC Plug and Cap and reattach hydraulic lines.

26. Remove pressure gauge from test port hose assembly.

PUMP B
PUMP A TEST PORT
TEST PORT

TEST PORT BULKHEAD

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OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

LOW PRESSURE STAND-BY

PORT X CONTROL

PUMP PRESSURE
COMPENSATOR CONTROL

CAP

LOCKNUT

PUMP A

PORT X LOW PRESSURE STAND-BY

CONTROL

PUMP PRESSURE
COMPENSATOR CONTROL

CAP

LOCKNUT

PUMP B

4-32
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

CHECK ACCUMULATOR PRE-CHARGE

A charge kit (UV404798), not provided with the machine, is required to test the accumulator pre-charge. The
charge kit is packed in a plastic carrying case and includes a charging and gauging unit and an 8 foot flexible
charging hose that connects to a commercially available nitrogen bottle. Two accumulators (400301) are installed
on the machine. To check the accumulator pre-charge, refer to the following.

1. In accordance with Operation procedures, set the brakes with the park brake/reset switch.

2. Shut vehicle off and tag OUT OF SERVICE.

Always drain the hydraulic fluid completely from the accumulator before performing any work.

3. At the brake manifold, located at the driver side engine end frame, pull up on both Manual Accumulator
Pressure Relief Valve pressure release knobs. This discharges all hydraulic oil from the accumulator,
allowing the accumulator piston to bottom against the hydraulic end cap. When released, the Manual
Accumulator Pressure Release will spring-return to the closed position.

4. At the accumulator, remove the valve protection cap. Slightly loosen the socket head cap screw one-half turn
with a 6mm Allen wrench.

5. Close the release valve.

Use caution to avoid looping or twisting the hose.

6. Attach the charging and gauging unit connector to the accumulator gas valve by hand. Turn the unit into a
position that the gauge can be easily read.

7. Open the accumulator gas valve by turning the T-handle counterclockwise. When the needle of the gauge
begins to move, turn the T-handle one more complete turn counterclockwise. The gauge now shows the
charging pressure in the accumulator. The pressure should be 725 PSI. If the pressure is less than 725 PSI,
see paragraph to charg the accumulator.

8. To remove the charging assembly, turn the T-handle all the way clockwise then open the release valve to
relieve residual gas charge in the charging assembly.

9. Hold the gas valve from turning and loosen the connector. Remove the charging and gauging unit.

10. Tighten the socket head cap screw one-half turn with the Allen wrench and replace valve protection cap.

CHARGE ACCUMULATOR

A charge kit (UV404798), not provided with the machine, is required to charge the accumulator. The charge kit is
packed in a plastic carrying case and includes a charging and gauging unit and an 8 foot flexible charging hose
that connects to a commercially available nitrogen bottle. Two accumulators (400301) are installed on the
machine. To charge an accumulator, refer to the following.

1. In accordance with Operation procedures, set the brakes with the park brake/reset switch.

2. Shut vehicle off and tag OUT OF SERVICE.

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OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Always drain the hydraulic fluid completely from the accumulator before performing any work.

3. At the brake manifold, located at the driver side engine end frame, pull up on both Manual Accumulator
Pressure Relief Valve pressure release knobs. This discharges all hydraulic oil from the accumulator,
allowing the accumulator piston to bottom against the hydraulic end cap. When released, the Manual
Accumulator Pressure Release will spring-return to the closed position.

4. Make sure the nitrogen supply is shut off at nitrogen bottle.

5. Connect the charging and gauging unit to the nitrogen bottle with the flexible hose at the nitrogen tank fitting.

6. At the accumulator, remove the valve protection cap. Slightly loosen the socket head cap screw one-half turn
with a 6mm Allen wrench..

7. Close the release valve.

Use caution to avoid looping or twisting the hose.

8. Attach the charging and gauging unit connector to the accumulator gas valve by hand. Turn the unit into a
position that the gauge can be easily read.

9. Turn the t-handle counterclockwise until the gauge starts showing the pressure in the accumulator (if any).

10. Open the nitrogen bottle shut-off valve slightly and SLOWLY fill the accumulator with gas. The first 20 to 25
PSI should take 2 to 3 minutes to fill. Shut off nitrogen flow when gauge indicates pre-charge pressure of 725
PSI.

11. Let the pre-charge set for 10 to 15 minutes. This will allow the gas temperature to stabilize. Close the
nitrogen bottle valve. If the desired pre-charge is exceeded, then slowly open the release valve until the
pressure equals 725 PSI.

12. To remove the charging assembly, turn the t-handle all the way clockwise then open the release valve to
relieve residual gas charge in the charging assembly.

13. Hold the gas valve from turning and loosen the connector. Remove the charging and gauging unit. Remove
the nitrogen bottle from charging and gauging assembly.

14. Tighten the socket head cap screw one-half turn with the Allen wrench and replace valve protection cap.

PRESSURE
RELEASE
KNOBS

4-34
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

T-HANDLE

RELEASE VALVE
CHECK VALVE

CONNECTOR
PRESSURE GAUGE

CHARGING AND GAUGING UNIT

VALVE PROTECTION CAP

(WHERE APPICABLE)

O-RING (WHERE APPICABLE)

ALLEN WRENCH 6MM

SOCKET HEAD
CAP SCREW (M8)

SEAL RING

ACCUMULTOR GAS VALVE

4-35
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

ADJUST BOOM ROLLERS

To adjust the boom rollers, refer to the following:

1. In accordance with Operation procedures, fully retract the boom and set the park brake.

2. Turn off the machine and tag OUT OF SERVICE.

3. Inspect and lubricate the roller assemblies as described in Service.

4. Visually inspect inner boom to bottom guide (inside of outer boom weldment) clearance. Clearance distance
should be 0.250”.

5. Loosen center hex head capscrew and remove the end two hex head capscrews attaching shims to bottom
roller, Roller #2 (400669). Retain washers. Re-shim Roller #2 (400669), as required to acquire the clearance
distance of 0.250”. Reinstall capscrews and washers and tighten to hold shims in place.

6. When Roller #2 is adjusted, remove shims in the same way from Roller #3 (402092) and Roller #4 (400669).

7. Measure distances between roller plates and the outer boom. Add 0.063” to measured dimension for total
shim thickness.

8. Install shims for Rollers #3 and #4. Check for 0.063” clearance between rollers and top of inner boom.

9. Remove shims from Roller #5 (402092) and Roller #7 (400669). Tighten two 1.00” mounting bolts in center of
roller mounting plate to 100 ft-lbs.

10. Measure distance between roller plates and the outer boom. Add 0.063” to measured dimension for total
shim thickness.

11. Install shims for Rollers #5 and #7. Check for 0.063” clearance between rollers and top of inner boom.
Check for 0.125” clearance between each roller and side of the inner boom.

12. Maintain equal shim stacks for Rollers #5 and #6 and Rollers #7 and #8 from one side to the other (i.e. plus or
minus 0.250”) to center inner to outer boom.

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 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

ROLLER #8 ROLLER #6

SECTION A-A SECTION B-B

ROLLER #5
ROLLER #7

ROLLER #4 ROLLER #3

ROLLER #1
ROLLER #2

4-37
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

ROLLER #4 SHIMS

ROLLER
PLATE
ROLLER #8

OUTER
BOOM
CENTER
CAPSCREW
INNER
BOOM

END
CAPSCREW

ROLLER #7

ROLLER #2

SECTION A-A

ROLLER #3

INNER
ROLLER #6
ROLLER #5 BOOM

OUTER
BOOM

ROLLER #1
SECTION B-B

4-38
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

ADJUST PARK BRAKE.

To adjust the park brake, refer to the following:

1. In accordance with Operation procedures, chock the wheels and start the machine (engine running).

2. At the lever end, between the clevis and the threaded end of the cable, remove the clevis pin and
hairpin.

3. Loosen the jam nut and turn the clevis to adjust the length.

4. Adjust the length until the cable it tight and there is no free play. Loosen several turns so there is a
little slack (so that the brakes do not drag in this position).

5. If necessary, adjustment can also be made between the threaded cable end and the brake canister
by loosening the locknut and turning the cable to adjust length.

6. When adjustment is complete, perform a brake test.

Clevis

Jam Nut
Lever End

Threaded Cable End

Brake Canister
Pins

4-39
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

4.3 LUBE CHART

Boom Extend Cylinder Pins

2 Grease Fittings

Rotary Actuator Tool Extend Cylinder Base End Pin

1 Grease Fitting 1 Grease Fitting

4-40
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Tool Pivot Pin

1 Grease Fitting

Tool Rotation
Bearing
12 Grease Fittings

Tool Extend Cylinder Rod End Pin

1 Grease Fitting

Boom Lift Cylinder Pins

QuickLub®

Boom Pivot Pin

QuickLub®

4-41
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Oscillation Bearing
1 Grease Fitting
QuickLub®

4-42
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Front Driveline Carrier Bearing

QuickLub®

4-43
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Front Driveline Carrier Bearing

QuickLub®

4-44
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Mid Drive Shaft Slip Joint

1 Grease Fitting

Mid Drive Shaft U-Joints

2 Grease Fittings (1 each)

4-45
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Rear Drive Shaft Slip Joint

1 Grease Fitting

Rear Drive Shaft U-Joints

2 Grease Fittings (1 each)

4-46
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

QuickLub® - Block E
Boom Pivot Pin
Front Driveline Carrier

Boom End Frame

QuickLub® - Block J
Push Blade Cylinders
(mounted just below Block C)

QuickLub® - Block C
Oscillation Lock Cylinder
Boom Lift Cylinder

QuickLub® - Block B
Steering Cylinder QuickLub® Block F QuickLub® Block A
Articulation Pivot

4-47
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Boom End Frame

QuickLub® - Block D
Inner & Outer Boom Rollers

4-48
 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

Boom End Frame

Grease Reservoir

Grease Pump Grease Fitting (Fill Point)

4-49
OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

4.4 FLUID LIST

HYDRAULIC OIL (UV400907)

MOBIL .......................................................................................................................................... DTE 26
CONOCO ..................................................................................................................................... CPS 37
SUN.................................................................................................................................SUNFLEET 300
EXXON.................................................................................................................................. NUTO H 68
GULF........................................................................................................................... HARMONY 68AW
TEXACO.........................................................................................................................................RO 68
SHELL ....................................................................................................................................TELLUS 68

GREASE (UV400908)
MOBIL ............................................................................................................ MOBILGREASE SPECIAL
CONOCO ........................................................................................................................SUPERLUBE M
ARCO ....................................................................................................................................... EP MOLY
EXXON................................................................................................................................ BEACON Q2
GULF...............................................................................................................................GULFEX MOLY
TEXACO........................................................................................................ MARFOK MULTI-GREASE
SHELL .......................................................................................................SUPER DUTY LITHIUM MDS

ENGINE COOLANT (UV400910)

TEXACO.....................................................................HAVOLINE DEX-COOL, PRE-MIX, 50/50 BLEND

ENGINE FUEL (33272)

ASTM ........................................................................................................................... #2 DIESEL FUEL

ENGINE OIL (UV400903)

VALVOLINE®PREMIUM BLUE® ............................................. SAE 15W-40 HEAVY DUTY ENGINE OIL
EXXON............................................................................................................................................. XD-3
CONOCO ........................................................................................................... DIESEL OIL S-3 FLEET
MOBIL ............................................................................................................................... DELVAC 1300
TEXACO.................................................................................................................. URSA OIL SUPER 3

TRANSMISSION FLUID (UV400904)

MOBIL ................................................................................................................. MULTI-PURPOSE ATF
CONOCO .......................................................................................................HYD TRANSMISSION C-3
SUN....................................................................................................................... C-3 TRANSMISSION
GULF.............................................................................................................................................HT C-3
TEXACO....................................................................................................................TORQUE FLUID 47
SHELL ................................................................................................................................... DONAX T-5

DRIVE AXLES
The drive axles have three different sections with oil. API-GL5 or Mobil HD90 can be used in
the center and planetary ends, which are connected internally. The wet disc brake piston
section is supplied with the machine hydraulic oil UV400907. The wet disc cooling housing is
lubricated with API-GL4 or Mobil 424 and will enter the cooling inlet and exit the cooling outlet
ports. This oil will be cycled through the axle ends by the cooling pump. Refer to documents
WN85601 and WN85602 (provided with this manual) for permissible oil recommendations.

Always refer to the Original Equipment Manufacturer’s literature for proper fluids
or lubricants. If the information provided in this manual conflicts with the
Original Equipment Manufacturer’s literature, ALWAYS follow the Original
Equipment Manufacturer’s instruction.

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 OPERATION AND MAINTENANCE MANUAL
MAINTENANCE

4.5 FILTER LIST

COMPONENT FILTER OR ELEMENT PART NUMBER

Primary Air Filter Element 401162

Safety Air Filter Element 401163

Diesel Engine
Primary Fuel Filter 702956
(Cummins Engine PN 701467)
Fuel/Water Separator 702509

Oil Filter 014607

Drive Axles
Oil Filter 706319
(Kessler Axles PN 708836)
Transmission
Filter Element 401168
(Transmission w/brake PN 404712)
Hydraulic Return (Spin-On Filter) 401172
Hydraulics
Hydraulic Tank (Filler/Breather Cap) 402797
(Hydraulic Schematic PN 709084)
High Pressure Filter Element 402011
Water Spray
Filter Element 90 472 028
(Water Spray Option PN 709124)

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MAINTENANCE

This page intentionally blank.

4-52
 OPERATION AND MAINTENANCE MANUAL
TROUBLESHOOTING

5.0 TROUBLESHOOTING

Only authorized personnel (trained and certified) shall troubleshoot this machine. Always review the Safety
section of this manual prior to troubleshooting this machine.

Section Page

General Troubleshooting ................................................................................................................ 5-2

Troubleshooting Guide.................................................................................................................... 5-3

Read and understand

manual and safety
information before
troubleshooting!

5-1
OPERATION AND MAINTENANCE MANUAL
TROUBLESHOOTING

GENERAL TROUBLESHOOTING

The purpose of this section is to aid personnel in the location, isolation, and correction of problems that occur
during operation of the SV-22 Scaler. The troubleshooting guide defines specific problems and solutions.
Checking common types of causes may eliminate the need for more specific troubleshooting. The following
preliminary checks should be made to expedite troubleshooting by eliminating common malfunctions.

a. Eliminate operator error as a cause. The SV-22 Scaler has been designed with certain safety
features to protect personnel and equipment. If the equipment appears to be operating as
designed, refer to the Operation section of this manual.

b. Refer to the Maintenance section of this manual to ensure the equipment has been maintained
properly and all adjustments and alignments have been correctly performed.

c. Verify that mounting hardware, electrical connections, and hydraulic connections are not loose
due to mechanical vibration.

d. Visually inspect the machine to make sure there are no fluid leaks. Repair all leaks.

f. Refer to the Electrical Schematic and verify that all electrical wiring and connections are correct
and intact. Ensure that there are no bare or broken electrical wires.

g. An indicator or lamp that fails to illuminate may be a failed bulb.

h. Check the circuit breakers and fuses before conducting an extensive disassembly procedure.

i. Refer to the Hydraulic Schematic and verify that all hydraulic hoses and connections are correct
and intact. Ensure that there are no cracked, loose, or burst hydraulic hoses or fittings.

TROUBLESHOOTING GUIDE

The following table is provided as a guide for troubleshooting. Symptoms/malfunctions, probable cause, and
corrective actions are listed. For certain malfunctions, multiple probable causes can exist. Eliminate causes that
can be corrected simply before attempting an extensive repair. Personnel should not attempt an action that
exceeds their maintenance capability.

Unless otherwise specified, before performing any corrective maintenance actions turn the main battery
disconnect switch to OFF and tag the equipment “OUT OF SERVICE.”

Tagging the electrical wires and/or hydraulic hoses prior to disconnecting will facilitate reconnection.

5-2
 OPERATION AND MAINTENANCE MANUAL
TROUBLESHOOTING

TROUBLESHOOTING GUIDE

Symptom/Malfunction Probable Cause Corrective Action

Engine will not start. Operator error. The machine is responding

correctly. Personnel shall study
Vehicle and Equipment
Operation procedures and
proceed.

Out of fuel Refer to Engine Service Manual

to re-pressurize fuel system. Add
fuel if necessary.

The engine switch (S2) is in the The engine start switch must be
OFF position or is faulty. in the ON START position to
start the machine. Refer to
Vehicle and Equipment
Operation procedures. Replace
switch if faulty.

The battery disconnect switch The battery disconnect switch

(S1) is in the OFF position or is must be in the ON position to
faulty. have power to the machine.
Refer to Vehicle and Equipment
Operation procedures. Replace
switch if faulty.

The directional control switch The directional control switch

(S30) is not in NEUTRAL must be in the NEUTRAL
position or is faulty. position to start the machine.
Refer to Vehicle and Equipment
Operation procedures. Replace
switch if faulty.

The park brake/relay switch (S26) The park brake/relay switch must
is not pressed or is faulty. be pressed in to engage the park
brake prior to machine start.
Refer to Vehicle and Equipment
Operation procedures. Replace
switch if faulty.

Start circuit relay (K1) failure. Replace relay.

High hydraulic oil temperature Replace switch if faulty.

condition or temperature switch Hydraulic oil temperature must
(S22) failure. be less than 180° F for the
machine to start. Indicator light
(DS6) will illuminate when
hydraulic oil is 180° or higher.
Wait until oil has cooled
(indicator no longer illuminated)
and restart engine.

5-3
OPERATION AND MAINTENANCE MANUAL
TROUBLESHOOTING

TROUBLESHOOTING GUIDE (CONT.)

Symptom/Malfunction Probable Cause Corrective Action

Engine will not start - Continued. Low hydraulic level switch Replace switch if faulty. Refer to
(S7-L) failure or low hydraulic Fluids List for fluid specifications
oil level. and capacity to refill hydraulic
oil.

Faulty starter motor (M1). Replace starter motor.

Plugged fuel filter. Refer to Engine Service Manual

for fuel filter replacement.

Broken alternator belt. Refer to Engine Parts Manual for

part number. Refer to Engine
Service Manual for repair.

Broken engine fan belt. Refer to Engine Parts Manual for

part number. Refer to Engine
Service Manual for repair.

Engine fault. Refer to Power View Manual and

Engine Service Manual for
information regarding engine
fault codes.

Machine will not travel forward. The directional control switch The directional control switch
(S30) is not in FORWARD must be in the FORWARD
position or is faulty. position to travel in that direction.
Refer to Vehicle and Equipment
Operation procedures. Replace
switch if faulty.

Forward solenoid (SV12) failure. Replace solenoid.

Machine will not travel in The directional control switch The directional control switch
reverse. (S30) is not in REVERSE must be in the REVERSE
position or is faulty. position to travel in that direction.
Refer to Vehicle and Equipment
Operation procedures. Replace
switch if faulty.

Reverse solenoid (SV13) failure. Replace solenoid.

Machine will not travel in Accelerator pedal failure (A5). Replace accelerator pedal.
forward or reverse, or travels
slowly.

Machine will not shift gears. Gear selector switch (S11) Replace switch.
failure.

Transmission solenoid (SV14, Replace faulty solenoid.

SV15, or SV16) failure.

5-4
 OPERATION AND MAINTENANCE MANUAL
TROUBLESHOOTING

TROUBLESHOOTING GUIDE (CONT.)

Symptom/Malfunction Probable Cause Corrective Action

Machine will not shift gears – Transmission failure. Refer to Transmission Service
Continued. Manual.

Machine will not turn left or Button (S34) failure on left hand Replace button.
right. control handle.

Trigger switch (S31) failure on Replace switch.

right hand control handle.

Right hand control handle valve Replace valve.

(400293) failure.

Steering cylinder (402203) Repair cylinder.

failure.

Machine is sluggish or has Hydraulic pressure settings are Adjust hydraulic system pressure
inefficient performance. out of adjustment. settings.

Service brakes will not set. Brake pedal actuator (402557) is Replace pedal if faulty.
faulty.

Park brake test push button (S13) The park brake test pushbutton
has been pressed or is faulty. releases the service brakes. Refer
to Vehicle and Equipment
Operation procedures. Replace
pushbutton if faulty.

Park brake solenoid (SV2) has The park brake test pushbutton
been activated or is faulty. activates the park brake test
solenoid and releases the service
brakes. Refer to Vehicle and
Equipment Operation procedures.
Replace solenoid if faulty.

Brake Manifold (400297) failure. Inspect and repair brake

manifold.

Park brake will not set. Park brake/reset switch (S26) Replace switch.
failure.

Scale brake mode is active or Deactivate scale brake mode.

pushbutton (S33) on right hand Refer to Vehicle and Equipment
control handle is faulty. Operation procedures Replace
pushbutton if faulty.

Park brake relay (K5) failure. Replace relay.

5-5
OPERATION AND MAINTENANCE MANUAL
TROUBLESHOOTING

TROUBLESHOOTING GUIDE (CONT.)

Symptom/Malfunction Probable Cause Corrective Action

Park brake will not set – Park brake pressure switch (S3) Replace switch.
Continued. failure.

Park brake solenoid cartridge Repair or replace cartridge and

valve in brake manifold (400297) valve.
and park brake manual override
valve (402453) have both failed.

Park brake will not set from right Park brake pushbutton (S35) Replace pushbutton.
hand control handle. failure on right hand control
handle.

Park brake will not release. Park brake/reset switch (S26) Replace switch.
failure.

Park brake release solenoid (SV3) Replace solenoid.

failure.

Park brake release valve (602638) Repair or replace valve.

failure.

Boom will not extend or retract. Left hand control handle valve Replace valve.
(400293) failure.

Boom extend cylinder Repair cylinder.

(402688, 402690) failure.

Oscillation lock valve (400300) Replace valve.

failure.

Oscillation lock cylinder Repair cylinder.

(701579) failure.

Boom will not lift or lower. Left hand control handle valve Replace valve.
(400293) failure.

Boom lift cylinder (402204) Repair cylinder.

failure.

Oscillation lock valve (400300) Replace valve.

failure.

Oscillation lock cylinder Repair cylinder.

(701579) failure.

Scale brake mode does not Scale brake mode pushbutton Replace pushbutton.
activate. (S33) on right hand control
handle is faulty.

5-6
 OPERATION AND MAINTENANCE MANUAL
TROUBLESHOOTING

TROUBLESHOOTING GUIDE (CONT.)

Symptom/Malfunction Probable Cause Corrective Action

Scale brake mode does not Scale brake solenoid (SV1) Replace solenoid.
activate - Continued. failure.

Scale mode relay (K13) failure. Replace relay.

Micrologix unit or memory Replace Micrologix unit or

module failure. memory module.

Tool does not rotate left. Pick rotate left solenoid (SV4) Replace solenoid.
failure.

Tool does not rotate right. Pick rotate right solenoid (SV5) Replace solenoid.
failure.

Tool does not rotate left or right. Button (S34) failure on left hand Replace button.
control handle.

Trigger switch (S31) failure on Replace switch.

right hand control handle.

Scale brake mode is not active or Activate scale brake mode. Refer
pushbutton (S33) on right hand to Vehicle and Equipment
control handle is faulty. Operation procedures. Replace
pushbutton if faulty.

Right hand control handle valve Replace valve.

(400293) failure.

Cushion valve (401254) failure. Replace valve.

Rotary actuator (400116) failure. Replace actuator.

Tool (optional) does not move Right hand control handle valve Replace valve.
forward and reverse. (400293) failure.

Tool cylinder (402107) failure. Repair or replace cylinder.

Hammer (optional) does not Hammer trigger switch (S36) Replace switch.
actuate. failure on left hand control
handle.

Hammer solenoid (SV8) failure. Replace solenoid.

Supply valve (601960) failure. Repair or replace valve.

5-7
OPERATION AND MAINTENANCE MANUAL
TROUBLESHOOTING

TROUBLESHOOTING GUIDE (CONT.)

Symptom/Malfunction Probable Cause Corrective Action

Water Spray (Optional) does not Hammer trigger switch (S36) Replace solenoid.
actuate. failure on left hand control
handle.

Water spray solenoid (SV28) Replace solenoid.

failure.

Supply valve (601960) failure. Repair or replace valve.

5-8
 WARRANTY AND LIMITATIONS OF DAMAGES

Oldenburg Group Incorporated (“OGI”) warrants to Purchaser, and to Purchaser only, that the products manufactured by it will conform to
the description in OGI final written quotation and/or acknowledgment of Purchaser’s purchase order covering the products to which this
warranty applies; that OGI will convey good title thereto; and that such products will, at the time of shipment and for a period of twelve
months or two thousand hours whichever occurs first after delivery to the original Purchaser be free from defects in material and
workmanship under normal use and service. No oral description or statements will constitute representations of warranties concerning OGI
products. This warranty shall not be applied to any products, which are subjected to misuse, negligence, accident or corrosion, nor shall it
apply to any products, which are altered by Purchaser or others.
Items excluded from this warranty are:
1. Tires, batteries, engines, and mounted equipment which are warranted to the purchaser by their respective manufacturers thereof.
2. Preventative maintenance or operating services including, but not limited to, consumables,
ie. Filters, Picks, Electrical Cables, Hoses, Fittings, Lubricants, Lights, Fuses, etc.
3. Repair and replacement due to normal wear and tear, misuse, abuse, neglect, accident or
Alterations not specifically authorized by OGI.
4. Failures related to impact of material on the Boom and main frame.
5. Failures related to vibration due to normal scaling operation or impacting from material on the main frame and or boom.
Items that will void this warranty are:
1. Altering original equipment design without written authorization from OGI.
2. Failure to shut down equipment for repair after problem is discovered.
3. Overloading or operating outside equipment designed specifications.
4. Failure to properly maintain products in accordance with OGI recommended procedures.
5. Improper care and storage.
6. Failure to file a warranty claim within (5) five business days of the failure will void that claim.
7. Failure to return the part or parts to an OGI representative for warranty consideration within (10) ten business days of the failure
will void that claim.
8. Tram Scaling will void all related failures.

OGI MAKES NO OTHER WARRANTIES WHATSOEVER WITH RESPECT TO SUCH PRODUCTS AND HEREBY DISCLAIMS
ANY IMPLIED WARRANTIES WITH RESPECT THERETO, INCLUDING, WITHOUT LIMITATION, WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

OGI obligation under this warranty is expressly limited to repair or replacement at its factory or other location designated by OGI of any
product or parts of products manufactured by OGI and covered by this warranty which shall, within twelve (12) months or two thousand
(2,000) hours whichever occurs first after delivery to the original Purchaser, be returned to OGI with transportation charges prepaid, and
which OGI examination shall disclose to its satisfaction to be defective. All replacement parts shall only be warranted for the length of the
original machine warranty (twelve months or two thousand hours after delivery to the original purchaser). The sole purpose to the exclusive
remedy set out here in shall be to provide Purchaser with free repair or replacement of the defective product. This exclusive remedy shall
not be deemed to have failed of its essential purpose so long as OGI is ready and willing to repair or replace in the prescribed manner.
However, OGI, at its option, may, in lieu of such repair or replacement, refund the purchase price applicable to such products or parts. If
warranty is granted, all standard freight costs (UPS, LTL) of the defective parts to and from the Purchaser by OGI shall be at OGI sole
expense. If OGI denies warranty to Purchaser, all freight costs to and from OGI shall be at Purchaser’s sole expense. Removal and
reinstallation of the replacement parts will be at the Purchaser’s sole expense.
Drivetrain – gearbox, transmission, axles for a period of twelve (12) months or first two thousand (2,000) hours of operation, whichever
shall occur first from date of delivery to the first user. Same terms and conditions as listed in previous paragraphs will apply. Tram Scaling
will void all Drivetrain related failures.
Frame – Limited warranty of five (5) years or the first ten thousand (10,000) hours, whichever shall occur first (from date of delivery to
the first user). OGI warrants the main frame (less mounted attachments & boom assembly) to be free from defects in material and
workmanship. Excluded are normal wear components (i.e. bushings, bearings, and rollers), purchased components (including, but not
limited to hydraulic cylinders, hoses and fittings). Physical damaged caused by impact from material. Tram Scaling will void all Frame
related failures.
OGI shall not be liable for any loss of profits, loss of use, loss of business, or damage to good will, personal injury damages, damage to property
or any incidental or consequential damages of any kind whatsoever resulting from breach of warranty, failure to comply with any obligations
under this Contract, or any other cause, nor shall OGI be liable for any damages, other than those expressly permitted under this Contract,
whether direct, indirect, special, consequential or exemplary, resulting from any cause. Purchaser or anyone else may bring no action for breach
of the warranty stated above or for any other claim for breach of this contract, more than one year after the date of delivery.
 Customer Survey of Equipment upon Delivery & Start Up

Customer: _____________________________________ Location: _______________________________________

Machine Description: _____________________________________________________________________________

(Model Number Description and Serial Number)

Date Shipped: ________________ Date Arrived: ________________ Dave In Service: _____________

Shipped From: _____________________________ Prepared By: ____________________________________

(Prepared by Customer’s Representative)

Please rate our performance in the following areas with respect to the equipment purchased. Place an “X” or
check mark in the column that best describes your opinion.

Question Poor Good Excellent

Adherence to Delivery Schedules
Correct / Complete Equipment Received
Condition of Equipment Received
Quality of Manuals / Literature
Start-up Assistance
Equipment Performance
Production Quality
Service Support
Other (Please Specify)

If you experienced any problems, were they resolved to the customer’s satisfaction?

Yes __________ No __________

Please indicate below, your overall level of satisfaction with Oldenburg Group Incorporated and its divisions as
a supplier of your equipment. Place an “X” or check mark next to the statement that best fits your opinion.

Rating Description
Completely Satisfied. OGI Exceeded Expectations
Reasonably Satisfied. OGI Met Expectations
Dissatisfied. OGI Did Not Meet Expectations

General Comments: _____________________________________________________________________

________________________________________________________________________________________________
________________________________________________________________________________________________
________________________________________________________________________________________________
____________________________________________________________

Signature: ______________________________________ Date: _______________

OGI Field Representative –

Please FAX completed form to Internal Sales Department Representative at (414) 446 6038
 FOR PARTS & SERVICE ASSISTANCE – CALL TOLL FREE (877) 243-7455
E-Mail: [email protected]

UNITED STATES
Mining Equipment Service Manager Stefan Gierko Office: (603) 542-9548
Cell: (603) 738-2255
Mining Equipment Parts Manager Debbie Borey Office: (603) 542-9548
Cell: (313) 559-7375
Director of Mining Product Sales Bill Rhoades Office: (603) 542-9548
Cell: (603) 848-0794
Home Office: (603) 495-0041
Director of Sales Engineering Steve Rudinec Office: (906) 776-3140
Cell: (906) 396-9850
Marketing Administrator Dave Sabalewski Office: (603) 542-9548
Northeast Sales Donald Miller Cell: (443) 975-9091
Southeast Sales Terry Robinette Cell: (303) 638-4232
Southeast Service Jim Smith Cell: (931) 267 8646
Southeast Service Bill Debord Cell: (931) 239-9926
Southeast Service Lorne Bellofatto Cell: (740) 416-1894
Southeast Service Matt (Glen) Jacobs Cell: (309) 533-3134
Midwestern Sales Jim Bible Cell: (573) 259-8329
Home Office: (573) 468-8329
Midwestern Service Mike Grant Cell: (636) 575-5755
Midwestern Service Toby Crawford Cell: (603) 289-0047

CANADA
Resource Equipment Sales Bob Ray Cell: (705) 542-5080
Perry Neel Office: (807) 221-4670
Cell: (705) 542-7210
Torrox International Ltd Carter Kosick Office: (902) 468-7666
Cell: (902) 497-1334

LATIN AMERICA
General Manager for Latin America and Sales Marcos Rosiles Office: +52 (492) 925 1668
Office: +52 (492) 925 1679
Office: +52 (492) 998 1979
Inside Mexico: 01 800 831 0565
Cell: +52 (492) 103 0834
Latin America Service Manager Martin Castanon Office: +52 (492) 925 1668
Office: +52 (492) 925 1679
Cell: +52 (492) 146 3277
Latin America Sales Manager Normando Bivar Office: +52 (492) 925 1668
Cell: +52 (492) 105 2162
Cell: +52 (492) 105 2172
Mexico Service Manager Gerardo Sanchez Cell: +52 (492) 146 3277
Latin America Service Manuel Reyes Cell: +52 (492) 103 2656
Latin America Service Eduardo Castanada Cell: +52 (492) 126 1151
Latin America Service Juan Rivera Office: +52 (492) 925 1668
Distributor Manager Jesus Fernandez Office: +52 (492) 925 1668
Parts Assistance Juan Mena Office: +52 (492) 925 1679
Parts Assistance Octavio Lara Cell: +52 (492) 145 1872