OPERATION & MAINTENANCE MANUAL

RS425C
RECLAIMER/STABILIZER
SERIAL NUMBER 526320 & UP

A08516 E02 Rev. C

June 2009

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Table of Contents

California Proposition 65 Warnings

The following warning applies to equipment supplied with lead-acid batteries:

Battery posts, terminals, and related accessories contain lead and

lead compounds, chemicals known to the State of California to
cause cancer and reproductive harm. Wash hands after handling.

The following warning applies to equipment supplied with diesel-powered engines:

Diesel engine exhaust and some of its constituents are known to

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

NOTICE
The illustrations, charts, photographs and layout examples shown in this manual
are intended solely to help you understand the text. Some illustrations show details
or attachments that may be different from your machine. Also guards and covers
may have been removed for illustrative purposes.
Continuing improvement and advancement of product design may have caused
changes to your machine which are not included in this manual. The information
contained in this document is subject to change without notice.
Whenever a question arises regarding your machine or this manual, please consult
your dealer, Terex Roadbuilding Parts Sales (1-800-264-7278) or Terex Roadbuild-
ing Product Support for the latest available information.

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The operator must read and understand all the instructions in this manual before operating the
machine.
Important Safety Information.....................7
Introduction.............................................................7
General...................................................................7
Intended Use..........................................................7
Symbols..................................................................7
Hazard Classification..............................................8
Safety Sign Maintenance........................................9
Safety Sign Pictorials..............................................9
Safety Sign Locations...........................................12
Personal Safety....................................................16
Operation and Repair Precautions....................... 16
Questions..............................................................18
Receive the Machine.................................21
Initial Inspection....................................................21
Before Operating the Machine.............................. 21
Roll Over Protection Structure (If Equipped)........ 22
Unload the Machine..............................................23
Controls......................................................29
General.................................................................29
Control Panels......................................................29
Other Controls (Not on Console).......................... 34
Other Gauges (Not on Console)........................... 36
Water/Emulsion Control Panel (Option)................ 37
Machine Operation....................................43
Before Starting the Engine....................................43
Start the Machine..................................................43
Start with a Boost..................................................47
After Engine Start.................................................50
Stop the Engine....................................................51
Non-Operational Travel.........................................52
Operating Adjustments.........................................54
Adjust Rear (B-End) Steering Indicator................ 54
Operating Techniques for Work in Soil.................. 55
During Operation..................................................63
Op. Techniques for Work in Dense Materials........ 64
Lower the Cutter Directly into Dense Material...... 69
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Table of Contents
Start Operation..........................................71
Load Control System............................................71
Adjust the Cutting Depth.......................................72
Start a Cut.............................................................75
End Operation............................................78
Park the Machine..................................................78
Machine Cleanup..................................................79
Transport the Machine..............................81
Shipping................................................................81
Maintenance...............................................85
Engine Running Procedures Safety Guidelines.... 85
Maintenance Recommendations.......................... 86
Cooling System Conditioner Elements................. 87
Fuel System..........................................................87
Hydraulic System..................................................88
Air Inlet System.....................................................88
Electrical System..................................................89
General ................................................................89
Coolant, Fuel and Lubricant ........................
Specifications............................................90
Coolant Specifications..........................................90
Fuel Specifications................................................90
Lubricant Specifications........................................91
Controls, Systems and Tools Used for
Maintenance...............................................91
Main Battery Disconnect Switch .......................... 91
Cutter Door Lock...................................................92
Cutter Retaining Chains........................................92
Compressed Air System.......................................93
Cutter Tools...........................................................93

Maintenance Notes....................................94
Key to Lubricants..................................................94
Filter Elements Part Numbers............................ 94
Refill Capacities (Approximate)............................ 94
Maintenance Schedule Chart...................95
Hydraulic System..................................................99
Ground Drive Axle Carrier and Planetary Ends.... 99
After First 25 Service Hours...................................99
After First 100 Service Hours.................................99
When Required......................................................100
Engine Cooling System .....................................100
Engine Air Intake System....................................101
Fuel System........................................................106
Fuel Tank............................................................ 110
Auxiliary Hydraulic Oil Filter................................ 111
Compressed Air System..................................... 111
Cutter Drum........................................................ 112
Cutter Drive Shaft Torque Limiter Clutch............ 113
Cutter Clutch....................................................... 115
Walk-Around Inspection...................................... 117
Every 10 Hours Or Daily....................................... 117
Hydraulic System................................................ 118
Cooling Systems................................................. 118
Engine Crankcase..............................................120
Engine Air Cleaner..............................................121
Ground Drive Transmission................................121
Ground Drive Axle Carrier and Planetary Ends.. 122
Cutter Axle..........................................................123
Cutter Transmission............................................123
Cutter Chaincases..............................................124
Cutter Drum........................................................124
Cutter Support Bearing Lubricator...................... 125
Tires....................................................................125
Fuel Tank............................................................126
Lubrication..........................................................126
Engine Air System..............................................129
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Every 50 Service Hours Or Weekly...................... 129
Batteries..............................................................130
Cutter Transmission Cooling System.................. 131
Cutter Differential Cooling System...................... 131
Cutter Drive Chains............................................132
Depth Gauge Pivot.............................................133
Every 100 Service Hours Or Two Weeks............. 134
Every 250 Service Hours Or Monthly.................. 134
Hydraulic Oil Filters.............................................134
Engine Oil and Oil Filters....................................134
Engine Cooling System......................................136
Engine Crankcase Breather................................138
Engine Valve Lash..............................................139
Alternator Belt and Fan Drive Belts.................... 139
Ground Drive Brakes..........................................142
Cutter Differential................................................145
Cutter Transmission............................................147
Electrical System................................................148
Lubrication..........................................................149
Every 500 Service Hours Or 3 Months................ 150
Hydraulic System................................................150
Engine Crankcase..............................................151
Cutter Chaincase Hubs.......................................152
Fuel Tank ...........................................................152
Hydraulic Oil Replenishing Tank.........................153
Fluid Sampling....................................................153
Every 1,000 Service Hours Or Yearly................... 164
Batteries..............................................................164
Ground Drive Axle Carrier and Planetary Ends.. 164
General Wheel Alignment Information................ 166
Alt. Method to Check Amount of Toe Present..... 167
Cutter Transmission Shift Linkage...................... 170
Engine Valve Lash..............................................171
Engine Cooling System......................................171
Every 2,000 Service Hours Or 2 Years................. 171
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Reference Information............................181
Pressure Settings...............................................181
Shipping Dimensions..........................................181
Fastener Torques................................................182
Standard Torque for Metric Fasteners................ 183
Standard Torque for Hose ClampsWorm Drive
Band Type...........................................................184
O-Ring Face Seal Fittings...................................184
Hydraulic Line Installation...................................185
Assembly of Fittings with Straight Threads and O-
Ring Seals..........................................................185
Torques for Flared and O-Ring Fittings............... 186
45 Flared and 45 Inverted Flare Fittings.......... 188

Common Symbols...................................190
Lines and Line Functions....................................190
Mechanical Devices............................................190
Pumps and Motors..............................................190
Reservoirs...........................................................190
Cylinders.............................................................191
Valves.................................................................191
Valve Actuators...................................................192
Accessories........................................................192
Electric Schematic Symbols...............................193
Switch Configurations.........................................193
Resistors.............................................................193
Contacts..............................................................193
Housings.............................................................193
Types of Grounds...............................................193
Lamp Symbols....................................................194
Solenoids/Coils...................................................194
Solenoids/Coils (continued)................................194
Control Relay......................................................194
Color Abbreviations.............................................195
Electrical Miscellaneous.....................................195
Electrical Miscellaneous (continued).................. 195
Common Abbreviations.......................................196
Conversion Factors.............................................198

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RS425C Safety

Important Safety Information

Introduction Intended Use

Owners, Users, and Operators:
Terex appreciates your choice of our machine for your
application. The number one priority at Terex is user
safety. We feel that you, as the machine owner, user,
or operator make a major contribution to safety if you
comply with OSHA, federal, state, and local regula-
tions,
read, understand and follow the instructions in this
and other manuals supplied with this machine,
use good, safe work practices in a common sense
way,
only have trained/certified operatorsdirected by
informed and knowledgeable supervisionrunning
the machine.
OSHA and Terex Roadbuilding prohibit the alteration
or modification of this machine without written manu-
facturers approval. Use only factory-approved parts to
service or repair this machine.
If there is anything that is not clear or which you
believe should be added, please contact Terex Road-
building Technical Publications, P.O. Box 1985, Okla-
homa City, OK 73101.
This machine and its approved attachments are de-
signed to reclaim and stabilize base.
Use of this machine in any other way is prohibited and
contrary to its intended use. Continuing improvement
and advancement of product design may have caused
changes to your equipment that are not included in this
publication.
Whenever a question arises regarding your equipment
or this publication, please consult your Terex Road-
building representative at 1-888-TEREXRB (1-888-
837-3972).
Symbols
Read and understand all safety precautions and
warnings before operating or performing lubrication,
maintenance, and repair on this product.
Specific safety warnings for all of these publications
are provided in the description of operations where
hazards exist. Labels and/or decals have also been
put on the product to provide instructions and to iden-
tify specific hazards. If these labels or decals are not
heeded, serious injury or death could occur to you or
other people.

Safety Alert Symbol

General
The safety alert symbol is used to
Most accidents involving product operation, mainte-
alert you to potential personal
nance, and repair are caused by failure to observe
injury hazards. Obey all safety
basic safety rules or precautions. An accident can
messages that follow this symbol
often be avoided by recognizing potentially hazardous
to avoid possible injury or death.
situations before an accident occurs. All personnel
must be alert to potential hazards. All personnel should
have the necessary training, skills, and tools to per-
form these functions properly.
Terex Roadbuilding is not responsible for the training
and familiarization of personnel who operate, main-
tain, or service Terex Roadbuilding machinery, except
for Terex Roadbuilding personnel. The owner, lessor,
renter, or user of the Terex Roadbuilding machinery
is responsible for properly training and familiarizing
the necessary personnel with the Terex Roadbuilding
machinery. Contact your Terex Roadbuilding represen-
tative concerning a Terex Roadbuilding training school
for your equipment.

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Safety
Hazard Classification
Specific safety warnings for all these publications are
provided in the description of operations where haz-
ards may exist. Labels and/or decals have also been
put on the product to provide instructions and to iden-
tify specific hazards. If these labels or decals are not
heeded, bodily injury or death could occur to you or
other persons. Warnings in this publication and on the
product labels are identified by the following symbols:
DANGER
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if
not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not
avoided, may result in minor or moderate injury.
NOTICE
NOTICE indicates a situation which, if not avoided,
may result in property or equipment damage.

RS425C
Terex cannot anticipate every possible circumstance
that might involve a potential hazard. The warnings in
this publication and on the product are therefore not all
inclusive. If a tool, procedure, work method or operat-
ing technique not specifically recommended by Terex
is used, you must satisfy yourself that it is safe for you
and others. You should also ensure that the product
will not be damaged or made unsafe by the operation,
lubrication, maintenance or repair procedures you
choose.
The information, specifications, and illustrations in this
publication are on the basis of information available
at the time it was written. The specifications, torques,
pressures, measurements, adjustments, illustra-
tions, and other items can change at any time. These
changes can affect the service given to the product.
Obtain the most complete and current information
before starting any job.
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RS425C Safety

Safety Sign Maintenance

Replace any missing or damaged safety signs. Keep
operator safety in mind at all times. Use mild soap and
water to clean safety signs. Do not use solvent-based
cleaners because they may damage the safety sign
material.
The illustrations under Safety Sign Pictorials define
the graphics used on each safety decal. The graphics
under Safety Sign Locations illustrate the location
and give an example of each safety decal located on
your equipment. During the daily inspection of the
equipment, check that the decals are present and in
good condition.

Safety Sign Pictorials

Flying Objects Hazard Fall Hazard

Stay clear when cutter is Do not climb on or off

operating. machine during operation.

Entanglement Hazard Do not insert hand into moving

components or openings.

Stop machine and remove key Crush Hazard

before servicing.

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Safety RS425C

Burn Hazard Start only from operators

station.

Do not touch hot surfaces. Injection Hazard

Allow surfaces to cool before
servicing.

Use a piece of cardboard or

Entanglement Hazard
paper to search for leaks.
Do not use your hand. Fluid
injected into the skin must be
surgically removed within a
few hours by a doctor who is
familiar with this type of injury,
or gangrene will result.

Stay clear when engine is Crush Hazard

running.

Crush Hazard Stay clear of area behind

machine while machine is in
operation.

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RS425C Safety

Use dust suppression or

Crush Hazard dust collection equipment to
minimize the dust exposure
during operation of this
machine.

Use approved respiratory

Install support device before protection to avoid inhalation
working under door. of dusts, when required by
Federal, State, and Local
safety and health regulations.

Inhalation Hazard Read and understand the

operators manual before
operating or maintaining the
machine.

Allow to cool before opening. Burn Hazard

Safety Alert Symbol

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Safety RS425C

Safety Sign Locations

1 3

2
3

BURN HAZARD DO NOT touch hot surfaces. NOISE HAZARD

Hot surfaces can burn Allow surfaces to cool Starting maching at ground Start only from operators
skin resulting in serious before servicing. level can cause serious station.
injury or death.
001010660000 injury or death. 526000944000

(1) 001010660000 (2) 526000944000

INJECTION HAZARD
Escaping fluid under
pressure can penetrate
skin, causing serious
injury.

Relieve pressure before

ENTANGLEMENT HAZARD
Contact with rotating cutter could
cause serious injury or death.
(3) 001010650000
disconnecting hydraulic
lines. Keep away from
leaks and pin holes. Use
a piece of cardboard or
paper to search for leaks.
Do not use hand.
Stay clear when engine is running. Fluid injected into skin
See operators manual for proper must be surgically removed
cutter maintenance procedures. within a few hours by a
Stop machine and remove key
before working around cutter. doctor familiar with this
001010650000 type of injury or gangrene
001010675000
will result.
(4) 001010675000

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RS425C Safety

3
6
7

5
8

ENTANGLEMENT HAZARD Stay clear when engine is running.

Contact with rotating cutter could
cause serious injury or death.
See operators manual for proper
cutter maintenance procedures.
Stop machine and remove key
before working around cutter.
001010650000

(3) 001010650000 CRUSH HAZARD DO NOT insert hand into

Serious injury or death moving components or openings.
Remove Key before servicing
can occur. machine. 001010661000

(7) 001010661000

ENTANGLEMENT HAZARD Keep away from fan

and belt when engine
Rotating parts can
is running. Stop engine
cause personal injury.
before servicing. 001010658000

(5) 001010658000

FLYING OBJECTS HAZARD Stay clear when

Contact with flying objects cutter is operating.
could result in death or
serious injury. 001010676000

(8) 001010676000

FALL HAZARD
Serious injury or death can DO NOT climb on or off machine
occur. during operation.
526000943000

(6) 526000943000

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Safety RS425C

CRUSH HAZARD CRUSH HAZARD

Machine may lunge backward.
Contact with moving machine
could result in serious
injury or death.
Stay clear of area behind Install support device before working
machine while machine is An unsupported door may fall under door.
in operation. resulting in death or serious
injury. See operators manual for instructions.
001010651000 001010652000

(9) 001010651000 (10) 001010652000

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RS425C Safety

WARNING
Inhalation Hazard
Death, serious injury, or
delayed lung disease may
result from breathing
hazardous dusts.

Hazardous dusts can be

generated during operation
of this equipment.

Use dust suppression or dust

collection equipment to
minimize the dust exposure
during operation of this
machine.

Use approved respiratory

protection to avoid inhalation
of dusts, when required by
Federal, State, and Local
safety and health regulations.
Improper operation or Read and understand
maintenance can result operators manual and all Contact your employer to
in serious injury or safety signs before using establish whether these
death. or maintaining machine. regulations require that you
use respiratory protection.
001010653000
001010677000

(11) 001010653000 (12) 001010677000

Runaway Possible
Machine could run over you or others.
Death or serious injury may result.
DO NOT transport machine in LOW range.
Loading machine for transport
Sh ft into LOW
*Drive machine onto tra ler
*Sh ft into HIGH
*Engage brakes
*Turn off machine
*Secure machine to tra ler
Unloading machine after transport
Remove the blocks and tiedowns
*Start machine and build air pressure
*APPLY HANDBRAKE
BURN HAZARD Allow to cool before *Shift into LOW
*Release park brakes
Hot fluid under opening. *Test transmission engagement by moving drive
control handle in either direction;
pressure can scald. *If resistance is felt, release handbrake and
drive off the trailer
001010674000
*If NO resistance is felt;
1. Slowly release handbrake until machine moves
and engages the transmission
(13) 001010674000 2. Completely release handbrake
3. Drive off trailer
FOR ADDITIONAL INFORMATION REFER TO THE
OPERATION & MA NTENANCE MANUAL
526000935000

(14) 526000935000

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Safety
Personal Safety
In addition to the specific maintenance and operating
instructions in this manual, the operator must read and
understand all instructions in this Introduction and in
the following sections.
Introduction
Terex Roadbuilding equipment is designed with the
safety of all personnel in mind. Never attempt to
change, modify, eliminate, or bypass any of the safety
devices installed at the factory. Guards, covers and
shields that are installed around moving parts are
meant to prevent accidental injury to operators and
other personnel. Do not remove them.
Make sure that everyone working on or near this
equipment is familiar with safety precautions.
Terex Roadbuilding recommends the basic safety
practices listed on this and the following pages.
Protective Gear
Machine personnel should wear the following protec-
tive gear while in the machine area:
Safety shoes
Safety glasses
Hard hat
Leather gloves when handling hot material
Hearing protection where required
NIOSH-approved respirator when working in
confined areas. Inhaling, ingesting or contacting
hazardous materials or fumes may cause personal
injury or illness. Confined space permits and ad-
equate ventilation are required.
Do not wear loose fitting or torn clothing. Remove all
jewelry and wrist watches when working on or around
the machine.
16
RS425C
Operation and Repair Precautions
Lockout and Tagout Procedures
Unexpected operation of machine components during
service or repair could cause personal injury or death.
Before performing work always:
Alert the operator that work is being done.
Place equipment breakers in the OFF position and
lock the breakers in this position.
Attach a DO NOT OPERATE or similar warning tag
on the breakers to alert other personnel.
For lockout/tagout standards, see OSHA regulation
20CFR1910.147 Lockout/Tagout of Hazardous En-
ergy. Refer to state and local regulations for additional
requirements.
General
Do not operate this equipment without proper training
and orientation.
Before starting or operating the equipment, be sure
that no personnel will be endangered. Ensure all
personnel are clear before applying power or operating
the equipment.
Make sure that all warning devices are working.
Do not operate or work on the equipment during
severe weather, such as high wind, heavy rain or
lightning, which may result in hazard to the operator or
damage to the equipment.
Mount and dismount this equipment only where steps
or hand holds are provided.
Do not try to climb on or off equipment when carrying
tools or supplies. Use a hand line to pull tools or equip-
ment up to high levels.
Secure all loose or hanging items before traveling or
lifting.
Relieve all pressure in air systems before any lines,
fittings, or related items are loosened, disconnected or
removed.
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RS425C Safety

Crushing or Cutting Prevention Remove all flammable materials and other debris
Make all repairs with the equipment parked on a level, before they accumulate in, on or around the machine.
hard surface. Block components so they will not fall or Do not expose components to independent flames of
roll while working on or under them. any type.

Do not work on any machine that is supported only Do not bend or strike high pressure lines. Do not install
by lift jacks or a hoist. Always block up a component bent or damaged lines, tubes or hoses.
before making repairs. Repair any loose or damaged fuel lines. Leaks can
Stay clear of all rotating and moving parts. cause fires.

Keep objects away from moving conveyors. They will Make sure that all clamps, guards and heat shields are
throw or cut any object or tool that falls or is pushed installed correctly to prevent vibration, rubbing against
into them. other parts and excessive heat during operation.

Do not use kinked or frayed wire cable. Wear gloves
when handling the wire cable.
Chips or other debris can fly off objects when struck.
Wear protective glasses to protect your eyes and
make sure that no one can be injured by flying debris
before striking any object. To avoid back injury, use
a hoist when lifting components that weigh 50 lb. (23
kg.) or more. Make sure that all chains, hooks, slings,
etc. are in good condition and have the correct capac-
ity. Be sure hooks are positioned correctly. Do not side
load lifting eyes during a lifting operation.
Fire or Explosive Prevention
All fuels and most lubricants are flammable.
Always have multiple fire extinguishers located
throughout the plant. Know how to use them. Inspect
and have them serviced as recommended on the
instruction plate.
Climbing
Use ladders and stairways to access all areas that
cannot be reached from the ground. Be sure ladders
and stairways are securely fastened before climbing.
Persons who have a fear of heights should not be
involved in climbing exterior ladders.
Do not use the top two rungs of a ladder as steps.
Make sure that ladders are in good condition.

Evacuate the area and call the fire department or ap-

propriate authorities if the smell of flammable liquid,
natural gas or other noxious agent is detected.
Do not smoke while refueling or in a refueling area.
Do not smoke in areas where flammable materials are
stored.
Have all loose or frayed electrical connections and
wires tightened, repaired or replaced before operating
the machine.
Keep all fuels and lubricants stored in properly-marked
containers and away from all unauthorized personnel.
Store all oily rags or other flammable material in a
protective container in a safe place.
Do not weld or flame cut on pipes or tubes that contain
flammable liquids.
Before welding or flame cutting on other areas, clean
the area thoroughly with a nonflammable solvent.

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Safety RS425C

Electrical Work Power Generation Equipment Service and Repair

Disconnect all power sources (battery and/or utility)
before starting electrical work.
Secure and tag main supply switches or cutout switch-
es in each circuit from which power could possibly by
fed to the circuit you will be working on before start-
ing the work. Lock switches in the open or off position
where switch-locking facilities are available.
Make sure that the person doing the work, or a person
designated by the worker, retains the key to switches
in accordance with OSHA. Then only one person can
remove the lock and restore the circuit.
Assume that all electrical leads are live until they are
carefully inspected and proven not to be.
When using a voltage tester to check circuits, verify
meter is functioning properly: First check the live side.
Next, check the dead side. Finally, recheck the live
side.
Do not smoke when inspecting battery electrolyte
(acid) level.
Never disconnect any charging unit circuit or battery
circuit cable from the battery while the charging unit
is operating. A spark can cause an explosion of the
hydrogen that is released from the electrolyte through
the battery outlets when the hydrogen mixes with air.
Refer to original manufacturers service and repair
manuals.
Switch the unit off-line (disconnect the unit from utility
power service) and lock it out or tag it Do Not Oper-
ate in accordance with OSHA.
Stop the generator engine.
Disconnect all batteries.
Discharge all capacitors.
Ensure that all testing equipment used is designated
for and correctly operated for the high voltage and cur-
rent tests being made.
Improper test equipment may fail and present a high
voltage shock hazard to its user.
Be alert for hot machine parts that can cause burns.
Questions
If you have any questions concerning this safety sec-
tion or any procedures contained in this manual, call
a Terex Roadbuilding Service Representative at (405)
491-2209 or (405) 787-6020.
In countries outside the United States, call your re-
gional sales and support representative.

Always keep electrolyte solution out of the reach of

children.
Keep electrolyte solution (an acid) out of contact with
skin and eyes. If the solution gets on your skin, im-
mediately wash with soap and water. Flush eyes with
large amounts of water for at least 15 minutes and
have someone call a physician.

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RS425C Safety

NOTES

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Safety RS425C

NOTES

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RS425C Receive the Machine

Receive the Machine

Initial Inspection Before Operating the Machine

As each load is signed for and accepted by the carrier, Before operating the machine, perform the steps de-
it becomes the property of the purchaser. To avoid scribed in the Daily Inspection chapter of this manual.
forfeiting claims, and damagewhether obvious or
hiddennormally must be reported to the transporta-
tion company within 5 days of receipt of the equipment
at the purchasers premises.
It is the responsibility of the purchaser to file for any
damage claims directly with the carrier. Terex Road-
building personnel cannot file for the purchaser.
1. When the equipment arrives at the job site,
inspect it for damage.
2. If a shipment is damaged in transit:
a. Note the damage on the bill of lading.
b. Do not unload the damaged equipment.
c. Immediately notify the carrier and request an
inspection. The inspection will be done by
the carrier or the carriers insurance com-
pany.
d. After the inspection, it will be determined
whether items will be repaired or replaced.
If the purchaser does not follow the above instructions,
the carrier may not honor any damage claims.

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Receive the Machine RS425C

Roll Over Protection Structure (If Equipped)

The Roll Over Protection Structure (ROPS) for the The ROPS must be properly secured in position for
RS425C consists of a roll bar and associated hard- maximum protection.
ware.

1
2

6
3
5

Lower the Roll Over Protection Structure (ROPS) Raise the Roll Over Protection Structure for
for Shipping Operation
If your machine is equipped with a ROPS, the ROPS 1. Remove any tie-downs from the ROPS struc-
must be lowered for shipping and raised before un- ture. Rotate the winch handle to raise the ROPS
loading it from the trailer. roll bar (4) into position to be secured.
1. Check to see that the cable (1) is installed prop- 2. Move the arms (3) rearward to align the bolt
erly to assist in folding the ROPS to the shipping holes in the arms with the bolt holes in the
position. mounting lugs. Install the bolts (1) mounting the
arms (3) to the mounting lugs.
2. Remove the bolts (2) that hold the ROPS roll bar
arms (3) to the rear mounts.
3. Hold the arms (3) in a vertical position while low-
ering the ROPS roll bar (4) to the mounting pads
(5). The arms (3) will rest on the mounting pads
(6).
4. The weight of the ROPS will hold the structure
on the pads in the lowered position.

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RS425C Receive the Machine

Unload the Machine

Make sure the trailer is on level ground before at-

tempting to unload the machine.

NOTE: If equipped with the A-B Direction Panel,

the position of travel A-End/B-End switch
(C8) determines how the machine controls
will respond. If switch (C8) is at A-END, the
controls respond as if the A-End is the front
of the machine. If switch (C8) is at B-End, the
controls respond as if the B-End is the front of
1. Move the battery disconnect switch (C35) to ON. the machine.
7. Set travel A-End/B-End switch (C8) in the direc-
tion desired.

Starting the engine with the cutter engaged can

cause personal injury. Push the cutter clutch control
in and move the cutter transmission shift lever to
neutral before starting the engine.

2. Unlock and open the vandalism cover for the

operators controls.
3. Remove the chains that hold the machine to the
transport.
4. Remove the chocks that were placed in front of
and behind each wheel.
5. Ensure that the service brake is set.
6. If equipped with an additive system, move the
8. Check that the cutter transmission shift lever
additive system panel power switch (C51) to
(C33) is at Neutral (N).
OFF.

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NOTICE
Make sure the transmission is in low gear. The
transmission could jump out of low gear during
transportation.

9. Check that controls are positioned as indicated:

Cutter clutch control (C18) Pushed in
(clutch disengaged)
Park brake control (C23) Cover down
moves switch down (Brakes set)
Propel transmission speed range selector
switch (C13) Downward (Slow) Cutter depth auto/manual selector switch
Four wheel drive selector switch (C14) (C19)Manual
Center (Four wheel) Propel Control (C15)Centered (Neutral)
Automatic load control selector (C28)
Manual
NOTE: A safety switch on the service brake (C30)
prevents the transmission from being shifted
while moving. The service brake must be used
to stop the machine and shift the propel trans-
mission.
10. Insert the key into the ignition switch (C10) on
the control panel.
NOTE: The engine cannot be started unless the
propel control (C13) is at N (neutral) and the
cutter clutch control (C18) is pushed in (clutch
disengaged).

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Unexpected starting of the engine may cause injury

to personnel near the machine. Sound the horn for
several seconds to alert all personnel before start-
ing the engine.

NOTICE
If the oil pressure gauge (C2) does not indicate pres-
sure within 5 seconds, stop the engine and have
necessary repairs made. Oil pressure should rise to
the normal range within 15 seconds.

12. Check the oil pressure gauge (C2) for an indica-

tion of oil pressure.
11. Use the horn switch (C24) to sound the horn 13. Allow the engine to idle for 3 to 5 minutes, or
several times, wait at least 5 seconds, then until the water temperature gauge (C3) begins to
rotate ignition switch (C10) clockwise to START rise.
position. Release the ignition switch as soon as
the engine starts.
If the engine fails to start after 30 seconds of
cranking, release the ignition switch. Wait 2
minutes to allow the starter motor to cool before
using it again. If the engine fails to start after
four attempts, make an inspection to determine
the cause.

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14. Hold the cutter manual elevation control switch

(C20) upward until the cutter is at the upper limit
of travel.

NOTE: If equipped with the A-B Direction Panel op-

tion, move the propel control (C15) very slowly
and carefully until you are sure the machine is
going to move the direction you expect. If the
machine moves opposite the way you want,
stop the machine and move travel A-End/B-
End switch (C8) to the opposite position.
If not equipped with the A-B Direction panel,
proceed to step 15.
15. Carefully drive the machine off the trailer.

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NOTES

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NOTES

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RS425C
Controls
General
Most of the controls and gauges are located on the
control console. However, a few described under
Other Controls (Not on Console) or Other Gauges
(Not on Console), are located elsewhere.
C1. Voltmeter: Shows the voltage supplied to the
machine.
C2. Oil Pressure Gauge: Indicates the engine oil
pressure whenever the ignition switch is set to
ON or START.
C3. Water Temperature Gauge: Indicates water tem-
perature.
C4. Engine ROM Gauge: Measures the Revolutions
Per Minute (RPM) of the engine.
C5. FPM/MPH Gauge (or MPM/KPH gauge): Shows
the total number of hours that the machine has
been in operation.
C6. Hydraulic Oil Temperature Gauge: Indicates the
temperature of the hydraulic oil.
C7. Cooler Temperature Gauge: Shows the tempera-
ture of the oil entering the cutter drive transmis-
sion.
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Controls
Control Panels
C8. Travel A-End/B-End Switch: Move to A-End and
the machine controls respond as if the A-End of
the machine is the front. The indicator above the
switch lights. The machine moves toward the A-
end when propel control (C15) is moved toward
the top of the control panel.
Move to B-End and the machine controls
respond as if the B-end of the machine is the
front. The indicator below the switch lights. The
machine moves toward the B-end when propel
control (C15) is moved toward the top of the
control panel.
C9. Hood-Pull: Move upward and the hood-pull cyl-
inders retract to hold the hood up while cutting in
the B-End direction.
Move downward and the hood-pull cylinders are
extended to lower the hood for cutting in the A-
End direction.
29
Controls RS425C

NOTICE
The machine must be stopped and the service
brake on to shift the propel transmission. To move
the machine in travel range, start with the main
axle in HI with the machine in 4-wheel drive. Once
the machine is rolling, turn off the 4-wheel drive.

C10. Ignition Switch: Allows the operator to start, stop
or power electronics and start engine.
Moving the key to OFF will shut down the
engine and stop all electrical power to the
controls.
Moving the key to ON will supply electrical
power to the controls without the engine start-
ing.
NOTICE
Set the speed range selector switch (C13) at slow
when working or parking the machine.
C13. Speed Range Selector Switch (Service Brake
Engaged when Shifting): Set at the upper posi-
tion and the machine travels in its maximum
(transit) speed range.
Set at the lower position and the machine travels
in its slowest (working) speed range.

Move to START to start the engine and pre-

pare for operation. Release to disengage the
starter motor.
C11. This number will not be used.
C12. Throttle Switch: Controls the engine RPM.
Hold the switch upward to increase engine
RPM.
Hold the switch downward to decrease engine
RPM.
Release the switch and the engine speed
remains constant. The switch will return to
center position.

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The farther the propel control is moved

upward or downward, the faster the machine
travels in that direction. Travel speed is also
dependent upon the position of the propel
transmission speed range selector switch and
engine RPM.
C16. Front Cutter Door Switch: Opens and closes the
cutter door (if equipped).
Hold upward and the front cutter door (door
nearer the operator) begins to open.
Hold downward and the front cutter door
begins to close.
Release the switch and the movement of the
front cutter door stops. The switch returns to
C14. Four Wheel Drive Selector Switch: Normally four the center position.
wheel drive will be used at all times during a cut. C17. Rear Cutter Door Switch: Opens and closes the
NOTE: Never make a cut with four wheel drive dis- rear cutter door.
engaged. Four wheel drive should be disen- Hold upward and the rear cutter door (door
gaged to obtain maximum travel speed only farthest from the operator) begins to open.
when traveling on firm level grade.
Hold downward and the rear cutter door be-
Set at upper position and four wheel drive gins to close.
is locked (for use in muddy conditions, deep Release the switch and the movement of the
cuts or when conditions warrant). rear cutter door stops. The switch returns to
Set at center position and four wheel drive is the center position.
engaged. NOTE: The amount that the rear cutter door is opened
Set at lower position and two wheel drive is is indicated on two scales easily seen by the
engaged. operator, one scale at each end of the cutter.
NOTE: Do not downshift four wheel drive while ma-
chine is moving.
C15. Propel Control: Moves machine forward or back-
ward, and varies speed.
Move upward and the machine moves for-
ward. If equipped with bi-directional controls,
the machine moves in the direction selected
with Travel A-End/B-End switch.
Move to the center position (neutral) and the
machine stops.
Move downward and the machine moves
backward. If equipped with bi-directional
controls, the machine moves in the direction
opposite that selected with Travel A-End/B-
End switch. The directional alarm sounds and
the backup lights come on at the end opposite
that selected with the switch.
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Controls RS425C

Starting the engine with the cutter engaged and

the cutter teeth resting on the ground can cause
the machine to lunge unexpectedly, throwing the
operator backward. Personal injury can result.

NOTICE
Engage or disengage the cutter clutch only with
the engine at low idle. Otherwise the cutter drive
mechanism may be damaged.

C18. Cutter Clutch Control: Engages or disengages

the cutter clutch.
With the engine at low idle and the cutter
teeth at least 2 in. (51 mm) above the ground,
pull the control outward to engage the cutter.
After the initial load on the engine has sub-
sided, hold the throttle switch upward until the
engine is operating at maximum speed.
To disengage the cutter, first hold the throttle
switch downward until the engine slows to
low idle, then push the clutch control inward.
Allow sufficient time for cutter rotation to stop
before lowering the cutter to the ground or
allowing anyone near the cutter.
C19. Cutter Depth Auto/Manual Selector Switch:
Automatically or manually controls the cutter
elevation.
Move upward and the cutter elevation is con-
trolled automatically by the machine.
Move downward and the cutter elevation is
controlled manually by the operator.

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C20. Cutter Manual Depth Control Switch: Manually
moves the cutter upward or downward.
Hold upward and the cutter moves upward, if
auto/manual switch (C19) is at Man.
Hold downward and the cutter moves down-
ward, if auto/manual switch (C19) is at Man.
C21. Lights Switch: Controls headlights, amber lights
and work lights.
Move upward and the headlights at the front
of the machine, and the amber and red lights
at the rear come on.
Move downward and the headlights, amber
lights and the work lights that light the work
area around the cutter come on.
Set at center position and headlights, tail
lights and work lights go off.
C22. Beacon Switch: Controls beacon lights, amber
and red lights.
Move upward and the beacon light (amber
strobe) flashes on and off continuously. At the
same time the amber lights at the front of the
machine and the red tail lights start flashing.
If the machine is equipped with bi-directional
controls, the amber lights at the end selected
with the Travel A-End/B-End switch and the
red tail lights at the opposite end start flash-
ing. The beacon light will operate only if the
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Controls
ignition key is moved to the On position. The
flashing amber and red lights will operate
whether the ignition is on or not.
Move switch to off and all flashing lights go
off.
C23. Park Brake Control: Engages or disengages
parking brake.
Open cover and move switch up to release
the parking brake.
Close cover and switch will move down to
engage the parking brake.
C24. Horn Switch: Sounds horn to warn or signal
personnel.
Hold in either horizontal direction to sound the
horn.
Release the switch to stop sounding the horn.
C25. Steering Wheel: Turns the wheels of the ma-
chine, allowing the operator to maneuver the
machine direction.
Turn the steering wheel clockwise and the
machine turns to the right.
Turn the steering wheel counterclockwise and
the machine turns to the left.
C26. Rear Steering Switch: Turns both rear wheels
either to the right or left.
Hold to the right to turn the rear wheels to
the right. The wheels at the end opposite the
direction selected with the travel A-End/B-End
switch turn to the left.
C27. Automatic Load Control Panel: Prevents the
engine from lugging below a set speed (RPM
Setpoint). There are two controls in the panel:
C28 and C29.
C28. Auto/Manual Switch: Selects automatic or man-
ual load control. This switch should be at auto
when the machine is working and at manual
when the machine is to be serviced or repaired
with the engine idling.
C29. Sensitivity Control: Adjusts the sensitivity of the
load control. This switch should normally be set
at the fourth mark toward Max.
33
Controls
C30. Service Brake Control: Push down to engage the
service brakes. The farther the control handle is
moved down, the harder the brakes are applied.
Pull up to disengage the service brakes.
C31. Brake Air Pressure Gauge: Indicates the air
pressure in the brake system. Normal pressure
is 90 to 100 psi (13 to 14.5 kPa).
34
RS425C
Other Controls (Not on Console)
C32. Cutter Automatic Depth Control: Regulates the
depth of cut when the cutter depth auto/manual
switch (see Control Panels) is at AUTO. See
the Operation chapter for procedures to prop-
erly use this control.
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RS425C
Starting the engine with the cutter engaged and
the cutter teeth resting on the ground can cause
the machine to lunge unexpectedly, throwing the
operator backward. Personal injury can result.
NOTICE
To avoid possible machine damage, shift the cutter
drive transmission only when
the machine is stopped and propel control is at
neutral,
the engine is at low idle,
the cutter clutch is disengaged,
or
the input and output shafts have stopped
running.
C33. Cutter Transmission Shift Lever: Move to one of
the positions shown to select the cutter rotation
speed (RPM) for that position: 1 is low speed,
2 is medium speed, 3 is high speed. Move to N
and the transmission is at neutral so the cutter
will not run.
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Controls
C34. Circuit Breakers: If excess current passes
through a circuit breaker, the circuit breaker
stops the electrical power to that circuit. To
restore power, push the breaker for that circuit
in. If the breaker repeatedly opens the circuit, an
overload or a short circuit in the circuit must be
corrected.
NOTE: The circuit breakers are located on the control
panel mounted on the engine cowling in the
operators station.
C35. Main Battery Disconnect Switch: Disconnects
the power from the battery to the machine.
Move the switch to OFF and the battery path
to ground is broken, stopping all battery
power to the machine.
Move the switch to ON and the battery path to
ground is restored.
35
Controls RS425C

Other Gauges (Not on Console)

C44. Fuel Level Gauge: Indicates the fuel level in the

fuel tank. Located on the operators platform
near the center of the machine.

Additional gauges, alarms, and indicators are installed

in the rear engine cowling where the operator can
readily see them.
C36. Travel Hydraulic Pressure Gauge: Shows the
pressure in the travel (ground drive) hydraulic
system. Normal pressure will vary from 0 to
about 4300 psi, the relief setting.
C37. Differential Lube Pressure Gauge: Shows the
pressure in the differential lubrication and cool-
ing system.
C45. Service Meter: Indicates the number of service
C38. Differential Lube Temperature Gauge: Shows units the engine has been in operation. Located
the temperature in the differential lubrication and on the center console panel.
cooling system.
C39. Alarm Indicators: Light if the differential lubrica-
tion and cooling system pressure gets too low or
the temperature gets too high.
C40. Alarm Horn: Sounds if the differential lubrication
and cooling system pressure gets too low or the
temperature gets too high. The switch for the
horn is located directly above it.
C41. Charge Pressure Gauge: Shows the pressure in
the charge pressure system.
C42. Auxiliary Pressure Gauge: Shows the pressure
in the auxiliary pressure system.
C43. Rear Steering Indicator: Shows the amount the
wheels are turned from straight ahead. All ma-
chines have a rear steering indicator.

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RS425C Controls

Water/Emulsion Control Panel (Option)

C46. The function and use of the Water/Emulsion

Control Panel controls or Additive Spray Con-
trol Panel controls are covered in the owners
manual for the specific spray system installed.

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NOTES

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RS425C Daily Inspection

Daily Inspection

6 12
5
14
4

4
1

3
10

Before the start of each day, walk around the machine 10. Inspect and repair damaged wheels and dam-
and check for the following: aged or excessively worn tires. Tighten any
loose wheel lug nuts and replace any that are
1. Inspect the cutter door for damage or excessive
missing. Check the air pressure.
wear. Check the cutter drum and housing.
11. Check the horn, backup alarm, lights, guards,
2. Check for loose or frayed wires. Check for loose
shields, etc., and make sure they are in working
or corroded connections.
order.
3. Inspect the radiator guards for trash buildup.
12. Inspect the operator station for cleanliness and
4. Inspect the cooling system for leaks and trash remove all trash and dirt buildup.
buildup. Check the hoses, radiator fins, radiator
13. Inspect the spray system microcontroller (if
caps, and the drain areas.
equipped) for a broken window or any signs of
5. Inspect the engine compartment for leaks and leaks. Repair any that are found.
for trash buildup.
14. Check the batteries located in the box to the left
6. Inspect the steps and handholds for good condi- of the engine compartment, in front of the left
tion and cleanliness. front tire. Make sure the battery connections are
okay and in good condition.
7. Be sure covers and guards are firmly in place.
Inspect for damage and for loose or missing 15. Check that all gauges on the control panel are
bolts. Check all ventilation holes for dirt and functioning properly.
trash buildup.
16. Check for proper tension of all belts.
8. Inspect the hydraulic system for leaks. Check for
frayed hoses and for loose hose connections.
9. Check for any leaks. If a substantial amount of
leakage exists, see the Maintenance chapter of
this manual for procedures to check the oil level.

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Daily Inspection RS425C

17. Check the engine oil level. Maintain the engine 19. Check the fuel level gauge. The tank should be
oil level between Full and Add marks on the filled at the end of the day.
dipstick.

20. Drain any moisture and sediment from the

fuel tank weekly. The fuel return line shutoff is
located under the tank. The fuel drain line is
located on the right side of the mainframe below
18. While the engine and radiator are cool to the the automatic cutter depth control.
touch, carefully remove the radiator cap. The
coolant should be within 1/2 in. (1 cm) of the
bottom of the fill tube. If it is low, add the correct
amount of coolant.

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21. Check the oil level in the hydraulic oil tank and
keep oil level near the top of the sight gauge. Do
not overfill the tank; allow for expansion of the oil
when it gets hot.

When oil is needed in the main tank, transfer

oil from the replenishing tank (1) with the hand
pump (2). When required, add oil to the replen-
ishing tank. Do not mix types of hydraulic oil
(see Lubricant Specifications in the Mainte-
nance chapter).

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NOTES

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RS425C Operation

Machine Operation

Before Starting the Engine Start the Machine

1. Read and understand this manual before start- Normal Start

ing and operating the machine. Follow all the
recommendations and instructions for optimum
performance of the machine.
2. Consult the engine manual that is supplied with
your machine before operating the machine. It
contains important information on breaking in
the engine and discusses the fuels and lubri-
cants that should be used for best performance
and life of the engine.
3. Dress for the job. Always wear safety glasses,
a hard hat, and safety shoes and wear hearing
protection. Do not wear loose clothing that can
catch in moving parts or can catch on a control
lever. Keep sleeves buttoned.
4. In cold weather operation, wear clothing that will
keep you warm without restricting your normal
movement.
An unkept, dirty machine can be hazardous. Keep
handles, walkways, steering wheel, etc. free from
Do not wear loose clothing that may easily be
come caught by moving parts. Serious injury may
result. It is recommended that the operator wear
safety glasses, hard hat and safety shoes at all
times.
Allow only one person, the operator, on the ma-
chine. Allow only trained and qualified persons to
operate the machine. Failure to do so may cause
personal injury, damage to nearby property, or
damage to the machine.
1. Board the machine using the steps and hand-
rails on the machine.
2. Unlock the vandalism cover and pull it open to
access the control panel.
3. Position the seat and the suspension for opera-
tor and control accessibility, then buckle the seat
belt once properly positioned.

NOTICE
oil, grease, dirt, and ice to avoid slipping and pos-
sible injury.

Remove any tools, rags, buckets, or other loose

5. Always use the steps and handrails on the objects on the machine. Damage to moving parts
machine to climb on or dismount the machine. or restriction of the operators controls may occur.
Never jump from the machine.
6. Perform the daily inspection as described in the
Daily Inspection chapter of this manual.
7. Check the hour meter and lube chart for periodic
maintenance. Refer to the Maintenance chapter
of this manual for more information.
NOTE: Do not operate the machine if any mainte-
nance is due. Remove the key, turn the main
power switch to OFF, and attach a warning tag
to the steering wheel. Even a minor defect can
be serious.

4. If equipped with an additive spray panel, (C46),

turn the panel off.

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Operation RS425C

5. Turn the main battery disconnect switch (C35) to

ON.

7. Check that the controls are positioned as indi-

cated:
Cutter clutch control (C18) Pushed in
(clutch disengaged)
Park brake control (C23) Cover down
moves switch down (Brakes set)
Propel transmission speed range selector
switch (C13)Downward (Slow)
6. Check that the cutter transmission shift lever Four wheel drive selector switch
(C33) is at N (neutral). (C14)Center (Four wheel)
Cutter depth auto/manual selector switch
(C19)MAN
Propel control (C15)Centered (Neutral)
Automatic load control Auto/Manual switch
(C28)MANUAL
8. Insert the key into the ignition switch (C10) on
the control panel and turn the switch clockwise
to ON.
9. Set the service brake (C30) by pushing the lever
down. The farther the lever is pushed down, the
harder the brakes are applied.
NOTE: The engine cannot be started unless the pro-
pel control (C15) is at Neutral and the cutter
clutch control (C18) is pushed in (disengaged).

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RS425C Operation

Unexpected starting of the engine may cause inju-

ry to personnel near the machine. Sound the horn
for several seconds before starting the engine to
alert all personnel.

10. Use the horn switch (C24) to sound the horn

several times.
11. Wait at least 5 seconds, then rotate the ignition
switch (C11) to the START position.
12. Release the ignition switch as soon as the en-
gine starts.
If the engine fails to start after 30 seconds of
cranking:
a. Release the ignition switch.
b. Wait 2 minutes to allow the starter motor to
cool before using it again.
If the engine fails to start after four attempts,
make an inspection to determine the cause.
NOTICE
If oil pressure is not indicated within 5 seconds,
stop the engine and have necessary repairs made.
Oil pressure should rise to normal range within 15
seconds.
8. Check the oil pressure gauge (C2) for an indica-
tion of oil pressure.
9. Allow the engine to idle for 3 to 5 minutes, or
until the needle in the water temperature gauge
(C3) begins to rise.

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Operation RS425C

Cold Weather Start

1. Complete steps 1 through 9 of Normal Start.

Unexpected starting of the engine may cause inju-

ry to personnel near the machine. Sound the horn
for several seconds before starting the engine to
alert all personnel.

4. While the engine is cranking, spray a 1-second

burst of starting fluid into the air cleaner inlet.
5. Wait at least 2 seconds for the engine to re-
spond.
6. Spray another 1-second burst of starting fluid.
7. Release the start switch as soon as the engine
starts.
If the engine fails to start after 30 seconds of
cranking:
a. Release the ignition switch and return to the
ON position.
b. Wait 2 minutes to allow the starter motor to
cool before using it again.
2. Use the horn switch (C24) to sound the horn If the engine fails to start after four attempts,
several times. make an inspection to determine the cause.
3. Wait at least 5 seconds, then rotate the ignition
switch (C11) to the START position.

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RS425C
NOTICE
If oil pressure is not indicated within 5 seconds,
stop the engine and have the necessary repairs
made. Oil pressure should rise to normal range
within 15 seconds.
8. When the engine has started, check the oil pres-
sure gauge (C2) for an indication of oil pressure.
9. Allow the engine to idle for 3 to 5 minutes, or
until the needle in the water temperature gauge
(C3) begins to rise.
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Operation
Start with a Boost
Batteries give off flammable fumes that can ex-
plode.
Prevent sparks near the batteries. They could
cause vapors to explode. Do not allow jumper
cable ends to contact each other or the machine.
Do not smoke when checking battery electrolyte
levels. Electrolyte is an acid and can cause per-
sonal injury if it contacts skin or eyes.
Always wear eye protection when starting a ma-
chine with jumper cables.
Improper jump procedures can cause an explosion
resulting in personal injury.
NOTICE
Always connect battery positive (+) to battery posi-
tive (+) and battery negative () to machine frame.
Jump only with a battery source and with the same
voltage as the stalled machine.
Turn off all lights and electrical accessories on the
stalled machine.
When starting from another machine, make sure
the machines do not touch. Contact between
machines could damage the engine bearings and
electrical circuits.
47
Operation
1. Make an initial check to find the reason the en-
gine does not start.
NOTE: Do not allow the positive cable clamps to
2. On the stalled machine:
a. Center the propel control (C15) at neutral.
Move all other controls to OFF, Neutral, or
STOP.
b. Check that the ignition switch (C10) is
turned counterclockwise to the off position.
c. Turn off all accessories.
d. If equipped with a water emulsion control
panel (C46), turn the panel off.
3. Move the boost start machine near enough to
the stalled machine for the cables to reach, but
do not allow the machines to touch each other.
4. Stop the engine on the boost machine. If using
an auxiliary power source, turn off the charging
system.
5. Make sure the battery caps are all in place and
tight on both machines.
48
RS425C
touch any metal other than the positive battery
terminals.
6. Connect positive (+) jumper cable (red) to posi-
tive cable terminal (1) of the discharged battery
set (2) on the stalled machine. The positive
terminal is connected to the starter terminal.
7. Connect the other end of the positive jumper
cable (red) to the positive (+) terminal (3) of the
boost battery set (4).
8. Connect one end of the negative () jumper
cable to the negative boost battery terminal (5).
The negative terminal is often connected to the
main battery disconnect switch.
9. Connect the other end of the negative () jumper
cable to frame (6) of the stalled machine away
from battery, fuel or hydraulic lines, or moving
parts.
10. Start the engine on the boost machine, or ener-
gize the charging system on the auxiliary power
source. Wait a minimum of 2 minutes for the bat-
teries on the stalled machine to partially charge.
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RS425C Operation

Starting the engine with the cutter engaged can

cause personal injury. Push the cutter clutch con-
trol in and move the cutter transmission shift lever
to Neutral before starting the engine.

11. Hold the throttle switch (C12) on the boost

machine upward until the throttle moves to about
1/2 speed.
12. Turn the ignition switch (C10) on the stalled
machine clockwise to the ON position.
13. Check the voltmeter (C1) for a reading of about
24 volts.
14. Check that the cutter clutch control (C18) is
pushed in and the cutter transmission shift lever
(C33) is at Neutral.
15. Rotate the ignition switch (C10) to the START
position to crank the engine.
If the engine fails to start after 20 seconds of
cranking:
a. Hold the throttle switch to decrease the
engine speed fully.
b. Continue to crank for 10 seconds. This will
clear the cylinders of unburned fuel.
If the engine fails to start after 30 seconds of
cranking:
a. Allow the starter to cool for 2 minutes.
b. Repeat the starting procedure.
If the engine fails to start after four attempts,
make an inspection to determine the cause.
16. Release the ignition switch as soon as the en-
gine starts.

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Operation RS425C

After Engine Start

Warm-Up
NOTICE
If oil pressure is not indicated within 5 seconds,
stop the engine and have necessary repairs made.

17. Check the oil pressure gauge (C2) for an indica-

tion of oil pressure.
18. Allow the engine to idle for 3 to 5 minutes, or
until the needle in the water temperature gauge
(C3) begins to rise.
19. Troubleshoot to find the reason the engine
would not start without a boost.

1. Allow the engine to warm up at low idle and no

load for 5 minutes.
2. Test all controls to see that they are functioning
properly.

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RS425C Operation

Stop the Engine

Cutter transmission shift lever

1. Position the following controls as noted:
Propel control (C15)Centered (Neutral)
Park brake control (C23)Cover down
(Brakes set)
Cutter clutch control (C18)Pushed in
(C33)At N (Neutral)
2. Hold the throttle switch (C12) downward until the
engine is near half speed.
3. Allow the engine to run with no load for at least 5
minutes to cool.
4. Reduce the engine speed to low idle.
5. Allow the engine to run at low idle for 30 sec-
onds.
6. Turn the ignition switch (C10) counterclockwise
to stop the engine.

Disengage the cutter clutch only with the engine at

low idle.

Propel transmission speed range switch

(C13)Downward (Slow)
Four wheel drive selector switch
(C14)Center (Four wheel)
Steering wheel (C25)Centered

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Operation RS425C

Non-Operational Travel

NOTE: The position of the travel A-End/B-End switch

(C8) determines how the machine controls will
respond. If switch (C8) is at A-End, the con-
trols respond as if the A-End is the front of the
machine. If the switch is at B-End, the controls
respond as if the B-End is the front of the ma-
chine. Decide which mode will be most natural
and comfortable for you to use, then set the
switch (C8) accordingly.
1. Set travel A-End/B-End switch (C8) as desired.
2. Set the cutter transmission to Neutral and en-
gage the clutch for non-operational travel protec-
tion of the pilot bearing and throw-out bearing.
NOTE: Move the machine only after the engine has
warmed up.
3. Set the cutter depth auto/manual selector (C19)
at MAN.
4. Hold the cutter manual depth control (C20) up-
ward until the cutter is as high as possible.
5. Lift the safety cover and move the switch up
(C23) to release the parking brake.

NOTICE
Do not downshift the machine when it is in four
wheel drive. If the four wheel drive is downshifted
when moving, the pumps can easily be damaged.

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RS425C Operation

7. Move the propel control (C15) upward until the

machine is moving at the desired travel speed.
8. Stop the machine by moving the propel control
Do not move the propel transmission speed range (C15) downward to Neutral.
switch (C13) or four wheel switch (C14) while the 9. Before stopping the engine, see Park Machine
machine is moving. If the travel speed range selec- at the end of this chapter.
tor switch or four wheel drive selector switch is
changed while the machine is moving, the imme-
diate and dramatic change in ground speed can
throw the operator forward or backward unexpect-
edly. Personal injury can result.

6. When the machine speed range switch (C13)

needs to be shifted from low to high for travel, or
from high to low:
a. Stop the machine on level ground.
b. Engage the service brake (C30).
c. Shift switch (C13) upward to high (or down-
ward to low).
d. Move the propel control (C15) slowly to be
sure the transmission is engaged in high
gear.

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Operation RS425C

Operating Adjustments Adjust Rear (B-End) Steering Indicator

Adjusting Cutter Depth Control Limit Switches

1. If equipped with the Travel A-B option, position

the machine on level grade and set travel A-End/
The automatic depth control limit switches are adjust- B-End switch (C8) to A-End.
able laterally to set the tolerances within which the
depth control operates. The distance between the 2. Use the rear steering switch (C26) to align the
switches determines the amount of variation in depth B-End tires as near as possible to straight ahead
control. The variation in depth increases as the dis- by sight.
tance between the switches is decreased.
To adjust the limit switches to the minimum tolerance:
1. Loosen the four capscrews (1) that secure the
limit switches (2) to their mounts.
2. Slide the switches horizontally until each switch
cam roller (3) is resting in the radius at each end
of the notch on cam (4).
3. Tighten the capscrews.
4. Raise each limit switch roller (3) 1/16 in. (1.6
mm) and listen for a click from inside the switch.
If the click is heard before or after the roller is
3. Place a stringline (1) along each side of and
raised 1/16 in. (1.6 mm), loosen the roller arm
parallel to the mainframe at a height as near the
shaft nut (5) and adjust the roller arm.
center of the tires as possible.
5. When the click is heard just as the roller arm is
4. Measure Distance A from the front of a tire to the
raised 1/16 in. (1.6 mm), tighten the roller arm
nearest stringline. Measure Distance B from the
shaft nut.
rear of the tire to the stringline. Both measure-
ments should be the same.
5. Use the rear steering switch (C26) to turn the
wheels until both measurements are the same.

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RS425C
6. Check the alignment of pointer (2) with the cen-
ter mark of the rear steering indicator (C41). The
center of the pointer (2) should be exactly at the
center of the indicator (C41).
7. If the pointer is not correctly aligned with the
steering indicator, adjust it.
a. Loosen the setscrew (3).
b. Adjust the position of the cable (4) in the
pointer.
c. Tighten the setscrew.
d. Check and adjust the position of the pointer
(2) until it is correctly aligned with the indica-
tor (C41).
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Operation
Operating Techniques for Work in Soil
Operation Hints
1. Estimate the cutter speed needed for the job
site conditions. The cutter transmission shift
lever provides the three different cutter operating
speed ranges shown above. Shift lever position
1 is the lowest speed and position 3 is the high-
est speed.
2. For normal operation, the rear cutter door should
be adjustable to provide the desired strike-off
height of the material being processed.
3. Periodically check the cutter teeth to see if they
need to be replaced. Cutter tooth life will vary
from location to location.
a. Stop the machine.
b. Disengage the cutter clutch.
c. Stop the engine.
d. Be sure the cutter has stopped turning.
e. Check for and replace worn or broken cutter
teeth. For replacement procedures, refer to
Cutter Drum under Maintenance.
NOTICE
Operating the cutter with worn or broken cutter
teeth can lead to broken tooth holders. Expensive
repairs and downtime result.
4. Overlap cuts by at least 6 in. (15 cm).
5. Adjust the rear (B-End) steering indicator as
described in Operating Adjustments before
starting operation. This will make steering of the
B-End wheels easier.
55
Operation RS425C

Load Control System A-B Directional Panel (Optional)

Use of the load control system takes the guesswork
out of operating the machine efficiently when making a
cut. The load control prevents stalling of the engine by
regulating the ground speed of the machine to main-
tain engine speed at 2100 RPM.
As the workload increases on the cutter, ground speed
is slowed until the engine can recover to acceptable
operating speed. Once the load control is activated,
the engine will automatically be kept close to maxi-
mum power, even if forward travel has to be stopped
altogether to do so.

Hood pull (C9)Upward, if Travel

A-End/B-End switch is at B-End. Downward,
if Travel A-End/B-End switch is at A-End.

The controls that adjust the load control system should

be set as follows:
Auto/manual selector switch (C28)AUTO
Sensitivity control (C29)Midpoint
In addition, the following controls should be positioned
as indicated:
Engine throttle switch (C12)Hold
upward until engine is at maximum RPM.
Propel transmission speed range selector
switch (C13)Downward (slow)
Four wheel drive selector switch
(C14)Center (four wheel)
Cutter clutch control (C18)Pulled
out (engaged)

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RS425C
Adjust the Cutting Depth
Keep all personnel at least 25 ft. (7.6 m) away from
the machine when starting a cut. Keep all person-
nel at least 25 ft. (7.6 m) away from the rear of the
machine while it is in operation.
NOTE: If the load control system is to be used, be
sure the controls are set as specified in Load
Control System.
1. Move the machine into position for the cut so all
wheels are straight ahead and the cutter is over
the point where the cut will be started. Move
propel control (C15) to Neutral.
2. Use the throttle switch (C12) to reduce engine
speed to low idle. Move propel transmission
speed range selector switch (C13) downward to
the slow range and, if equipped, four wheel drive
selector switch (C14) upward to four-wheel.
3. Set cutter depth auto/manual selector switch
(C19) to MAN. Use cutter manual depth control
switch (C20) to lower the cutter until the teeth
are about 51 mm (2 in) above grade.
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Operation
4. Use door switches (C17) and (C16) to lower the
cutter doors until the rubber flaps are touching
the grade, then move flasher switch (C22) to
On. If the machine does not have the Travel A-B
option, there will not be a front cutter door switch
(C16).
5. If the machine is equipped with the Travel A-B
Directional option, check that travel A-End/B-End
switch (C8) is positioned correctly for the cut to
be made.
NOTICE
To avoid possible machine damage, shift the cutter
transmission only when the machine is stopped
and propel control is at Neutral, the engine is at
low idle, the cutter clutch is disengaged, and the
input and output shafts have stopped turning.
NOTE: Any of three different cutter speeds can be
used by placing the cutter transmission shift
lever at one of the positions shown below.
Shift lever position 1 is the lowest speed and
position 3 is the highest speed.
6. Select the cutter transmission setting for the de-
sired cutter speed and set the shift lever at the
selected setting.
57
Operation RS425C

NOTICE
Engage or disengage the cutter clutch only with
Lowering the cutter too quickly when starting a
the engine at low idle. Otherwise the cutter drive
cut can cause the cutter to ride up onto the uncut
mechanism may be damaged.
surface and make the machine lunge in any direc-
tion. The machine may also lunge if the cutter hits
an obstruction while making a cut.
Either of the above can cause personal injury or
death.

10. Use the cutter manual depth control switch

7. Set the engine at low idle with the throttle switch
(C12).
8. Pull cutter clutch control (C18) out to engage the
cutter.
9. After the cutter is turning freely, hold the throttle
switch (C12) upward until the engine is at full
speed.
(C20) to slowly lower the cutter to the desired
depth then move the cutter depth auto/manual
selector switch (C19) upward to the automatic
position. The cutter depth is shown by the
pointer on the depth gauge located on the cutter
elevation cylinder.
NOTE: If your machine is not equipped with the Travel
A-B option, you will not have a front cutter
door switch (C16).
11. As the cutter is lowered into the cut, use door
switches (C16) and (C17) to raise the cutter
doors as necessary.
NOTE: If the machine is equipped with the Travel A-B
option, the following instructions apply.
12. If travel A-End/B-End switch (C8) is at B-End,
move hood-pull switch (C9) upward. If travel
A-End/B-End switch is at A-End, move hood pull
switch downward.

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RS425C Operation

Contact with the rotating cutter can cause injury or

death. Disengage the cutter clutch and wait until
the cutter has stopped turning before working on
or near the cutter.

13. Move propel control (C15) slightly forward to cut

a distance equal to a few machine lengths.
14. Move propel control (C15) to Neutral to stop
forward movement and push park brake control
(C23) in to set the park brake.
15. Allow the cutter to rotate for about 1 minute to
clear cut material away from the teeth.
16. Reduce the engine speed to low idle with throttle
17. Note the position of the pointer on the depth
switch (C12) then push the cutter clutch control
gauge and measure the depth to which the
(C18) in to disengage the cutter.
cutter has dug. Scales are located on the cutter
elevation cylinder.
NOTE: Each mark on the depth scale represents ap-
proximately 1 in. (2.54 cm).
18. If the cut is not to the depth desired, move the
adjusting rod. Moving the adjusting rod inward
decreases the depth of cut, and moving the
adjusting rod outward increases the depth of cut.
a. Loosen the locknut (1).
b. Turn the depth adjusting rod (2) until the
depth gauge pointer has been moved
enough to add or subtract the necessary
amount from the initial setting.
c. Tighten the locknut.

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Operation
NOTICE
Do not set the depth control to a depth beyond the
extended length of the cutter lift cylinders or over-
heating of the hydraulic oil and unnecessary wear
on the housing wear plates may result.
19. Repeat steps 10 through 18 until the proper
depth of cut is achieved.
60
RS425C
Start a Cut
Lower the cutter slowly. Keep all personnel at least
25 ft. (7.6 m) away from the machine when start-
ing a cut. Keep all personnel at least 25 ft. (7.6 m)
away from the rear of the machine while it is in
operation.
NOTE: If the load control system is to be used, be
sure the controls are set as specified in Load
Control System.
1. Move the machine into position so that all of the
wheels are straight ahead and the cutter is over
the point where the cut will be started.
2. Move the propel control (C15) to Neutral.
3. Use the throttle switch (C12) to reduce the en-
gine speed to low idle.
4. Move the propel transmission speed range
switch (C13) to center to slow the speed.
5. Move the four wheel switch (C14) to center to
four wheel.
6. Set the cutter depth auto/manual selector switch
(C19) to Manual.
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RS425C Operation

NOTICE
To avoid possible machine damage, shift the cutter
transmission only when the machine is stopped
and propel control is at Neutral, the engine is at
low idle, the cutter clutch is disengaged, and the
input and output shafts have stopped turning.

NOTE: Any of three different cutter speeds can be

used by placing the cutter transmission shift
lever at one of the positions shown below.
Shift lever position 1 is the lowest speed and
position 3 is the highest speed.

7. Use the cutter manual depth control switch

(C20) to lower the cutter until the teeth are about
2 in. (51 mm) above grade.
8. The front door switch (C16) is not available on
machines without the Travel A-B option. Use
door switches (C16) and (C17) to lower the cut-
ter doors until the rubber flaps are touching the
grade, then move the beacon switch (C22) to
ON.
9. Check that travel A-End/B-End switch (C8) is 10. Select the cutter transmission setting for the de-
positioned correctly for the cut to be made. sired cutter speed and set the shift lever (C33)
at the selected setting.

NOTICE
Engage or disengage the cutter clutch only with
the engine at low idle. Otherwise the cutter drive
mechanism may be damaged.

11. Set the engine at low idle with the throttle switch
(C12).
12. Pull the cutter clutch control (C18) out to engage
the cutter.
13. After the cutter is turning freely, hold the throttle
switch (C12) forward until the engine is at full
speed.

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Operation RS425C

Lowering the cutter too quickly when starting a

cut can cause the cutter to ride up onto the uncut
surface and make the machine lunge in any direc-
tion. The machine may also lunge if the cutter hits
an obstruction while making a cut.
Either of the above can cause personal injury or
death.

14. Use the cutter manual depth control (C20) to

slowly lower the cutter to the desired depth.
15. Move the cutter depth auto/manual selector
switch (C19) forward to the automatic position.
The cutter depth is shown by the pointer on the
depth gauge (1).
16. Machines not equipped with the Travel A-B
option will not have the front door cutter switch
(C16). As the cutter is lowered into the cut, use
door switches (C16) and (C17) to raise the cut-
ter doors as necessary.
17. For machines equipped with the Travel A-B
option, the following instructions apply. If Travel
A-End/B-End switch is at B-End, move the hood-
pull switch (C9) upward. If Travel A-End/B-End
switch is at A-End, move the hood-pull switch
downward.
18. Move the propel control (C15) to the desired
speed.

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RS425C
During Operation
Hydraulic Oil Temperature
It is extremely important that the hydraulic oil tempera-
ture be checked periodically during operation.
NOTICE
Continuous operation of the machine with high
hydraulic oil temperatures will cause rapid wear
and failure of the pumps and motors.
If the hydraulic oil temperature rises above 180F
(83C) and remains there or continues to rise, perform
the following steps:
1. Stop the machine.
2. Thoroughly clean the exterior surfaces of the
radiator, hydraulic oil cooler, and cutter transmis-
sion oil cooler.
a. Use an air hose to remove any loose mate-
rial.
b. If necessary, use a steam cleaner to remove
any remaining material.
3. Check the condition of the engine coolant.
a. If the coolant shows signs of system ero-
sion, flush and clean the cooling system.
If the hydraulic oil temperature is still too high:
1. Stop the machine.
2. Troubleshoot the system.
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Operation
Cutter Transmission Oil Cooler Temperature
If the cutter transmission oil cooler temperature rises
above 220F (104C) and remains there or continues
to rise, try making a cut that is not as deep as the
present one.
If the temperature is still too high, perform the following
steps:
1. Stop the machine.
2. Thoroughly clean the exterior surfaces of the
cutter transmission oil cooler.
a. Use an air hose to remove any loose mate-
rial.
b. If necessary, use a steam cleaner to remove
any remaining material.
If the cutter transmission oil temperature is still too
high:
1. Stop the machine.
2. Troubleshoot the system.
Ground Drive System
If, during operation, the ground drive system seems to
be sluggish and/or there is a rattling or pinging noise in
the ground drive system, perform the following steps:
1. Stop the machine.
2. Check the ground drive suction line for a partial
blockage or if the valve is not open all the way.
3. If the problem persists, contact your Terex Road-
building representative.
63
Operation RS425C

Operating Techniques for Work in Dense

Materials
Operation Hints
Operation techniques in dense materials differs from
operation in less-dense materials. Dense materials
include surfaces such as roads or parking lots that are
paved with asphalt, surfaces of highly compacted soil,
and, in some cases, frozen soil.

Unexpected engagement of the cutter can cause 2. If possible, run cutter (1) deep enough to mix
personal injury or death. Push the cutter clutch some base material (2) with asphalt surface ma-
control in and move the cutter transmission shift terial (3). This will help improve the cutter tooth
lever to neutral whenever the cutter is stopped. life.
Keep all personnel at least 25 ft. (7.6 m) away from
the machine when starting a cut. Keep all person-
nel at least 25 ft. (7.6 m) away from the rear of the
machine while it is in operation.

1. Estimate the cutter speed needed for the job site

3. If space permits, make a first cut transverse
conditions. The cutter transmission shift lever
to the normal cut at the starting point. In most
provides three different cutter operating speed
cases, this will allow the cutter to start cutting in
ranges shown above. Shift lever position 1 is
the less dense material, such as a road shoulder
the lowest speed and position 3 is the highest
and work its way into and across the dense ma-
speed.
terial, such as an asphalt road. The transverse
cut provides an abrupt starting point for the
normal cut, greatly reducing the possibility of the
machine lunging.

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RS425C Operation

Make a Transverse Cut

Lowering the cutter too quickly when starting a

cut can cause the cutter to ride up onto the uncut
surface and make the machine lunge in any direc-
tion. The machine may also lunge if the cutter hits
an obstruction while making a cut.
Either of the above can cause personal injury or
death.
Lower the cutter slowly. Keep all personnel at
least 7.6 meters (25 ft.) away from the machine
when starting a cut. Keep all personnel at least 7.6
meters (25 ft.) away from the rear of the machine
while it is in operation.

4. If space does not permit making a transverse

cut, the cutter transmission must be set at 1
when the cutter is lowered into the dense mate-
rial. Use the manual control to lower the cutter
very slowly.
5. For normal reclamation operations, the rear
cutter door should be adjusted to provide the
desired strike-off height of the material being
processed.
6. Periodically check the cutter teeth to see if they
need to be replaced. Cutter tooth life will vary
from location to location.
a. Stop the machine.
b. Disengage the cutter clutch.
c. Stop the engine. 1. Move the machine into position for the trans-
verse cut so that all wheels are straight ahead
d. Be sure the cutter has stopped turning. and the cutter is over the point where the trans-
e. Check for and replace worn or broken cutter verse cut will be started.
teeth. For replacement procedures, refer to
2. Move the propel control (C15) to Neutral.
Cutter Drum under Maintenance.
3. Use the throttle switch (C12) to reduce the en-

NOTICE gine speed to low idle.

4. Move the propel transmission speed range
Operating the cutter with worn or broken cutter switch (C13) rearward to the slow range.
teeth can lead to broken tooth holders. Expensive
5. Move the four wheel drive switch (C14) centered
repairs and downtime result.
to four wheel.
6. Set the cutter depth auto/manual selector switch
7. Overlap cuts by at least 6 in. (15 cm). (C19) to Manual.
7. Use the cutter manual depth control (C20) to
lower the cutter until the teeth are about 2 in. (51
mm) above grade.

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Operation RS425C

NOTICE
To avoid possible machine damage, shift the cutter
transmission only when:
the machine is stopped and the propel control
is at Neutral,
the engine is at low idle,
the cutter clutch is disengaged,
the input and output shafts have stopped turn-
ing.

NOTE: Any of three different cutter speeds can be

used by placing the cutter transmission shift
lever at one of the positions shown below.
8. If the machine is equipped with the Travel A-B Shift lever position 1 is the lowest speed and
option, use door switches (C16) and (C17) to position 3 is the highest speed.
lower the cutter doors until the rubber flaps are
touching grading, then move beacon switch
(C22) to on. There will not be a front cutter door
switch (C16) if the Travel A-B option is not on
the machine.
9. Check that Travel A-End/B-End switch (C8) is
positioned correctly for the cut to be made.

10. Select the cutter transmission setting for the de-

sired cutter speed and set the shift lever at the
selected setting.

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RS425C Operation

NOTICE
Engage or disengage the cutter only with the en-
Lowering the cutter too quickly when starting a
gine at low idle. Otherwise the cutter drive mecha-
cut can cause the cutter to ride up onto the uncut
nism may be damaged.
surface and make the machine lunge in any direc-
tion. The machine may also lunge if the cutter hits
11. Set the engine at low idle with throttle switch an obstruction while make the cut.
(C12) and pull the cutter clutch control (C18) out Either of the above can cause personal injury or
to engage the cutter. After the cutter is turning death.
freely, hold the throttle switch (C12) forward until
the engine is at full speed.

12. Use the cutter manual depth control switch

(C20) to slowly lower the cutter to the desired
depth.
13. Move the cutter depth auto/manual selector
switch (C19) upward to the automatic position.
The cutter depth is shown by the pointer (1) on
the depth gauge (2).
14. If the machine is not equipped with a Travel A-B
option, there will not be a front cutter door switch
(C16).
As the cutter is lowered into the cut, use door
switches (C16) and (C17) to raise the cutter door
as necessary.

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Operation RS425C

Unexpected engagement of the cutter can cause

personal injury or death. Push the cutter clutch
control in and move the cutter transmission shift
lever to neutral whenever the cutter is stopped.

22. Reduce the engine speed to low idle with the

throttle switch (C12).
23. Push the cutter clutch control (C18) in
24. Move the transmission shift lever to Neutral to
disengage the cutter.
25. Raise the cutter out of the cut.
15. When the machine is equipped with the Travel 26. Move the machine to the starting point of the
A-B option, and if the travel A-End/B-End switch normal cut.
(C8) is at B-end, move the hood-pull switch (C9)
27. Lower the cutter to the bottom of the transverse
upward. If the Travel A-End/B-End switch (C8) is
cut.
at A-end, move the hood-pull switch downward.
28. Start the normal cut.
16. Move the propel control (C15) forward slightly
to start the machine forward into the transverse
cut.
17. When near the dense material, slow the ma-
chine as much as possible until after the cut-
ter has made complete contact with the dense
material.
18. Increase travel speed slowly.
19. After the cutter has moved completely through
the dense material, move the propel control
(C15) to Neutral to stop forward movement.
20. Push the park brake (C23) in to set the brake.
21. Allow the cutter to rotate for about 1 minute to
clear all cut material away from the teeth.

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RS425C
Lower the Cutter Directly into Dense
Material
NOTE: If at all possible, avoid lowering the turning
cutter directly into dense material (see Make
a Transverse Cut earlier in this chapter). If it
is absolutely necessary, follow the procedure
below.
Keep all personnel at least 25 ft. (7.6 m) away from
the machine when starting a cut. Keep all person-
nel at least 25 ft. (7.6 m) away from the rear of the
machine while it is in operation.
1. Move the machine into position so that all
wheels are straight ahead and the cutter is over
the point where the cut will be started.
2. Move the propel control (C15) to Neutral.
3. Push the park brake control (C23) in to set the
brake.
4. Use the throttle switch (C12) to reduce the en-
gine speed to low idle.
5. Move the propel transmission speed range
switch (C13) downward to slow range.
6. Move the four wheel switch (C14) to center to
four wheel.
7. Set the cutter depth auto/manual selector switch
(C19) to Manual.
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Operation
8. Use the cutter manual depth control switch
(C20) to lower the cutter until the teeth are about
2 in. (51 mm) above grade.
9. If the Travel A-B option is installed, use door
switches (C16) and (C17) to lower the cutter
door until the rubber flaps are touching grade,
then move the beacon switch (C22) to ON. The
front cutter door switch (C16) will not be present
if the Travel A-B option is not installed.
10. Check that the Travel A-End/B-End switch (C8)
is positioned correctly for the cut to be made.
NOTICE
To avoid possible machine damage, shift the cutter
transmission only when:
the machine is stopped and the propel control
is at Neutral,
the engine is at low idle,
the cutter clutch is disengaged,
the input and output shafts have both stopped
turning.
NOTE: Any of three different cutter speeds can be
used by placing the cutter transmission shift
lever at one of the positions shown below.
Shift lever position 1 is the lowest speed and
position 3 is the highest speed.
11. Select the cutter transmission setting for the de-
sired cutter speed and set the shift lever at the
selected setting.
69
Operation RS425C

Lowering the cutter too quickly when starting a

cut can cause the cutter to ride up onto the uncut
surface and make the machine lunge in any direc-
tion. The machine may also lunge if the cutter hits
an obstruction while making the cut.
Either of the above can cause personal injury or
death.

NOTICE
Engage or disengage the cutter only with the en-
gine at low idle. Otherwise the cutter drive mecha-
nism may be damaged.

12. Set the engine at low idle with the throttle switch
(C12).
13. Pull the cutter clutch control (C18) out to engage
the cutter.
14. After the cutter is turning freely, hold the throttle
switch (C12) upward until the engine is at full
speed.
15. Use the cutter manual depth control switch
(C20) to slowly lower the cutter into the grade.
The cutter depth is shown by the pointer (1)
on the depth gauge (2). If the machine starts
to bounce up and down or rock side to side,
release the manual depth control switch (C20)
momentarily before continuing into the cut.
16. As the cutter is lowered into the cut, use door
switches (C16) and (C17) to raise the cutter
doors as necessary. The front cutter door switch
(C16) will not be on the control panel if there is
not the Travel A-B option.
17. If the Travel A-End/B-End switch (C8) is at B-
end, move the hood-pull switch (C9) upward. If
the Travel A-End/B-End switch is at A-end, move
the hood-pull switch downward.

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RS425C Operation

Start Operation

Load Control System

Using the load control system takes the guesswork out
of operating the machine efficiently when making the
cut. The load control prevents stalling of the engine by
regulating the ground speed of the machine to main-
tain engine speed at 2100 RPM.
As the engine becomes overloaded due to the work-
ing load on the cutter, ground speed is slowed until the
engine can recover to an acceptable operating speed.
Once the load control is activated, the engine will
automatically be kept close to maximum power, even if
the machine travel speed has to be stopped altogether
to do so.

18. Continue lowering the cutter until it is at the

desired cutting depth. Move the cutter depth
auto/manual selector switch (C19) upward to the
automatic position. The cutter depth is shown by
the pointer on the depth gauge.
19. Start the normal cut.

The controls that adjust the load control system should

be set as follows:
Auto/manual selector switch (C28)....... AUTO
Sensitivity control (C29)................ At midpoint
In addition, the following controls should be positioned
as indicated:
Engine throttle (C12)................... Hold upward
until engine is at maximum RPM
Propel transmission speed range switch
(C13).................................... Downward (slow)
Four wheel drive selector switch
(C14).................................Center (four wheel)
Cutter clutch control (C18)...............Pulled out
(engaged)

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Operation RS425C

Adjust the Cutting Depth

If the machine is equipped with the Travel A-B option:
Hood-pull (C9)................................ Upward, if
Travel A-End/B-End switch is at B-end
Hood-pull (C9)Downward,
if Travel A-End/B-End switch is at A-end

With the controls positioned as described above, the

machine is ready to start a cut with the load control
system activated.
NOTE: If the load control is used, the propel handle
(C15) has to be pushed all the way forward to
work properly.

Lower the cutter slowly. Keep all personnel at least

25 ft. (7.6 m) away from the machine when start-
ing a cut. Keep all personnel at least 25 ft. (7.6 m)
away from the rear of the machine while it is in
operation.

NOTE: If the load control system is to be used, be

sure the controls are set as specified in Load
Control System.
1. Move the machine into position for the cut so
that all wheels are straight ahead and the cutter
is over the point where the cut will be started.
2. Move the propel control (C15) to Neutral.
3. Use the throttle switch (C12) to reduce the en-
gine speed to low idle.
4. Move the propel transmission speed range
switch (C13) downward to slow range.
5. Move the four wheel drive switch (C14) to center
to four wheel.
6. Set the cutter depth auto/manual selector switch
(C19) to Manual.
7. Use the cutter manual depth control switch
(C20) to lower the cutter until the teeth are about
2 in. (51 mm) above grade.

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RS425C Operation

11. Select the cutter transmission setting for the de-

sired cutter speed and set the shift lever at the
selected setting.

8. If the machine is equipped with the Travel A-B NOTICE

option, use door switches (C16) and (C17) to
Engage or disengage the cutter only with the en-
lower the cutter doors until the rubber slaps are
gine at low idle. Otherwise the cutter drive mecha-
touching grade.
nism may be damaged.
9. Move the beacon switch (C22) to ON. The cutter
front door switch (C16) will not be on the control
panel if the Travel A-B option is not installed. 12. Set the engine at low idle with the throttle switch
(C12).
10. Check that Travel A-End/B-End switch (C8) is
positioned correctly for the cut to be made. 13. Pull the cutter clutch control (C18) out to engage
the cutter.

NOTICE 14. After the cutter is turning freely, hold the throttle
switch (C12) forward until the engine is at full
To avoid possible machine damage, shift the cutter speed.
transmission only when:
the machine is stopped and the propel control
is at neutral,
the engine is at low idle,
the cutter clutch is disengaged,
the input and output shafts have stopped turn-
ing.

NOTE: Any of three different cutter speeds can be

used by placing the cutter transmission shift
lever at one of the positions shown below.
Shift lever position 1 is the lowest speed and
position 3 is the highest speed.

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Operation
Lowering the cutter too quickly when starting a
cut can cause the cutter to ride up onto the uncut
surface and make the machine lunge in any direc-
tion. The machine may also lunge if the cutter hits
an obstruction while making the cut.
Either of the above can cause personal injury or
death.
15. Use the cutter manual depth control switch
(C20) to slowly lower the cutter to the desired
depth.
16. Move the cutter depth auto/manual selector
switch (C19) upward to the automatic position.
The cutter depth is shown by the pointer (1) on
the depth gauge (2).
17. As the cutter is lowered into the cut, use door
switches (C16) and (C17) to raise the cutter door
as necessary. The cutter front door switch (C16)
will not be on the control panel if the Travel A-B
option is not installed.
18. If the Travel A-End/B-End switch is at B-end,
move the hood-pull switch (C9) upward. If the
Travel A-End/B-End switch is at A-end, move the
hood-pull switch downward.
74
RS425C
19. Move the propel control (C15) slightly forward to
cut a distance equal to a few machine lengths.
20. Move the propel control (C15) to Neutral to stop
the forward movement.
21. Push the park brake control (C23) in to set the
park brake.
22. Allow the cutter to rotate for about 1 minute to
clear cut material away from the teeth.
Unexpected engagement of the cutter can cause
personal injury or death. Push the cutter clutch
control in and move the cutter transmission shift
lever to Neutral whenever the cutter is stopped.
23. Reduce the engine speed to low idle with the
throttle switch (C12).
24. Push the cutter clutch control (C18) in.
25. Move the cutter transmission shift lever to neu-
tral to disengage the cutter.
26. Note the position of the pointer (1) on the depth
gauge (2) and measure the depth to which the
cutter has dug.
NOTE: Each mark on the depth scale represents ap-
proximately 1 in. (2.54 cm).
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RS425C
27. If the cut is not to the depth desired, move the
adjusting rod. Moving the adjusting rod inward
decreases the depth of cut and moving the ad-
justing rod outward increases the depth of cut.
a. Loosen the locknut (3).
b. Turn the depth adjusting rod (4) until the
depth gauge pointer has been moved
enough to add or subtract the necessary
amount from the initial setting,
c. Tighten the locknut.
NOTICE
Do not set the depth control to a depth beyond the
extended length of the cutter lift cylinders or over-
heating of the hydraulic oil and unnecessary wear
on the housing wear plates may result.
28. Repeat steps 15 through 27 until the proper
depth of cut is achieved.
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Operation
Start a Cut
NOTE: If the load control system is to be used, be
sure the controls are set as specified in Load
Control System.
Keep all personnel at least 25 ft. (7.6 m) away from
the machine when starting a cut. Keep all person-
nel at least 25 ft. (7.6 meters) away from the rear of
the machine while it is in operation.
1. Move the machine into position so that all
wheels are straight ahead and the cutter is over
the point where the cut will be started.
2. Move the propel control (C15) to Neutral.
3. Use the throttle switch (C12) to reduce the en-
gine speed to low idle.
4. Move the propel transmission speed range
switch (C13) downward to slow range.
5. Move the four wheel drive switch (C14) to center
to four wheel.
6. Set the cutter depth auto/manual selector switch
(C19) to Manual.
7. Use the cutter manual depth control switch
(C20) to lower the cutter until the teeth are about
2 in. (51 mm) above grade.
75
Operation RS425C

10. Select the cutter transmission setting for the de-

sired cutter speed and set the shift lever at the
selected setting.

8. If equipped with the Travel A-B option, use door

switches (C16) and (C17) to lower the cut-
NOTICE
ter door until the rubber flaps are touching the Engage or disengage the cutter only with the en-
grade, then move beacon switch (C22) to ON. gine at low idle. Otherwise the cutter drive mecha-
If not equipped with the Travel A-B option, the nism may be damaged.
cutter front door switch will not be on the control
panel.
11. Set the engine at low idle with the throttle switch
9. Check that the Travel A-End/B-end switch (C8)
(C12)
is positioned correctly for the cut to be made.
12. Pull the cutter clutch control (C18) out to engage

NOTICE the cutter.

13. After the cutter is turning freely, hold the throttle
To avoid possible machine damage, shift the cutter switch (C12) forward until the engine is at full
transmission only when: speed.
the machine is stopped and the propel control
is at neutral,
the engine is at low idle,
the cutter clutch is disengaged,
the input and output shafts have stopped turn-
ing.

NOTE: Any of three different cutter speeds can be

used by placing the cutter transmission shift
lever at one of the positions shown below.
Shift lever position 1 is the lowest speed and
position 3 is the highest speed.

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RS425C
Lowering the cutter too quickly when starting a
cut can cause the cutter to ride up onto the uncut
surface and make the machine lunge in any direc-
tion. The machine may also lunge if the cutter hits
an obstruction while making a cut.
Either of the above can cause personal injury or
death.
14. Use the cutter manual depth control switch
(C20) to slowly lower the cutter to the desired
depth.
15. Move the cutter depth auto/manual selector
switch (C19) forward to the automatic position.
The cutter depth is shown by the pointer on the
depth gauge.
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Operation
16. If the Travel A-B option is installed, and the
Travel A-End/B-End switch (C8) is at B-end,
move the hood-pull switch (C9) upward. If the
Travel A-End/B-end switch is at A-end, move the
hood-pull switch downward.
17. Move the propel control (C15) to the desired
speed.
Unexpected engagement of the cutter can cause
personal injury or death. Push the cutter clutch
control in and move the cutter transmission shift
lever to neutral whenever the cutter is stopped.
77
Operation RS425C

End Operation

Park the Machine

1. Choose a level parking area.

2. Stop the machine by moving the propel control
(C15) to neutral.
3. Release the steering wheel to allow the wheels
to straighten.
4. Push the park brake control (C23) in to set the
park brake. Hot oil and hot components can cause personal
5. Use the throttle switch (C12) to adjust the engine injury. Do not allow hot oil or hot oil components
to no more than half speed. to contact the skin.

6. Allow the engine to run with no load for at least 5

minutes to cool. 8. Check the crankcase oil level with the engine
stopped.
7. Use the throttle switch (C12) to reduce the en-
gine speed to low idle. NOTE: Before you perform this maintenance, do not
operate the engine for at least 10 minutes to
allow the oil to drain back into the oil pan. This
will give an accurate reading on the dipstick.
9. Maintain the oil level between the ADD and
FULL marks on the CHECK WITH ENGINE
STOPPED side of the dipstick (3). Do not fill the
crankcase oil level above the FULL mark on the
dipstick.
10. Remove the oil filler cap (4) and add oil if neces-
sary.
11. Clean and reinstall the oil filler cap.
12. Restart the engine and use the cutter manual
depth control (C20) to lower the cutter to the
ground.

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RS425C Operation

Machine Cleanup
The machine should be thoroughly cleaned at the end
of each day of operation. The process of cleaning will
reveal loose bolts, loose hydraulic lines and fittings,
and other trouble spots. Be especially careful to clean
all oil, grease, dirt, or mud from the handrails, stepping
points and operators platform to prevent falls. Clean
any grease or oil from the controls so that a sure grip
is available when any control is needed.

13. Turn the ignition switch (C10) to OFF.

14. Remove the key from the ignition switch.

14. Turn the main battery disconnect switch (C35) to

OFF.

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Operation RS425C

NOTES

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RS425C Transport the Equipment

Transport the Machine

Shipping
For information on the shipping specifications of the
equipment, see Shipping Dimensions in the Appen-
dix of this manual.

Make sure the trailer is on level ground before at-

tempting to load the machine.

2. Check that controls are set as follows:

Cutter clutch control (C18)Pushed in
(clutch disengaged)
Cutter depth auto/manual selector
(C19)MAN
Park brake control (C23)Cover
down moves switch down (brakes ON)
Automatic load control auto/manual switch
(C28)MANUAL
Propel control (C15)Centered (Neutral)
Starting the engine with the cutter engaged can
cause personal injury. Push the cutter clutch con- Propel transmission speed range selector
trol in and move the cutter transmission shift lever switch (C13)Downward (Slow)
to Neutral before starting the engine. Four wheel drive selector switch
(C14)Center (Four Wheel)
3. Start the engine and let it warm up for 3 to 5
1. Set the cutter transmission shift lever (C33) to
minutes, or until the water temperature begins to
Neutral (N).
rise.
4. Hold the cutter manual depth control switch
(C20) upward until the cutter is at the upper limit
of travel.

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Transport the Equipment
NOTE: If the machine is equipped with the A-B Travel
Panel, the position of travel A-End/B-End
switch (C8) determines how the machine con-
trols will respond. If switch (C8) is at A-end,
the controls respond as if the A-end is the front
of the machine. If the switch is at B-end, the
controls respond as if the B-end is the front of
the machine.
5. Set the travel A-End/B-End switch (C8) in the
direction desired.
6. Lift the switch cover and move the toggle switch
(C23) up to release the park brake control.
7. Carefully drive the machine onto the trailer.
8. Set the service brake (C30) by moving the lever
down.
82
RS425C
9. Position blocks under the cutter.
10. Hold the cutter manual elevation control switch
(C20) downward until the cutter is resting on the
blocks.
11. Push the park brake control cover (C23) down.
12. Stop the engine.
a. Turn the ignition switch (C10) counterclock-
wise to the OFF position.
b. After the engine stops, turn the key back to
the ON position.
c. Pull the cutter clutch control (C18) out to en-
gage the cutter clutch. Engaging the clutch
minimizes the wear on the bearings caused
by transporting the machine.
13. Remove the key from the switch.
14. Move the console cover into position.
15. Install a lock on the console cover.
16. Turn the main battery disconnect switch (C35) to
OFF.
17. Securely block the machine.
18. Tie the machine down.
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RS425C Transport the Equipment

NOTES

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Transport the Equipment RS425C

NOTES

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RS425C Maintenance

IMPORTANT SAFETY INFORMATION FOR SERVICE AND MAINTENANCE

MACHINE PREPARATION
Engine Running Procedures Safety
Guidelines

Before performing any maintenance or repairs, shut
off the machine, remove the key from the ignition,
move the battery disconnect switch to OFF, and
attach a DO NOT OPERATE tag to the operators
console.
Always move the battery disconnect switch to OFF
when performing any maintenance or service pro-
cedure. Performing maintenance or service with a
running engine could cause injury or death.
If the maintenance or service procedure requires a
running engine, always have at least two personnel
on hand to perform the maintenance or service as
detailed below.

Some maintenance and service procedures may

require a running engine. For those procedures, one
person must always be stationed at the operators
console or near an emergency stop switch to kill the
engine immediately.
Refer to the Safety chapter of this manual for addi-
tional information concerning operator and machine
safety.

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Maintenance
Maintenance Recommendations
Always move the battery disconnect switch to OFF
when performing any maintenance or service pro-
cedure. Performing maintenance or service with a
running engine could cause injury or death.
If the maintenance or service procedure requires a
running engine, always have at least two personnel
on hand to perform the maintenance or service as
detailed below.
Some maintenance and service procedures may
require a running engine. For those procedures, one
person must always be stationed at the operators con-
sole or near an emergency stop switch to immediately
kill the engine.
Refer to the Safety chapter of this manual for addi-
tional information concerning operator and machine
safety.
NOTE: Always refer to the engine manual for all
engine-specific procedures that should be
followed. While this section does include
some engine-related procedures. The engine
manual goes into further detail and depth. If
you do not have a copy, contact Terex Road-
building at 1-888-837-3972 and speak with a
Part Sales or Product Support representative.
Cooling System
NEVER add coolant to an overheated engine; allow
the engine to cool first.
Check the specific gravity of the coolant solution fre-
quently in cold weather to ensure adequate protection.
If the machine is to be stored in, or shipped to, an area
with freezing temperatures the cooling system must be
protected to the lowest expected outside temperature.
All water is corrosive at engine operating tempera-
ture. The cooling system should be protected with a
3% concentration of cooling system conditioner at all
times, regardless of the concentration of antifreeze.
86
RS425C
Excessive coolant conditioner (greater than the recom-
mended 3% initial fill) together with concentrations of
antifreeze greater than 65%, cause a mud-like deposit
to form. This may result in radiator tube blockage and
overheating.
DO NOT add liquid cooling system conditioner when a
cooling system conditioner element is used.
DO NOT use the cooling system conditioner element
with Dowtherm 209 Full-Fill coolant. Follow recom-
mendations provided with Dowtherm 209 Full-Fill
coolant.
Premix coolant solution to provide protection to the
lowest expected outside temperature. Pure undiluted
antifreeze will freeze at -10F (-23C).
Coolant mixtures in excess of 50% antifreeze should
NOT be used unless temperatures below -30F
(-34C) are expected. In this case increase to 60%
antifreeze, but as the outside air temperatures start to
be consistently above 32F (0C), switch back to the
50/50 mixture.
Antifreeze concentrations in excess of 63% provide
less rather than more freeze protection.
A good practice to follow after operating an engine is
to return the engine speed to low idle for 5 minutes
before shutting the engine down. This reduces the sur-
face temperature of the heads and liners minimizing
localized boiling at these areas. This will also reduce
the plating effect of the compounds in the coolant.
Use clean water that is low in scale-forming mineral.
DO NOT use softened water.
Filling at over 5 U.S. gallons (19 liters) per minute can
cause air pockets in the cooling system.
After draining and refilling the cooling system, AL-
WAYS operate the engine with the radiator cap
removed until the coolant level stabilizes. Recheck the
coolant level and add coolant as necessary to fill the
system.
The engine cooling system is protected to -40F
(-40C) with a permanent-type antifreeze, when
shipped from the factory.
Operate with a thermostat in the cooling system year-
round. Overheating will occur without a thermostat.
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RS425C
Cooling System Conditioner Elements
A 3% concentration of cooling system conditioner
can be maintained by installing a coolant conditioner
precharge element at initial fill, and then replacing with
a normal coolant conditioner element after every 250
service hours of operation.
If coolant conditioner elements are not used, adding
cooling system conditioner to the coolant will maintain
a 3% concentration.
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Maintenance
Fuel System
Do not fill the fuel tank to the top. If the fuel tank is
filled to the top, the fuel will expand as it gets warm
and may overflow. The fuel could ignite and cause a
fire that could result in serious injury or death. Allow
for expansion of the fuel.
NOTICE
Fill the fuel tank at the end of each day of operation
to drive out moist air and to prevent condensation.
Do not fill the fuel filter with fuel before installing it.
Contaminated fuel will cause accelerated wear to the
fuel system parts.
NOTE: After changing the fuel filter, always prime the
fuel system to remove air bubbles from the
system (see Prime Fuel Filter in this chapter).
Drain water and sediment from any fuel storage tank
weekly, and before the tank is refilled. This will help
prevent water or sediment being pumped from the
storage tank into the machine fuel tank.
Use only fuel as recommended in the Coolant, Fuel
and Lubricant Specification section of this chapter.
87
Maintenance
Hydraulic System
NOTICE
Make-up oil added to the hydraulic oil replenishing
tank must mix with the oil already in the system. Use
only the same type of oil as already in the system
(see Lubricant Specifications).
If the hydraulic oil becomes cloudy, water or air is
entering the system. Water or air in the system will
cause pump failure. Change the hydraulic oil (see
Hydraulic System under Every 2000 Service Hours or
Yearly).
88
RS425C
Air Inlet System
Change the air cleaner primary element when the
indicator red signal (1) is locked in view.
Check that the dust ejector valve (2) is not inverted,
damaged or plugged. If the valve is inverted, check for
restrictions in the air inlet system.
NOTE: Refer to Engine Air Inlet System under
When Required for procedures to change the
air cleaner elements.
The primary element can be cleaned up to three times
before replacement. This element, when cleaned,
should be thoroughly checked for rips or tears in the
filter material. Replace the primary element every year,
even though it has not been cleaned six times.
Normally the secondary element should be replaced at
the time the primary element is replaced for the third
time. However, if the primary element has been dam-
aged to a degree that could have allowed an exces-
sive amount of dirt to enter the secondary element,
change both the primary and secondary elements.
NOTICE
Do not try to reuse the secondary element by clean-
ing it. Always use a new element.
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RS425C
Electrical System
NOTICE
Use extreme care when arc welding on the machine
or the spray system microcontroller (if equipped)
may be damaged. Always turn the battery disconnect
switch to OFF and connect the ground for the welder
near the part of the machine being welded.
When boost-starting the machine, follow the instruc-
tions in the Operation chapter to start the machine
properly.
This machine has a 24-volt electrical system. Use
only equal voltage for boost starting. Use of a
welder or higher voltage will damage the electrical
system.
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Maintenance
General
Accumulated grease and oil on a machine is a fire
hazard. Remove this debris with steam cleaning or
high-pressure water, at least every 1,000 hours or
each time any significant quantity of oil is spilled
on a machine.
Wipe all fittings, caps, and plugs before servicing.
Keep a close watch for leaks. If leaking is observed,
find the source and correct the leak.
Check the fluid levels more frequently than the recom-
mended periods if leaking is suspected or observed.
89
Maintenance RS425C

Coolant, Fuel and Lubricant

Specifications
Fuel Specifications
For optimum engine performance, always use ASTM

NOTICE
No. 2D fuel.

The coolant, fuel, and lubricant specifications in

this manual are designed for optimum engine per-
formance. Any alteration or deviation from these Do not mix gasoline, alcohol, or gasohol with diesel
specifications may result in engine failure and fuel. This mixture can cause an explosion and result
could void your warranty. If you have any questions in death or serious injury.
about any coolant, fuel or lubricant not listed in this
manual, call Terex Roadbuilding Product Support at
1-888-837-3972. If the machine is or will be operating in temperatures
below 32F (0C), it is acceptable to use blends of
No. 2D and No. 1D fuel. Refer to the Caterpillar C-13
DIT ATAAC Operation and Maintenance Manual for
Coolant Specifications
more information.
Use a 50/50 mixture of high-quality water and fully-for-
mulated antifreeze or fully-formulated coolant when fill-
ing the cooling system. The fully-formulated antifreeze NOTICE
and fully-formulated coolant must meet TMC RP 329
It is extremely important to keep the diesel fuel clean
or TMC RP 330 specifications. More information is
and free of dirt or water. Severe damage to both the
available in the Caterpillar C-13 DIT ATAAC Opera-
fuel pump and fuel injectors can occur with even the
tion and Maintenance manual.
smallest amount of dirt.

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RS425C Maintenance

Controls, Systems and Tools Used

for Maintenance
Lubricant Specifications Main Battery Disconnect Switch
Diesel Engine Oils (DEO)
Use 15W-40 engine oil. Refer to the Caterpillar C-13
DIT ATAAC Operation and Maintenance Manual for
more information.
The percentage of sulfur in the fuel will affect the
engine oil recommendations. If the fuel has over 0.5%
sulfur content, the engine oil must have a TBN of 20
times the percentage of fuel sulfur (TBN as measured
by the ASTM D-2896 method). If the sulfur content is
greater than 1.5% by weight, use an oil with a TBN
of 30 and reduce the oil change interval by one half.
Consult your dealer for correct engine oil recommen-
dations.
The main battery disconnect switch is located in the
Higher TBN values are essential to retard the corro- left front fender compartment. When the switch is at
sive damage to metal engine parts. OFF it removes the batteries from the electrical circuit.
Your oil supplier should be able to furnish the correct The main battery disconnect switch should be turned
oil. to OFF any time
the batteries are being charged;
Hydraulic Oil (HO)
an electrical component is being removed, installed,
Exxon Univis N46 or equivalent with a viscosity greater
or serviced;
than 140.
or
Cutter Transmission a major repair procedure is being performed.
Use Exxon Univis N46 lubricant or equivalent.

Transmission Oil (TO)

Use SGO-50.

Synthetic Gear Lube (SGL)

Use EP 80W-140 (synthetic oil only).

Cutter Chaincases, Ground Drive Transmission,

Cutter and Ground Drive Axles (MPL)
Use an API gear lubricant classification GL-5 (MIL-L-
2105C).

Lubricating Grease (MPGM)

Use multipurpose-type grease (MPGM), which con-
tains 3% to 5% molybdenum disulfide. NLGI No. 2
Grade is suitable for most temperatures. Use NLGI
No. 1 or No. 0 Grade for extremely low temperatures.

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Maintenance RS425C

Cutter Door Lock Cutter Retaining Chains

The cutter can fall and cause injury or death. If the

cutter is raised off the grade, properly install the
retaining chains before working on or near the cut-
ter.

Lock the Door Open

1. Hold the cutter door control upward until the rod
of door cylinder (1) is fully retracted.
2. Lift the free end of the locking bar (2) and slide
the bar onto the end of the cylinder rod pin (3).
Be sure the pin extends fully through the bar.

Unlock the Door

1. Pull the end of the locking bar (2) outward off the The cutter retaining chains must be properly installed
end of pin (3). in the brackets whenever the cutter is raised above
2. Lay the bar on the cutter door. grade and left above grade. This is especially neces-
sary if work is to be done under the cutter.

Engage the Chains

1. Raise the cutter slightly above the desired
height.
2. Stretch the chains as tight as possible by hand,
then install the chains in the slots in the brack-
ets.
3. Gently lower the cutter until the chains are taut.
4. Stop the engine.

Disengage the Chains

1. Start the engine and raise the cutter slightly.
2. Disengage both chains from the brackets.
3. Lower the cutter to grade.
4. Stow the chains in the provided channels on the
chaincases.

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Compressed Air System Cutter Tools

1. Air hammerused with a 15 punch to remove
teeth from the holders
2. Cutter tooth pullerused to remove cutter teeth
when an air hammer is not available or is not con-
venient to use
3. Angled hammer punchused with a hand-held
hammer to remove teeth from the holders
4. Air hammer angled punchused with an air ham-
mer to remove teeth from the holders
5. Filler bar with 1/2 in. 13 UNC 2A x 3 in. bolts
6. Chain ratchet toolused to remove and install
drive chains

The compressed air system supplies the air to drive

the air hammer, which is used to change the cutter
teeth. Quick disconnect couplings allow an air hose to
be quickly connected or disconnected.

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Maintenance
Maintenance Notes
1. Pull the oil sample at the hydraulic sampling port
(see the Fluid Sampling procedures in the Ev-
ery 500 Service Hours or 3 Months section).
The oil cleanliness level for continuous operation
is an ISO particle count of 18/13 or lower.
2. If the fuel has over 0.5% sulfur content, the CD
engine oil must have a TBN of 20 times the
percentage of fuel sulfur (TBN as measured by
the ASTM D-2896 method). If the sulfur content
is greater than 1.5% by weight, use an oil with a
TBN of 30 and then reduce the oil change inter-
val by one half.
Key to Lubricants
HO AW 46 (>140)
MPGM Multipurpose Type Grease
80W-140 Synthetic Gear Lube
DEO Diesel Engine Oil
TO Transmission Oil SGO 50
Lubriplate 1200-2
94
RS425C
Filter Elements Part Numbers
Engine
1. Oil Filter 00401312700
2. Primary Fuel Filter 004013121699
3. Primary Fuel Filter Seals 004013121701
4. Secondary Fuel Filter 004013121708
5. Coolant Filter 004013341001
6. Primary Air Filter 004003040001
7. Secondary Air Filter 004003040002
Hydraulics
1. Propel Pump Charge Filter 002008549001
2. Auxiliary System Filter 002008549001
(Indicator light on the Control Panel)
3. Cutter Axle Filter 002008571000
4. Hydraulic Tank Filter Replacement Kit
002016661003
5. Hydraulic Tank Breather 002016661004
Refill Capacities (Approximate)
Fuel Tank 250 gal. (946 l)
Hydraulic Oil Tank 50 gal. (189.3 l)
Engine Oil 9 gal. (34.1 l)
Cooling System 18 gal. (68.1 l)
Transmission 3 gal. (11.4 l)
Front Axle 9 gal. (34.1 l)
Planetary (each) 0.4 gal. (1.5 l)
Cutter Drive Axle 6 gal. (22.7 l)
Cutter Chaincase (each) 1 gal. (3.9 l)
Lubrication Pump 0.5 gal. (1.9 l)
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RS425C Maintenance

Maintenance Schedule Chart

ITEM SERVICE LUBE

AFTER FIRST 25 SERVICE HOURS

Change the ground drive and return filter elements after the initial
Hydraulic System
25 service hours. Thereafter, replace them every 100 service hours.

AFTER FIRST 100 SERVICE HOURS

Change the oil in the axle carrier and planetary ends after initial 100
Front Drive Axle 80W-140
service hours. Thereafter, change the oil every 1,000 service hours.
Change the oil in the planetaries after initial 100 service hours.
Rear Drive Axle 80W-140
Thereafter, change the oil every 1,000 service hours.

WHEN REQUIRED
Engine Cooling System Drain and clean if the engine overheats or the solution is dirty.

Engine Air Intake System Replace or clean the primary and/or secondary air filters.
Fuel System Replace the primary and/or secondary fuel filters.
Fuel Tank Drain any water and/or sediment from the fuel tank.
Auxiliary Hydraulic Oil Filter Replace the auxiliary system filter.
Compressed Air System Check the oil level of the air system lubricator.
Cutter Drum Check the cutter bits. Replace if necessary.
Cutter Drive Shaft Torque Check the thickness of the torque limiting clutch assembly if the
Limiter Clutch clutch seems to be slipping.
Cutter Clutch Install and/or adjust the cutter clutch as needed.
Change or clean the hydraulic filters and strainers when indicated
Hydraulic System
by alarms or visual indicators.

EVERY 10 SERVICE HOURS OR DAILY

Check all safety equipment and replace as necessary. Check the
Walk Around Inspection condition of all safety, warning, and caution stickers. Replace them
if you can not read them. Record any visible defects in a log.
Check the oil level in the hydraulic tank at the sight glass. Refill from
the replenishing tank until the oil level is 4 in. from the top of the
Hydraulic System HO
sight glass. Check the hydraulic hoses for leakage, cracks, or dam-
age of any kind; repair or replace hoses that show signs of damage.
Check the engine coolant level in the sight glass. Add more coolant
if liquid is not visible in the sight glass. Check the coolant hoses for
damage. Tighten connections or repair/replace hoses. Check the
cooling assembly for core blockage. Clean as required.
Cooling Systems
Clean the radiator, charge air, hydraulic oil cooler, and differential oil
cooler cores with compressed air to remove dust, leaves, etc.
Clean the cutter transmission oil cooler core with air, water, or
steam.

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Maintenance RS425C

ITEM SERVICE LUBE

Check the oil level. Maintain the oil level between the ADD and
Engine Crankcase DEO
FULL marks on the Engine Stopped side of the dipstick.
Check the air cleaner indicator, which will show a red signal when
cleaning or a change is required (change the secondary element at
Engine Air Cleaner
every third change of the primary element). Check the dust ejector
valve.
Ground Drive Transmission Check the oil level. Add more, if needed. 80W-140
Check the axle transmission, axle carrier, and planetary ends for oil 80W-140
level; fill as required.
Front Drive Axle
Lubricate the axle planetary pivots, tie rod ends, and steering cylin-
der rod ends. Three shots are needed at each service point. MPGM
Check the planetary oil level; fill as required. 80W-140
Rear Drive Axle Lubricate the center pivot pin, tie rod ends, and leg bearings. Three
shots are needed at each service point. MPGM
Cutter Axle Check the oil level; fill as required. 80W-140
Check the oil level; fill as required. Check the transmission oil cooler
TO
for core blockage; clean as required.
Cutter Transmission
Lubricate the cutter driveshaft. Two shots are needed at each ser-
MPGM
vice point.
Check the oil level; fill as required.
80W-140
Cutter Chaincases Lubricate the chaincase hub and sprocket bearings. Three shots
MPGM
are needed at each service point.
Cutter Drum Check the cutter teeth and holders; replace as required.
Cutter Support Bearing
Fill the cutter support bearing lubricator. MPGM
Lubricator
Check the condition and air pressure. Replace or inflate as re-
Tires
quired.
Check the fuel level as indicated on the fuel tank gauge on the
Fuel Tank operators control panel. Add fuel to the tank if needed. Drain water
and sediment.
Lubricate the following items: cutter hood cylinder, cutter hood
saddle, ground drive axle, chaincase sprocket bearings, chaincase
Lubrication
lift cylinders, tie rod ends, rear bolster pivot pin, rear bolster tie rod,
and pump shafts.
Lubricate the cutter hood and cutter lift cylinder ends; 2 shots are
Cutter Housing needed at each service point. Lubricate the saddle assembly; fill MPGM
until lube is visible.
LUBRI-
Cutter Lower Drive Check the automatic lube system reservoir; fill as required. PLATE
1200-2
Cutter Driveshaft Torque Check the assembly for wear; service when its thickness is 3.46 in.
Limiter (87.9 mm).
Make sure the back-up alarm sounds when the machine is traveling
Back-Up Alarm in reverse. If there is no sound, check all electrical wiring and con-
nections. Replace as needed.

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ITEM
Electrical Wiring
Compressed Air System
Hydraulic Hoses
Engine Belts
Engine Fuel Filter
Engine Battery
Engine Oil
EVERY 50 SERVICE HOURS OR WEEKLY
Engine Air System
Batteries
Cutter Transmission Cooling
System
Cutter Differential Cooling
System
Cutter Drive Chains
Cutter Depth Control
Tires/Wheels
Exhaust System
EVERY 100 SERVICE HOURS OR MONTHLY
Hydraulic Oil Filters
EVERY 250 SERVICE HOURS OR 6 MONTHS
Engine Oil
Engine Fuel Filters
Engine Coolant
Engine Crankcase Breather
Engine Valve Lash
Alternator Belt and Fan
Drive Belts
Ground Drive Brakes
Cutter Differential
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Maintenance
SERVICE LUBE
Check all the electrical wiring for wear, frayed ends, or damage of
any kind. Repair/replace all wiring that is damaged.
Check the oil lubricator level; fill as required. Check the filter; drain
the water as required.
Check all hoses for leakage, cracks, or damage of any kind. Repair
or replace all hoses that show signs of damage.
Check the fan and alternator belt; tighten or replace as required.
Drain the filter/water separator.
Keep the terminal and battery cable clamps clean. Apply grease to
prevent corrosion and damage to terminals.
Check the oil level. Add more oil if the oil level is below the safe DEO
area of the dipstick. 15W-40
Check the air tubes for leaks. Tighten the connections and repair or
replace any damaged air tubes.
Clean the batteries and check the electrolyte levels; fill as required.
Clean the strainer.
Clean the strainer.
Check the chain tension; adjust as required
Lubricate the pivot. One shot is needed at each service point. MPGM
Check the tire inflation for the recommended pressure. Check the
torque on the lug nuts for the recommended ftlb.
Check the exhaust tubes for leaks. Tighten the connections. Repair
or replace any damaged tubes or insulation.
Change the hydraulic oil reservoir filter.
DEO
Change the engine oil.
15W-40
Change the primary and secondary fuel filters.
Change the coolant conditioner.
Check the breather at the first oil change; clean if required.
Check the valve lash at the first oil change; adjust if required.
Check the condition of the alternator belt. Adjust the tension or
replace if needed.
Check the condition of the fan drive belts. Adjust the tension or
replace if needed.
Check the condition and operation. Repair or replace if required.
Change the fluid. 80W-140
97
Maintenance RS425C

ITEM SERVICE LUBE

Cutter Transmission Change the fluid. TO
Check the wiring harnesses for damage. Repair or replace as
Electrical System
needed.
Lubricate the fittings on the fan bearing; two shots are needed at
each fitting. MPGM
Lubricate the fittings on the clutch release lever and the clutch
Lubrication MPGM
release bearing.
Lubricate the ground drive axle and the ground drive axle universal MPGM
joints.
Engine Fan Check the fan drive pulley assembly. Repair or replace if needed.
Cutter Axle Change the fluid. 80W-140
Cutter Transmission Change the fluid. 80W-140

EVERY 500 SERVICE HOURS OR 3 MONTHS

Hydraulic System Change the hydraulic tank breather.
Engine Crankcase Breather Clean the breather.
Cutter Chaincase Hubs Clean the breathers.
Fuel Tank Clean the breather.
Hydraulic Oil Replenishing
Clean the breather.
Tank
Check the contamination level of the fluids in the hydraulic system
ground drive hydrostatic loop, cutter drive axle, the wheel ends
Fluid Sampling
main propel axle, the planetary wheel drive, the main propel axle,
and the engine lube.

EVERY 1,000 SERVICE HOURS OR YEARLY

Batteries Check the battery retainer nuts. Tighten if needed.
Change the oil in the axle transmission, axle carrier, and planetary
Front Drive Axle ends. 80W-140
Check the toe-in; adjust if required.
Check the toe-in; adjust if required.
Rear Drive Axle 80W-140
Change the oil in the planetaries.
Cutter Transmission Shift
Lubricate the fittings. Two shots are needed at each service point. MPGM
Linkage

EVERY 2,000 SERVICE HOURS OR 2 YEARS

Engine Valve Lash Check the engine valve lash; adjust if required.
Drain, clean, and refill the engine cooling system. Change the anti-
Engine Cooling System
freeze solution.
Hydraulic System Change the hydraulic oil. HO

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AFTER FIRST 25 SERVICE HOURS AFTER FIRST 100 SERVICE HOURS

Hydraulic System Ground Drive Axle Carrier and Planetary

Change the Filter Elements
Change the ground drive and return filter elements af-
ter the first 25 hours of machine operation. See Every
100 Service Hours or 2 Weeks for the procedure.
Ends
Change the Oil
Change the oil after the first 75 to 100 hours of opera-
tion. Thereafter change the oil every 1,000 service
hours or at least once a year. See Every 1,000 Ser-
vice Hours or Yearly for procedures.

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Maintenance RS425C

WHEN REQUIRED WHEN REQUIRED

Engine Cooling System

Drain
At operating temperature, the engine coolant is hot
and under pressure. Check the coolant level only
after the engine has cooled and the fill cap is cool
enough to touch with your bare hand.
Steam and hot water can cause personal injury. Re-
move the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.
Clean
1. Fill the system with a commercially available
cleaning solution and clean water. See Caterpil-
lar Operation and Maintenance Manual, C13
Engines in the Maintenance chapter, Cooling
System Flush.
2. Start and run the engine for 1/2 hour. The solu-
tion should be at least 180F (82C).
3. Stop the engine and allow it to cool. Loosen the
radiator cap slowly to relieve pressure.
4. Remove the radiator cap.
5. Open the drain valve.
6. Drain the cleaning solution.
7. Flush the system with clean water until the drain-
ing water is clean. Do not run the engine while
flushing.
8. Close the radiator drain valve.

1. With engine and radiator cool, loosen the radia-

tor cap slowly to release pressure. Remove the
radiator cap.
NOTE: Local environmental regulations probably
require that the antifreeze be captured and
properly disposed of or reused. Make proper
preparations to capture the antifreeze.
2. Attach a hose to the fitting (1) located on the
right front of the machine next to the square ac-
cess panel (2).
3. Place a suitable container under the hose to
catch the coolant.
4. Open the square access panel (2) to reach and
open the radiator drain valve (3) and allow the
coolant to drain.
5. Clean and close the radiator drain valve.

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WHEN REQUIRED
Refill
When changing antifreeze solution, replace the
conditioner maintenance element with the correct
conditioner precharge element.
1. If equipped, remove the coolant conditioner
maintenance element and install a coolant con-
ditioner precharge element. See Engine Cool-
ing System under 250 Hour Service.
2. Mix the antifreeze solution to provide protection
to the lowest expected ambient temperature.
3. Refill the engine cooling system with the recom-
mended mixture of coolant and water. Do not
install the radiator cap yet. See Refill Capaci-
ties earlier in this chapter.
4. Start and run the engine at low idle.
5. Increase the engine rpm to high idle.
6. Run the engine at high idle for one minute in
order to purge the air from the cavities of the
engine block.
7. Stop the engine.
8. Bring the coolant level up to where it is visible in
the sight glass.
9. Clean the radiator cap.
10. Inspect the gasket on the cap.
a. If it is damaged, discard the old radiator cap
and replace it with a new cap.
b. Use a pressurizing pump to test the pres-
sure of the cap. The correct pressure should
be stamped on the face of the radiator cap.
c. If the cap has the correct pressure, install
the cap.
11. Start the engine and check for coolant leaks at
all of the hose connections.
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Maintenance
WHEN REQUIRED
Engine Air Intake System
Change the Primary Air Filter Element
1. Remove the wing nut (1).
2. Remove the primary element (2). Do not remove
the secondary element (3).
3. Inspect the primary element for dust streaks on
the inside. If any are found, the element is dam-
aged. Throw the element away.
4. Inspect the primary element gasket. If the gasket
is not smooth and flat, or if it is damaged in any
way that might allow dust to get by, throw the
element away.
5. Clean the inside surface of the body (4).
6. Inspect the dust ejector valve (5) for damage.
7. Be sure the valve is securely in place and is not
inverted.
8. If the primary element is to be cleaned, see
Clean the Primary Air Filter Element for clean-
ing procedures.
9. Inspect the gasket washer on the wing nut (1).
Replace it if a good air seal cannot be guaran-
teed.
10. Install the new or cleaned primary element (2).
11. Secure the element with the wing nut (1).
101
Maintenance RS425C

WHEN REQUIRED WHEN REQUIRED

Change the Secondary Air Filter Element Clean the Primary Filter Element

Pressure can cause personal injury. When using

pressure air for cleaning, wear a protective face
shield, protective clothing and protective shoes. The
maximum air pressure must be below 30 psi (206
kPa) for cleaning purposes.

NOTICE
Do not clean the filter elements by bumping or tap-

NOTICE ping them. Do not use gasoline or other volatile

solvents to clean an element. The element or the
engine could be damaged.
Do not use compressed air to clean the air cleaner
body when the secondary element is not in place. To
do so will force dirt into the engine. Never attempt The dirty primary element can be cleaned up to three
to clean a secondary element. times by one of three methods: (1) washing in a solu-
tion of water and detergent, (2) blowing with com-
pressed air, or (3) washing with water alone.
1. Remove and inspect the primary element (1).
See Change the Primary Air Filter Element. Detergent and water are best when the element is
loaded with a combination of exhaust carbon, soot, oil
2. Remove the wing nut (2).
and dust. Compressed air is effective when the ele-
3. Remove the secondary element (3). ment is loaded with dust. Washing with water alone will
often work when air is not available and the element
4. Inspect the gasket washer on the wing nut (2).
has only dust on it.
If a good air seal cannot be guaranteed, replace
the seal. Whichever method of cleaning is used, the element
should be handled carefully to keep it from being punc-
5. Remove any dislodged dust from the air cleaner
tured or dented.
outlet. Clean completely inside the surface of the
body (4). The primary element is strong enough to take normal
handling, but it will not stand an unlimited amount of
6. Install a new secondary element (3).
abuse.
7. Secure the secondary element with a wing nut
(2).
8. Install the primary element (1) and secure with a
wing nut (5).

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WHEN REQUIRED
Clean with Detergent and Water
1. If compressed air is available, remove the loose
dust by blowing from the inside of the element.
Use less than 30 psi (206 kPa), keep the nozzle
at least 1 in. (25 mm) away from the element,
and blow on the inside only. If compressed air
is not available, run water through the element
from the inside. Use a gentle water streamless
than 40 psi (275 kPa).
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Maintenance
WHEN REQUIRED
2. Soak the element in a solution of water and
detergent.
3. Gently swish the element around the solution to
help loosen the dirt.
4. With a gentle stream of waterless than 40 psi
(275 kPa)rinse the entire element until the
water comes through the element clear. Good
rinsing is important.
5. Dry the element thoroughly before inspecting
it. Mechanical dryers can be used, heated air
must be circulated and must be less than 160F
(71C). Do not use a light bulb to dry the ele-
ment.
103
Maintenance RS425C

WHEN REQUIRED WHEN REQUIRED

Clean with Air Only Clean with Water Only

1. Direct a jet of compressed air against the inside 1. Run water through the element from the inside
of the element. To prevent possible personal only. Use a gentle stream of water, less than 40
injury and damage to the filter medium, use less psi (275 kPa).
than 30 psi (206 kPa), and keep the nozzle at
2. Run water through the element until the water
least 1 in. (25 mm) away from the medium.
comes through clear.
2. Move the nozzle up and down each pleat, con-
3. Dry the element thoroughly before inspecting it.
tinuing until no more dust is being removed. Do
Mechanical dryers can be used, but heated air
Not blow air against the outside of the element,
must be circulated and must be less than 71C
or the dirt will merely be forced farther into the
(160F). Do not use a light bulb to dry the ele-
pleats.
ment.

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WHEN REQUIRED
Inspection After Cleaning
1. After cleaning and drying the element, inspect
it for a damaged gasket, a ruptured filter me-
dium or dust on the inside of the element. If the
gaskets condition is such that a good air seal
cannot be guaranteed, or if the filter medium is
ruptured, discard the element and replace it with
a new one of the same model. Proper sealing of
the element gasket is very important.
2. A good method to detect filter medium ruptures
is to place a bright light inside the element.
Inspection of the element from the outside will
then disclose, by a bright spot of light, any holes
or ruptures. Any hole in the element will allow
dust to enter the engine. Discard any damaged
element.
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Maintenance
WHEN REQUIRED
Service Hints
1. Store new and cleaned spare filter elements so
that they are protected from dust and potential
damage.
2. When replacing a filter element, be sure the cor-
rect size and model element is used.
3. Replace the element after one year or after six
cleanings, whichever occurs first.
4. Keep a spare element (new or cleaned) on hand
to reduce vehicle downtime for servicing.
5. This is a dry-type air cleaner. Do not use oil.
6. Do not operate the engine without the primary
element installed.
7. If excessive dust is found in the air transfer duct
or the engine intake system, check the following:
the connection between air cleaner outlet and
the engine
the air cleaner outlet to body joint for leaks
the element gasket washers and element
gasket
the element filter medium for holes, cracks, or
breaks
105
Maintenance
WHEN REQUIRED
Fuel System
Pressurized air can cause personal injury.
Use all cleaning solutions with care.
Fuel leaked or spilled onto hot surfaces or electrical
components can cause a fire.
Remove all smoking materials from the area.
Turn the disconnect switch to OFF or disconnect the
batteries when changing the filters.
NOTICE
When replacing fuel filters, do not add fuel to the new
filters before installing them. Contaminated fuel will
cause accelerated wear to fuel system parts.
Change the primary element and secondary element
at 250 service hours or 6 months.
106
RS425C
WHEN REQUIRED
Change the Primary Fuel Filter Element
Fuel leaked or spilled onto hot surfaces or electrical
components can cause a fire. To help prevent pos-
sible injury, turn the start switch off when changing
fuel filters or water separator elements. Clean up fuel
spills immediately.
NOTE: A 10 to 15 micron absolute high efficiency fuel
filter is required for Caterpillar electronic fuel
injectors.
1. Close the fuel shutoff valve that is located under
the fuel tank.
2. Remove the fuel filter element (1) from the
mounting base (2) while the bowl (3) is attached.
The primary fuel filter is located next to the front
motor mount on the left side of the engine.
3. Use a suitable container to catch any fuel that
might spill. Clean up any spilled fuel immedi-
ately.
4. Properly dispose of the fuel in the fuel filter.
5. Remove the bowl (3) from the filter element. The
bowl is reusable. Do not discard the bowl.
6. Dispose of the used element.
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14. Run the engine for one minute.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any
disconnected components.
15. Stop the engine and check for leaks again.
Detection of leaks is difficult while the engine
is running. The primary filter/water separator is
under suction. A leak will allow air to enter the
fuel. If air enters the fuel, check the components
for over tightening or under tightening.

7. Remove the O-ring from the gland of the bowl.

8. Inspect the O-ring for damage and for deteriora-
tion.
a. Replace the O-ring if necessary.
b. Clean the O-ring, bowl, and mounting base.
9. Lubricate the O-ring with clean diesel fuel.
10. Install the bowl (3) on a new element.
11. Tighten the bowl by hand. Do not use tools to
tighten the bowl.

NOTICE
The primary fuel filter may be prefilled with fuel to
avoid rough running/stalling of the engine due to
air. Do not fill the secondary filter with fuel before
installation. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause ac-
celerated wear to fuel system parts.

NOTICE
The water separator is under suction during normal
engine operation. Ensure that the vent plug is se-
curely tightened to help prevent air from entering
the fuel system.

12. Open the fuel shutoff valves (for the suction and
return lines) located under the tank.
13. Start the engine and check for leaks.

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Maintenance
WHEN REQUIRED
Change the Secondary Fuel Filter Element
Fuel leaked or spilled onto hot surfaces or electrical
components can cause a fire. To help prevent pos-
sible injury, turn the start switch off when changing
fuel filters or water separator elements. Clean up fuel
spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any
disconnected components.
1. Stop the engine.
2. Turn off the ignition switch.
3. Close the fuel shutoff valve (for the suction fuel
line) located under the fuel tank.
4. Unlock the fuel priming pump (1) in order to
relieve residual pressure in the fuel system.
5. Remove the used fuel filter (2). Use a cloth or
use a container to catch excess fuel.
6. Clean the filter element mounting base (3) and
sealing surface. Be sure all of the old seal is
removed.
108
RS425C
WHEN REQUIRED
NOTICE
In order to maximize fuel system life and prevent
premature wear out from abrasive particles in the
fuel, a two-micron absolute high efficiency fuel filter
is required for all Caterpillar hydraulic electronic
unit injectors.
7. Coat the seal of the new filter element with clean
diesel fuel.
NOTICE
Do not fill the secondary fuel filter with fuel before
installing. The fuel would not be filtered and could
be contaminated. Contaminated fuel will cause ac-
celerated wear to fuel system parts.
8. Install the new filter element (2) by hand.
a. Tighten the fuel filter until the gasket con-
tacts the base (3).
b. Continue to tighten according to the instruc-
tions on the fuel filter. Do not overtighten the
fuel filter.
NOTE: Do not remove the plug (4) in the fuel filter
base to release air from the fuel system during
periodic service to the fuel filter. Periodic re-
moval of the plug will result in increased wear
of the threads in the filter base.
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WHEN REQUIRED
9. Open the fuel shutoff valve (for the suction line)
located under the fuel tank.
10. Prime (1) the fuel system (see the following sec-
tion, Prime the Fuel System).
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking engine again.
11. Start the engine according to normal proce-
dures.
12. Look for leaks around the filters.
13. Immediately increase the engine rpm between
1000 and 1200 rpm with no load. The engine will
begin to misfire briefly until air from the fuel filter
is purged. No damage to the engine will occur.
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Maintenance
WHEN REQUIRED
Prime the Fuel System
Fuel leaked or spilled onto hot surfaces or electrical
components can cause a fire. To help prevent pos-
sible injury, turn the start switch off when changing
fuel filters or water separator elements. Clean up fuel
spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over any
disconnected components.
Prime the fuel system to fill the fuel filter or to purge
trapped air. The fuel system should be primed under
the following conditions: running out of fuel, storing the
filter, or replacing the fuel filter.
NOTICE
Do not loosen the lines at the fuel manifold. The fit-
tings may be damaged and/or a loss of priming pres-
sure may occur when the fuel lines are loosened.
1. Open the fuel priming pump and operate the
fuel priming pump until the check valve clicks.
This procedure will require considerable strokes.
Lock the fuel priming pump.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
2. Promptly start the engine. If the engine runs
rough, continue to operate the engine at low idle.
Do not raise the engine rpm above idle, until the
engine runs smoothly.
3. If the engine does not start, repeat steps 1 and
2.
109
Maintenance RS425C

WHEN REQUIRED WHEN REQUIRED

Fuel Tank
Drain the Water and Sediment
Fuel quality is critical to the performance and the
service life of the engine. Water in the fuel can cause
excessive fuel system wear. Condensation occurs dur-
ing the heating and cooling of fuel. The condensation
occurs as the fuel passes through the fuel system and
the fuel returns to the fuel tank. This causes water to
accumulate in fuel tanks. Draining the fuel tank regu-
larly and obtaining fuel from reliable sources can help
to eliminate water in the fuel.
1. Allow the machine to stand at least 15 minutes
after adding fuel or after operation to let water
and sediment settle.

9. Disconnect the short hose from the valve (3).

10. Insert the plug (2) into the valve (3).
11. Open the fuel suction and return shutoff valve
under the tank (1).

2. Close the fuel suction and return shutoff valve

(1) located under the fuel tank.
NOTE: Local environmental regulations probably re-
quire that the diesel be captured and properly
disposed of or reused. Make proper prepara-
tions to capture the diesel.
3. Remove the plug (2) from the fuel drain valve
(3).
4. Attach a short hose to the valve.
5. Place the other end of the hose in a suitable
container.
6. Open the valve (3).
7. Allow the water and sediment to drain.
8. Close the valve.

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WHEN REQUIRED WHEN REQUIRED

Auxiliary Hydraulic Oil Filter Compressed Air System

Replace the Auxiliary System Filter Check the Lubricator Oil Level

The compressed air system lubricator and regulator

are located in the right front fender compartment.
At operating temperature, the hydraulic oil tank is
hot and under pressure. Hot oil can cause burns.
Remove the filters only when the engine is stopped
and the filter is cool enough to touch with your bare
hand.
1. Visually check the oil level in lubricator (1).
2. If the oil level is low, relieve the air pressure.
a. Close the shutoff valve (2).
b. Open the petcock at bottom of filter regulator
(3).
3. Close the petcock at the bottom of the filter
regulator.
4. Add oil to the lubricator (1).

1. Clean the area around the filter head (1).

2. Remove the filter (2).
3. Dispose of the filter in accordance with local
environmental regulations.
4. Apply a light layer of lubricating oil to the gasket
sealing surface (3).
5. Install the new filter (2) by hand-tightening only.

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Maintenance
WHEN REQUIRED
Cutter Drum
Check the Cutter Bits
1. Raise the cutter door and install the pin to lock
the door fully open. See Cutter Door Lock and
Cutter Retaining Chains earlier in this chapter.
Engagement of the cutter drive system can cause
personal injury or death. Disengage the cutter
clutch, stop the engine, move the cutter transmis-
sion shift lever to Neutral, and remove the key from
the ignition switch. Attach a Do Not Operate tag to
the controls.
2. Check the cutter bits (3) for excessive wear.
Replace the bits if distance (X)from the hold-
ers (4) to end of the carbide tips (5)measures
1.2 in. (30 mm) or less, when the bits are worn
normally as shown in view A.
If the supporting metal (6) is worn away from the
carbide tips (5) as in view B, measure distance
(X), from the bit holders (4) to the remaining end
of the tip supporting metal (6).
See Replace the Cutter Bits for procedures.
3. At the same time the bits are checked, also
check the cutter flighting, mounting blocks,
and bit holders for breaks or cracks. Repair or
replace as necessary.
112
RS425C
WHEN REQUIRED
Replace the Cutter Bits
The following procedure describes using an air-oper-
ated punch to remove the cutter bits. If a manual bit
puller or drive pin and hammer will be used instead of
a punch, see the following section, Alternatives for
Removing the Cutter Bit(s).
1. Raise the cutter door and install the pin to lock
the door fully open. See Cutter Door Lock and
Cutter Retaining Chains earlier in this chapter.
Engagement of the cutter drive system can cause
personal injury or death. Disengage the cutter
clutch, stop the engine, move the cutter transmis-
sion shift lever to Neutral, and remove the key from
the ignition switch. Attach a Do Not Operate tag to
the controls.
2. Insert the tip of an air-operated punch (1) into
the opening at the rear of the bit holder (2).
3. Use the air hammer to drive the bit (3) out.
4. Position the new bit (3) in the holder (2).
5. Drive the bit into place with a hammer. Be sure
the keeper spring on the bit is engaged with the
holder.
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RS425C Maintenance

WHEN REQUIRED WHEN REQUIRED

Cutter Drive Shaft Torque Limiter Clutch

Alternatives for Removing the Cutter Bit(s) Check the Thickness
Instead of using a punch, a manual bit puller or a drive
pin and hammer can be used to remove a bit.
NOTE: A manual bit puller is supplied with each ma-
chine.
Perform the following steps if you are using a manual
bit puller:
1. Place the puller on the shoulder of the bit.
2. Sharply strike the underside of the puller with a
hammer.

Perform the following steps if you are using a drive pin

and hammer:
1. Insert the drive pin into the opening in the bit
holder
2. Strike the drive pin sharply with a hammer.

The torque limiting clutch requires no routine mainte-

nance. If the clutch seems to be slipping, check the
thickness of the assembly as shown in the illustration
above. If the assembly is worn to a thickness of (3.46
in. (87.9 mm) or less, replace the output hub and the
friction plate assemblies. See the following section,
Replace the Output Hub and Friction Plate Assem-
blies.

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Maintenance RS425C

WHEN REQUIRED WHEN REQUIRED

Replace the Output Hub and Friction Plate 8. Remove the pressure plate (7).
Assemblies
9. Remove the output hub (8).

1. Wire the ends of the drive shaft together so it will

not separate. It has been dynamically balanced
and must be dynamically balanced again if it
separates.
2. Remove the bolts (1) from the universal joint (2).
3. Lower the drive shaft out of the way.
4. Support the torque limiter clutch (3).
5. Remove the bolts (4) from the companion flange
(5).
6. Move the torque limiter to a clean work area.
10. Remove the separator plates (9) and friction
discs (10).
11. Remove the bearing (11) from the drive flange
(12).
12. Install the new bearing.
13. Install the output hub (8) in the pressure plate
(7).
14. Assemble the separator plates (9) and new fric-
tion discs (10) on the torque pins (13).
15. Position the drive flange, with the bearing output
hub (8) and torque pins (13) aligning with the
holes in the separator plates.
16. Arrange the spring cup bolts in the holes as
shown.
17. Tighten the flanged locknuts (6). Do not exceed
55 ftlb of torque.
18. Install the torque limiter clutch assembly in the
drive line.

7. Remove the locknuts (6) from the ends of the

spring cup bolts.

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WHEN REQUIRED WHEN REQUIRED

Cutter Clutch
Installation

6. Crack open the needle valve (4).

1. Remove the lever clutch shifter (1) from the 7. Disengage the clutch by rotating the actuator
transmission. arm (3) either manually or with a minimum 90
2. Bench assemble the air cylinder (2) in the re- psi (620 kPa) air pressure to the head end of the
tracted position. air cylinder.
3. Bench assemble the clutch actuator arm (3) with 8. Check that the clutch is disengaged. Refer to the
components. following section, Check Clutch Disengage-
ment.
4. Bolt the assembly to the transmission.
NOTE: When possible, use shop or compressor air
a. Rotate the assembly as needed to engage connected to the 1/4 in. tube fitting (5) at the
the actuator arm spline onto the shaft spline head end.
of the transmission.
The throw-out bearing should be against the
b. Leave 1/8 in. - 1/4 in. (0.32 cm - 0.64 cm)
brake plate when the clutch is disengaged. The
slack at the clutch spline by rotating the
throw-out bearing can be seen through the ac-
assembly toward the engine. There should
cess hole of the transmission.
be no load on the throw-out bearing by the
forks.
5. Tighten the bolts to the transmission and the
actuator arm onto the splined shaft.
Starting the engine with the cutter engaged can cause
personal injury. Push the cutter clutch control in and
move the cutter transmission shift lever to Neutral
before starting the engine. Ensure all personnel are
a safe distance away from the cutter.

9. Start the engine with the clutch disengaged and

the transmission in neutral. Refer to the Opera-
tion chapter for the proper starting procedure.
10. Raise the cutter above the ground surface sev-
eral inches.
11. With air pressure of 90-100 psi (620-689 kPa),
reduce the engine speed to low idle.

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Maintenance RS425C

WHEN REQUIRED WHEN REQUIRED

12. Place the cutter transmission into first gear.

LIGHTS

P
R
O
P
T E
H L
R
O
T
T
L IGNITION
E

C
U 18. Adjust the needle valve (4) at the air cylinder to
T
T obtain smooth but rapid engagement of the cut-
HORN E
FRONT DOOR R
6 ter drive system.
P
T
R
A
19. Disengage the clutch.
N
S
REAR DOOR
CLUTCH 20. Check that the clutch is disengaged. Refer to the
P following section, Check Clutch Disengage-
526009235000

R
C
U
T
T
ment.
REAR STEERING E
R
BRAKE

13. Engage the clutch by pulling out the control

switch (6).
14. Disengage the clutch.
15. Check that the clutch is fully disengaged. Refer
to the following section, Check Clutch Disen-
gagement.
16. Put the engine back in neutral.
21. Tighten the jam nuts (7) to maintain the correct
17. Perform steps 10 through 13 to go through the length.
second and third gears of the transmission.

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WHEN REQUIRED EVERY 10 HOURS OR DAILY

Walk-Around Inspection
Check Clutch Disengagement Inspect the Machine
1. Put the engine at low idle.
2. Push the clutch control button in.
3. Observe the cutter drive shaft; rotation should
stop.
4. If rotation continues, adjust the turnbuckle.
a. Stop the engine.
b. Disengage the clutch.
c. Adjust the turnbuckle approximately 1/16 in.
(0.16 cm).
d. Start the engine. Refer to the Operation
chapter for the proper starting procedure. See the Daily Inspection chapter.
e. Repeat steps 1 through 4 until the clutch is
properly disengaged.
NOTE: To ensure proper turnbuckle adjustment, re-
check the over-center position of the linkage
by disconnecting the air lines when the clutch
is disengaged. If the turnbuckle is correctly
adjusted, the clutch will stay disengaged, even
with the air lines disconnected.

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Maintenance
EVERY 10 HOURS OR DAILY
Hydraulic System
Check the Oil Level
NOTE: The hydraulic oil tank is located just behind
the fuel tank. Do not overfill the tank. Allow for
expansion of the oil when it gets hot.
1. Use the sight gauge to check the oil level in the
hydraulic oil tank.
2. Keep the oil level near the top of the sight
gauge.
3. Transfer oil from the replenishing tank (1) to the
main tank with the hand pump (2).
NOTE: When required, add oil to the replenishing
tank. Do not mix types of hydraulic oil (see Lu-
bricant Specifications earlier in this chapter).
118
RS425C
EVERY 10 HOURS OR DAILY
Cooling Systems
Check the Engine Coolant Level
At operating temperature, the engine coolant is hot
and under pressure. Check the coolant level only
after the engine has been stopped and the fill cap is
cool enough to touch with your bare hand.
Steam can cause personal injury. Remove the fill cap
slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.
1. Remove the fill cap (1) slowly to relieve any
pressure.
2. The coolant level should be within 1/2 in (13
mm) of the bottom of the radiator fill tube (2).
3. Inspect the condition of the cap (1) gasket. Re-
place the cap gasket if necessary.
4. Add coolant if necessary.
5. Install the fill cap (1).
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RS425C Maintenance

EVERY 10 HOURS OR DAILY EVERY 10 HOURS OR DAILY

Clean the Radiator, Charge Air, Hydraulic Oil Clean the Cutter Transmission Oil Cooler Core
Cooler, and Differential Oil Cooler Cores

Pressurized air can cause personal injury. When

Pressurized air can cause personal injury. When
using pressurized air for cleaning, wear a protec-
tive face shield, protective clothing, and protective
shoes. The maximum air pressure must be below 30
psi (205 kPa) for cleaning purposes.
using pressurized air for cleaning, wear a protec-
tive face shield, protective clothing, and protective
shoes. The maximum air pressure must be below 30
psi (205 kPa) for cleaning purposes.

The charge air cooler (1), hydraulic oil cooler (2),

differential oil cooler (3), and engine radiator (4) are
located behind the grill at the front of the machine.
Compressed air, water, or steam can be used to
The transmission oil cooler is located just in front of
remove dust, leaves, and general debris. Clean as
the cutter housing.
required by the condition of the radiator or oil cooler
core. Compressed air, water, or steam can be used to
remove dust, leaves, and general debris. Clean as
The use of compressed air is preferred.
required by the condition of the oil cooler core.

NOTICE The use of compressed air is preferred.

Water at high pressure may damage the radiator or

oil cooler.
NOTICE
Water at high pressure may damage the oil cooler.

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Maintenance RS425C

EVERY 10 HOURS OR DAILY EVERY 10 HOURS OR DAILY

Engine Crankcase
Check the Oil Level
NOTE: Before you perform this maintenance, do not
operate the machine for at least 10 minutes,
which will allow the oil to drain back into the oil
pan. This will give an accurate reading on the
dipstick.
Maintain the oil level between the ADD and FULL
marks on the Engine Stopped side of the dipstick. Do
not fill the crankcase oil level above the FULL mark on
the dipstick.

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot oil components to
contact the skin.
The engine must be stopped before checking the
crankcase oil level.
2. Check the dipstick (1). If the oil level is below the
ADD mark, add oil.
1. Make sure the engine is stopped before check-
ing the crankcase oil level. a. Turn the handle on the oil filler counterclock-
wise to loosen the oil filler cap (2).
b. Remove the cap.
c. Fill the crankcase with the correct oil. See
Refill Capacities earlier in this chapter.
3. Replace the oil filler cap.
4. Clean and reinstall the oil filler cap.

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EVERY 10 HOURS OR DAILY EVERY 10 HOURS OR DAILY

Engine Air Cleaner Ground Drive Transmission

Check the Air Cleaner Indicator Check the Oil Level

Service the air cleaner with the engine stopped.

The ground drive assembly includes the hydraulic mo-

tor (1), a 2-speed transmission (2), and the axle (3).
The axle includes a carrier (4) and the planetary ends
on which the drive wheels mount.
1. Make sure that the engine is stopped.
1. Position the machine on level grade.
2. Check that the dust ejector valve (1) is not
2. Stop the engine.
plugged, damaged, or inverted. If the valve is
inverted, check for restrictions in the air inlet 3. Remove transmission check plug (5).
system.
4. Add lubricant until check plug port level is
3. When the red signal of the indicator (2) remains reached.
locked in view after the engine is stopped, re-
5. Install the check plug.
move the primary element and either clean the
element or replace it with a new element.
4. Replace the secondary element with a new
element every third time the primary element is
cleaned or replaced.
NOTE: Refer to Change the Primary Air Filter
Element, Change the Secondary Air Filter
Element, and Clean the Primary Filter Ele-
ment under When Required for procedures to
change both air cleaner elements and to clean
the primary element.

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Maintenance RS425C

EVERY 10 HOURS OR DAILY EVERY 10 HOURS OR DAILY

Ground Drive Axle Carrier and

Planetary Ends
Check the Oil Level

Unexpected starting of the engine can cause injury

The ground drive assembly includes the hydraulic mo-
tor (1), a 2-speed transmission (2), and the axle (3).
The axle includes a carrier (4) and the planetary ends
on which the drive wheels mount.
1. Position the machine on level trade.
2. Stop the engine.
3. Remove the carrier check plug (5).
4. Add lubricant until the check plug port level is
reached.
5. Install the check plug.
to personnel working on the machine. Sound the
horn for several seconds before starting the engine
to warn personnel.
6. Sound the horn to warn nearby personnel that
the engine is about to be started.
7. Start the engine.
8. Move the machine until one planetary end check
plug (6) is horizontal with the center of the plan-
etary end (7).
9. Stop the engine.
10. Remove the check plug (6).
11. Add lubricant until the check plug port level is
reached.
12. Allow time for the oil to flow throughout the plan-
etary end.
13. Add more oil.
14. Install the check plug.
15. Repeat steps 6 through 14 for the other plan-
etary end.

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EVERY 10 HOURS OR DAILY EVERY 10 HOURS OR DAILY

Cutter Axle Cutter Transmission

Check the Axle Oil Level Check the Oil Level

1. Position the machine on level grade.

2. Stop the engine.
3. Remove the axle check plug. The cutter transmission oil level dipstick is under the
deck grating, on the left side of the transmission tun-
4. Add lubricant until the check plug port level is nel.
reached.
1. Position the machine on level grade.
5. Install the check plug.
2. Stop the engine.
3. Remove the dipstick and check the oil level (ar-
row).
4. If necessary, add oil to maintain the level be-
tween the marks on the dipstick.

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Maintenance RS425C

EVERY 10 HOURS OR DAILY EVERY 10 HOURS OR DAILY

Cutter Chaincases Cutter Drum

Check Oil Levels Check the Cutter Bits
Check the cutter bits and replace them as necessary.
See Cutter Drum under When Required for proce-
dures.

1. Park the machine on level grade.

2. Lower the cutter to grade.
3. Stop the engine.
4. Remove the check plug from one chaincase.
5. If oil does not flow from the plug port, add oil.
a. Remove the fill plug.
b. Add oil until it reaches the plug port level.
6. Install the plug.
7. Repeat the procedure for the other chaincase.

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RS425C
EVERY 10 HOURS OR DAILY
Cutter Support Bearing Lubricator
Fill the Cutter Bearing Lubricator
1. Locate the cutter bearing lubricator (1) mounted
near the left side of the cutter and behind the
operators station.
2. Connect a hand-operated lubrication gun to the
grease fitting (2) and apply lubricant to fill the
line.
NOTE: Use only MPGM lubricant; do not use a substi-
tute (see Lubricant Specifications).
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Maintenance
EVERY 10 HOURS OR DAILY
Tires
Check the Condition and Air Pressure
A tire bead blowout can cause personal injury. Use a
clip-on check and a hose long enough to allow you
to stand behind the treat while inflating a tire.
1. Check each tire for abnormal wear or loose
wheel lug nuts. Repair as necessary.
2. Check the air pressure of each tire. Adjust the
pressure if needed:
Front tires................................... 50 psi (304 kPa)
Rear tires................................... 28 psi (192 kPa)
125
Maintenance RS425C

EVERY 10 HOURS OR DAILY EVERY 10 HOURS OR DAILY

Fuel Tank Lubrication

Fill the Fuel Tank Lubricate the Fittings

Fuel leaked or spilled onto hot surfaces or electrical

components can cause a fire. Remove all smoking
materials from the area.

Cutter Hood Cylinder2 fittings

Apply lubricant slowly until excess is observed or

resistance is felt.

The amount of fuel remaining in the tank is shown by

the fuel level gauge (1). Fill the fuel tank at the end
of each day of operation to drive out moist air and to
prevent condensation.
1. Remove the fuel tank cap (2) to add fuel.
2. Do not fill the tank to the top. Fuel expands as it Cutter Hood Saddle4 fittings
gets warm and may overflow.
Apply lubricant slowly until the excess is observed or
3. Install the fuel tank cap. resistance is felt.
NOTE: Do not allow the fuel tank to get empty. If the
tank does get empty, see Prime the Fuel Sys-
tem under When Required.

Ground Drive Axle2 fittings each end, 1 above the axle and 1
below the axle

Apply lubricant slowly until excess is observed or

resistance is felt.

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RS425C Maintenance

EVERY 10 HOURS OR DAILY EVERY 10 HOURS OR DAILY

Chaincase Sprocket Bearings1 fitting each chaincase

Tie Rod Ends1 fitting each end with lube hose attached
Apply lubricant slowly until resistance is felt.
Apply lubricant slowly until excess is observed or
resistance is felt.

Chaincase Lift Cylinders2 fittings each cylinder Rear Bolster Pivot Pin2 fittings

Apply lubricant slowly until excess is observed or Apply lubricant slowly until excess is observed or
resistance is felt. resistance is felt.

Ground Drive Axle2 fittings on each end of the axle, connected by

hoses to grease fittings on the frame, forward from the cutter hous- Rear Bolster Tie Rod2 fittings, one at each end with lube hose
ing, on the left and right side of the machine attached

Apply lubricant slowly until excess is observed or Apply lubricant slowly until excess is observed or
resistance is felt. resistance is felt.
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Maintenance RS425C

EVERY 10 HOURS OR DAILY EVERY 10 HOURS OR DAILY

Lubricate the Drive Shafts

1. Connect a lubrication gun to one lubrication fit-

Pump Drive Shaft3 fittings, two universal joints (1) and a slip shaft
(2)
Cutter Transmission Drive Shaft2 fittings, two universal joints (3)
ting (4) of either universal joint.
2. Apply pressure until lubricant appears at all four
cross seals (5).
3. If it is necessary to add more lubricant, use the
second lubrication fitting (4), if accessible.
4. If a seal (5) does not relieve (pop):
a. Move the shaft laterally in all four directions.
b. Pull or push on the shaft in the direction
opposite the cross seal not relieving while
continuing to apply lubricant gun pressure
until lubricant appears at that seal.
c. Use lubrication fitting (4) nearest the seal
not relieving if that fitting is accessible.
5. Repeat steps 1 through 4 for the other universal
joint.

The standard slip shaft drive shaft (2) has one lubrica-
tion fitting.

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EVERY 10 HOURS OR DAILY EVERY 50 SERVICE HOURS OR WEEKLY

Engine Air System

Check the Air Inlet and Exhaust

6. Connect the lubrication gun to the sliding spline

section fitting (6).
7. Apply pressure until lubricant appears at pres-
sure relief hole (7) in the welch plug at the
sleeve end of the spline.
1. Check all clamps, bolts, and ducting on the en-
gine air inlet and exhaust systems.
2. Make repairs as required to prevent leaks and to
ensure the air cleaner and muffler are securely
mounted.

8. Cover the relief hole with a finger and continue

to apply pressure until lubricant appears at the
sleeve yoke seal (8).

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Maintenance RS425C

EVERY 50 SERVICE HOURS OR WEEKLY EVERY 50 SERVICE HOURS OR WEEKLY

Batteries
Clean the Batteries Check the Electrolyte Levels

Batteries give off flammable fumes that can explode.

Do not smoke when observing the battery electrolyte
levels. Electrolyte is an acid and can cause personal
injury if it contacts skin or eyes. Always wear protec-
tive glasses when working with batteries.

At the proper charging rate and in a moderate climate,

a battery should not require more than 30 cc (1 oz)
of water per cell per week. In extreme temperatures,

NOTICE check the cells weekly due to higher cell water usage.

Battery Electrolyte Chart

A battery will be damaged if baking soda gets into
Battery Interval
the battery cells.
Conventional 100 hours
Low Maintenance 250 hours
The batteries are located in the left front fender com-
Maintenance Free None Required
partment.
1. Mix a weak solution of baking soda and water.
2. Apply the solution with a bristle brush.
3. Thoroughly rinse the batteries and battery box
with clean water.
4. Apply petroleum jelly or silicone lubricant to the
battery cable clamps, terminals, all clamp bolt
threads, and retainer bolt threads.

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RS425C
EVERY 50 SERVICE HOURS OR WEEKLY
Cutter Transmission Cooling System
Clean the Strainer
1. Remove the strainer.
2. Check for metal particles.
3. Note the types and amounts of particles found
on each screen.
4. If an excess of metal particles is found:
a. Check the oil level (see Cutter Transmis-
sion under Every 10 Service Hours or
Daily) and add oil as necessary.
b. Check the strainer weekly until only a rea-
sonable amount of metal particles is found.
c. If an excess of metal is still found after the
first month of operation, locate the cause.
5. If only a small amount of metal particles is found:
a. Check the screen again at the first 250
hours of monthly service.
b. Check the screen at every 250 service hours
or monthly thereafter.
6. Clean the screen.
7. Install the screen.
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Maintenance
EVERY 50 SERVICE HOURS OR WEEKLY
Cutter Differential Cooling System
Clean the Strainer
NOTE: The differential cooling system strainer is
located under the mainframe near the cutter
differential.
1. Remove the strainer.
2. Check for metal particles.
3. Note the types and amounts of particles on each
screen.
4. If an excess of metal particles is found:
a. Check the oil level (see Cutter Axle under
Every 10 Service Hours or Daily) and add
oil as necessary.
b. Check the strainer weekly until only a rea-
sonable amount of metal particles is found.
c. If an excess of metal is still found after the
first month of operation, locate the cause.
5. If only a small amount of metal particles is found:
a. Check the screen again at the first 250
hours of monthly service.
b. Check the screen at every 250 service hours
or monthly thereafter.
6. Clean the screen.
7. Install the screen.
8. Thoroughly clean around filter (4) and the fitting
connections (5).
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EVERY 50 SERVICE HOURS OR WEEKLY EVERY 50 SERVICE HOURS OR WEEKLY

Cutter Drive Chains

9. Disconnect the filter. Check the Chain Tension Adjustment
10. Cap or plug the hose fittings.
11. Remove the bolts from the filter.
12. Take the filter to a clean work area.
13. Note the type and amount of particles trapped
by the screen.
14. Perform steps 4 and 5.
15. Thoroughly clean the filter by backflushing it.

The slack in each cutter drive chain is automatically

adjusted by a hydraulic cylinder (1). The pressure
applied to the cylinder should be 90 to 110 psi (620 to
760 kPa).

NOTICE
Continued operation of the cutter with the hydraulic
pressure above 110 psi (760 kPa) will be detrimental
to chain and bearing life.

1. Set the pressure of the hydraulic chain tension

adjuster.
a. Unscrew the setscrew on the back side of
the pressure-reducing valve (2) all the way
out.
b. Start the machine.
c. Run it at low idle.
2. Open the needle valve (3) to set the pressure
on the gauge (4) to 100 psi +/- 10 psi (690 kPa
+/- 70 kPa), but not to exceed 110 psi (760 kPa).
3. Tighten the setscrew on the pressure reducing
valve (2).

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EVERY 50 SERVICE HOURS OR WEEKLY EVERY 50 SERVICE HOURS OR WEEKLY

Depth Gauge Pivot

Lubricate Fitting

Depth Gauge Pivotone fitting

Apply lubricant slowly until excess is observed or

4. Engage the cutter system and watch gauge (4)
resistance is felt.
for any pressure fluctuation.
If the pressure is not between the minimum and
maximum pressure settings, repeat steps 1, 2,
and 3.
5. Once the pressure has been set properly, disen-
gage the cutter.
6. Stop the engine.
7. Close the needle valve (3).

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Maintenance
EVERY 100 SERVICE HOURS OR TWO WEEKS
Hydraulic Oil Filters
Change the Hydraulic Reservoir Filter
At operating temperature, the hydraulic oil tank is
hot and under pressure. Hot oil can cause burns.
Remove the filter only when the engine is stopped
and the filter is cool enough to touch with your bare
hand.
1. Unbolt and remove the filter cover (1) from the
top of the hydraulic reservoir.
2. Remove the filter element (2) from the tank by
lifting it upward through the opening in the top of
the tank.
3. Dispose of the used filter element in accordance
with local environmental regulations.
4. There will be two gaskets (3) in the filter kit. One
will be installed under the filter cover and the
second will be placed under the circular flange a
few inches below the upper gasket and cover.
5. Install the filter cover and bolts.
6. Tighten the bolts alternately and in even incre-
ments.
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EVERY 250 SERVICE HOURS OR MONTHLY
Engine Oil and Oil Filters
Change the Oil and Oil Filter Elements
NOTE: The percentage of sulfur in the fuel will affect
the engine oil recommendations. If the fuel
has over 0.5% sulfur content, the CD engine
oil must have a TBN of 20 times the percent-
age of fuel sulfur (TBN as measured by the
ASTM D-2896 method). Your oil supplier
should be able to furnish the correct oils. If the
sulfur content is greater than 1.5%, consult
your Caterpillar dealer for correct engine oil
recommendations.
Hot oil and components can cause personal injury.
Do not allow hot oil or hot components to contact
skin.
NOTE: Local environmental regulations probably
require that the engine oil be captured and
properly disposed of or reused. Be sure to
make proper preparations to capture the oil.
1. Make sure the engine is stopped and the oil is
still warm.
2. Remove the crankcase oil drain plug (1).
3. Allow the oil to drain.
4. Clean the drain plug (1) in clean nonflammable
solvent.
5. Install the drain plug in the crankcase.
6. Wipe the dirt from the oil filter element (2).
7. Remove the oil filter element with an oil filter
wrench.
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RS425C
EVERY 250 SERVICE HOURS OR MONTHLY
8. Discard the oil filter element.
9. Wipe the sealing surface of the filter element
mounting base (3).
10. Make sure all of the old gasket material is re-
moved.
11. Apply a light coating of clean engine oil to the
gasket of the new filter element.
12. Install the new filter element by hand until the
gasket contacts the mounting base.
13. Tighten the element by hand according to the
instructions on the oil filter. Do not overtighten.
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Maintenance
EVERY 250 SERVICE HOURS OR MONTHLY
Fill the Engine Crankcase
14. Turn the handle (4) counterclockwise to loosen
the oil filler cap.
15. Remove the cap.
16. Fill the crankcase with the correct oil (see Refill
Capacities).
17. Install the oil filler cap.
18. Turn the handle (4) clockwise until the cap is
tightened.
19. Ensure that the lubrication system has oil and
that the oil filters are filled.
a. Start the engine.
b. Reduce the engine speed to low idle.
c. Run the engine for two minutes.
d. Check for oil leaks.
20. Shut off the engine.
21. Wait a minimum of 10 minutes before checking
the oil level on the dipstick (5), to allow enough
time for the oil to drain back into the oil pan.
22. Maintain the oil level between the ADD and
FULL marks on the side of the dipstick marked
Engine Stopped.
135
Maintenance
EVERY 250 SERVICE HOURS OR MONTHLY
Engine Cooling System
Check the Coolant Lines and Clamps
At operating temperature, the engine coolant is hot
and under pressure. Stop the engine and allow it to
cool before checking for leaks.
1. Check for cracked, soft, or otherwise deterio-
rated coolant hoses and replace as necessary.
2. Check all coolant line joint connections and hose
clamps, and tighten any that are loose.
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RS425C
EVERY 250 SERVICE HOURS OR MONTHLY
Change the Coolant Conditioner Element
At operating temperature, the engine coolant is hot
and under pressure. Steam can cause personal
injury. Check the coolant level only after the engine
has cooled and the fill cap is cool enough to touch
with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.
NOTICE
All water is corrosive at engine operating tempera-
ture. Use a Caterpillar coolant conditioner element
to treat either plain water or the ethylene glycol solu-
tion. When changing antifreeze solution, replace the
maintenance element with the correct conditioner
precharge element. Excessive coolant conditioner
(greater than the recommended 3% initial fill) to-
gether with concentrations of antifreeze greater than
65% cause a mud-like deposit to form. This may re-
sult in radiator tube blockage and overheating. The
Caterpillar coolant conditioner element must not be
used with Dowtherm 209 coolant.
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RS425C Maintenance

EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY

Add the Liquid Coolant Conditioner

At operating temperature, the engine coolant is hot

If the machine is not equipped with a conditioner ele-
ment, see Add Liquid Coolant Conditioner.
1. Close the inlet valve (1) and outlet valve (2) by
turning the valves clockwise at element base (3).
2. Remove the coolant conditioner element (4) and
discard it.
3. Clean the element base (3). Make certain all of
the old element gasket material is removed.
4. Use the correct maintenance element (or pre-
charge element, if changing antifreeze solution)
for the cooling system. The elements are sized
to the coolant system capacity.
5. Coat the seal of the element with a thin film of
clean engine oil or antifreeze.
6. Install the element (4) until the seal contacts the
base (3).
7. Tighten an additional 3/4 turn.
8. Open the inlet valve (1) and outlet valve (2).
and under pressure. Check the coolant level only
after the engine has cooled and the fill cap is cool
enough to touch with your bare hand. Steam can
cause personal injury.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.
NOTICE
All water is corrosive at engine operating tempera-
ture. Use a Caterpillar coolant conditioner element
to treat either plain water or the ethylene glycol solu-
tion. When changing antifreeze solution, replace the
maintenance element with the correct conditioner
precharge element. Excessive coolant conditioner
(greater than the recommended 3% initial fill) to-
gether with concentrations of antifreeze greater than
65% cause a mud-like deposit to form. This may re-
sult in radiator tube blockage and overheating. The
Caterpillar coolant conditioner element must not be
used with Dowtherm 209 coolant.

Unexpected starting of the engine can cause injury

to personnel working on the machine. Sound the
horn for several seconds before starting the engine
to warn personnel.

9. Sound the horn to warn nearby personnel that

the engine is about to be started.
10. Start the engine.
11. Check for leaks.
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Maintenance RS425C

EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY

Engine Crankcase Breather

Check and Clean

If the system is equipped with a coolant conditioner

Check and, if necessary, clean the engine crankcase
element, see Change Coolant Conditioner Element.
breather at the first oil change. Clean the breather ev-
Otherwise add liquid conditioner as described below.
ery 500 service hours or 3 months, whichever occurs
1. Loosen the radiator fill cap slowly to relieve all first, thereafter. See Every 500 Service Hours or 3
pressure before removing the cap. Months for procedures.
2. It may be necessary to drain enough coolant
from the radiator to allow for the addition of the
liquid cooling system conditioner.
3. Add Caterpillar cooling system conditioner to
maintain the proper concentration: add 1 pt.
(0.5 l) of liquid cooling system conditioner for
every 4 gal. (15 l) of cooling system capacity at
initial fill. At every 250 service hours thereafter,
add 1 pt. (0.5 l) for every 20 gal. (75 l) of cooling
system capacity.
4. Inspect the filler cap gasket. Replace the cap if
the gaskets are damaged.
5. Install the filler cap.

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EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY

Engine Valve Lash Alternator Belt and Fan Drive Belts

Check and Adjust Check the Belt(s) Condition
Check and adjust the engine valve lash at the first oil
change. Thereafter, check and adjust the engine valve
lash every 2,000 service hours or yearly. See Every
2,000 Service Hours or Yearly for procedures. Starting of the engine can cause personal injury.
Perform the lockout and tagout procedure listed in
the Safety chapter.

1. Check the belt(s) for excessive wear, fraying,

and cracking.

NOTICE
Belts must be replaced in complete matched sets.
Never replace only one belt of a set. The new belt
will carry all the load and fail rapidly.

2. Adjust or replace the belts if needed. See the

following sections for instructions.

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Maintenance RS425C

EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY

Adjust the Alternator Belt Tension Replace the Alternator Belt

1. Loosen the locknut (1) on the belt tightener rod.

2. Check for proper belt deflection.
a. Apply a force of 25 lb. (110 N) perpendicular 1. Remove the fan guard bolts and the fan guard
to each drive belt midway between the driv- (3).
ing and driven pulleys.
b. Measure the belt deflection. Proper belt
deflection is 9/16 to 13/16 in. (14 to 20 mm).
c. Turn the adjustment nut (2) until the correct
belt deflection is obtained.
3. Tighten the locknut (1).
4. Check the belt adjustment.

2. Loosen the locknut (2), then turn the adjust-

ing nut (2) until the belt can be slipped off the
sheave.
3. Attach a lifting device to the fan and remove the
bolts that attach the fan to the fan drive.
4. Loosen the fan drive mounting bolts until the
belts can be removed.
5. Remove the fan drive belts and the alternator
drive belt.
6. Install the new alternator drive belt and the
existing fan drive belts and adjust the tension on
each.
7. Install the fan and fan guard (3).

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EVERY 250 SERVICE HOURS OR MONTHLY
Adjust the Fan Drive Belt Tension
1. Loosen the mounting bolts (4).
2. Check for proper belt deflection.
a. Apply a force of 25 lb. (110 N) perpendicular
to each drive belt midway between the driv-
ing and driven pulleys.
b. Measure the belt deflection. Proper belt
deflection is 9/16 to 13/16 in. (14 to 20 mm).
c. Turn the adjustment nut (2) until the correct
belt deflection is obtained.
3. Tighten the mounting bolts (4).
4. Check the belt adjustment.
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Maintenance
EVERY 250 SERVICE HOURS OR MONTHLY
Replace the Fan Drive Belts
1. Remove the fan guard.
2. Attach a lifting device to the fan (5) and remove
the bolts that attach the fan to the fan drive.
3. Loosen the fan drive mounting bolts (4) and turn
the adjusting bolt (2) until the fan drive belts can
be removed.
4. Remove the fan drive belts.
5. Install the new fan drive belts and adjust the ten-
sion.
6. Install the fan (5) and the fan guard.
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Maintenance RS425C

EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY

Ground Drive Brakes

Check the Condition and Operation Compress and Lock the Brake Springs
1. Check the condition and thickness of the linings
to determine if you must reline the brakes. Be
sure each lining is thick enough to last until the
next inspection. Many brake linings contain asbestos fibers, a cancer
2. Lock the brake springs at the compressed posi- and lung disease hazard. Use caution in handling
tion (see Compress and Lock Brake Springs) and maintenance of brakes and linings.
and check the clearance between the lining and
the drums (see Check Brake Shoe Clearance).
1. Position the machine on level grade and block
3. Inspect for any leaks and correct the cause of the lines.
any found.
a. Disassemble the brake.
b. Correct the cause of the leak.
c. Remove the grease from all components.
d. Use new grease during reassembly of the
brake.
4. Check operation of the service brake system,
the emergency brake system and the park brake
system. Be sure all the brake systems operate
correctly.

2. With the engine running, pull the park brake

control (1) out to compress the park brake spring
and disengage the park brake.
3. Be sure the service brake control (2) is set at the
disengaged position.

4. Remove the release pin (3) from the storage

position above the brake chamber.
5. Insert the release pin into brake chamber (4).
6. Turn the release pin with a wrench until the
brake is held in the disengaged position.

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EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY

Check the Brake Shoe Clearance
NOTE: Check the clearance at the center of each
brake show, not at the ends.
1. Lock the brake springs at the compressed
position (see Compress and Lock the Brake
Springs).
Adjust the Brake Shoe Clearance
1. Position the machine on level grade.
2. Block the wheels.
3. Stop the engine.
4. Raise one wheel and tire off the ground with a
jack.
5. Position the safety stands so the tire will still be
off the ground, and lower the machine onto the
stands.
6. Lock the brake springs at the compressed
position (see Compress and Lock the Brake
Springs).

2. Remove the dust plate from the top of the hub.

7. Remove the dust plate from the top of the hub.

3. Use a feeler gauge to check the clearance

between the center of each lining and the drum.
The clearance must be 0.020 to 0.040 in. (0.5 to
1.00 mm). Adjust the brakes if the clearance is
not correct (see Adjust the Brake Shoe Clear-
ance).
4. Install the dust plate at the top of the hub.

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Maintenance
EVERY 250 SERVICE HOURS OR MONTHLY
Be careful not to damage the seals when adjusting
the brake. If you do damage a seal, replace it with
a new one.
8. Use an adjusting spoon or a screwdriver to turn
the star wheel on the adjuster in the direction
to move the linings against the drum. Turn the
adjuster until you feel a heavy drag on the drum
when you rotate the wheel.
NOTE: If you cannot raise the wheel from the ground
or cannot turn the wheel, turn the adjuster until
the linings are against the drum. Do not force
the adjuster after the linings touch the drum.
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RS425C
EVERY 250 SERVICE HOURS OR MONTHLY
9. Turn the star wheel to move the linings away
from the drum until you feel a very light drag on
the drum when you turn the wheel.
NOTE: If you cannot turn the wheel, turn the star
wheel 8 notches, 8 clicks of the detent, in the
direction to move the lining away from the
drum.
10. Use a feeler gauge to check the clearance be-
tween the center of the lining and the drum. The
clearance must be 0.20 to 0.40 in. (0.5 to 1 mm).
Continue to turn the star wheel until the clear-
ance is correct.
11. Repeat the procedure for the other brake shoe.
12. Install the dust cover at the top of the hub.
13. Repeat the procedure for the other wheel.
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EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY

Cutter Differential
Change the Oil

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

4. Remove the bolts and swing the front grille

open.

NOTE: Local environmental regulations probably

require that the differential oil be captured and
properly disposed of or reused. Be sure to
make proper preparations to capture the oil .
1. Place a suitable container beneath the cutter dif-
ferential drain plug (1) to catch the oil.
2. Thoroughly clean around the hose (2), then
disconnect the hose from the housing.
3. Allow the oil to drain from the hose. 5. Locate the cutter differential oil cooler (3), which
is part of the radiator housing.
6. Place a suitable container beneath the radiator
to catch the hydraulic oil.
7. Disconnect the lower hose from the hydraulic oil
cooler and allow the oil to drain.
8. Reconnect the hose to the cooler.

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Maintenance
EVERY 250 SERVICE HOURS OR MONTHLY
9. Thoroughly clean around filter (4) and the fitting
connections (5), then disconnect the filter. Cap
or plug the hose fittings.
10. Remove the bolts (6) from the filter. Take the
filter to a clean work area.
11. After noting the type and amount of particles
trapped by the screen, thoroughly clean the filter
by backflushing it.
NOTE: If an excess of metal particles is found, find
the cause of the metal particles.
12. Install the filter and the mounting bolts and con-
nect the hose fittings.
13. Add oil through the top port until it reaches the
proper level on the dipstick (7).
14. Reinstall the hose in the top port.
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RS425C
EVERY 250 SERVICE HOURS OR MONTHLY
Starting the engine with the cutter engaged can
cause personal injury. Push the cutter clutch control
in and move the cutter transmission shift lever to
neutral (N) before starting the engine.
Unexpected starting of the engine can cause injury
to personnel working on the machine. Sound the
horn for several seconds before starting the engine
to warn personnel.
15. Clear the area of the cutter.
16. Sound the horn to warn nearby personnel that
the engine is about to be started.
17. Start the engine.
18. Raise the cutter off the ground.
19. Set the cutter transmission at the slow speed
and engage the cutter.
20. Let the cutter turn for no more than 2 minutes.
Contact with the rotating cutter can cause injury or
death. Disengage the cutter clutch, set the cutter
transmission shift elver at Neutral and wait until the
cutter has stopped turning before working on or
near the cutter.
21. Slow the engine to low idle.
22. Push the cutter clutch control in and move the
cutter transmission shift lever to Neutral.
23. After the cutter stops turning, lower it to the
ground and stop the engine.
24. Allow the machine to stand at least 5 minutes.
25. Remove the plugs.
26. Add oil through the top port until it reaches
check the port level again.
27. Repeat steps 11 through 14 until the oil stays at
check plug level.
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RS425C
EVERY 250 SERVICE HOURS OR MONTHLY
Cutter Transmission
Change the Oil
NOTE: Local environmental regulations probably
require that the transmission oil be captured
and properly disposed of or reused. Be sure to
make proper preparations to capture the oil.
1. Locate the cutter transmission oil cooler (1)
under the mainframe just forward of the cutter.
2. Place a suitable container beneath the oil cooler
to catch the oil.
3. Disconnect both hoses (2) from the oil cooler
and drain the oil.
4. Reconnect the hoses to the cooler.
5. Disconnect the hose (3) from the bottom of the
transmission.
6. Remove the strainer (4) from the transmission.
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Maintenance
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7. Take the strainer to a clean work area.
8. After noting the types and amounts of particles
trapped by the strainer, thoroughly clean it.
NOTE: If an excess of metal particles is found, find
the cause of the metal particles.
9. Thoroughly clean around the oil dipstick (5).
10. Unscrew the dipstick, raise it out, and set it aside
where it will not get dirty.
11. Place a funnel in the pipe (6) that holds the dip-
stick, and fill with clean oil (see Refill Capaci-
ties earlier in this chapter).
12. Install the dipstick.
Starting the engine with the cutter engaged can
cause personal injury. Push the cutter clutch control
in and move the cutter transmission shift lever to
neutral (N) before starting the engine.
13. Clear the area of the cutter.
14. Sound the horn several times to warn nearby
personnel that the engine is about to be started.
15. Start the engine.
16. Raise the cutter off the ground.
17. Set the cutter transmission at the slow speed
and engage the cutter.
18. Let the cutter turn for no more than 2 minutes,
then disengage the cutter.
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Maintenance RS425C

EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY

Electrical System
19. After the cutter stops turning, lower it to the Check the Wiring Harnesses
ground.
20. Stop the engine.
21. Allow the machine to stand for at least 6 min-
utes.
22. Check the oil level.
a. Unscrew the dipstick and raise it out.
b. Wipe it off, and reinsert it into the pipe.
c. Raise the dipstick out again and check the
oil level.
23. Add oil as necessary to bring the level to the
FULL mark on the dipstick. 1. Visually check the wiring for damage such as
broken insulation and frayed wires (alternator,
regulator, battery, and other wiring harness con-
nections).
2. Check for loose or corroded connections.
3. Schedule repairs if possible; make immediate
repairs if necessary.

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EVERY 250 SERVICE HOURS OR MONTHLY EVERY 250 SERVICE HOURS OR MONTHLY

Lubrication
Lubricate the Fittings

Ground Drive Axle Universal Joints2 fittings each front axle univer-
sal joint, 1 top and 1 bottom
Ground Drive Axle2 fittings on each end of the axle, connected by
hoses to grease fittings on the frame, forward from the cutter hous-
ing, on the left and right side of the machine

Fan Bearingone fitting.

Apply lubricant until resistance is felt.

Apply lubricant slowly until excess is observed or

resistance is felt.

Clutch Release Lever (1)2 fittings.

Clutch Release Bearing (2)1 fitting.

NOTE: A hose runs from the release bearing to a

grease fitting attached to the out end of the
cutter differential carrier to provide access to
the grease fitting.

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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS

Hydraulic System
Change the Hydraulic Oil

At operating temperature, the hydraulic tank is hot

and under pressure. Hot oil can cause burns. Allow
the tank and the hydraulic oil to cool before chang-
ing the hydraulic oil.

NOTICE
When changing the hydraulic oil, cleanliness must be
kept in mind at all times. Dirty hydraulic oil causes
extremely accelerated wear. Clean the outside of the
hydraulic oil tank before starting, perform the work
in a clean area using clean tools, and keep your
hands clean.

NOTE: Local environmental regulations probably

require that the hydraulic oil be captured and
properly disposed of or reused. Be sure to
make proper preparations to capture the oil.
There are three valves (1) on the bottom of the hy-
draulic oil reservoir (2). If one of the valves is not con-
nected, it can be used to drain the hydraulic fluid from
the system.
1. Close all the valves (1).
2. Thoroughly clean around the hose and fittings
before attaching the drain hose.
3. Route the other end of the drain hose to a suit-
able container and allow the used hydraulic fluid
to drain for disposal in accordance with local
environmental regulations.
4. Remove the breather filter (3).
5. Remove the top two covers (4).
6. Remove the internal filter (5) from the tank.
7. Change the filter or replace the gaskets as
needed.
8. Thoroughly clean the inside of the tank and top
covers with clean nonflammable solvent.
9. Install the internal filter and gaskets.
10. Install the top covers (4) and new breather filter
(3).

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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS

Engine Crankcase
11. Close the drain valve. Clean the Breather
12. Disconnect the drain hose from the valve. If a
hydraulic hose was originally connected to the
valve used for draining, reconnect the hydraulic
hose to the valve. Hot oil and components can cause personal injury.
13. Open the valves with the hoses connected. Do not allow hot oil or components to contact skin.

14. Fill the tank with clean hydraulic oil. Use the
same type of oil as already in the system or
drain the rest of the system before adding the
different oil. See Lubricant Specification and
Refill Capacities.
15. Change the hydraulic oil filter elements. See
Hydraulic Oil Filters under Every 100 Service
Hours or Two Weeks.

1. Loosen the hose clamp (1).

2. Disconnect the fumes disposal tube (2).
3. Remove the mounting bolts (3).
4. Remove the breather assembly (4).
5. Wash the breather (4) in nonflammable solvent.
6. Allow the breather (4) to drain dry, then wipe.
7. Inspect the gasket. Replace if necessary.
8. Install the breather (4).
9. Install the mounting bolts (3).
10. Connect the fumes disposal tube (2).
11. Tighten the hose clamp.

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Maintenance RS425C

EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS

Cutter Chaincase Hubs Fuel Tank

Clean the Breathers Clean the Breather

Fuel leaked or spilled onto hot surfaces or electrical

components can cause a fire. Remove all smoking
materials from the area.

1. Remove the breather.

2. Clean the breather in nonflammable solvent.
3. Allow the breather to drain dry.
4. Wipe off the breather and the area where the
breather installs.
5. Install the breather.

1. Remove the breather.

2. Clean the breather in nonflammable solvent.
3. Allow the breather to drain dry.
4. Wipe off the breather and the area where the
breather installs.
5. Install the breather.

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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS

Hydraulic Oil Replenishing Tank Fluid Sampling

Clean the Breather Hydraulic System Ground Drive Hydrostatic Loop

1. Remove the breather.

2. Clean the breather in nonflammable solvent.
3. Allow the breather to drain dry.
4. Wipe off the breather and the area where the
breather installs.
5. Install the breather.
The contamination level of the hydraulic system
ground drive hydrostatic loop fluid should be checked
through a pressure test point located at the high pres-
sure gauge connection. To check the contamination
level, you will need a fluid sampling kit, which is avail-
able from Terex Roadbuilding. From this kit you will
need the following:
polyprophylene tube, 1/4 O.D. x 0.035 wall x 100
ft. bulk roll

You will also need

2 sampling bottles, 3 oz. and 100 mL.
a sampling hose assembly, which is standard
equipment on the machine
clean shop towels
a 1-gallon container, premarked in 1/4 in. incre-
ments
1. Operate the machine for at least 30 minutes to
bring the system up to an operating temperature
of 140F, to ensure that the loop oil is mixed with
the system oil.
2. Stop the machine on a flat and level area with
approximately one machine length of clear area
to the front and three machine lengths clear to
the rear.
3. Stop the engine.
4. Lift and remove the long, narrow section of deck
plate in the operator station deck.

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Maintenance
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5. Locate the pressure test point quick couple male
fitting (2) at the ground drive pump, near the
right-hand end of the long opening n the deck,
and remove the dust cap.
The fluid will be hot and may be under pressure.
Wear proper protective clothing such as gloves, a
long-sleeved shift and eye protection while remov-
ing the level fill plug.
6. Thoroughly clean the fitting and areas surround-
ing the fitting using engine starting fluid or an
equivalent solvent.
7. Install the fluid sampling hose assembly (3),
which was provided as a standard part of the
machine shipping group, making certain that the
quick coupling is made and that the needle valve
is completely closed.
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EVERY 500 SERVICE HOURS OR 3 MONTHS
8. Make certain that the fitting in the end of the
needle valve is clean.
9. Restart the engine and position the engine
throttle at Idle.
10. Using the ground drive control level, move the
machine in reverse approximately two machine
lengths and then forward to approximately the
original position. Repeat this reverse and for-
ward motion three times.
11. Place the graduated 1-gallon container on a flat
level surface where it is within easy reach of the
needle valve on the sampling hose assembly.
12. Position the needle valve (4) so that it is over the
opening of the container and open the needle
valve slowly until hydraulic fluid flows into the
container.
13. Adjust the flow rate from the needle valve until
the level in the container changes approximately
1/2 the distance between the 1/4 gallon gradu-
ation mark (1 pint) in 26 to 30 seconds. Allow at
least one pint of fluid to collect in the container.
14. Once the flow rate has been established, do not
turn off the needle valve or make an adjustment
to the needle valve prior to taking the sample.
15. With fluid still flowing into the container, remove
the cap from one sampling bottle, placing the
cap open side down on one of the clean shop
towels.
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EVERY 500 SERVICE HOURS OR 3 MONTHS
16. Place the open sampling bottle (5) under the
flow stream coming from the needle valve and
allow it to fill to the first graduation mark from the
top of the bottle.
17. Remove the sampling bottle from the flow
stream and recap the bottle immediately.
18. Turn off the needle valve.
19. Stop the engine.
20. Remove the sampling hose assembly from the
male quick connect test fitting and replace the
dust cap.
21. Label the sampling bottle using the sample iden-
tification labels provided in the fluid sampling kit.
22. Mail the sample to the lab for analysis. No more
than 24 hours should elapse between the time
that the sample was obtained and when it is
shipped to the lab.
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Maintenance
EVERY 500 SERVICE HOURS OR 3 MONTHS
Cutter Drive Axle
To check the contamination level of the cutter drive
axle fluid, you will need a fluid sampling kit, which is
available from Terex. From this kit you will need the
following:
polyprophylene tube, 1/4 O.D. X 0.035 wall x
100 ft. bulk roll
vacuum pump
2 sampling bottles, 3 oz. and 100 mL
You will also need
clean shop towels
tools to remove the level check plug from the
axle
1. Operate the cutter drive of the machine for a
minimum of 30 minutes to bring the axle to the
minimum operating temperature of 140F.
2. Stop the machine on a flat, level area.
3. Set the wheel brakes.
4. Lower the rotor until it is resting upon the surface
of the area where the machine is parked.
Obtaining this sample requires placing personnel
under the machine. Follow all safety precautions.
5. Locate the lube fill plug at the rear of the axle
housing above and to the left side of the axle
centerline.
The fluid will be hot and may be under pressure.
Wear proper protective clothing such as gloves, a
long-sleeved shift and eye protection while remov-
ing the fill plug.
6. Remove the fill plug and place it on a clean shop
towel.
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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS

11. Insert the free end of the tube into the fill hole
in the differential housing of the axle making
certain that the free end of the tube is in the
lube oil inside the axle housing. There should be
approximately 6 in. of tube visible between the
pump and the fill hole.

7. Prepare the polyprophylene sampling tube (1)

by cutting approximately a 16 in. long piece from
the bulk roll.

12. While holding the barrel of the pump horizontal

and with the squeeze fitting oriented in the up-
ward direction, work the pump until lube oil flows
into the sampling bottle (4). Continue pumping
until the fluid level in the bottle is at the highest
graduation mark on the bottle.
13. Remove the tube from the fill hole.
8. Locate the vacuum pump (2) used for oil sam- 14. Remove the cap of the sample bottle immedi-
pling.
ately.
15. Remove the sampling tube from the vacuum
pump and dispose of it by an environmentally
acceptable method.
16. Refill the axle with clean new lube oil to replace
the volume during the fluid sampling process.
17. Label the bottle with the label provided.
18. Place the labeled sample bottle inside the ship-
ping container provided and mail it to the lab for
analysis. Send the sample to the lab within 24
hours of obtaining the sample.

9. Install the tube into the squeeze fitting (3) on the

pump until approximately 1/2 in. of tube is pro-
truding beyond the inside surface of the sample
bottle connection feature of the pump.
10. Install the sampling bottle onto the pump.

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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS

Wheel Ends, Main Propel Axle

To check the contamination level of the wheel ends
main propel axle fluid, you will need a fluid sampling
kit, which is available from Terex. From this kit you will
need the following.
polyprophylene tube, 1/4 O.D. X 0.035 wall x
100 ft. bulk roll
vacuum pump
2 sampling bottles, 3 oz. and 100 mL

You will also need

clean shop towels
tools to remove the level check plug from the 6. Prepare the sampling tube (1) by cutting ap-
axle proximately a 16 in. long piece from the bulk
tubing provided in the Terex Roadbuilding fluid
NOTE: If this procedure is performed immediately sampling kit.
following the hydraulic fluid sampling proce-
dure (see Hydraulic System Ground Drive
Hydrostatic Loop earlier in this section), then
steps 1 and 2 can be skipped.
1. Operate the cutter drive of the machine for a
minimum of 30 minutes to bring the axle to the
minimum operating temperature of 140F.
2. Stop the machine on a flat, level area.
3. Using the ground drive control, position the
machine so that the level check plug on the
left wheel end of the main propel axle is either
ahead of or behind the vertical centerline of the
axle and approximately 1 in. above the horizon- 7. Locate the vacuum pump (2) in the fluid sam-
tal centerline of the axle. pling kit.
4. Set the brake.

The fluid will be hot and may be under pressure.

Wear proper protective clothing such as gloves, a
long-sleeved shirt and eye protection while removing
the level check plug.

5. Remove the level check plug and place it on one

of the clean shop towels.

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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS

13. Remove the sampling bottle from the pump and

8. Push the tubing through the squeeze fitting (3)
on the vacuum pump until the end of the tub-
ing protrudes beyond the inside surface of the
sample bottle connection feature approximately
1/2 - 1 in. and tighten the squeeze fitting.
9. Install a sampling bottle onto the bottle connect-
ing feature of the pump.
10. Insert the free end of the tubing attached to the
vacuum pump through the level check hole until
the free end of the tube is oriented downward
and approximately 1/2 of its length is into the
hole.
replace the cap immediately.
14. Release the squeeze fitting, remove the polypro-
phylene tube from the pump and discard the tub-
ing in an environmentally appropriate location.
15. Replace the volume of fluid removed from the
wheel end with new clean fluid.
16. Replace the level check plug.
17. Label the sampling bottle using the sample iden-
tification labels provided in the fluid sampling kit.
18. Release the wheel brake and repeat steps 3
through 17 for the right wheel end.
19. Place the labeled sampling bottles inside the
shipping containers provided and mail them to
the lab for analysis. Send samples to the lab
within 24 hours of obtaining them.

11. Holding the barrel of the pump horizontally and

positioning the squeeze fitting upward, operate
the vacuum pump until the bottle starts to fill (4).
Continue to operate the pump until the fluid level
has reached the top graduation on the bottle.
12. Remove the tube from the level check hole.

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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS

Planetary Wheel Drive

To check the contamination level of the planetary
wheel drive fluid, you will need a fluid sampling kit,
which is available from Terex. From this kit you will
need the following.
polyprophylene tube, 1/4 O.D. X 0.035 wall x
100 ft. bulk roll
vacuum pump
2 sampling bottles, 3 oz. and 100 mL

You will also need

clean shop towels
6. Making a clean cut, remove a piece of the 1/4
tools to remove the level check plug from the inch polyprophylene tubing (1) approximately 16
axle inches long from the bulk tubing provided in the
Terex Roadbuilding Fluid Sampling Kit.
NOTE: If this procedure is performed immediately
following the hydraulic fluid sampling proce-
dure (see Hydraulic System Ground Drive
Hydrostatic Loop earlier in this section), then
steps 1 and 2 can be skipped.
1. Operate the machine for a minimum of 30
minutes in working range or 15 minutes in travel
range to bring the wheel ends to operating tem-
perature.
2. Stop the machine on a flat, level area.
3. Using the ground drive control, position the
machine so that the level check plug on the
left planetary wheel drive is either ahead of or
7. Locate the vacuum pump (2) in the fluid sam-
behind the vertical centerline of the wheel and
pling kit.
approximately 1 in. above the horizontal center-
line of the axle.
4. Set the wheel brakes.

The fluid will be hot and may be under pressure.

Wear proper protective clothing such as gloves, a
long-sleeved shirt and eye protection while removing
the level check plug.

5. Remove the level check plug and place it on one

of the clean shop towels.

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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS

13. Remove the sampling bottle from the pump and

8. Push the tubing through the squeeze fitting (3)
on the vacuum pump until the end of the tub-
ing protrudes beyond the inside surface of the
sample bottle connection feature approximately
1/2 - 1 in. and tighten the squeeze fitting.
9. Install a sampling bottle onto the bottle connect-
ing feature of the pump.
10. Insert the free end of the tubing attached to the
vacuum pump through the level check hole until
the free end of the tube is oriented downward
and approximately 1/2 of its length is in the hole.
replace the cap immediately.
14. Release the squeeze fitting, remove the polypro-
phylene tube from the pump and discard the tub-
ing in an environmentally appropriate location.
15. Replace the volume of fluid removed from the
wheel end with new clean fluid.
16. Replace the level check plug.
17. Label the sampling bottle using the sample iden-
tification labels provided in the fluid sampling kit.
18. Release the wheel brake and repeat steps 3
through 17 for the right planetary wheel drive.
19. Place the labeled sampling bottles inside the
shipping containers provided and mail them to
the lab for analysis. Send samples to the lab
within 24 hours of obtaining them.

11. With the barrel of the vacuum pump held hori-

zontally and the squeeze fitting oriented upward,
operate the vacuum pump until the bottle starts
to fill (4). Continue to operate the pump until the
fluid level has reached the top graduation on the
bottle.
12. Remove the tube from the level check hole.

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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS

Main Propel Axle

To check the contamination level of the main propel
axle fluid, you will need a fluid sampling kit, which is
available from Terex. From this kit you will need the
following:
polyprophylene tube, 1/4 O.D. X 0.035 wall x
100 ft. bulk roll
vacuum pump
2 sampling bottles, 3 oz. and 100 mL

You will also need

7. Prepare the polyprophylene sampling tube (1)
clean shop towels by cutting approximately a 16 in. long piece from
tools to remove the level check plug from the the bulk roll.
axle

1. Operate the machine for a minimum of 30 min-

utes to bring the axle to operating temperature.
2. Stop the machine on a flat, level area.
3. Set the wheel brakes.
4. Lower the rotor until it is resting upon the surface
of the area where the machine is parked.

8. Locate the vacuum pump (2) used for oil sam-

Obtaining this sample requires placing personnel pling.
under the machine. Follow all safety precautions.

5. Locate the level check plug at the rear of the

axle housing above and to the right side of the
axle centerline.

The fluid will be hot and may be under pressure.

Wear proper protective clothing such as gloves, a
long-sleeved shift and eye protection while removing
the level fill plug.
9. Insert the tube into the squeeze fitting (3) on the
pump until approximately 1/2 in. of tube is pro-
6. Remove the level fill plug and place it on a clean
truding beyond the inside surface of the sample
shop towel.
bottle connection feature of the pump.
10. Install the sampling bottle onto the pump.

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EVERY 500 SERVICE HOURS OR 3 MONTHS
11. Insert the free end of the tube into the fill hole
in the differential housing of the axle making
certain that the free end of the tube is in the
lube oil inside the axle housing. There should be
approximately 7 in. of tube visible between the
pump and the fill hole.
12. While holding the barrel of the pump horizontal
and with the squeeze fitting oriented in the up-
ward direction, work the pump until lube oil flows
into the sampling bottle (4). Continue pumping
until the fluid level in the bottle is at the highest
graduation mark on the bottle.
13. Remove the tube from the fill hole.
14. Remove the cap of the sample bottle immedi-
ately.
15. Remove the sampling tube from the vacuum
pump and dispose of it by an environmentally
acceptable method.
16. Refill the axle with clean new lube oil to replace
the volume removed during the fluid sampling
process.
17. Label the bottle with the label provided.
18. Place the labeled sample bottle inside the ship-
ping container provided and mail it to the lab for
analysis. Send the sample to the lab within 24
hours of obtaining the sample.
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EVERY 500 SERVICE HOURS OR 3 MONTHS
Engine Lube, Test Port in Place
To check the contamination level of the engine lube
fluid, you will need a fluid sampling kit, which is avail-
able from Terex. From this kit you will need the follow-
ing:
polyprophylene tube, 1/4 O.D. X 0.035 wall x
100 ft. bulk roll
vacuum pump
2 sampling bottles, 3 oz. and 100 mL
You will also need
clean shop towels
tools to remove the level check plug from the
axle
1. Operate the machine until the engine is at a
normal operating temperature of approximately
190F.
2. Stop the machine on a flat, level area and posi-
tion the engine throttle at the idle position.
3. Set the wheel brakes.
4. Open the engine enclosure and locate the pres-
sure probe fitting (1) from which the oil sample
will be taken.
NOTE: Usually this fitting will be located in close
proximity to the oil filters. In some cases, it will
be installed in the pressure manifold to which
the filters are mounted. In other cases, it will
be installed into a port in the oil supply gallery
in the side of the engine block.
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EVERY 500 SERVICE HOURS OR 3 MONTHS EVERY 500 SERVICE HOURS OR 3 MONTHS

5. Remove the dust cap from the pressure probe

fitting on the engine and make certain that the
fitting and the area surrounding it are clean.
The fluid will be hot and may be under pressure.
Wear proper protective clothing such as gloves, a
long-sleeved shift and eye protection.

10. Allow the fluid to flow until it has reached the

topmost graduation mark on the sample bottle.
11. Remove the pump from the sampling fitting on
the engine.
12. Remove the sampling bottle from the pump and
replace the cap immediately.
13. Replace the dust cap on the sampling fitting on
6. Remove the dust cap from the pressure probe the engine.
fitting on the vacuum pump (2) and make certain
14. Replace the dust cap on the pressure probe on
that the internal and external surfaces of the
the vacuum pump.
probe are clean.
15. Fill out the sample information on the label pro-
7. Remove the cap from the sampling bottle and
vided with the bottle and apply the label to the
place it open-side down on a clean shop towel.
bottle.
8. Attach the sampling bottle to the vacuum pump.
16. Place the sampling bottle in the shipping con-
tainer provided.
17. Apply the mailing label to the shipping container
and mail the sample to the lab. Send the sample
within 24 hours of obtaining it.

9. Insert the probe on the vacuum pump into the

sampling fitting on the engine (3).

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EVERY 1,000 SERVICE HOURS OR YEARLY EVERY 1,000 SERVICE HOURS OR YEARLY

Batteries Ground Drive Axle Carrier and Planetary

Ends
Tighten the Retainer
Change the Oil
Change the oil after the first 75 to 100 hours of opera-
tion. Thereafter change the oil every 1,000 service
hours or at least once a year. Drain the oil while the
axle is still warm.

The batteries are located in the left front fender com-

partment. Tighten the battery retainer nuts if neces-
sary.

The ground drive assembly includes the hydraulic

motor (1), a 2-speed transmission (2), and an axle
(3). The axle includes the carrier (4) and the planetary
ends on which the drive wheels mount.
NOTE: Local environmental regulations probably
require that the axle oil are captured and
properly disposed of or reused. Make proper
preparations to capture the oil.

1. Stop the machine on a level surface with the

planetary end/fill/level/drain plug (5) at the bot-
tom of the left planetary end (6) or right plan-
etary end (7).

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EVERY 1,000 SERVICE HOURS OR YEARLY

2. Jack the opposite wheel up to help drain the 12. Clean and install all plugs.
oil from the planetary and wheel touching the
13. Drive the machine without a load for 1 or 2 miles
ground.
at slow speeds to circulate the lubricant through-
3. Rotate the planetary that is off the ground to out the axle and planetary ends.
place the fill/level/drain plug at the bottom.

4. When the oil from the planetary on the ground

has drained, jack that wheel up and rotate it to
place the fill/level/drain plug (5) at the horizontal
centerline of the planetary end.
5. Lower the opposite wheel to the ground, and re-
move the fill/level/drain plug (5) from the bottom
of the planetary end (7).
6. Allow the oil to drain.
7. When the oil has drained, jack up and rotate the
wheel to place the fill/level/drain plug (5) at the
horizontal centerline of the planetary end (7).
8. Lower both wheels to the ground. Both planetar-
ies should now have the fill/level/drain plugs at
the horizontal centerline.

NOTICE
To ensure proper oil level, add oil to both planetary
ends and to the carrier.

9. Fill both planetary ends and the housing carrier

with oil.
10. Wait for the oil to distribute evenly throughout
the axle and gearboxes.
11. Check the oil levels and add more oil if neces-
sary.

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EVERY 1,000 SERVICE HOURS OR YEARLY EVERY 1,000 SERVICE HOURS OR YEARLY

General Wheel Alignment Information

Front AlignmentCheck the Amount of Toe
Present

Toe is a figure that is equal to the distance from the

wheel assembly centerline to the wheel assembly
centerline at the rear of the tires (dimension Y) minus
the distance from the wheel assembly centerline to
the wheel assembly centerline at the front of the tires
(dimension X). The resulting figure is the amount of
toe present. If the result is a positive number, the tires
are toed in. If the result is a negative number, the tires
are toed out.
1. Park the machine on level ground.
2. Determine how far up the tires you can run a
tape measure without the machine structure in-
terfering. This measurement is measurement A,
which should be approximately 20 to 24 in. (51
to 61 cm).

For example:
If measurement Y is 40 in. and measurement X is 39
in., there is 1 in. of toe-in.
Y X = TOE
40 39 = 1

If measurement Y is 39 inches and measurement X is

40 inches, there is 1 inch of toe-out.
Y X = TOE
39 40 = 1

Recommended toe settings:

Front..................................... 3/16 in. +/ 3/16 in. toe-in
Rear...................................... 5/32 in. +/ 3/32 in. toe-in

The alignment can be checked on both the front and

rear axles using a 20 ft. tape measure and a magic
marker or piece of chalk.

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EVERY 1,000 SERVICE HOURS OR YEARLY EVERY 1,000 SERVICE HOURS OR YEARLY

Alternate Method to Check the Amount of Toe Present

Use the following procedure to check the amount of
toe without having to locate the centers of the tires.

1. Attach a bar (1) to the center of each wheel hub.

The bars must be long enough to extend beyond
the tires at the front and back, and must be hori-
zontal.
2. Measure the distance between the bars at the
NOTE: The centers of the tires are easily identified back of the tires (Y dimension).
by the molding marks left when the tires are 3. Measure the distance between the bars at the
manufactured. front of the tires (X dimension).
2. Using a piece of chalk or a magic marker, mark 4. Subtract dimension X from dimension Y.
this measurement at the front center and rear
center of each front tire. 5. Use the resulting figure as the amount of toe
present.
3. Measure the amount of toe present on the front
axle.
a. Measure the distance between the molding
marks, at the marked level on the rear of the
tires (Y dimension).
b. Measure the distance between the marks on
the front of the tires (X dimension).
c. Subtract the dimension X from dimension Y.
d. Use the resulting figure as the amount of toe
present on the front axle.

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Maintenance
EVERY 1,000 SERVICE HOURS OR YEARLY
Adjust the Toe
1. Use jacks or another lifting device to raise the
front of the machine enough to unload the axle.
2. Block the machine up.
NOTE: Adjustments can only be made in complete
turns of the tie rod end. Each turn equals ap-
proximately a 9/16 in. (14 mm) change in toe.
3. Turn the wheels one direction or the other to
gain access to one tie rod end (1).
168
RS425C
EVERY 1,000 SERVICE HOURS OR YEARLY
4. Loosen the large lock nut (2) and back it off at
least 2 turns.
5. Loosen locknut (3) on the tie rod end.
6. Remove the cotter pin (4).
7. Loosen the slotted nut (5).
8. Remove the capscrew (6) with a drift and ham-
mer.
9. Turn the tie rod end (1) the required number of
full turns to obtain the correct toe reading.
10. Replace the capscrew.
11. Check the toe-in. If necessary, repeat steps 5
through 10.
12. Retighten all nuts and bolts.
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RS425C
EVERY 1,000 SERVICE HOURS OR YEARLY
Rear AlignmentCheck Amount of Toe Present
NOTE: See Alternate Method to Check the Amount
of Toe Present under Front Alignment
Check Amount of Toe Present for another
way to check the amount of toe present.
1. Park the machine on level ground.
2. Measure from the ground to the center of the
rear hub, measurement A, which should be ap-
proximately 30 in. (76 cm).
NOTE: The centers of the tires are easily identified by
the molding mark left when the tires are manu-
factured.
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Maintenance
EVERY 1,000 SERVICE HOURS OR YEARLY
3. Using a piece of chalk or a magic marker, mark
this measurement at the front center and rear
center of each rear tire.
4. Measure the amount of toe present on the rear
axle.
a. Measure the distance between the molding
marks at the marked level on the rear of the
tires (Y dimension).
b. Measure the distance between the marks on
the front of the tires (X dimension).
c. Subtract dimension X from dimension Y.
d. Use the resulting figure as the amount of toe
present.
169
Maintenance RS425C

EVERY 1,000 SERVICE HOURS OR YEARLY EVERY 1,000 SERVICE HOURS OR YEARLY

Cutter Transmission Shift Linkage

Adjust the Toe Lubricate Fittings

NOTE: One rear axle tie rod end has left hand
threads, and the other tie rod end has right
hand threads. This allows easy toe adjust-
ment.
1. Loosen the jamnuts (1) on the rear tie rod (2).
Cutter Transmission Shift Linkage2 fittings, 1 fitting in each univer-
sal joint; the linkage is located under the deck grating at the left side
of the operators station.
Apply lubricant slowly until excess is observed at all
four cross seals. If a seal does not relieve (pop), move
the shaft laterally in all four directions opposite the
cross seal not relieving while continuing to apply lubri-
cant gun pressure until lubricant appears at that seal.

2. Turn the tie rod in the proper direction to correct

the toe.
a. To increase the amount of toe-in, turn the tie
rod in direction A.
b. To decrease the amount of toe-in, turn the
tie rod in direction B.
3. Check the amount of toe present. If necessary,
repeat step 2.
4. Tighten the jamnuts (1).

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RS425C Maintenance

EVERY 2,000 SERVICE HOURS OR 2 YEARS EVERY 2,000 SERVICE HOURS OR 2 YEARS

Engine Valve Lash Engine Cooling System

Measure and Adjust Valve Lash
Consult Caterpillar Engine Operation and Mainte-
nance Manual for the procedures to measure and
adjust the valve lash.
Drain
At operating temperature, the engine coolant is hot
and under pressure. Check the coolant level only
after the engine has cooled and the fill cap is cool
enough to touch with your bare hand.
Steam and hot water can cause personal injury. Re-
move the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent personal
injury.

1. With the engine and radiator cool, loosen the

radiator cap slowly to release pressure.
2. Remove the radiator cap.
NOTE: Local environmental regulations probably
require that the antifreeze be captured and
properly disposed of or reused. Make proper
preparations to capture the antifreeze.

3. Attach a hose to the fitting (1) located on the

right front of the machine next to the square ac-
cess panel (2).
4. Place a suitable container under the hose to
catch the coolant.

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Maintenance RS425C

EVERY 2,000 SERVICE HOURS OR 2 YEARS EVERY 2,000 SERVICE HOURS OR 2 YEARS

10. Stop the engine.

11. Drain the neutralizing solution.
12. Flush the system with clean water until the drain-
ing water is clean. Do not run the engine while
flushing.
13. Close the radiator drain valve.
14. Refill the engine cooling system.

5. Open the square access panel (2) to reach and

open the radiator drain valve (3) and allow the
coolant to drain.
6. Clean and close the radiator drain valve.

Clean
1. Fill the system with a commercially available
cleaning solution.

Unexpected starting of the engine can cause injury

to personnel working on the machine. Sound the
horn for several seconds before starting the engine
to warn personnel.

2. Sound the horn several times to warn nearby

personnel that the engine is about to be started.
3. Start and run the engine for 1/2 hour.
4. Stop the engine.
5. Drain the cleaning solution.
6. Flush the system with clean water until the drain-
ing water is clean. Do not run the engine while
flushing.
7. Close the radiator drain valve.
8. Fill the system with neutralizing solution.
9. Start and run the engine for 10 minutes.

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RS425C
EVERY 2,000 SERVICE HOURS OR 2 YEARS
Refill
NOTE: When changing antifreeze solution, replace
the conditioner maintenance element with the
correct conditioner precharge element.
1. If equipped, remove the coolant conditioner
maintenance element and install a coolant con-
ditioner precharge element. See Engine Cool-
ing System under Every 250 Service Hours or
Monthly.
2. Mix the antifreeze solution to provide protection
to the lowest expected ambient temperature. If
there is no coolant conditioner element, leave
room to add liquid conditioner.
3. To help avoid air pockets, add coolant slowly,
at 5 gal. (19 l) per minute or less. See Refill
Capacities.
4. Add liquid conditioner if there is no element.
5. Bring the coolant level to within 1/2 in. (13 mm)
of the bottom of the fill tube.
6. Start the engine with the radiator cap off.
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Maintenance
EVERY 2,000 SERVICE HOURS OR 2 YEARS
7. Run the engine at low idle.
8. Increase the engine rpm to 1500.
9. Run the engine at high idle for one minute in
order to purge the air from the cavities of the
block.
10. Stop the engine.
11. Check the coolant level again and keep it within
1/2 in. (13 mm) of the bottom of the fill tube.
12. Inspect the radiator cap seal; replace it if it is
damaged.
13. Install the radiator cap. The correct pressure for
the cooling system filler cap is stamped on it. If
the cooling system filler cap does not retain the
correct pressure when tested (use a pressurized
pump), install a new cooling system filler cap.
14. Check for coolant leaks at all of the hose con-
nections.
15. Stop the engine.
173
Maintenance RS425C

NOTES

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RS425C Schematics

Electrical Schematic
Sheet 1 of 4

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Schematics RS425C

Electrical Schematic
Sheet 2 of 4

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RS425C Schematics

Electrical Schematic
Sheet 3 of 4

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Schematics RS425C

Electrical Schematic
Sheet 4 of 4

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RS425C Schematics

NOTES

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Schematics RS425C

NOTES

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RS425C Appendix

Reference Information

Pressure Settings Shipping Dimensions

Auxiliary System Height........................................... 9 ft. 9 in. (2,970 mm)

System Pressure....................... 2,500 psi (17,237 kPa) Length...................................... 23 ft. 11 in. (7,160 mm)
Width............................................ 8 ft. 1 in. (2,235 mm)
Ground Drive System
Weight...................................... 49,000 lbs. (22,246 kg)
Charge Pressure........... 290-400 psi (1,999-2,758 kPa)
Pressure Limiter Setting............. 4200 psi (28,958 kPa)
Brake Release....................... 95-110 psi (655-758 kPa)

Compressed Air System..... 95-110 psi (655-758 kPa)

Hydraulic Chain Tensioner 95-110 psi (655-758 kPa)

Differential Cooling System.. 10-100 psi (69-689 kPa)

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Appendix RS425C

Fastener Torques
General Torque for Standard Bolts, Nuts and Ta- Torques for Taperlock Studs with Standard
perlock Studs Threads
The following charts give general torques for bolts, Thread Size Standard Torque
nuts and taperlock studs of SAE Grade 5 or better Inch Nm ftlb
quality.
1/4 83 62
Exceptions to these torques are given in Service 5/16 17 5 13 4
Manuals where needed.
3/8 35 5 26 4

Torques for Bolts and Nuts with Standard Threads 7/16 45 10 33 7

1/2 65 10 48 7
Thread Size Standard Torque
9/16 90 15 65 11
Inch Nm ftlb
5/8 110 15 80 11
1/4 12 4 93
3/4 170 20 125 15
5/16 25 7 18 5
7/8 260 30 190 22
3/8 45 7 32 5
1 400 40 300 30
7/16 70 15 50 10
1 1/8 500 40 370 30
1/2 100 15 75 10
1 1/4 650 50 480 37
9/16 150 20 110 15
1 3/8 750 50 550 37
5/8 200 25 150 20
1 1/2 870 50 640 37
3/4 360 50 265 35
7/8 570 80 420 60
1 875 100 640 80
1 1/8 1100 150 800 100
1 1/4 1350 175 1000 120
1 3/8 1600 200 1200 150
1 1/2 2000 275 1480 200
* 1 Newton meter (Nm) is approximately the same as
0.1 mkg.

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RS425C Appendix

Standard Torque for Metric Fasteners

NOTICE
Torques for Bolts and Nuts with Metric Threads
Metric ISO* Thread
Be very careful never to mix metric with U.S. custom- Thread Size Standard Torque
ary (standard) fasteners. Mismatched or incorrect Nm** ftlb
fasteners will cause machine damage or malfunction M6 12 4 93
and may even result in personal injury.
M8 25 7 18 5
M10 55 10 40 7
Original fasteners removed from the machine should M12 95 15 70 10
be saved for reassembly whenever possible. If new M14 150 20 110 15
fasteners are needed, they must be of the same size
and grade as the ones that are being replaced. M16 220 30 160 20
M18 325 50 240 35
The material strength identification is usually shown on
the bolt head by numbers (8.8, 10.9, etc.). The follow- M20 450 70 330 50
ing chart gives standard torques for bolts and nuts with M22 600 90 440 65
Grade 8.8. M24 775 100 570 75
M27 1150 150 840 110
M30 1600 200 1175 150
M33 2000 275 1480 200
M36 2700 400 2000 300
* ISOInternational Standard Organization
** 1 Newton meter (Nm) is approximately the same as
0.1 mkg.

Torques for Taperlock Studs with Metric Threads

Thread Size Standard Torque
Metric Nm* ftlb
M6 83 62
M8 17 5 13 4
M10 35 5 26 4
M12 65 10 48 7
M14 90 15 65 11
M16 110 15 80 11
M20 170 20 125 15
M24 400 40 300 30
M30 650 50 480 37
M36 870 50 640 37
* 1 Newton meter (Nm) is approximately the same as
0.1 mkg.

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Appendix RS425C

Standard Torque for Hose ClampsWorm O-Ring Face Seal Fittings

Drive Band Type
The following chart gives the torques for initial installa-
tion of hose clamps on a new hose and for reassembly
or retightening of hose clamps on an existing hose.

Initial Installation
Torque on New Hose (1) O-Ring Face Seal Fitting. (2) O-Ring Groove. (3) Straight Thread
O-Ring Port Fitting End. (4) O-Ring. (5) O-Ring Face Seat Nut.
Clamp Width Nm* lb in.
0.625 in. (16 mm) 7.5 0.5 65 5
Straight Thread O-Ring Fitting
0.531 in. (13.5 mm) 4.5 0.5 40 5
0.312 in. (8 mm) 0.9 0.2 82 (For O-Ring Face Seal Fitting Only)
Reassembly or THREAD SIZE STANDARD TORQUE
(in.) Nm* ftlb
Retightening Torque
5/16 - 24 5 1.5 41
Clamp Width Nm* lb in.
3/8 - 24 12 2 91
16 mm (.625 inch) 4.5 0.5 40 5
7/16 - 20 20 4 15 3
13.5 mm (.531 inch) 3.0 0.5 25 5 1/2 - 20 30 5 22 4
8 mm (.312 inch) 0.7 0.2 62 9/16 - 18 40 5 30 4
* 1 Newton meter (Nm) is approximately the same as 3/4 - 16 100 15 75 10
0.1 mkg. 7/8 - 14 135 15 100 10
1 1/16 - 12 200 25 150 20
1 3/16 - 12 250 25 185 20
1 5/16 - 12 300 40 220 30
1 5/8 - 12 300 40 220 30
1 7/8 - 12 300 40 220 30
2 1/2 - 12 300 40 220 30
* 1 Newton meter is approximately the same as 0.1 mkg.

O-Ring Face Seal Fitting Nut

THREAD SIZE STANDARD TORQUE
(in.) Nm* ftlb
9/16 - 18 16 3 12 2
1 1/16 - 16 30 4 22 3
1 3/16 - 16 50 7 37 5
1 - 14 90 10 65 7
1 3/16 - 12 120 15 90 10
1 7/16 - 12 160 20 120 15
1 11/16 - 12 190 20 140 15
2 - 12 215 25 160 15

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RS425C
Hydraulic Line Installation
Use the following procedure to connect a metal tube to
a hose.
1. Install the tube in the clamps.
2. Tighten the bolts finger tight.
3. Install the hose.
4. Tighten all fittings finger tight.
5. Position the hose so that it does not make con-
tact with the machine or another hose.
6. Tighten the fittings and the clamps.
7. Tighten the bolts on both connections.
Unexpected starting of the engine can cause injury
to personnel working on the machine. Sound the
horn for several seconds before starting the engine
to warn personnel.
8. Sound the horn to warn nearby personnel that
the engine is about to be started.
9. Start the engine.
10. Move the implement control levers through the
range of all positions.
11. Look at the hose during movement of the imple-
ment. Make sure the hose is not in contact with
the machine or other hoses.
12. Shut off the engine.
13. If necessary, put the hose in a new position
where it will not make contact when the imple-
ment is moved.
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Appendix
Assembly of Fittings with Straight
Threads and O-Ring Seals
This type of fitting is used in many applications. The
tube end of the fitting will be different in design so that
it can be used in many different applications. However,
the installation procedure for the fitting is the same for
all applications. If the tube end of the fitting body is the
same as in the illustration (either an elbow or a straight
body) it will be necessary to assemble the sleeve on
the tube before connecting the tube to the end.
Elbow Body Assembly
1. Put the locknut (3), backup washer (4), and
O-ring seal (5) as far back on fitting body (2) as
possible.
2. Hold these components in this position.
3. Put the end of the fitting (6) into the part it is
used on and turn it until the backup washer (4)
just makes contact with the face of the part it is
used on. The other end of the fitting (1) connects
to the tube.
4. Put the fitting assembly in its correct position.
a. Turn the fitting body (2) counterclockwise
(out) a maximum of 359.
b. Tighten the locknut (3) to the torque shown
in the correct chart for the fitting used.
NOTE: If the fitting is a connector (straight fitting), the
hex on the body takes the place of the locknut.
To install this type of fitting, tighten the hex
against the face of the part it goes into.
185
Appendix RS425C

Torques for Flared and O-Ring Fittings

The torques shown in the charts that follow are to ring plugs, O-ring fittings, and swivel nuts when used
be used on the nut part of 37 flared, 45 flared, and in applications to 3,000 psi (20,700 kPa).
inverted flare fittings (when used with steel tubing), O-

37 Flared and Straight Thread O-Ring Fittings

37 Flared and Straight Thread O-Ring Fittings

(Except O-Ring Face Seal Fittings)
Nominal Tube O.D. Thread Size Standard Torque
Metric Inch (inches) Nm ftlb
3.18 0.125 5/16 5 1.5 41
4.76 0.188 3/8 11 1.5 81
6.35 0.250 7/16 16 2 12 1
7.94 0.312 1/2 20 3 15 2
9.52 0.375 9/16 25 4 18 3
12.70 0.500 3/4 50 7 37 5
15.88 0.625 7/8 65 7 48 5
19.05 0.750 1 1/16 100 10 75 7
22.22 0.875 1 3/16 120 10 90 7
25.40 1.000 1 5/16 135 15 100 11
31.75 1.500 1 5/8 180 15 135 11
38.10 1.500 1 7/8 225 15 165 11
50.80 2.000 2 1/2 320 15 240 22

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RS425C
Tightening Other Fittings
Hi Duty (Shear Sleeve) Tube Fittings
1. Make sure the tube has been put through the
nut and makes contact against the tube shoulder
in the fitting body.
2. Turn the nut with a wrench until a small de-
crease in torque is felt. This indicates that the
sleeve has been broken off the nut.
3. Hold the tube to prevent turning and tighten the
nut 1 1/2 turns.
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Appendix
Hi Seal Fittings
1. Put the nut and sleeve over the tubing with the
short heavy end of the sleeve facing the end of
the tubing.
2. Put the tube end against the counterbore in the
body of the fitting.
3. Tighten until nut is over the last thread on the
body.
The remainder of space is used whenever the
fitting is removed and installed again.
187
Appendix RS425C

45 Flared and 45 Inverted Flare Fittings

45 Flared and 45 Inverted Fittings

Nominal Tube O.D. Thread Size Standard Torque
Metric Inch (inches) Nm ftlb
3.18 0.125 5/16 5 1.5 41
4.76 0.188 3/8 8 1.5 61
6.35 0.250 7/16 11 2 81
7.94 0.312 1/2 17 3 13 2
9.52 0.375 5/8 30 3 22 4
11.11 0.438 3/4 50 7 37 5
12.70 0.500 3/4 38 4 28 3
15.88 0.625 7/8 50 5 37 4
19.05 0.750 1 1/16 90 8 65 6
22.22 0.875 1 1/4 100 10 75 7

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RS425C Appendix

Tightening Other Fittings Flex Fittings

Ermeto Tube Fittings

1. Put the nut and sleeve over the tubing.

1. Put the nut and sleeve over the tube with the 2. Push the tube into the counterbore of the fitting
head or shoulder end of sleeve next to nut. body as far as possible.
2. Push the tube into the counterbore of the fitting 3. Tighten the nut until it is against the hex part of
body as far as possible. the fitting body.
3. Turn the nut clockwise until the sleeve holds the
tube and prevents movement.
4. Tighten the nut 1 1/4 turns more to seat sleeve
and give a locking action.
5. When removal and reassembly is necessary, put
the sleeve over the tube and tighten the nut until
a sudden increase in torque is felt.
6. Tighten 1/6 to 1/3 turn more to seat the sleeve.

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Appendix RS425C

Common Symbols

Lines and Line Functions Pumps and Motors

Solid Line Main Line
Fixed Displacement Hydraulic
Pump
Dashed Line Pilot Line

Variable Displacement
Dotted Line Exhaust or Hydraulic Pump
Drain Line

Pressure Compensated
Enclosure Outline
Variable Displacement Pump

Lines Crossing Not Fixed Displacement Hydraulic

Connected Pump
(Two Directional Flow)
Lines Crossing Not
Connected Hydraulic Motor Fixed
Displacement
Connected Lines

Hydraulic Motor Variable

Displacement
Liquid Supply

Hydraulic Oscillator
Gaseous Supply

Flexible Line

Reservoirs
Reservoir Open to
Atmosphere
Mechanical Devices
Two Parallel Lines Pressurized
Mechanical Connection
(Drive Shaft, Actuating
Lever, etc.)
Line to Reservoir Below Fluid
Level
Flexible Line

Flexible Line Line to Reservoir Above Fluid

Level

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RS425C Appendix

Cylinders Valves (continued)

Single Acting Regulating or Selector Valves

2 Position 2 Way Valve

Double Acting
Single Rod End 2 Position 3 Way Valve

Double Acting
2 Position 4 Way Valve
Double Rod End

3 Position 4 Way Closed

Double Acting, Single Rod Center Valve
End, Fixed Cushion Both
Ends
3 Position 4 Way Open
Center Crossover Valve

Double Acting, Single Rod

End, Adjustable Cushion Rod Valve Capable of Infinite
Ends Positioning (Indicated by
Lines Drawn Parallel to
Envelope)

Differential Cylinder Pilot Operated Pressure Relief

Valve

Pressure Reducing Valve

Valves
Non-Adjustable Restrictor
Check Valve

Adjustable Restrictor

Pilot Operated Check Valve

Pressure Compensated
Adjustable Restrictor

ON OFF Pressure and Temperature

Manual Shut Off Compensated Adjustable
Restrictor

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Appendix RS425C

Valve Actuators Accessories

Solenoid Filter

Detent
Cooler

Spring
Heater

Manual

Temperature Controller

Shuttle

Accumulator, Gas Charged

Push Button

Reversible Motor
Push Pull Lever

Port or Test Point

Pedal Operated
Pressure Indicator

Mechanically Operated Temperature Indicator

Pressure Switch
Pressure Compensated

Quick Disconnect Couplers

Pilot Pressure Remote Supply (Disconnected)

Quick Disconnect Couplers

Liquid Supply (Connected)

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RS425C Appendix

Electric Schematic Symbols Contacts

Fuse Maintained

Circuit Breaker Momentary

Connection Symbols

Housings

Control Relay
Switch Configurations
S.P.S.T.
Volt Meter

S.P.D.T.
Pressure Gauge

D.P.S.T.
Temperature Gauge

Motor
D.P.D.T.

Types of Grounds

Ground
Resistors
Fixed
Internal External

Variable

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Appendix RS425C

Lamp Symbols Solenoids/Coils (continued)

Head/park Light
Proximity Switch/Sensor

Solenoids/Coils
Limit Switch
Valve Coil

Solenoid/Valve Coil Single Solenoid

Control Relay Coil

Double Solenoid

Pressure

Dual Solenoid

Temperature

Hand
Control Relay
Relay Assembly
Diode

Liquid Level Float Relay Coil

Circuit Crossing
Normally Open (N.O.) Relay
Contact

Normally Closed (N.C.) Relay

Mechanical Connection Contact

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RS425C Appendix

Color Abbreviations Electrical Miscellaneous (continued)

RED Red BLK Black
Pressure Switch
YEL Yellow BLU Blue
WHT White BRN Brown
GRN Green PNK Pink

Magnetic Pick-Up

Electrical Miscellaneous

Horn/Alarm EDC
(Electronic Displacement
Control)
Alternator

Master Disconnect Switch

Starter

Back Up Alarm

Battery

Switch Bank

Circuit Breaker

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Appendix RS425C

Common Abbreviations

A or AMP Amperes HSG Housing

ABS Absolute HVAX Heating Ventilation and Air Conditiong
AFEX Automatic Fire Extinguisher HYD Hydraulic
AC Alternating Current ID Inside Diameter (as of a hose or tube)
A/C Air Conditioning IN Inch
ACCY Accessory IN LBS Inch Pounds
API American Petroleum Institute ISO International Standards Organization
ANSI American National Standards Institute JIC Joint Industrial Conference
ASAE American Society of Agricultural Engineers IGN Ignition
ASA American Standards Association KG or kg Kilogram (metric measurement of
AUX Auxiliary mass)
BSPP British Standard Pipe KPA or kPa Kilo-Pascal (metric measurement for
pressure
BAT Battery
KPH or kPH Kilometers per Hour
B+ Battery Positive Post
KW or kW Kilo Watt
BHP Brake Horsepower
LED Light Emitting Diode
C Coil
LCD Liquid Crystal Display
C Degrees Celsius (temperature)
LF Left Front
CB Circuit Breaker
LH Left Hand
CC or CM3 Cubic Centimeter
LR Left Rear
CID Cubic Inch Displacement
L/M Liters per Minute
IN3/REV Cubic Inches per Revolution
M or m Meters
CM Centimeter
M3 Cubic Meters
CR Control Relay
MPH Miles per Hour
CYL Cylinder
MA or mA Milliamperes
DC Direct Current
MAN Manual
DCA Diesel Coolant Additive
MV or mV Millivolt
DVM Digital Volt Meter
MTR Motor
ENG Engine
N Newton
EX Example
NEG or (-) Negative
F Degrees Fahrenheit (temperature)
NM or Nm Newton Meters (metric measurement
FPM Feet per Minute
for torque)
FT LBS Foot Pounds (of torque or turning effort)
Null Neutral Adjustment
FU Fuse
NPT National Pipe Thread
GAL Gallons
Ohms
GPM Gallons per Minute (of fluid flow)
OD Outside Diameter (as of a hose or tube)
GR Grade
PA or Pa Pascal (metric measurement for pres-
HDC Hydraulic Displacement Control sure)
HP Horsepower PCS Pressure Control Servo

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PSI Pressure Differential (Delta pressure)

PDB Pump Drive Box
PLI Pounds per Linear Inch
P/N Part Number
POT Potentiometer
POS or (+) Positive
PPM Parts per Million
PPU Pulse Speed Pick Up
PRES Pressure
PSI Pounds per Square Inch (English measure-
ment for pressure)
PTO Power Take Off
RF Right Front
RH Right Hand
RPM Revolution per Minute
RR Right Rear
SAE Society of Automotive Engineers
SIG Signal
SOL Solenoid
STD Standard
T Travel Range
TACH Tachometer
TEMP Temperature
UNC or NC Unified National Course (designation
for course fastener threads)
VAC Volts Alternating Current
VDC Volts Direct Current
V Volts
YD3 or CU. YD. Cubic Yard

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Appendix RS425C

Conversion Factors

Subject Multiply By Result/Multiply By Result

Area Square Feet 0.092 903 Square Meters 10.763 91 Square Feet
Force Ounce Force 0.278014 Newton 3.596 942 Ounce Force
Pound Force 4.448222 Newton 0.224 809 Pound Force
Length Inch 25.4 Millimeter 0.039 370 Inch
Foot 0.304 8 Meter 3.280 804 Foot
Mile 1.609 344 Kilometer 0.621 371 Mile
Mass Pound 0.453 592 Kilogram 2.204 622 Pound
Mass/Area Ton/Acre 2241.702 Kilogram/Hectare 0.000 446 Ton/Acre
3 3
Density Pounds/Yard 0.593 276 Kilogram/Meter 1.685 555 Pounds/Yard3
Power Horse Power 0.74 5 700 KiloWatt 1.341 02 Horse Power
Pressure PSI 6.894 757 KiloPascal 0.145 038 PSI
Temperature F .5555 X (F -32) C (1.8 X C)+32 F
Torque Pound Inch 0.112 985 Newton Meter 8.850 748 Pound Inch
Pound Foot 1.355 818 Newton Meter 0.737 562 Pound Foot
Speed MPH 1.609 344 KPH 0.621 371 MPH
Volume Cubic Inch 16.387 060 Cubic Centimeter 0.061 024 Cubic Inch
Cubic Foot 0.028 317 Cubic Meter 35.314 660 Cubic Foot
Cubic Yard 0.764 555 Cubic Meter 1.307 950 Cubic Yard
Fluid Ounce 29.573 530 Cubic Centimeter 0.033 814 Fluid Ounce
Quart, U.S. 0.946 353 Liter 1.056 688 Quart, U.S.
Quart, Imperial 1.136 523 Liter 0.879 877 Quart, Imperial
Gallon, U.S. 3.785 412 Liter 0.264 172 Gallon, U.S.
Gallon, Imperial 4.546 092 Liter 0.219 969 Gallon, Imperial
Flow GPM, U.S. 3.785 412 Liter/Minute 0.264 172 GPM, U.S.
GPM, Imperial 4.546 092 Liter/Minute 0.219 969 GPM, Imperial
Horse Power U.S. 1.014 Metric Horse Power 0.986 300 U.S. Horse Power
Net Engine 0.815 PTO HP*
Net Engine 0.70 Max Drawbar HP*

* Approximation Based on Observed Test

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