C O P P E R H E A D 4

O W N E R 'S M A N U A L

M A C H IN E S E R IA L N U M B E R :

D A T E O F M A N U F A C T U R E :

S o m e ro E n te rp ris e s , p ro v id e s th e fo llo w in g s e rv ic e s
th ro u g h th e S e rv ic e C e n te r in H o u g h to n , M I a t (9 0 6 ) 4 8 2 -7 2 5 2 .

T e c h n ic a l a s s is ta n c e w ith th e o p e ra tio n a n d m a in te n a n c e
o f S o m e ro P ro d u c ts .

T ro u b le S h o o tin g a s s is ta n c e .

S a le s o f P a rts a n d A c c e s s o rie s fo r y o u r S o m e ro p ro d u c ts .

P ro d u c t lite ra tu re w ith te c h n ic a l s p e c ific a tio n s o n o u r

c u rre n t p ro d u c ts .

2 4 H o u r E m e rg e n c y S e rv ic e P a g e r.

C O R P O R A T E O F F IC E S A L E S A N D S E R V IC E U K O F F IC E

1 6 8 3 1 L in k C o u rt P .O . B o x 3 0 9 B ro o m b a n k R o a d
F t. M y e rs , F L 3 3 9 1 2 4 6 9 8 0 S ta te H ig h w a y M 2 6 C h e s te rfie ld T ra d in g E s ta te
P H O N E (2 3 9 ) 2 1 0 -6 5 0 0 H o u g th o n , M I 4 9 9 3 1 C h e s te rfie ld S 4 1 9 Q J
F A X (2 3 9 ) 2 1 0 -6 6 0 0 P H O N E (9 0 6 ) 4 8 2 -7 2 5 2 U n ite d K in g d o m
F A X (9 0 6 ) 4 8 3 -2 7 7 4 P H O N E + 4 4 (0 ) 1 2 4 6 4 5 4 4 5 5
F A X + 4 4 (0 ) 1 2 4 6 2 6 1 6 7 3

7 8 0 3 0 1 0 2 3 -0 0
E N T E R P R I S E S , I N C
 C O P P E R H E A D
O W N E R 'S M A N U A L
T A B L E O F C O N T E N T S

S E C T IO N D E S C R IP T IO N

W A R R A N T Y

S P E C IF IC A T IO N S

T O T H E O P E R A T O R

E N G IN E M A N U A L S

O P E R A T O R 'S A N D S E R V I C E M A N U A L

A . S A F E O P E R A T IN G
S A F E T Y A N D IN F O R M A T IO N D E C A L S

B . O P E R A T IO N S

C . S E R V IC E A N D M A IN T E N A N C E

D . H Y D R A U L IC O P E R A T IO N

E . W IR IN G D IA G R A M

P A R T S C A T A L O G

1 0 .0 0 M A J O R C O M P O N E N T S
S A F E T Y A N D IN F O R M A T IO N D E C A L S

2 0 .0 0 A X L E , F R A M E , C O M P O N E N T S

3 0 .0 0 C O V E R S

4 0 .0 0 H E A D A S S E M B L Y

5 0 .0 0 H Y D R A U L I C S /E L E C T R I C A L
M A N IF O L D
H Y D R A U L IC H O S E G U ID E
E L E C T R IC A L L A Y O U T

6 /0 2
E N T E R P R I S E S , I N C
 C O P P E R H E A D 4

O W N E R 'S M A N U A L

G L O S S A R Y O F A B B R E V IA T IO N S A N D T E R M S

A d j. - A d ju s ta b le
D e g . - D e g re e
D ia . - D ia m e te r
H y d . - H y d ra u lic
N C - N a tio n a l C o a rs e T h re a d
E le v .- E le v a tio n
O R B - " O " R in g B o s s
J IC - A s u s e d in th is m a n u a l, re fe rs to a 3 7 D e g re e F la re fittin g c o n fo rm in g to th e s ta n d a rd s
e s ta b lis h e d b y th e J o in t In d u s tria l C o u n c il
P S I - P o u n d s P e r S q u a re In c h ( 1 P S I = .0 6 9 b a r ) ( 1 b a r = 1 4 .5 P S I )
N M - N e w to n -M e te rs
F T . L B S . - F o o t P o u n d s
T h rd L c k - T h re a d L o c k in g C o m p o u n d
S e rv T h rd L c k - S e rv ic e a b le T h re a d L o c k in g C o m p o u n d
N O T E : (S e r v ic e a b le th r e a d lo c k in g c o m p o u n d is to b e u s e d o n a ll th r e a d e d h o le s u n le s s
o th e r w is e n o te d )
N o n -S e rv T h rd L c k - N o n -S e rv ic a b le T h re a d L o c k in g C o m p o u n d

B o lt d e s c rip tio n :

G r8 H x H d C s 5 /1 6 -1 8 X 3 /4 Z c

G ra d e H e x H e a d C a p sc re w B o lt s iz e T h re a d s p e r in c h L e n g th Z in c c o a te d

E N T E R P R I S E S
 C O P P E R H E A D S P E C IF IC A T IO N S
G E N E R A L D IM E N S IO N S

6 /0 2 II.
 C O P P E R H E A D S P E C IF IC A T IO N S

G E N E R A L

M o d e l S -9 2 1 0 (C o p p e rh e a d )
C la s s ific a tio n M o b ile (W a lk B e h in d ) C o n s tru c tio n E q u ip m e n t
T y p e C o n c re te S c re e d in g M a c h in e
M a n u fa c tu re r S o m e ro E n te r p ris e s

P O W E R U N IT

M a n u fa c tu re r H o n d a
E n g in e M o d e l G X 2 7 0 R A 2
Ig n itio n E le c tro n ic
C y c le 4 -S tro k e , 1 c y lin d e r, 2 :1 re d u c tio n c lu tc h
H o rse P o w e r 9 H p ( 6 .7 5 k W ) a t 3 6 0 0 rp m
F u e l G a s o lin e , 8 7 O c ta n e m in im u m
B a tte ry /E le c tric a l 1 2 V D C w ith 1 0 A m p A lte rn a to r
C o n tro l M a n u a l th ro ttle w ith e le c tric s h u to ff

P O W E R T R A IN

T y p e E n g in e -d riv e n h y d ra u lic g e a r p u m p
P ro p u ls io n H y d ra u lic d riv e m o to rs fo r w h e e ls
C o n tro l H a n d c o n tro ls - M e c h a n ic a l P ro p o rtio n a l h y d ra u lic c o n tro ls
W h e e ls 2 6 " (6 6 0 m m ) S te e l W e ld m e n t
T ire s 2 6 " x 2 .1 0 " ( 6 6 0 m m x 5 0 m m ) S o lid F ille d T ire s w ith a g g re s s iv e th re a d s

H Y D R A U L IC S Y S T E M

P u m p D o u b le O u tle t F ix e d d is p la c e m e n t, 0 .3 1 C I R ( 5 c c ) & 0 .2 4 C I R ( 4 c c )
S y s te m P re ssu re 2 5 0 0 p s i ( 2 0 6 8 4 k P a ) f o r H e a d lif t & V ib ., 3 4 0 0 p s i ( 2 3 4 4 2 k P a ) f o r P r o p e l
R a te d V o lu m e tric
F lo w R a te 2 .3 g p m (5 c c ) a n d 1 .8 g p m ( 4 c c ) a t 1 8 0 0 r p m
F iltra tio n 1 0 M ic ro n T a n k T o p R e tu rn -lin e F ilte r
R e s e rv o ir 2 .3 2 g a llo n s ( 8 .7 9 L )
V a lv e T y p e s C a rtrid g e v a lv e s w ith p re s s u re c o m p e n s a te d flo w c o n tro ls
O il c o o le r R e tu rn lin e

6 /0 2 II.
 C O P P E R H E A D S P E C IF IC A T IO N S

F U N C T IO N S

V ib ra to r H e a d H y d ra u lic v ib ra to r, 3 0 0 0 -5 0 0 0 R P M (2 0 6 8 4 -3 4 4 7 3 k P a )
P lo w E le c tric a l L in e a r A c tu a to rs w ith 4 " s tro k e , L a s e r C o n tro lle d
H e a d L ift 1 .5 " H y d r a u lic c y lin d e r , M a n u a l s w itc h , 1 3 " H e ig h t

F L U ID C A P A C IT IE S

E n g in e O il 1 .1 6 q u a r ts ( 1 .1 0 L )
F u e l T a n k 1 .5 9 g a llo n s ( 6 .0 4 L )
T ra n sm is s io n 0 .3 2 q u a rts
H y d ra u lic O il 2 .3 2 g a llo n s ( 8 .8 2 L )

G E N E R A L D IM E N S IO N S

O v e ra ll W id th 1 0 ' ( 3 2 .7 5 " o v e r tir e s ) ( 3 .0 0 m ) ( 0 .8 2 m o v e r tir e s )

o r 8 ' ( 3 2 .7 5 " o v e r tir e s ) ( 2 .4 0 m ) ( 0 .8 2 m o v e r tir e s )
O v e r a ll L e n g th 9 0 " ( 2 .1 6 m )
O v e r a ll H e ig h t 4 1 " ( 1 .0 0 m )
G ro u n d C le a ra n c e 9 " ( 0 .2 3 m )
W e ig h t 6 6 0 # (3 1 0 # p e r tire a n d 4 0 # o n h e a d )
(3 0 0 k g ) ( 1 4 1 k g p e r tire a n d 1 8 k g o n h e a d )

M A C H IN E B E N E F IT S A N D F E A T U R E S

E lim in a te 2 -3 L a b o re rs ; R a k e rs a n d W e t P a d s
P o w e re d th in w h e e ls to re d u c e o p e ra to r e ffo rts
H y d ra u lic h e a d lift fo r m a n e u v e ra b ility
L a s e r q u a lity flo o r fla tn e s s a n d im p ro v e d m a te ria l u s a g e
T h e g ra d e is s e t b y th e P lo w w h ic h is la s e r c o n tro lle d
T o ta l o f 4 in c h e s o f tra v e l o n th e P lo w
Q u ic k jo b s ite s e tu p
1 0 ' a n d 8 ' v ib ra to r a n d p lo w s iz e s
H e a d (v ib ra to r) a n g le a d ju s tm e n t, s id e v ie w (a tta c k a n g le )
R e m o v a b le h e a d , re le a s e p in s a n d q u ic k c o n n e c ts
S in g le a n d D u a l S lo p e c a p a b ilitie s
E a s y to tra n s p o rt a n d c le a n

6 /0 2 II.
 T O T H E O P E R A T O R

T H IS O P E R A T IN G A N D S E R V IC E M A N U A L o u tlin e s th e d e ta ile d o p e ra tin g , s e rv ic e

a n d s a fe ty p ro c e d u re s fo r y o u r C O P P E R H E A D . R e a d th is m a n u a l c a re fu lly . F a ilu re to
d o s o c o u ld re s u lt in p e rs o n a l in ju ry o r e q u ip m e n t d a m a g e .

T H IS M A N U A L IS C O N S ID E R E D P A R T O F Y O U R C O P P E R H E A D a n d s h o u ld
re m a in w ith th e m a c h in e w h e n it is s o ld .

T H E L E F T A N D R IG H T -H A N D S ID E o f y o u r C O P P E R H E A D is d e te rm in e d b y th e
o p e ra to r b e in g in th e o p e ra tin g p o s itio n b e h in d th e h a n d le s .

M E A S U R E M E N T S A R E G I V E N I N B O T H U .S . A N D M E T R I C E Q U I V A L E N T S .
U s e th e c o rre c t re p la c e m e n t p a rts a n d s p e c ifie d g ra d e , o r h ig h e r g ra d e fa s te n e rs .

6 /0 2 III.
 S A F E T Y

R E A D T H IS M A N U A L A N D F O L L O W
S A F E T Y IN S T R U C T IO N S B E F O R E
O P E R A T IN G T H E M A C H IN E C A
U T
IO N

L e a r n to o p e r a te th e m a c h in e a n d its c o n tr o ls p r o p e r ly .
N e v e r le t a n y o n e o p e r a te w ith o u t in s tr u c tio n .
R e a d th e s a fe ty m e s s a g e s in th is m a n u a l a n d o n y o u r
m a c h in e s a fe ty s ig n s . K e e p s a fe ty s ig n s c le a n a n d in W
A R
N I

g o o d c o n d itio n . R e p la c e d a m a g e d s a fe ty s ig n s .
N G

R E C O G N IZ E S A F E T Y IN F O R M A T IO N
A N D S IG N A L W O R D S
A s a fe ty s y m b o l is u s e d w ith th e s ig n a l w o r d s D A N G E R
D A N G E R , W A R N IN G a n d C A U T IO N .
D A N G E R d e n o te s th e m o s t s e r io u s h a z a r d .
W A R N I N G is in te r m e d ia te b e tw e e n D A N G E R a n d
C A U T IO N .
W A R N IN G
C A U T I O N d e n o te s th e le a s t s e r io u s h a z a r d .
C A U T IO N

P R E P A R E F O R E M E R G E N C IE S
K e e p a fir s t a id k it a n d fir e e x tin g u is h e r h a n d y .
K e e p e m e r g e n c y p h o n e n u m b e r s fo r d o c to r s,
a m b u la n c e , h o s p ita l a n d fir e w ith y o u a t a ll tim e s .

A -B -C

6 /0 2 A .1 0 .1
 S A F E T Y

W E A R P R O T E C T IV E C L O T H IN G
W e a r c lo s e fittin g c lo th in g a n d s a fe ty e q u ip m e n t
a p p r o p r ia te to th e jo b .
P r o lo n g e d e x p o s u r e to lo u d n o is e c a n c a u s e im p a ir m e n t
o r lo s s o f h e a r in g . O p e r a to r a n d r a k e r s m u s t w e a r
su ita b le h e a r in g p r o te c tiv e d e v ic e s s u c h a s e a r m u ffs o r
e a r p lu g s .
G iv e fu ll a tte n tio n to o p e r a tin g y o u r C O P P E R H E A D
L A S E R S C R E E D s a fe ly .

H A N D L E F U E L S A F E L Y
F u e l is h ig h ly fla m m a b le . D o n o t r e fu e l y o u r
C O P P E R H E A D S C R E E D w h ile s m o k in g o r n e a r o p e n
fla m e o r s p a r k s .
S to p e n g in e a n d le t c o o l fo r a m in im u m o f tw o (2 )
m in u te s b e fo r e r e fu e lin g .
R e fu e l o u td o o r s.
P r e v e n t fir e s b y k e e p in g y o u r m a c h in e c le a n o f s p ille d
fu e l. U s e a fu n n e l to r e fu e l.

W O R K IN V E N T IL A T E D A R E A
E n g in e e x h a u st fu m e s c a n c a u s e s ic k n e s s o r d e a th . I f it
is n e c e ssa r y t o o p e r a te y o u r m a c h in e in a n e n c lo s e d
a r e a , r e m o v e th e e x h a u s t fu m e s fr o m th e a r e a w ith a n
e x h a u st p ip e e x te n s io n
I f y o u d o n o t h a v e a n e x h a u s t p ip e e x te n s io n , o p e n th e
d o o r s a n d g e t o u ts id e a ir in to th e a r e a .

6 /0 2 A .1 0 .2
 S A F E T Y

A V O ID H IG H -P R E S S U R E F L U ID S
E s c a p in g flu id u n d e r p r e s s u r e c a n p e n e tr a te th e s k in
a n d c a u s e s e r io u s in ju r y .
R e lie v e p r e s s u r e b e fo r e d is c o n n e c tin g h y d r a u lic o r
o th e r lin e s . T ig h te n a ll c o n n e c tio n s b e fo r e a p p ly in g
p r e ssu r e .
IF A N A C C ID E N T O C C U R S , S E E A D O C T O R
IM M E D I A T E L Y . A n y flu id in je c te d in to th e s k in m u s t
b e s u r g ic a lly r e m o v e d w ith in a fe w h o u r s o r g a n g r e n e
m a y r e s u lt.

B A T T E R Y C H A R G IN G
C A U T IO N : B a tte ry g a s c a n e x p lo d e . K e e p
s p a rk s a n d fla m e s a w a y fro m b a tte rie s .
A lw a y s r e m o v e g r o u n d e d (-) b a tte r y c la m p fir s t a n d
r e p la c e it la s t.
Q u ic k c h a r g in g s h o u ld o n ly b e d o n e in a n e m e r g e n c y .
S lo w c h a r g in g is p r e fe r r e d .
P lu g c h a r g e r in to a n e le c tr ic a l o u tle t w ith th e p o w e r
o ff. D O N O T c o n n e c t te r m in a ls w ith p o w e r o n .

D IS P O S E O F W A S T E P R O P E R L Y
U s e le a k p r o o f c o n ta in e r s w h e n d r a in in g flu id s s u c h a s
o il, fu e l, c o o la n t, filte r s a n d b a tte r ie s . D o n o t u s e fo o d
o r b e v e r a g e c o n t a in e r s th a t m a y m is le a d s o m e o n e in to
d r in k in g fr o m th e m .
D O N O T p o u r w a s te o n to th e g r o u n d , d o w n a d r a in , o r
in to a n y w a te r s o u r c e .

6 /0 2 A .1 0 .3
 S A F E T Y

V in y l G r a p h ic W a s h in g I n s tr u c tio n s
T h e v in y l g r a p h ic s a p p lie d to y o u r m a c h in e a r e m a d e o f h ig h 1 2 "

q u a lity " O E M a p p r o v e d " m a te r ia ls th a t h a v e b e e n p r o v e n to N o z z le

la s t u n d e r h a r s h c o n d itio n s , b u t w ill n o t h o ld u p to d ir e c t a n d 1 5 °

d e lib e r a te h ig h p r e s s u r e p o w e r w a s h in g . I t is r e c o m m e n d e d S ID E V IE W

th a t s u r fa c e s w ith v in y l g r a p h ic s a p p lie d b e p r e r in s e d to
r e m o v e la r g e lo o s e d ir t a n d th e n w a s h e d u s in g a s o ft b r u s h .
F o r s u r fa c e s th a t m u s t b e w a s h e d u s in g a h ig h p r e s s u r e p o w e r 1 2 "
w a s h e r , c a r e m u s t b e ta k e n to o n ly s p r a y th e g r a p h ic s w ith a N o z z le
1 5 d e g r e e fa n n o z z le a t a n a n g le o f 9 0 d e g r e e s fr o m th e s u r fa c e
b e in g w a s h e d . T h e n o z z le s h o u ld n e v e r g e t c lo s e r th a n 1 2 T O P V IE W 9 0 °

in c h e s fr o m th e g r a p h ic a n d th e p o w e r w a s h e r o u tp u t p r e s s u r e
s h o u ld n o t e x c e e d 2 5 0 0 p s i.

N E V E R L O O K D IR E C T L Y IN T O D O N O T O P E R A T E T H E M A C H IN E
T H E L A S E R B E A M U N D E R T H E IN F L U E N C E O F
S e t L a s e r T r a n s m itte r a t a h e ig h t o f s e v e n (7 ) fe e t D R U G S O R A L C O H O L !
a b o v e t h e b e n c h m a r k h e ig h t . ( S e e B .4 .7 )

D o n o t p la c e th e C o p p e r H e a d X D o n a d e c k L IF T P O IN T S
u n til a s tr u c tu r a l e n g in e e r h a s b e e n c o n s u lte d ! W e ig h t w /1 0 ' h e a d :
7 7 5 lb s (3 5 2 k g )

B e fo r e p la c in g th is
m a c h in e o n a n e le v a te d d e c k , c o n s u lt a
str u c tu r a l e n g in e e r to v e r ify th a t t h e d e c k m e e ts th e
str u c tu r a l r e q u ir e m e n ts to su p p o r t th e C o p p e r H e a d X D .
T h e C o p p e r H e a d X
D w e ig h s a p p r o x im a te ly 7 7 5 lb s .
S e e p a g e B .2 .1 f o r m a c h in e w e ig h t a n d g r o u n d p r e ssu r e
s p e c ific a tio n s .
7 8 0 1 0 1 2 2 7 -0 0

7 8 0 1 0 1 1 3 5 -0 0

1 /0 4 A .1 0 .4
 S A F E T Y

P R E C A U T IO N S W H E N W E L D IN G
I f it b e c o m e s n e c e s s a r y to w e ld o n a n a s s e m b le d
C o p p e r h e a d S c r e e d :
1 ) D is c o n n e c t th e b a tte r y c a b le s fr o m th e b a tte r y .
2 ) I f w e ld in g n e a r th e b a tte r y , r e m o v e th e b a tte r y to a
s a fe lo c a tio n .
3 ) A lw a y s c o n n e c t th e w e ld e r 's g r o u n d c la m p a s c lo s e
a s p o s s ib le to th e a r e a b e in g w e ld e d . N e v e r c o n n e c t
g r o u n d c la m p to th e lo w e r fr a m e w h ile w e ld in g o n th e
u p p e r fr a m e . M a jo r c o m p o n e n ts m a y b e d e str o y e d .

T O A V O ID A N E L E C T R IC A L S H O R T
A L W A Y S T U R N O F F T H E M A S T E R
S W IT C H W H E N T H E M A C H IN E IS
U N A T T E N D E D .

D O N O T B Y P A S S S A F E T Y D E V IC E S
If a n y sa fe t y d e v ic e s u c h a s th e E n g in e S to p B u tto n o r E n g in e
O p e r a to r P r e s e n c e S w itc h b e c o m e d a m a g e d o r S to p
in o p e r a tiv e , r e p a ir o r r e p la c e th e m b e fo r e o p e r a tin g B u tto n
th e m a c h in e .

6 /0 2 A .1 0 .5
5 /0 3

7 8 0 1 0 1 1 1 8 -0 2 2 p c s.
7 8 0 1 0 1 1 2 0 -0 1 1 p c s.

7 8 0 1 0 1 1 3 5 -0 0 1 p c s.

7 8 0 1 0 1 1 4 1 -0 0 3 p c s.
M o v in g p a rts c a n
c ru s h a n d c u t.
K e e p h a n d s c le a r.
F o llo w lo c k o u t p ro c e d u re

C O P P E R H E A D D E C A L L O C A T IO N S
7 8 0 1 0 1 1 5 5 -0 0 1 p c s. b e fo re s e rv ic in g .
M o v in g p a rts c a n
c ru s h a n d c u t.
D o n o t o p e ra te w ith
g u a rd re m o v e d .
F o llo w lo c k o u t p ro c e d u re
b e fo re s e rv ic in g .
7 8 0 1 0 1 1 5 4 -0 0 3 p c s.
P in c h P o in ts .
M o v in g p a rt c a n c ru s h o r c u t.
K e e p c le a r .

7 8 0 1 0 1 1 1 9 -0 1 2 p c s.

7 8 0 1 0 1 1 6 7 -0 0 2 p c s.

7 8 0 1 0 1 1 2 8 -0 0 2 p c s.
P in c h P o in t.
K e e p h a n d s c le a r
d u rin g o p e ra tio n .

7 8 0 1 0 1 1 4 1 -0 0 3 p c s. 7 8 0 1 0 1 1 5 4 -0 0 3 p c s.
M o v in g p a rts c a n P in c h P o in ts .
c ru s h a n d c u t. M o v in g p a rt c a n c ru s h o r c u t.
K e e p h a n d s c le a r. K e e p c le a r .
F o llo w lo c k o u t p ro c e d u re
b e fo re s e rv ic in g .
A .1 0 .6
5 /0 3

7 8 0 1 0 1 1 1 8 -0 2 2 p c s.

7 8 0 1 0 1 1 1 9 -0 1 2 p c s.
7 8 0 1 0 1 0 2 8 -0 0 1 p c s.

C O P P E R H E A D D E C A L L O C A T IO N S
7 8 0 1 0 1 0 7 7 -0 1 1 p c s.
B u rn H a z a rd .
H o t s u rfa c e in s id e .
A llo w to c o o l b e fo re
s e rv ic in g .

7 8 0 1 0 1 1 0 9 -0 0 1 p c s.
F ire H a z a rd .
7 8 0 1 0 1 1 2 8 -0 0 2 p c s. T u rn fu e l a n d m a s te r
P in c h p o in t. s w itc h to O F F p o s itio n
K e e p h a n d s c le a r b e fo re tra n sp o rtin g
d u rin g o p e ra tio n . th is m a c h in e .

7 8 0 1 0 1 1 6 7 -0 0 2 p c s.

7 8 0 1 0 1 1 5 4 -0 0 3 p c s. 7 8 0 1 0 1 1 4 1 -0 0 3 p c s.
P in c h p o in ts . M o v in g p a rts c a n
M o v in g p a rt c a n
A .1 0 .7

c ru s h a n d c u t.
c ru sh o r c u t. K e e p h a n d s c le a r.
K e e p c le a r. F o llo w lo c k o u t p ro c e d u re
b e fo re s e rv ic in g .
5 /0 3

7 8 0 1 0 1 1 2 4 -0 0 1 p c s.

7 8 0 1 0 1 1 2 5 -0 0 1 p c s.

C O P P E R H E A D D E C A L L O C A T IO N S
7 8 0 1 0 1 1 6 6 -0 0 2 p c s. F la m m a b le g a se s
H o t su rfa c e . m a y b e p re se n t.
D o n o t to u c h . A v o id c a u s in g
T o a v o id p o s s ib le s k in b u rn s , sp a rk s.
d is c o n n e c t a n d lo c k o u t p o w e r
a n d a llo w s u rfa c e to c o o l
b e fo re s e rv ic in g .

7 8 0 1 0 1 1 2 6 -0 0 1 p c s.
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7 8 0 1 0 1 1 3 4 -0 0 1 p c s. m a n u a l b e fo re u s in g th is m a c h in e .
F a ilu re to fo llo w o p e ra tin g
in s tru c tio n s c o u ld re s u lt in in ju ry
o r d a m a g e to e q u ip m e n t.
A .1 0 .8
5 /0 3

7 8 0 1 0 1 1 6 5 -0 0 1 p c s. 7 8 0 1 0 1 1 6 4 -0 0 1 p c s.

7 8 0 1 0 1 1 6 6 -0 0 2 p c s.
H o t su rfa c e .
D o n o t to u c h .
T o a v o id p o s s ib le s k in b u rn s ,

C O P P E R H E A D D E C A L L O C A T IO N S
d is c o n n e c t a n d lo c k o u t p o w e r
a n d a llo w s u rfa c e to c o o l
b e fo re s e rv ic in g .

7 8 0 1 0 1 1 3 1 -0 0 1 p c s.
F la m m a b le .
H y d ra u lic flu id c a n
ig n ite a n d b u rn .
D o n o t o p e ra te if
le a k s a re d e te c te d .

7 8 0 1 0 1 0 7 8 -0 1 1 p c s.
S k in in je c tio n h a z a rd .
P ro te c t h a n d s a n d b o d y fro m h ig h p re s s u re flu id s .
R e lie v e p re s s u re b e fo re d is c o n n e c tin g h y d ra u lic
o r o th e r lin e s a n d tig h te n a ll c o n n e c tio n s
b e fo re a p p ly in g p re s s u re .
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A .1 0 .9

im m e d ia te " S u rg ic a l T re a tm e n t"
7 8 0 1 0 1 1 3 3 -0 0 1 p c s. F a ilu re to fo llo w th is w a rn in g c a n
re s u lt in a m p u ta tio n o r s e rio u s in ju ry .
5 /0 3

R iv e t, A lu m ,
7 8 0 4 0 1 0 1 3 -0 0 1 p c . 3 /3 2 O d X 3 /8 L g
2 0 7 3 1 4 p c s.

C O P P E R H E A D D E C A L L O C A T IO N S
7 8 0 1 0 1 1 4 8 -0 1 1 p c .
H y d ra u lic a n d
7 8 0 1 0 1 0 6 0 -0 1 1 p c . e le c tric p o w e r
so u rc e s p re se n t.
T u rn m a s te r s w itc h
o ff b e fo re se rv ic in g .
A .1 0 .1 0

7 8 0 4 0 1 0 1 5 -0 1 1 p c .
 C O P P E R H E A D O P E R A T O R C O N T R O L S
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6 /0 2 B .1 .1
      C O N T R O L S

R e f e r to F ig u r e B .1 .1 . C a llo u t n u m b e r s o n th e f ig u r e s c o r r e s p o n d to th e ite m n u m b e rs b e lo w . S e e th e e n g in e
m a n u a l fo r th e c o n tro ls o n th e e n g in e .

1 ) O P E R A T O R P R E S E N C E S W I T C H - T h e le ft s id e h a n d le b a r h a s a " O p e ra to r p re s e n c e s w itc h " fo r s a fe ty

w h ic h m u s t b e h e ld d o w n fo r th e m a c h in e to o p e ra te . W h e n y o u le t g o o f th is s w itc h th e d riv e tra in a n d th e
v ib ra to r c o m e to a c o m p le te s to p . H o w e v e r, e v e n w h e n th is s w itc h is re le a s e d , th e e n g in e a n d th e h e a d lift
fu n c tio n w ill c o n tin u e to o p e ra te .

2 ) D R I V E S P E E D C O N T R O L - T h e rig h t h a n d le b a r h a s a tw is t g rip w h ic h c o n tro ls th e s p e e d o f th e

C o p p e r h e a d 's d r i v e t r a i n : i n o t h e r w o r d s , h o w f a s t t h e w h e e l s t u r n . T w i s t i n g t h e g r i p t o w a r d t h e r e a r o f t h e
m a c h in e w ill in c re a s e th e s p e e d o f th e w h e e ls w h ile tw is tin g th e g rip to w a rd th e fro n t o f th e m a c h in e w ill
d e c re a s e th e s p e e d o f th e w h e e ls . T h e re a re tw o v e ry im p o rta n t fa c ts re la tin g to th is c o n tro l th a t y o u s h o u ld
ta k e n o te o f. O n e , th is c o n tro l d o e s n o t c h a n g e th e s p e e d o f th e e n g in e , it ju s t re g u la te s th e a m o u n t o f
h y d ra u lic d riv e d e liv e re d to th e w h e e ls . A n d tw o , th e tw is t g rip is n o t s p rin g lo a d e d , w h ic h m e a n s th a t o n c e
y o u s e t it to a c e rta in p o s itio n , it w ill s ta y th e re a n d n o t re tu rn to th e O F F o r N E U T R A L p o s itio n . T h e re fo re ,
i t 's v e r y i m p o r t a n t t h a t y o u r e m e m b e r t o m a n u a l l y r e t u r n t h i s c o n t r o l t o t h e O F F p o s i t i o n , w h i c h d i s e n g a g e s
th e d riv e , b e fo re d e p re s s in g th e O p e ra to r P re s e n c e S w itc h o n th e o th e r h a n d le b a r. O th e rw is e , w h e n y o u
d e p re s s th e O p e ra to r P re s e n c e S w itc h o n th e le ft h a n d le b a r to s ta rt m o v in g in fo rw a rd o r re v e rs e , th e m a c h in e
w ill ju m p q u ic k ly to th e d riv e s p e e d s e t b y th is c o n tro l.

3 ) V I B R A T O R M A S T E R S W IT C H - T h e V ib ra to r M a s te r s w itc h s e ts th e v ib ra to r to A U T O o r tu rn s if o ff
c o m p le te ly . W h e n th is s w itc h is in th e A U T O p o s itio n , th e v ib ra to r w ill n o t o p e ra te if th e m a c h in e is s e t to
d r iv e fo rw a r d o r is u n a tte n d e d . H o w e v e r , w h e n th e m a c h in e is s e t in re v e rs e a n d th e O p e ra to r P re s e n c e S w itc h
is d e p re sse d to b e g in a sc re e d in g p a s s , th e v ib ra to r w ill s ta rt a u to m a tic a lly .

4 ) P R O P E L S W I T C H - T h e P r o p e l s w i t c h c o n t r o l s t h e d i r e c t i o n o f t h e C o p p e r h e a d 's m o v e m e n t w h e n t h e
d riv e is e n g a g e d . It h a s tw o p o s itio n s , F O R W A R D a n d R E V E R S E .

5 ) H O U R M E T E R /B A T T E R Y I N D I C A T O R - T h e H o u r M e te r w ill c o u n t w h e n e v e r th e M a s te r S w itc h is
O N a n d in d ic a te s h o w m a n y to ta l h o u rs th e m a c h in e h a s b e e n ru n n in g . T h is in fo rm a tio n is p rim a rily u s e d to
d e te rm in e w h e n m a in te n a n c e fu n c tio n s s h o u ld b e p e rfo rm e d o n th e C o p p e rh e a d . T h e B a tte ry In d ic a to r s h o w s
th e c h a rg e s ta tu s o f th e b a tte ry .

6 ) E L E V A T I O N C O N T R O L S W I T C H E S - J u s t b e lo w th e H o u r M e te r/B a tte ry In d ic a to r is a ro w o f th re e
s w itc h e s . T h e s e s w itc h e s , w o rk in g to g e th e r, c o n tro l th e e le v a tio n , o r h e ig h t, o f th e le ft a n d rig h t s id e s o f th e
p lo w in re la tio n to th e v ib ra to r p la te . T h e c e n te r s w itc h to g g le s th e e le v a tio n c o n tro l o f th e p lo w b e tw e e n A u to
a n d M a n u a l o p e ra tio n . U n d e r a ll n o rm a l s c re e d in g c o n d itio n s , th is s w itc h s h o u ld b e s e t to th e A U T O p o s itio n .
S i n c e t h e e l e v a t i o n o f t h e p l o w i s c r i t i c a l t o s c r e e d i n g a h i g h q u a l i t y f l o o r , l e t 's r e v i e w i n d e t a i l h o w t h i s
s w itc h a ffe c ts th e o p e ra tio n o f th e m a c h in e . W h e n th e E le v a tio n A u to /M a n u a l S w itc h is s e t to th e A U T O
p o s itio n , th e O p e ra tio n s B o x , u s in g re fe re n c e in fo rm a tio n fro m th e la s e r re c e iv e rs , c o n tin u o u s ly s e n d s
in s tru c tio n s to th e lin e a r a c tu a to rs o n th e s c re e d h e a d to k e e p th e p lo w a t th e c o rre c t h e ig h t.

If o n e o f th e la s e r re c e iv e rs lo s e s th e re fe re n c e s ig n a l, th e O p e ra tio n s B o x w ill le a v e th e s c re e d h e a d a t th e la st
k n o w n c o rre c t h e ig h t u n til th e s ig n a l fro m th e la s e r tra n s m itte r is re a c q u ire d . L ik e w is e , if b o th la s e r re c e iv e r s
lo s e th e re fe re n c e s ig n a l, th e n th e O p e ra tio n s B o x w ill k e e p th e p lo w a t th e la s t k n o w n c o rre c t h e ig h t. A t th a t
p o in t, th e o p e ra to r w ill b e e ffe c tiv e ly o p e ra tin g th e m a c h in e m a n u a lly , a lth o u g h th e m a c h in e re m a in s s w itc h e d
in to th e A U T O m o d e .

6 /0 2 B .1 .2
A ls o in th e A U T O m o d e , w h e n e ith e r s id e o f th e p lo w is lo c k e d b e c a u s e th e re fe re n c e s ig n a l h a s b e e n lo s t, th e
L e ft a n d R ig h t E le v a tio n S w itc h e s c a n b e u s e d to m o v e th e p lo w u p o r d o w n if n e c e s s a ry to c o n tin u e a c c u ra te
s c re e d in g . T h is a llo w s th e o p e ra to r to c o n tro l s c re e d in g h e ig h t o n o n e o r b o th s id e s o f th e p lo w w ith o u t a n y
re fe re n c e to th e s ig n a l fro m th e la s e r tra n s m itte r. W h e n o n e o f th e s e s w itc h e s is a c tiv a te d , th e p lo w o n th a t
s id e o f th e s c re e d h e a d w ill c o n tin u e m o v in g u n til th e s w itc h is re le a s e d o r th e a c tu a to r re a c h e s its lim it. T h e
p lo w w ill th e n s ta y in th a t p o s itio n u n til th e re fe re n c e s ig n a l is re a c q u ire d o r th e E le v a tio n S w itc h fo r th a t s id e
is a c tiv a te d a g a in . A g a in , in th is m o d e , a s s o o n a s th e la s e r re fe re n c e s ig n a l is re a c q u ire d b y e ith e r o n e o f th e
re c e iv e rs , th e O p e ra tio n s B o x w ill a u to m a tic a lly b e g in a d ju s tin g th e p lo w h e ig h t o n th a t s id e o f th e s c re e d
h e a d u p a n d d o w n to m e e t th e re fe re n c e g ra d e . W h e n th e o th e r re c e iv e r re a c q u ire s th e re fe re n c e s ig n a l, th e
p lo w w ill a g a in b e u n d e r fu ll a u to m a tic c o n tro l. W h e n th e E le v a tio n A u to /M a n u a l s w itc h is s e t to th e
M A N U A L p o s itio n , th e h e ig h t o f th e p lo w is n o t re fe re n c e d to th e la s e r tra n s m itte r a t a ll. In s te a d th e h e ig h t o f
th e p lo w is a ffe c te d o n ly b y th e L e ft a n d R ig h t E le v a tio n s w itc h e s . T h e o p e ra tio n o f th e s e L e ft a n d R ig h t
E le v a tio n s w itc h e s in th is m o d e , h o w e v e r, c o n tin u e to w o rk a s o u tlin e d b e fo re . T h e y c a u s e th e p lo w o n th a t
s id e o f th e s c re e d h e a d to m o v e u p o r d o w n u n til th e s w itc h is re le a s e d o r th e a c tu a to r h its its lim it.

7 ) S I D E L O C K S W I T C H - T h e S i d e L o c k S w i t c h c o n t r o l s a k e y f e a t u r e o f t h e C o p p e r h e a d , i t 's a b i l i t y t o
d riv e o v e r u n e v e n g ro u n d w h ile k e e p in g th e s c re e d h e a d le v e l a n d c o n s ta n tly re fe re n c e d to th e la s e r
tra n s m itte r. In o rd e r to a c c o m p lis h th is , th e m a c h in e w a s d e s ig n e d w ith a n u p p e r fra m e a n d a lo w e r fra m e ,
w h ic h a re c o n n e c te d b y a p iv o t jo in t. T h a t a llo w s th e lo w e r fra m e to m o v e u p o r d o w n o n e ith e r s id e w h ile th e
u p p e r fra m e s ta y s le v e l. A n d b e c a u s e th e s c re e d h e a d is a tta c h e d o n ly to th e u p p e r fra m e , th e s c re e d h e a d is
is o la te d fro m th e e ffe c t o f b u m p s a n d o b s ta c le s o n th e s u b -flo o r. W h e n th e S id e L o c k S w itc h is s e t to th e O N
p o s itio n , th e u p p e r a n d lo w e r fra m e s a re lo c k e d to g e th e r a n d d o n o t m o v e in d e p e n d e n tly . T h is is u s e fu l w h e n
tra n s p o rtin g th e m a c h in e o n s ite b e c a u s e , o th e rw is e , th e u p p e r fra m e w o u ld tip fro m s id e to s id e , fo rc in g th e
o p e ra to r to p ro v id e b a la n c e . W h e n th is s w itc h is in th e O F F p o s itio n , th e u p p e r fra m e c a n m o v e fro m s id e to
s id e in d e p e n d e n tly o f th e lo w e r fra m e . T h is m a y o c c a s io n a lly b e u s e fu l d u rin g p la c e m e n t o p e ra tio n s , b u t th e
p re fe rre d a p p ro a c h w h ile s c re e d in g is to le a v e th is s e ttin g in A U T O . W h e n th e S id e L o c k S w itc h is in th e
A U T O p o s itio n , th e u p p e r a n d lo w e r fra m e s a re lo c k e d a t a ll tim e s , e x c e p t w h e n th e C o p p e rh e a d is
p e rfo rm in g a n a c tu a l s c re e d in g p a s s . In o th e r w o rd s , w h e n th e P ro p e l S w itc h is s e t to R E V E R S E a n d th e
O p e ra to r P re s e n c e S w itc h is d e p re s s e d , th e S id e L o c k w ill b e re le a s e d a n d th e tw o fra m e s w ill m o v e fro m s id e
to s id e in d e p e n d e n tly . W ith a n y o th e r c o m b in a tio n o f c o n tro l s e ttin g s , th e fra m e s w ill b e lo c k e d to g e th e r,
w h ic h re d u c e s s tra in o n th e o p e ra to r a n d a llo w s e a s ie r m a n e u v e rin g b e tw e e n p a s s e s o n fre s h c o n c re te .
T h e re fo re , in m o s t c irc u m s ta n c e s , th e o p e ra to r s h o u ld le a v e th is s w itc h s e t in th e A U T O p o s itio n .

8 ) M A S T E R S W I T C H /M A S T E R S W I T C H IN IC A T O R L IG H T - W h e n th e M a s te r S w itc h is tu rn e d O N ,
a ll e le c tric a l a n d h y d ra u lic fu n c tio n s o n th e m a c h in e a re e n a b le d . W h e n th e M a s te r S w itc h is tu rn e d O F F , th e
e n tire m a c h in e is in o p e ra b le , w ith o n e e x c e p tio n , th e m a c h in e c a n b e s ta rte d a n d c o n tin u e to ru n . T h e
In d ic a to r L ig h t w ill g lo w re d w h e n th e M a s te r S w itc h is tu rn e d O N a n d , a s it w a s m e n tio n e d b e fo r e , th e H o u r
M e te r w ill b e g in re g is te rin g e la p s e d tim e o f o p e ra tio n .

9 ) L E V E L - T h is b u b b le le v e l in d ic a te s w h e th e r th e m a c h in e is o rie n te d c o rre c tly fo r s c r e e d in g o p e ra tio n s .

T h is is im p o r ta n t, b e c a u s e if th e m a c h in e is n o t p ro p e rly le v e le d , th e n th e a tta c k a n g le o f th e s c re e d h e a d w ill
b e w ro n g a n d p o o r s c re e d in g re s u lts w ill o c c u r. D u rin g th e c o u r se o f a jo b , th e le v e l s h o u ld b e c h e c k e d a t th e
b e g in n in g o f e a c h p a s s to in s u re th a t th e m a c h in e a n d th e s c re e d h e a d a re c o rre c tly a lig n e d .

1 0 ) E N G I N E S T O P S W I T C H - T w is tin g th e E n g in e S to p s w itc h c lo c k w is e a llo w s th e e n g in e to b e s ta rte d .

P u s h in g th is c o n tro l d o w n s h u ts o ff th e e n g in e a n d c a n b e u s e d d u rin g o p e ra tio n s a s a n e m e rg e n c y " k ill
s w itc h " .

6 /0 2 B .1 .2
1 1 ) E N G I N E T H R O T T L E C O N T R O L - P u s h in g th e E n g in e T h ro ttle C o n tro l fo rw a rd d e c re a s e s th e s p e e d
o f th e e n g in e a n d p u llin g it b a c k in c re a s e s th e s p e e d o f th e e n g in e . D u rin g s c re e d in g o p e ra tio n s , th e th ro ttle
w o u ld n o rm a lly b e p u lle d a ll th e w a y b a c k s o th a t th e e n g in e w a s o p e ra tin g a t fu ll s p e e d .

1 2 ) H E A D L I F T S W I T C H - T h e H e a d L ift S w itc h lifts th e s c re e d h e a d u p a n d d o w n to le v e l th e m a c h in e .

T h is s w itc h s h o u ld a ls o b e u s e d to lift th e s c re e d h e a d u p to its fu ll h e ig h t p rio r to m a n e u v e rin g th e m a c h in e
a ro u n d th e jo b s ite .

1 3 ) T R A C T IO N A S S I S T S W I T C H - T h e T ra c tio n A s s is t S w itc h is s e t in th e O F F p o s itio n d u rin g m o st

n o rm a l o p e ra tio n s . In th e O F F p o s itio n , th e C o p p e rh e a d 's w h e e ls tu rn in d e p e n d e n tly , w ith h y d ra u lic p o w e r
flo w in g to th e w h e e l m o to r w h ic h is e n c o u n te rin g th e le a s t re s is ta n c e . In th e O N p o s itio n , th e h y d ra u lic
s y s te m is d e s ig n e d to b a la n c e p o w e r b e tw e e n th e tw o w h e e l m o to rs . T h is a llo w s tra c tio n to b e im p ro v e d w h e n
w h e e l s lip p a g e is e n c o u n te re d . N O T E : T h e C o p p e rh e a d m a y b e a little d iffic u lt to m a n e u v e r w h e n th e tra c tio n
a s s is t is O N .

6 /0 2 B .1 .2
 F R A M E

T h e fra m e o f th e C o p p e rh e a d in c o rp o ra te s th e e n g in e , h e a d lift, h y d ra u lic s , a n d th e d riv e tra in , w h ic h

in c lu d e s th e w h e e ls o f th e m a c h in e . A ls o , s e p a ra te , b u t u s u a lly m o u n te d o n th e m a c h in e , a re fo u r (4 )
c o u n te rw e ig h ts .

T h e e n g in e is a H o n d a G X 2 7 0 w ith a m a x im u m o u tp u t o f 9 h o rs e p o w e r. T h e e n g in e p o w e rs th e
C o p p e r h e a d 's h y d r a u l i c s y s t e m a n d a l s o k e e p s t h e b a t t e r y c h a r g e d . T h e b a t t e r y , i n t u r n , p o w e r s t h e l a s e r
re c e iv e rs a n d lin e a r a c tu a to rs , a s w e ll a s th e in d ic a to r lig h t, s w itc h e s , a n d o th e r e le c tric a l c o m p o n e n ts .

B e f o r e y o u b e g i n u s i n g t h e C o p p e r h e a d , i t 's i m p o r t a n t t h a t y o u r e a d a n d u n d e r s t a n d t h e H o n d a E n g i n e
O w n e r 's M a n u a l . I t c o n t a i n s c o m p l e t e o p e r a t i n g i n s t r u c t i o n s , d e t a i l e d s e r v i c e s c h e d u l e s , a n d i m p o r t a n t
s a fe ty in fo rm a tio n .

T h e H e a d L ift is a h y d ra u lic c y lin d e r th a t m o v e s th e s c re e d h e a d u p a n d d o w n in re la tio n to th e c h a s s is .

T h is a llo w s th e s c re e d h e a d to s it le v e l o n th e p la c e m e n t re g a rd le s s o f th e d e p th o f th e c o n c re te . A n d ,
s in c e th e w h e e ls o f th e C o p p e rh e a d re st o n th e s u b -flo o r, a n d th e s u b -flo o r h e ig h t u s u a lly v a rie s q u ite a
b it a c ro s s th e e n tire p la c e m e n t, re g u la r a d ju s tm e n ts to th e H e a d L ift a re n e e d e d d u rin g s c re e d in g
o p e ra tio n s .

T h e h y d ra u lic s y s te m h a s n in e (9 ) p rim a ry c o m p o n e n ts . S e e s e c tio n D . fo r H y d ra u lic O p e ra tio n .

T h e d riv e tra in s im p ly c o n s is ts o f tw o h y d ra u lic m o to rs , o n e fo r e a c h w h e e l, a n d th e w h e e ls th e m s e lv e s .

C O P P E R H E A D G R O U N D P R E S S U R E
M a c h in e w e ig h t = 6 6 0 lb s . (3 0 0 k g )

G r o u n d p r e s s u r e p e r tir e *

S ta n d a rd M T B T ire
4 1 .2 5 p s i (2 8 4 K P a )
p e r tire
A T V T ire
4 .1 p s i ( 2 8 K P a )
p e r tire

* G ro u n d p re s s u re d e te rm in e d d u rin g m a n e u v e rin g w h ile h e a d e le v a te d o ff g ro u n d .

N O T E : C o n s u lt s tr u c tu r a l e n g in e e r b e fo r e u s in g C o p p e r h e a d o n a n y jo b s ite .

1 2 /0 2 B .2 .1
 S C R E E D H E A D

T h e s c re e d h e a d is c o m p o s e d o f fiv e (5 ) c o m p o n e n ts a n d a ls o h o ld s th e m a s ts fo r th e tw o la s e r re c e iv e rs .

1 . S c re e d H e a d S u p p o rt - A s its n a m e im p lie s , th is s u p p o rts th e s c re e d h e a d .

2 . V ib ra to r G e a r B o x - T h is g e a r b o x h o u s e s th e c o m p o n e n ts th a t p ro v id e v ib ra tio n to th e v ib ra to r p la te .

3 . V ib ra to r p la te - T h is p la te p ro v id e s flo a ta tio n fo r th e fro n t o f th e m a c h in e a n d s e a ls th e fre s h ly

s c re e d e d c o n c re te .

4 . L in e a r A c tu a to rs - T h e s e p re c is io n e le c tric d e v ic e s c o n tro l th e e le v a tio n o f th e p lo w .

5 . P lo w - T h e p lo w a c tu a lly c u ts th e c o n c re te to g ra d e a n d is c o n tro lle d b y th e lin e a r a c tu a to rs .

T U R N B U C K L E S E T T IN G
2 -1 /2 " = 3 D e g re e A tta c k A n g le

R e c o m m e n d e d m a x im u m s e ttin g o f 3 -1 /8 " = 6 D e g re e A tta c k A n g le

R e c o m m e n d e d m in im u m s e ttin g o f 2 -1 /8 " = 1 D e g re e A tta c k A n g le

1 2 /0 2 B .2 .2
 IT E M S T O B R IN G T O A J O B S IT E

1 .) L a s e r T r a n s m itte r 9 .) C o p p e r h e a d G r a d e r o d
2 .) T r ip o d /C o lu m n c la m p 1 0 .) B a tte r ie s f o r L a s e r
3 .) G a s 1 1 .) R u b b e r B o o ts
4 .) T a c h o m e te r 1 2 .) S a f e ty G la s s e s
5 .) S c r u b B r u s h f o r w a s h in g 1 3 .) C o p p e r h e a d C o u n te r W e ig h ts
6 .) G e n e r a l to o l s e t 1 4 .) E a r P lu g s
7 .) S p a r e tir e 1 5 .) S p a r e P a r ts K it
8 .) H a r d h a ts

P R E S T A R T M A C H IN E C H E C K a n d S A F E T Y C H E C K
B e fo re s ta rtin g th e m a c h in e , p e rfo rm th e fo llo w in g c h e c k s :
1 .) C h e c k th e e n g in e o il le v e l.
2 .) C h e c k f u e l le v e l.
3 .) C h e c k th e a ir f ilte r .
4 .) C h e c k th e h y d r a u lic o il le v e l.
5 .) C h e c k th e b a tte r y c o n d itio n .
6 .) C h e c k th e c o n d itio n o f th e h y d r a u lic c o o le r f in s .
If th e fin s b e c o m e o ily , d irt w ill s tic k to th e m a n d e v e n tu a lly b lo c k a ir flo w .
7 .) C h e c k f o r a n y o b s tr u c tio n s a t th e e n g in e c o o lin g a ir in ta k e a n d d is c h a r g e .
8 .) C h e c k h y d r a u lic p u m p a n d a s s o c ia te d h o s e s a n d f ittin g s f o r le a k s .
9 .) C h e c k h y d r a u lic o il f ilte r a n d a s s o c ia te d h o s e s a n d f ittin g s f o r le a k s .
1 0 . ) C h e c k t i r e c o n d i t i o n . C h e c k t i r e p r e s s u r e o n A T V 's .
1 1 .) C h e c k c ir c u u it b r e a k e r s .
1 2 .) E n s u r e a ll g u a r d s a n d s a f e ty d e c a ls a r e in p la c e .
1 3 .) S e t T u r n b u c k le to 2 1 /2 in c h e s b e tw e e n tu r n b u c k le e n d s in s id e tu r n b u c k le b o d y .
1 4 .) V e r if y a c c u r a c y o f L e v e l in d ic a to r .
1 5 .) L e v e l m a c h in e w ith H e a d lif t.
1 6 .) V e r if y L a s e r /E le c tr o n ic s w o r k in g p r o p e r ly .
1 7 .) C h e c k v ib r a to r s p e e d .

1 2 /0 2 B .3 .1
 S T A R T IN G T H E M A C H IN E
R e fe r to th e e n g in e m a n u a l fo r e n g in e s ta rtin g a n d s to p p in g in s tru c tio n s .
W a rm u p p r o c e d u r e to b e u s e d w h e n th e a m b ie n t te m p e r a tu r e is b e lo w 3 2 ° F . ( S e e p a g e B .3 .4 )

C A U T IO N :
H y d ra u lic o il s h o u ld re a c h 8 0 ° F b e fo re u s in g m a c h in e to s c re e d
c o n c re te . R u n a h y d ra u lic fu n c tio n to w a rm h y d ra u lic o il, re c o m m e n d e d
fu n c tio n is p ro p e l. D o n o t e n g a g e p u m p if h y d ra u lic o il is b e lo w -1 3 ° F .

2 .) C h e c k to b e su re th a t th e e n g in e
s w itc h is o n . N O T E : T h is s w itc h s h o u ld
1 .) B e s u r e th a t P r o p e l T w is t is o f f . a lw a y s b e o n , th e E n g in e S to p S w itc h is
u se d a s th e m a in e n g in e s w itc h . S e e s te p 7 .

3 .) O p e n s id e d o o r to lo c a te f u e l 4 .) B e s u r e th e f u e l v a lv e le v e r is O N .
v a lv e a n d c h o k e . N O T E : F u e l s h o u ld b e o ff w h ile tra n s p o rtin g .

1 2 /0 2 B .3 .2
 5 .) If th e e n g in e is c o ld , m o v e th e
c h o k e le v e r to th e C L O S E D p o s itio n . 6 .) M o v e th e th r o ttle le v e r a w a y f r o m th e
T o re s ta rt a w a rm e n g in e , le a v e th e S L O W p o s itio n , a b o u t 1 /3 o f th e w a y
c h o k e le v e r in th e O P E N p o s itio n . to w a rd th e F A S T p o s itio n .

7 .) T u r n e n g in e s to p s w itc h c lo c k w is e . 8 .) P u ll th e s ta r te r c o r d lig h tly u n til

y o u fe e l re s is ta n c e , th e n p u ll b ris k ly .
R e tu rn th e s ta rte r g rip g e n tly .

9 .) M o v e th e th r o ttle le v e r to th e
F A S T p o s itio n . T u rn M a s te r S w itc h O N a n d
th e C o p p e rh e a d is re a d y fo r O p e ra tio n .

C O L D W E A T H E R S T A R T P R O C E D U R E
1 ) S ta rt th e e n g in e a t a lo w R P M a n d le a v e ru n n in g u n til e n g in e is w a rm e d (S e e H o n d a m a n u a l).
2 ) T u rn v ib ra to r s w itc h o ff.
3 ) O n c e e n g in e is w a rm , p ro p e l a ro u n d th e jo b s ite to w a rm th e h y d ra u lic o il -- B E F O R E ru n n in g
th e v ib ra to r. D o th is fo r 1 0 m in u te s o r s o . If it is c o ld e r, ru n th e m a c h in e lo n g e r.
4 ) D r o p t h e e n g i n e R P M 's t o a p p r o x i m a t e l y 1 /2 th ro ttle .
5 ) R u n th e v ib ra to r in s h o rt b u rs ts fo r 3 -1 0 s e c o n d s.
6 ) L e t th e v ib ra to r ru n fo r 5 m in u te s .

1 2 /0 2 B .3 .3
 H A N D H E L D
R E C E IV E R L A S E R R E C E IV E R S

L A S E R C O P P E R H E A D
T R A N S M IT T E R G R A D E R O D P L A C E T H E C O P P E R H E A D
G R A D E R O D O N T O P O F
T H E P L O W A S S E M B L Y
A P P R O X IM A T E L Y
C O P P E R H E A D 6 1 /2 - 7 ft.
G R A D E R O D ( 1 .9 8 - 2 .1 3 M )

9 0

S U B -G R A D E D E S IR E D G R A D E

S E T U P P R O C E D U R E
1 .) S ta r t u p L a s e r T r a n s m itte r a t 6 .5 - 7 f e e t a b o v e g r a d e . B e s u r e th e L a s e r T r a n s m itte r is s e t u p in a
lo c a tio n th a t w ill n o t h a v e a n y th in g in th e w a y to c a u s e in te rfe re n c e .
2 .) E s ta b lis h a n d s e t g r a d e o n th e C o p p e r h e a d G r a d e R o d .
3 .) P o s itio n M a c h in e in c o n c r e te , m a k in g s u r e b o th la s e r r e c e iv e r s a r e c le a r to th e tr a n s m itte r a n d
s w itc h e le v a tio n c o n tro l to m a n u a l.
4 .) U s in g le v e l in d ic a to r , le v e l th e m a c h in e w ith H e a d L if t.
5 .) N e a r th e la s e r r e c e iv e r m a s t, p la c e th e C o p p e r h e a d G r a d e R o d r in g o n to p o f p lo w a n d h o ld v e r tic a l.
6 .) U s in g r a is e /lo w e r e le v a tio n c o n tr o l, a d ju s t h e ig h t o f p lo w u n til C o p p e r h e a d G r a d e R o d in d ic a te s
p ro p e r g ra d e .
7 .) R e p e a t S te p # 6 f o r o p p o s ite s id e a n d th e n r e c h e c k o r ig in a l s id e .
8 .) O n c e th e p lo w is o n - g r a d e , m a n u a lly lo w e r th e la s e r r e c e iv e r ( f r o m to p d o w n ) u n til
t h e L E D 's i n d i c a t e t h e o n - g r a d e s i g n a l , r e p e a t t h e p r o c e s s f o r t h e o p p o s i t e s i d e .
9 .) S w itc h e le v a tio n c o n tr o l to a u to m a tic .
1 0 .) S c r e e d a p p r o x im a te ly 6 f e e t th e n v e r if y g r a d e a n d m a k e a d ju s tm e n ts if r e q u ir e d .

S H U T D O W N P R O C E D U R E
1 .) P o s itio n p lo w 1 " fro m to p .
2 .) T u r n o ff m a c h in e .
3 .) S h u t o ff F u e l.
4 .) U se p re s s u re w a s h e r to c le a n m a c h in e .

1 2 /0 2 B .3 .4
 L O A D IN G A N D U N L O A D IN G P R O C E D U R E S
T h e b e s t w a y to tra n s p o rt th e C o p p e rh e a d is o n a d e d ic a te d tra ile r. O f c o u rs e , b e fo re y o u u s e a n y tra ile r
f o r t h i s p u r p o s e , y o u s h o u l d c h e c k t o s e e w h e t h e r t h e o n e y o u 'r e c o n s i d e r i n g i s u p t o t h e t a s k . A t t h e
v e r y l e a s t , i t m u s t h a v e s t u r d y r a m p s a n d a l o a d r a t i n g t h a t i s m o r e t h a n a d e q u a t e f o r t h e C o p p e r h e a d 's
w e ig h t a n d s iz e .
T o lo a d th e C o p p e rh e a d , s ta rt b y s e ttin g th e p a rk in g b ra k e o n y o u r v e h ic le a n d c h o c k th e w h e e ls o f th e
tra ile r. T h e n lo w e r th e d riv e -o n ra m p a n d c h e c k to m a k e s u re th a t it is s e c u re ly a tta c h e d .
N e x t, u s in g th e e n g in e p o w e r o f th e C o p p e rh e a d , d riv e th e m a c h in e u p o n to th e tra ile r.
T h e n , s e c u re th e C o p p e rh e a d b y th re a d in g n y lo n s tra p s th ro u g h th e m a c h in e a n d c in c h in g th e s tra p s u p
tig h t.
S o m e ro re c o m m e n d s th a t y o u tra n s p o rt th e C o p p e rh e a d w ith th e s c re e d h e a d a tta c h e d . H o w e v e r, in
so m e c a s e s , th a t m a y n o t b e fe a s ib le , in w h ic h c a s e y o u m u s t re m o v e th e s c re e d h e a d fro m th e m a c h in e
b e fo re lo a d in g . If th is is n e c e s s a ry , s ta rt b y s e ttin g th e k ic k s ta n d o n th e m a c h in e s o th a t it d o e s n 't f a l l
o v e r b a c k w a rd s w h e n y o u re m o v e th e s c r e e d h e a d . T h e n d is c o n n e c t th e q u ic k re le a s e h y d ra u lic fittin g s
a n d d o th e s a m e f o r th e tw o q u ic k re le a s e e le c tric a l fittin g s . F in a lly , p u ll o u t th e re ta in in g c lip s o n th e
tw o la rg e c o tte r p in s w h ic h h o ld th e s c re e d h e a d to th e tu rn b u c k le a n d th e lift a rm . T h e s c re e d h e a d is
n o w fre e a n d c a n b e s e t a s id e .
O n c e th e s c re e d h e a d h a s b e e n d e ta c h e d fro m th e m a c h in e is s h o u ld b e tie d d o w n to th e tra ile r w ith
n y lo n s tra p s a s w e ll. B e c a re fu l n o t to tig h te n th e s tra p s m o re th a n n e c e s s a ry - to o m u c h d o w n w a rd
p re s s u re c a n d a m a g e th e v ib ra to r flo a t o r th e p lo w .

S e c u re th e C o p p e rh e a d
to a tra ile r w ith th e
tie d o w n s tra p s a v a ila b le
fro m o u r C u s to m e r S u p p o rt
D e p a rtm e n t 9 0 6 -4 8 2 -7 2 5 2 .
P a rt # 7 4 0 8 0 1 2 5 4 -x x

T ie D o w n L o c a tio n s o n T ie D o w n L o c a tio n s o n
F r o n t o f m a c h in e B a c k o f m a c h in e

B e s u r e to tu r n th e M a s te r S w itc h o ff w h ile tr a n s p o r tin g th e C o p p e r h e a d .

1 2 /0 2 B .4 .1
U n lo a d in g th e C o p p e rh e a d is s im p ly th e re v e rs e o f th e lo a d in g p ro c e d u re .

F i r s t , r e m o v e t h e s t r a p s h o l d i n g t h e C o p p e r h e a d t o t h e t r a i l e r 's b e d . O f c o u r s e , i f t h e s c r e e d h e a d h a s
b e e n d e ta c h e d , th e n it s h o u ld b e re m o v e d fro m th e tra ile r firs t a n d s e t a s id e .

B e fo re ro llin g o r d riv in g th e C o p p e rh e a d o ff th e tra ile r, c h e c k to s e e th a t th e c o u n te rb a la n c e v a lv e o n th e

h y d ra u lic s y s te m is c lo s e d . In th is p o s itio n , th e h y d ra u lic s y s te m p ro v id e s s o m e b ra k in g a c tio n to th e
d riv e tra in w h ic h w ill p re v e n t th e C o p p e rh e a d fro m fre e w h e e lin g d o w n a n d in c lin e . In fa c t, u n d e r a ll
n o rm a l o p e ra tin g a n d tra n s p o rta tio n c o n d itio n s , th is v a lv e s h o u ld re m a in c lo s e d . It s h o u ld o n ly b e
o p e n e d if y o u n e e d to m o v e th e m a c h in e o v e r le v e l g ro u n d w h e n th e e n g in e is n o t ru n n in g . A s w a s
m e n tio n e d e a rlie r, o p e n in g th is v a lv e b y p a s s e s th e h y d ra u lic s y s te m o n th e d riv e tra in a n d a llo w s th e
m a c h in e to ro ll fre e ly . A fte r th is fin a l s a fe ty c h e c k is c o m p le te , th e C o p p e rh e a d c a n b e d riv e n o r ro lle d
o ff th e b a c k o f th e tra ile r.

If th e s c re e d h e a d n e e d s to b e re a tta c h e d , s ta rt b y p o s itio n in g th e s c re e d h e a d a t th e fro n t o f th e m a c h in e .

T h e n b rin g th e a tta c h m e n t c o u p lin g s fo r th e lift a rm a n d th e tu rn b u c k le to g e th e r, in s e rt th e c o tte r p in s ,
a n d re p la c e th e re ta in in g c lip s . F in a lly , re a tta c h th e e le c tric a l a n d h y d ra u lic c o n n e c to rs .
N o w , b e fo re y o u m o v e th e m a c h in e to th e p la c e m e n t a re a , c h e c k th e ro u te y o u p la n to ta k e a n d m a k e
su re th a t it is fre e o f o b s ta c le s th a t c o u ld d a m a g e th e m a c h in e . T h e sc re e d h e a d in p a rtic u la r is a
p re c is io n d e v ic e a n d in s o m e c a s e s m a y h a v e to b e re m o v e d in o r d e r to g e t it s a fe ly o n to th e jo b s ite .
A n d , re m e m b e r, w ith th e s c re e d h e a d re m o v e d , th e C o p p e rh e a d w ill b e b a c k h e a v y . T h e re fo re , a s y o u
m o v e th e m a c h in e a ro u n d , y o u w ill h a v e to h o ld u p o n th e c o n tro l h a n d le s in o rd e r to p re v e n t th e
C o p p e rh e a d fro m fa llin g o v e r b a c k w a rd s .

W i t h t h e r o u t e p l a n n e d a n d a n a s s i s t a n t s t a n d i n g b y , y o u c a n n o w m o v e t h e m a c h i n e . H e r e 's t h e
p ro c e d u re fo r g e ttin g u n d e r w a y .

1 . In c re a s e th e e n g in e s p e e d b y p u llin g th e T h ro ttle L e v e r to w a rd th e re a r o f th e m a c h in e .

2 . P u s h d o w n o n th e h a n d le b a rs to lift th e h e a d u p o ff th e g ro u n d .

3 . S e t th e P ro p e l s w itc h to d riv e fo rw a rd .

4 . P u s h d o w n o n th e O p e ra to r P re s e n c e S w itc h .

5 . R o ta te th e D riv e S p e e d C o n tro l to w a rd th e o p e ra to r.

W h e n y o u 'r e m a n e u v e rin g th e C o p p e rh e a d a ro u n d th e w o rk s ite , s e t th e sc re e d h e a d a s h ig h a s p o s s ib le

b y a c tiv a tin g th e H e a d L ift s w itc h a n d b e o n th e lo o k o u t fo r o b s tru c tio n s. K e e p in m in d th a t th e s c re e d
h e a d is s u b s ta n tia lly w id e r th a n th e m a c h in e its e lf a n d is o n ly s u p p o rte d a t tw o p o in ts b y th e H e a d L ift.
S o , if y o u ru n in to s o m e th in g w ith th e sc re e d h e a d , e v e n a t lo w sp e e d , i t 's v e r y lik e ly th a t d a m a g e to th e
m a c h in e w ill re s u lt.

1 2 /0 2 B .4 .1
 L IF T IN G & M O V IN G T H E M A C H IN E

L IF T P O IN T S
T h e C o p p e rh e a d c a n b e m o v e d b y th e lift p o in ts p ro v id e d .

1 .) S h u t d o w n m a c h in e .
2 .) T u rn o ff a ll p o w e r.
3 .) S o m e ro re c o m m e n d s th a t y o u u s e th e o p tio n a l liftin g d e v ic e th a t is a v a ila b le fo r p u rc h a s e o r a n
e q u iv a le n t d e v ic e ra te d fo r 1 0 0 0 lb s . a n d a b o v e .
§ trip le c h a in lo o p w ith h o o k s
§ th re e liftin g s tra p s w ith h o o k s
§ trip le c a b le lo o p w ith h o o k s
4 .) H o o k lif tin g e y e s lo c a te d o n fra m e a n d h a n d le b a r (p ic tu re d b e lo w ).
5 .) S lo w ly lif t m a c h in e a n d c h e c k b e fo r e liftin g o v e rh e a d .

L IF T P O IN T S
W e ig h t w /1 0 ' h e a d :
6 6 0 lb s (3 0 0 k g )

7 8 0 1 0 1 1 3 5 -0 0

F O R K L IF T 7 8 0 1 0 1 1 3 5 -0 0

T h e C o p p e rh e a d c a n a ls o b e m o v e d w ith a fo rk lift. F irs t, b e s u re th a t th e k ic k s ta n d is in th e u p p o s itio n .

A p p ro a c h th e C o p p e rh e a d fro m th e s id e a t a lo w s p e e d w ith fo rk s lo w . B e e x tra c a re fu l n o t to b u m p th e
C o p p e rh e a d w ith th e fo rk s . L ift a n d d riv e a t a lo w s p e e d .

1 2 /0 2 B .4 .2
 L A S E R S Y S T E M

T h e G C R re c e iv e rs w ill w o rk w ith m o st o f th e s ta n d a rd la s e r tra n sm itte rs c u rre n tly in u s e b y th e

c o n s tru c tio n in d u s try . H o w e v e r, th e tra n s m itte r y o u s e le c t w ill n e e d to m e e t c e rta in m in im u m g u id e lin e s
in o rd e r fo r th e C o p p e rh e a d to p e rfo rm a t its b e s t. T h e k e y th in g s to lo o k fo r a re th e ra te a t w h ic h th e
la s e r tra n s m itte r ro ta te s a n d th e a c c u ra c y o f th e b e a m its e lf. (T h e ro ta tio n s p e e d m u st b e a m in im u m o f
6 0 0 rp m a n d th e b e a m its e lf s h o u ld b e a c c u ra te to p lu s -o r-m in u s 1 /1 6 o f a n in c h a t 1 0 0 fe e t fro m th e
tra n s m itte r .)

T h e la s e r re c e iv e rs h a v e a lig h t th a t in d ic a te s w h e n th e u n it h a s p o w e r a s w e ll a s
v is u a l g ra d e in d ic a to rs . T h e re c e iv e rs a re a ls o e q u ip p e d w ith a n a rra y o f o p tic a l
s e n s o rs p ro te c te d b y tra n s p a re n t w in d o w s . T h e o p tic a l s e n s o rs a re d iv id e d in to
in d iv id u a l s e g m e n ts a rra n g e d a lo n g th e v e rtic a l a x is o f th e re c e iv e rs . W h e n e v e r
th e la s e r re fe re n c e s ig n a l h its o n e o f th e o p tic a l se n so rs o n a s e g m e n t th a t is a b o v e
o r b e lo w th e c o rre c t " s trik e -p o in t" , th e g ra d e in d ic a to r o n th e re c e iv e r w ill d is p la y
a n u p -a rro w o r a d o w n -a rro w s h o w in g w h e th e r th e s c re e d h e a d is h ig h o r lo w re la tiv e
to th e re fe re n c e s ig n a l. A t th e s a m e tim e , th e re c e iv e r a ls o s e n d s a s ig n a l to th e
O p e ra tio n s B o x in d ic a tin g w h e th e r th e p lo w n e e d s to m o v e u p o r d o w n to
re m a in o n g ra d e .

T h e O p e ra tio n s B o x th e n a c tiv a te s th e lin e a r a c tu a to r o n th e a p p ro p ria te s id e o f

th e p lo w u n til th e re fe re n c e b e a m is a g a in h ittin g th e c o rre c t " s trik e -p o in t" o n
th e re c e iv e r.

O b v io u s ly , s e ttin g u p th e se re c e iv e rs c o rre c tly is c ru c ia l to th e p e rfo rm a n c e o f th e C o p p e rh e a d . In o rd e r

to s e t u p th e la s e r re c e iv e rs o n th e C o p p e rh e a d to th e c o rre c t h e ig h t, a h a n d - h e ld re c e iv e r is u s e d in
c o n ju n c tio n w ith th e C o p p e rh e a d G ra d e R o d to ta k e b e n c h m a rk s. A b e n c h m a rk re c o rd s th e v e rtic a l
d is ta n c e b e tw e e n th e d e s ire d p la c e m e n t e le v a tio n a n d th e la s e r s ig n a l e m itte d b y th e tra n s m itte r.

T h e h a n d -h e ld re c e iv e r u se s a u d io to n e s a n d a l i q u i d c r y s t a l d i s p l a y a r r o w t o t e l l t h e o p e r a t o r w h e n i t 's
d ire c tly in th e p a th o f th e in v is ib le la s e r b e a m . It o p e ra te s in th re e m o d e s , fin e , m e d iu m a n d c o a rs e . F o r
u se w ith th e C o p p e rh e a d it s h o u ld a lw a y s b e i n f i n e m o d e . W e 'l l d i s c u s s t h e d e t a i l s o f h o w t o t a k e a
b e n c h m a rk la te r in th is m a n u a l. (S e e B .4 .9 )

C o p p e rh e a d G ra d e R o d
A s s e m b ly # 7 0 0 6 0 1 0 3 3 -x x

6 /0 2 B .4 .3
 P L A N N IN G & P R E P A R A T IO N

P la n n in g a n d p re p a ra tio n is th e k e y to e v e ry s u c c e s s fu l jo b a n d , g e n e ra lly s p e a k in g , it a ll b e g in s th e d a y
b e f o r e y o u 'r e s c h e d u l e d t o s c r e e d .

F irs t o f a ll, y o u s h o u ld fa m ilia riz e y o u rs e lf w ith th e jo b s ite its e lf.

-W ill y o u b e w o rk in g u n d e r a ro o f o r o u ts id e ?
-W h a t 's t h e w e a th e r fo re c a s t?
-W h a t 's t h e m ix d e s ig n ?
-W ill th e r e b e a n a c c e le ra to r in th e c o n c re te ?
- H o w m a n y y a rd s p e r h o u r w ill b e p o u re d ?

A ls o , y o u n e e d to m a k e s u re th a t y o u a n d th e C o p p e rh e a d a re re a d y to g o to w o rk a n d to c o n tin u e
w o rk in g w ith o u t u n n e c e s s a ry in te rru p tio n s .

-C h a rg e a ll re c h a rg e a b le b a tte rie s , e s p e c ia lly y o u r la s e r tra n s m i t t e r 's b a t t e r y

a n d b rin g s p a re b a tte rie s fo r a n y e q u ip m e n t th a t u s e s th e m , lik e th e h a n d -h e ld
re c e iv e r. R e m e m b e r, w ith o u t a b a c k u p p la n , o n e d e a d b a tte ry in a p ie c e o f
e q u ip m e n t c a n p u t y o u o u t o f w o rk in th e m id d le o f a jo b .
- F u e l th e m a c h in e a n d m a k e s u re y o u h a v e s u ffic ie n t e x tra g a s to c o m p le te th e jo b .
- M a k e s u r e y o u 'v e p a c k e d e v e r y t h i n g y o u n e e d :
1 . Y o u r la s e r tra n s m itte r a n d a trip o d o r a c o lu m n c la m p .
2 . T h e C o p p e rh e a d G ra d e R o d .
3 . C o u n te rw e ig h ts fo r th e m a c h in e .
4 . A ta c h o m e te r.
5 . A s e t o f g e n e ra l to o ls a n d e x tra fu s e s .
6 . A s p a re tire .
7 . A s c ru b b ru s h fo r c le a n in g th e C o p p e rh e a d .
8 . Y o u r h a rd h a t, s a fe ty g la s s e s , ra in g e a r, a n d ru b b e r b o o ts .
9 . T h i s O w n e r 's m a n u a l a n d s p a r e p a r t s .
1 0 . A fire e x tin g u is h e r.
1 1 . E a r p lu g s .
1 2 . S p a re p a rts k it.

6 /0 2 B .4 .4
 C O P P E R H E A D S E T U P

T h e d a y o f th e jo b , p la n o n re a c h in g th e jo b s ite a t le a s t o n e h o u r b e fo re th e s c h e d u le d a rriv a l o f th e
c o n c re te . A fte r th e m a c h in e is u n lo a d e d d o a th o ro u g h w a lk -a ro u n d in s p e c tio n . If y o u fin d a s e rio u s
p ro b le m w ith th e m a c h in e s p e a k im m e d ia te ly to y o u r su p e r v is o r s o th a t th e c o n c re te d e liv e ry c a n b e
p u sh e d b a c k (if n e c e ssa ry ) u n til re p a irs h a v e b e e n c o m p le te d .

N e x t, c h e c k th e flu id le v e ls , in c lu d in g th e e n g in e o il a n d th e h y d ra u lic o il. A ls o c o n firm th a t th e fu e l

ta n k is to p p e d o f f a n d c h e c k th e v ib r a to r g e a r b o x o il le v e l ( S e e C .3 .4 ). I n s p e c t th e a ir f ilte r a n d c h e c k
th e c o n d itio n o f th e b a tte ry . C h e c k fo r a n y o b s tru c tio n s a t th e e n g in e c o o lin g a ir in ta k e a n d d is c h a rg e .
C h e c k th e h y d ra u lic p u m p a n d o il filte r a n d lo o k fo r c h a ffe d , le a k in g o r b ro k e n h o s e s a n d fittin g s . C h e c k
fo r a n y s ig n s o f w e a r th a t re q u ire y o u r a tte n tio n b e fo re g o in g to w o rk . C h e c k th e tire s a n d in s p e c t th e m
t o m a k e s u r e t h e y 'r e i n g o o d c o n d i t i o n . C h e c k t h e f u s e s . M a k e s u r e a l l m a c h i n e g u a r d s , c o v e r s a n d
s a f e ty d e c a ls a r e in p la c e . S e t th e T u r n b u c k le to 2 .5 " . ( T h is m e a s u r e m e n t is ta k e n f r o m th e e n d o f th e
le f t h a n d tu r n b u c k le to th e e n d o f th e r ig h t h a n d tu r n b u c k le in s id e o f th e tu r n b u c k le b o d y .) V e r if y th e
a c c u ra c y o f th e L e v e l In d ic a to r.

A tta c h th e m a s ts to th e s c re e d h e a d . S lid e th e b o tto m o f e a c h m a s t in to th e s u p p o rt o n th e s c re e d h e a d

a n d tig h te n th e re ta in in g c la m p . R a is e th e m a st s o th a t th e m o u n tin g p o in t fo r th e la s e r re c e iv e rs is a t
a b o u t th e h e ig h t o f th e la s e r tra n s m itte r. N o w y o u c a n m o u n t th e la s e r re c e iv e rs to th e m a s ts . T o d o th is ,
s lid e th e re c e iv e rs o n to th e m a s ts a n d tig h te n th e th re a d e d k n o b . In itia lly , th e re c e iv e rs s h o u ld b e a im e d
s o th a t th e y w ill h a v e a c le a r fie ld o f v ie w to th e la s e r tra n s m itte r a s y o u b e g in th e s c re e d in g p ro c e s s .
T h e re a re ju s t a fe w ite m s le ft to c h e c k , b u t th e y re q u ire th e e n g in e to b e ru n n in g firs t. B e fo re w e re v ie w
th e s e ite m s , l e t 's b r i e f l y r e v ie w th e e n g in e s ta rtin g p ro c e s s . T o b e g in w ith , a t th e C o n tro l P a n e l, y o u
s h o u ld tu rn o n th e M a s te r S w itc h a n d re s e t th e E n g in e O n /O ff s w itc h . T h e n , o p e n th e a c c e s s p a n e l o n
th e fra m e c o v e r a n d c a rry o u t th e fo llo w in g se q u e n c e :

1 . M o v e th e fu e l v a lv e le v e r to th e O N p o s itio n .
2 . If th e e n g in e is c o ld , m o v e th e c h o k e le v e r to th e C L O S E D p o s itio n .
If th e e n g in e is w a rm , th e c h o k e is le ft in th e O P E N p o s itio n .
3 . M o v e th e th ro ttle le v e r a w a y fro m th e S L O W p o s itio n , a b o u t 1 /3 o f
th e w a y to w a rd th e F A S T p o s itio n .
4 . T u rn th e e n g in e s w itc h to th e O N p o s itio n .
5 . P u ll th e s ta rte r g rip lig h tly u n til y o u fe e l s o m e re s is ta n c e , th e n p u ll b ris k ly .

C o m p le te d e ta ils o n s ta rtin g a n d s to p p in g th e e n g in e , a s w e ll a s o p e ra tin g , s a fe ty , a n d s e rv ic e

in s tru c tio n s , a re c o n ta in e d in th e e n g in e O w n e rs M a n u a l. Y o u s h o u ld fa m ilia riz e y o u rs e lf w ith th is
m a n u a l b e fo re u s in g th e C o p p e rh e a d a n d re fe r to it a s n e e d e d d u rin g o p e ra tio n s o r m a in te n a n c e .

O n c e th e e n g in e is s ta rte d , m a k e s u re to le t it w a rm u p . A t th e s a m e tim e y o u c a n w a rm th e h y d ra u lic o il

in th e s y s te m b y e ith e r d riv in g th e m a c h in e a ro u n d o r a c tiv a tin g th e v ib ra to r w h ile th e m a c h in e is
s ta n d in g s till. N O T E : In c o ld w
e a th e r th e m a c h in e m u s t b e d riv e n fo r a t le a st 5 m in u te s b e fo re tu rn in g
o n th e v ib ra to r. A ls o , o n c e th e
h y d ra u lic o il is c irc u la tin g in th e s y s te m , it m a y ta k e a w h ile to re a c h th e
o p tim a l te m p e ra tu re o f 8 0 d e g re e s F a h re n h e it.

6 /0 2 B .4 .5
W h e n y o u 'r e s a t i s f i e d t h a t t h e e n g i n e a n d t h e h y d r a u l i c o i l a r e s u f f i c i e n t l y w a r m e d u p , l e v e l t h e m a c h i n e
w ith th e H e a d L ift s w itc h , v e rify th a t th e la s e r e le c tro n ic s a re w o rk in g , a n d fin a lly , c h e c k th e s p e e d o f
th e v ib ra to r.

L a s t, b u t n o t le a s t, ta k e a m o m e n t to p ro te c t y o u r C o p p e rh e a d fro m d ry in g c o n c re te . S p ra y th e s c re e d
h e a d , th e s ta b iliz e rs a n d w h e e ls - a n y th in g th a t w ill c o m e in to c o n ta c t w ith w e t c o n c re te - w ith a fo rm
o il o r o th e r c o n c re te re le a s e a g e n t.

A t th is p o in t, if e v e ry th in g h a s c h e c k e d o u t O K , y o u c a n m o v e o n to s e ttin g u p th e la s e r tra n s m itte r.

6 /0 2 B .4 .6
 L A S E R T R A N S M IT T E R S E T U P

T h e re a re m a n y ty p e s o f la s e r tra n s m itte rs in u s e b y th e c o n s tru c tio n in d u s try , a n d y o u m a y a lre a d y h a v e

a u n it th a t w ill w o rk w ith th e C o p p e rh e a d . If n o t, y o u w ill n e e d to p u rc h a s e a la s e r tra n s m itte r in o rd e r to
u se th e s y s te m . W h e n c h o o s in g a la s e r tra n s m itte r, k e e p in m in d th e ty p e o f w o r k y o u 'r e p la n n in g to d o
a n d s e le c t a m o d e l th a t w ill a c c o m m o d a te y o u r n e e d s. I f y o u o n ly s c re e d fla t p la c e m e n ts th e n a m o d e l
lik e th e T rim b le S p e c tra P re c is io n L a se r M o d e l L 8 0 0 w o u ld b e a g o o d c h o ic e .

H o w e v e r, if y o u a ls o p la n to s c re e d s lo p e d p la c e m e n ts , e v e n o c c a s io n a l l y , y o u 'l l n e e d a m o d e l lik e th e
T rim b le S p e c tra P re c is io n L a se r M o d e l G L 7 2 2 . T ra n sm itte r s lik e th e G L 7 2 2 c a n b e p re c is e ly tilte d s o
th a t th e p la n e o f re fe re n c e lig h t re m a in s p a ra lle l to a g ra d e o f u p to 1 0 % u p h ill o r d o w n h ill a n d a lo n g
o n e o r tw o a x is . O th e r tra n s m itte rs w ill v a ry b e tw e e n m a x im u m s e ttin g s o f 5 % , 1 0 % , o r e v e n 2 0 %
s lo p e s . W h e n d o in g s te e p e r jo b s , d e te rm in in g th e m a x im u m s lo p e th e tra n s m itte r c a n a c h ie v e w ill
b e c o m e m o re im p o rta n t.

A ls o , e v e ry tra n s m itte r h a s s o m e m e th o d fo r le v e lin g th e b a s e u n it. C h e c k th e in s tru c tio n m a n u a l fo r

y o u r s p e c ific tra n s m itte r to d e te rm in e th e a p p lic a b le p ro c e d u re s .

F in a lly , s o m e la s e r tra n s m itte rs h a v e m u ltip le lo u v e re d w in d o w s w h ic h c a n b e c lo s e d to p re v e n t th e

la s e r b e a m fro m s h
b e c a u se y o u c a n o p
a re a . If y o u r tra n s m
p a rt o f th e b e a m d o
o th e r s h in y s u rfa c e
a n d c o n fu s e th e C o
in in g o n a re a s o f p o te n tia l re fle c tio n . T h is is h e lp fu l w h e n s e ttin g u p th e tra n s m itte r
e n o n ly th o s e w in d o w s th a t a re n e c e s s a ry to a llo w lig h t to p a s s o v e r th e p la c e m e n t
itte r d o e s n o t h a v e th is c a p a b ility th e n y o u s h o u ld ta k e p r e c a u tio n s to m a k e s u r e th a t
e s n o t s h in e a w a y fro m th e p la c e m e n t a re a w h e re it c o u ld s trik e a p a n e o f g la s s o r
. R e fle c te d b e a m s th a t b o u n c e b a c k to w a rd th e p la c e m e n t a re a c a n c a u s e in te rfe re n c e
p p e r h e a d 's c o n t r o l s y s t e m .

I f y o u 'v e c h o s e n a s p o t f o r y o u r t r a n s m i t t e r t h a t i s n e x t t o a s u i t a b l e c o l u m n , y o u c a n m o u n t t h e
t r a n s m i t t e r w i t h a c o l u m n c l a m p . I f n o t , y o u 'l l h a v e t o u s e a t r i p o d . W h e n u s i n g a t r i p o d , i t 's i m p o r t a n t t o
m a k e s u r e t h a t t h e l e g s d o n 't s l i p d u r i n g s c r e e d i n g o p e r a t i o n s . T h e b e s t w a y t o i n s u r e t h a t t h e l e g s w i l l
re m a in s ta b le is to p o s itio n th e fe e t o f th e trip o d in e x is tin g s a w c u ts o r o th e r in d e n ta tio n s . O n c e th e fe e t
a re p la c e d , p re s s th e m d o w n firm ly w ith y o u r fo o t. A ls o c h e c k to m a k e s u re th a t a ll th e n u ts a n d b o lts o n
y o u r trip o d a re tig h t a n d th a t th e s a fe ty c h a in s a re a tta c h e d . F in a lly , re m e m b e r th a t th e s a fe ty c h a in s
s h o u l d h a n g l o o s e l y b e t w e e n t h e l e g s s o t h a t t h e y w o n 't t r a n s f e r v i b r a t i o n s f r o m l e g t o l e g .

A s w a s m e n tio n e d e a rlie r, th e C o p p e rh e a d d e te rm in e s th e h e ig h t o f th e sc re e d h e a d b y c o n s ta n tly

c h e c k in g th e re fe re n c e s ig n a l fro m a la s e r tr a n s m itte r. In o p e ra tio n , th e tra n s m itte r is m o u n te d n e a r th e
fro n t o f th e p la c e m e n t a n d a t a h e ig h t o f a b o u t se v e n (7 ) fe e t a b o v e th e b e n c h m a rk h e ig h t. K e e p in g th e
tra n s m itte r a t le a s t th is h ig h a b o v e th e flo o r m a k e s it le s s lik e ly th a t th e la s e r w ill b e b lo c k e d b y p e o p le
o r o th e r m o v in g o b s tru c tio n s .

T h e re a re tw o g u id in g p rin c ip le s fo r c h o o s in g a s p o t fo r th e tra n s m itte r. F irs t, y o u w a n t th e tra n s m itte r in

a s p o t w h e re th e a ir is c le a n e r a n d i t w o n 't b e d i s t u r b e d d u rin g th e jo b . S e c o n d , y o u w a n t to re d u c e
sh a d o w a re a s a s m u c h a s p o s s ib le . S h a d o w a re a s a re th o s e p la c e s w h e re th e la s e r b e a m is b lo c k e d b y
c o lu m n s o r o th e r im m o v a b le o b s tru c tio n s . W h e n th e m a c h in e p a s s e s th r o u g h o n e o f th e se s h a d o w a re a s,
o n e o r b o th o f th e C o p p e rh e a d 's l a s e r r e c e i v e r s w i l l l o s e a lin e -o f-s ite c o n n e c tio n to th e tra n s m itte r a n d
s c re e d in g a c c u ra c y w ill b e c o m p ro m is e d .

6 /0 2 B .4 .7
If o n e o f th e C o p p e rh e a d 's t w o l a s e r r e c e i v e r s l o s e s t h e tra n s m itte r s ig n a l, th a t re c e iv e r w ill s to p s e n d in g
re fe re n c e in fo rm a tio n to th e O p e ra tio n s B o x . W h e n th a t h a p p e n s, th e O p e ra tio n s B o x im m e d ia te ly lo c k s
th e lin e a r a c tu a to rs o n th a t s id e o f th e s c re e d h e a d s o th a t th e p lo w h o ld s th e la s t k n o w n re fe re n c e
p o s itio n . A t th a t p o in t, th e re c e iv e r o n th e o th e r s id e o f th e s c re e d h e a d w ill s till b e s e n d in g re fe re n c e
in fo rm a tio n to th e O p e ra tio n s B o x a n d th e p lo w w ill c o n tin u e to h o ld g ra d e b y re fe re n c e to th e la s e r
tra n s m itte r.

H o w e v e r, if b o th o f th e C o p p e r h e a d 's l a s e r r e c e iv e rs a re b lo c k e d fro m se e in g th e tra n s m itte r, th e n a ll

re fe re n c e w ill b e lo s t, th e fe e d b a c k lo o p w ill b e b ro k e n , a n d th e m a c h in e w ill lo c k b o th lin e a r a c tu a to rs
a t th e la s t k n o w n re fe re n c e p o in t. Y o u o n ly c h o ic e a t th is p o in t, o th e r th a n m o v in g th e la s e r tr a n sm itte r,
is to o p e ra te th e m a c h in e in fu ll m a n u a l m o d e u n til it p ic k s u p th e la se r s ig n a l a g a in . O f c o u rs e , d u rin g
m a n u a l o p e ra tio n th e re w ill b e lo s s o f a c c u ra c y a n d sp e e d .

B y n o w it s h o u ld b e o b v io u s th a t c a re fu lly c h o o s in g a lo c a tio n fo r th e la s e r tra n s m itte r c a n m a k e th e

d iffe re n c e b e tw e e n a n e a s y d a y o r lo n g a n d d iffic u lt p la c e m e n t.

A w o rd o f c a u tio n is c a lle d fo r re g a rd in g th e u s e o f la s e r tra n s m itte rs o n a c o n s tru c tio n s ite . R e m e m b e r

th a t, e v e n th o u g h th e s e d e v ic e s u s e a lo w e r-p o w e r la s e r, th e y c a n s till c a u s e e y e d a m a g e . S o n e v e r lo o k
d ire c tly a t th e la s e r b e a m .

F in a lly , w e s tro n g ly u rg e y o u to c o n s u lt th e O w n e rs M a n u a l p ro v id e d w ith y o u r s p e c ific la s e r

tra n s m itte r fo r c o m p le te in s tru c tio n s o n s e t u p a n d o p e ra tio n a s w e ll a s m o re s p e c ific s o n s a fe ty .

6 /0 2 B .4 .8
 C O P P E R H E A D
G C R S E T U P /C A L I B R A T I O N I N S T R U C T I O N S
1 .0 B U T T O N I D E N T I F I C A T I O N

B U T T O N F U N C T IO N
C O R R E C T IO N IN C R E A S E (Y E L L O W , ) IN C R E A S E S C O R R E C T IO N S P E E D W H E N T H E
E N G A G E B U T T O N IS P R E S S E D

C O R R E C T IO N D E C R E A S E (Y E L L O W , ) D E C R E A S E S C O R R E C T O N S P E E D W H E N T H E
E N G A G E B U T T O N IS P R E S S E D

E N G A G E (R E D ) E N G A G E S T H E S E L E C T E D C O R R E C T IO N M O D E ,
W H E N U S E D A L O N E , M O V E S A C T U A T O R A T
S P E E D S E T IN S E L E C T E D M O D E (Y E L L O W L E D
A B O V E T H E T U R T L E O R R A B B IT )
S E L E C T (G R E E N ) A L L O W S Y O U T O P U T T H E G C R IN C A L IB R A T IO N
M O D E , A N D S E L E C T W H IC H C A L IB R A T IO N M O D E
(Y E L L O W L E D A B O V E T U R T L E O R R A B B IT ) Y O U
W A N T T O A D JU S T .

2 .0 V A L V E T Y P E S E L E C T I O N ( N O T A L L G C R 'S H A V E T H I S O P T I O N , S O M E A R E S E T T O " P T " A L R E A D Y )

1 ) S W IT C H C O P P E R H E A D M A S T E R S W IT C H T O T H E " O F F " P O S IT IO N .
2 ) S W IT C H L A S E R S Y S T E M A U T O /M A N U A L S W IT C H T O T H E " M A N U A L " P O S IT IO N .
3 ) S W IT C H C O P P E R H E A D M A S T E R S W IT C H T O T H E " O N " P O S IT IO N .
4 ) P R E S S A N D H O L D T H E T W O Y E L L O W B U T T O N S S IM U L T A N E O U S L Y U N T IL T H E F O U R M O D E
Y E L L O W L E D S L IG H T A N D A V A L V E S E L E C T IO N G R E E N L E D K IG H T S .
5 ) W E W A N T P T V A L V E S E L E C T IO N , W H IC H IS T H E F IR S T G R E E N L E D O N T H E L E F T (S E E P H O T O
# 1 ), S O IF T H A T IS N O T O N , P R E S S E IT H E R T H E Y E L L O W U P O R D O W N B U T T O N S T O C Y C L E
T H R O U G H A N D S E L E C T T H E M A C H I N E 'S V A L V E T Y P E .
6 ) A F T E R S E L E C T IN G P T V A L V E T Y P E , P R E S S T H E G R E E N S E L E C T B U T T O N T O E X IT T H E V A L V E
S E L E C T IO N M O D E A N D E N T E R T H E V A L V E C A L IB R A T IO N M O D E .
7 ) IF Y O U N E E D T O A D J U S T T H E G C R U P /D O W N S P E E D S T H E N G O T O S E C T I O N 3 .0 .
8 ) T O G E T O U T O F C A L IB R A T IO N M O D E , T U R N P O W E R O F F A N D O N W IT H M A S T E R S W IT C H .

3 .0 G C R V A L V E M O D E A N D S P E E D A D J U S T M E N T S

1 ) S U P P O R T T H E V IB R A T O R P L A T E S O T H A T T H E P L O W W IL L N O T T O U C H T H E G R O U N D
T H R O U G H O U T IT S E N T IR E S T R O K E .
2 ) T O A D JU S T T H E L E F T S ID E A C T U A T O R S S P E E D S , A D JU S T T H E R IG H T A C T U A T O R S O T H A T IT IS
P O S IT IO N E D IN T H E M ID D L E O F IT S S T R O K E , T O M IN IM IZ E B IN D IN G O N T H E S ID E B E IN G
A D JU S T E D . T O A D JU S T T H E R IG H T S ID E , C E N T E R T H E L E F T A C T U A T O R .
3 ) S T A R T E N G IN E A N D R U N IT A T F U L L T H R O T T L E T O P R O V ID E F U L L V O L T A G E T O T H E
A C T U A T O R S .
4 ) S W IT C H C O P P E R H E A D M A S T E R S W IT C H T O T H E " O F F " P O S IT IO N .
5 ) S W IT C H L A S E R S Y S T E M A U T O /M A N U A L S W IT C H T O T H E " M A N U A L " P O S IT IO N .
6 ) S W IT C H C O P P E R H E A D M A S T E R S W IT C H T O T H E " O N " P O S IT IO N .
7 ) P R E S S A N D H O L D T H E G R E E N S E L E C T B U T T O N (A B O U T 2 S E C O N D S ) O N T H E G C R R E C E IV E R
U N T IL T H E F IR S T V A L V E S E L E C T IO N G R E E N L E D L IG H T S A N D T H E F IR S T C A L IB R A T IO N M O D E
Y E L L O W L E D L IG H T S , S E E P H O T O # 1 B E L O W . W E A R E U S IN G P T V A L V E S E L E C T IO N , S O T H E
F I R S T G R E E N L E D O N T H E L E F T S H O U L D B E O N , I F N O T S E E S E C T I O N 2 .0 T O S E T T O C O R R E C T
V A L V E T Y P E .
8 ) W E W A N T T H E R A B B IT U P A N D D O W N S P E E D S T O B E S E T A T M A X S P E E D (5 -6 S E C O N D S F U L L
S T R O K E ), A N D T H E T U R T L E S P E E D S (7 -8 S E C O N D S F U L L S T R O K E ) T O B E S E T S L IG H T L Y
S L O W E R , S O T O S T A R T , L O W E R T H E S ID E O F T H E P L O W B E IN G A D JU S T E D F U L L Y D O W N , W IT H
T H E M A N U A L S W IT C H O N T H E C O N S O L E .

6 /0 2 B .4 .8 a
 P H O T O # 1

V a lv e S e le c tio n L E D
P T m o d e sh o w n

C a lib ra tio n M O D E L E D

9 ) T O B E G I N T U R T L E U P S P E E D A D JU S T M E N T S , P R E S S A N D H O L D T H E R E D E N G A G E B U T T O N A N D
T IM E T H E S T R O K E F R O M B O T T O M T O T O P , W E W A N T IT T O B E 7 -8 S E C O N D S . IF IT IS N O T IN
T H A T R A N G E Y O U W IL L H A V E T O A D JU S T IT .
A ) F IR S T G E T T H E P L O W B A C K D O W N B Y P R E S S IN G T H E G R E E N S E L E C T B U T T O N U N T IL
T H E R A B B IT D O W N L E D L IG H T S , T H E N P R E S S T H E R E D B U T T O N T O B R IN G T H E P L O W
D O W N .
B ) N O W P R E S S T H E G R E E N B U T T O N T O L IG H T U P T H E T U R T L E U P L E D .
C ) T O S L O W D O W N T H E T U R T L E U P S P E E D , P R E S S A N D H O L D T H E R E D B U T T O N A N D
Y E L L O W D O W N B U T T O N S IM U L T A N E O U S L Y .
D ) T O S P E E D U P T H E T U R T L E U P S P E E D , P R E S S A N D H O L D T H E R E D B U T T O N A N D Y E L L O W
U P B U T T O N S IM U L T A N E O U S L Y . A S S H O W N IN P H O T O # 2 .
E ) R E T U R N T H E P L O W T O T H E D O W N P O S IT IO N B Y F O L L O W IN G S T E P (A ).
F ) T IM E T H E T U R T L E U P S P E E D B Y F O L L O W IN G S T E P (9 ) T O S E E IF IT IS IN T H E 7 -8 S E C O N D
R A N G E , IF N O T R E P E A T S T E P S (A ) T H R U (F ).
G ) IF IT IS IN T H E R A N G E T H E N M O V E O N T O T U R T L E D O W N S P E E D , W H IC H Y O U W O U L D
A D JU S T T H E S A M E A S T H E T U R T L E U P S P E E D .
1 0 ) A F T E R T H E T U R T L E S P E E D S A R E S E T A T 7 -8 S E C O N D S , N O W C H E C K T H E R A B B IT S P E E D S , T H E Y
S H O U L D B E M A X E D O U T A T 5 -6 S E C O N D S . T O C H E C K A N D A D JU S T T H E R A B B IT S P E E D S
F O L L O W S T E P S 9 ) T H R U 9 G ) A B O V E , B U T V A R Y T H E S T E P S S L IG H T L Y B E C A U S E Y O U A R E
A D JU S T IN G T H E R A B B IT A N D N O T T H E T U R T L E .

T U R T L E S P E E D S :
F U L L S T R O K E U P O R D O W N = A B O U T 7 -8 S E C O N D S

R A B B IT S P E E D S :
F U L L S T R O K E U P O R D O W N = A B O U T 5 -6 S E C O N D S

P H O T O # 2

1 1 ) T O G E T T H E G C R 'S O U T O F C A L I B R A T I O N M O D E , S W I T C H T H E C O P P E R H E A D M A S T E R S W I T C H
T O T H E O F F P O S IT IO N A N D T H E N B A C K O N .
6 /0 2 B .4 .8 b
 S C R E E D IN G O P E R A T IO N S
T A K IN G A B E N C H M A R K
P e rh a p s th e m o s t c ritic a l ta s k in a ll o f sc re e d p re p a ra tio n is ta k in g a b e n c h m a rk . A b e n c h m a rk is a
p re c is e m e a s u re m e n t o f th e d is ta n c e b e tw e e n th e fin is h e d flo o r e le v a tio n a n d th e h e ig h t o f th e la s e r
b e a m . T h e b e n c h m a rk is u s e d to se t th e s a m e d is ta n c e b e tw e e n th e sc re e d h e a d a n d th e m a s t-m o u n te d
l a s e r r e c e i v e r s . I t 's a l s o u s e d to d o u b le c h e c k th a t th e la s e r b e a m is ru n n in g e x a c tly p a r a lle l to th e o n -
g ra d e re fe re n c e p o in ts a ll a ro u n d th e p la c e m e n t.

B e fo re y o u b e g in , re m e m b e r to w o rk c a re fu lly th ro u g h o u t th is p ro c e d u re . M a k in g a n e rro r a t th is p o in t
c o u l d c a u s e t h e e n t i r e f l o o r t o b e p l a c e d a b o v e o r b e l o w g r a d e - a n d t h a t 's a n e x p e n s i v e m i s t a k e t o
c o rre c t a fte r th e fa c t.

T o s ta rt w ith , a tta c h th e h a n d -h e ld re c e iv e r to th e C o p p e rh e a d G ra d e R o d . P re s s th e o n /o ff b u tto n o n c e

to tu rn th e re c e iv e r o n .

T h e re c e iv e r h a s th re e (3 ) s e n s itiv ity s e ttin g s , m a k e s u re th a t th e re c e iv e r is in th e fin e m o d e . U s e th e

b u tto n to s e le c t b e tw e e n th e m . S e t th e a u d io le v e l. T h e re a re th re e s e ttin g s . C h o o s e a n a u d io le v e l th a t
c a n b e h e a rd e a s ily o v e r th e g e n e ra l n o is e o f th e jo b s ite .

N e x t a sk y o u r su p e rv is o r o r fo re m a n to p o in t y o u to th e g ra d e re fe re n c e p o in t o n th e jo b s ite th a t is
c lo s e s t to y o u r tra n s m itte r. T h is g ra d e re fe re n c e sh o u ld b e u s e d to ta k e y o u r b e n c h m a rk . O n c e y o u fin d
th e g ra d e re fe re n c e , e x te n d th e g ra d e s tic k s o th a t th e re c e iv e r is h ig h e n o u g h to re a c h th e ro ta tin g b e a m
o f th e la s e r tra n s m itte r w h e n th e g ra d e s tic k is s ittin g o n th e g ra d e re f e re n c e . H o ld th e g ra d e s tic k o v e r
th e g ra d e re fe re n c e p o in t a n d h ig h e n o u g h s o th a t th e re c e iv e r is a b o v e th e t r a n s m i t t e r 's r e fe re n c e b e a m .

T h e n , u s in g th e b u b b le le v e l o n th e g ra d e s tic k a s a re fe re n c e , k e e p th e g ra d e s tic k p e rfe c tly p lu m b a n d

s lo w ly lo w e r th e re c e iv e r u n til y o u h e a r th e to n e th a t in d ic a te s th a t it h a s fo u n d th e la se r b e a m . D u rin g
th is in itia l a d ju s tm e n t to th e g ra d e r e fe re n c e p o in t, w h e n s e ttin g th e s c re e d h e a d , a n d th ro u g h o u t th e
p ro c e s s o f c h e c k in g th e h e ig h t o f th e fin is h e d c o n c re te , it is a b s o lu te ly im p e ra tiv e th a t y o u a lw a y s s ta rt
h ig h a n d lo w e r th e re c e iv e r in to th e tra n s m itte r 's r e f e r e n c e b e a m . T h a t 's b e c a u s e t h e r e c e iv e r h a s w h a t is
c a lle d a d e a d b a n d .

In fin e m o d e , th is d e a d b a n d is a p p ro x im a te ly 1 /1 6 th o f a n in c h . T h e re fo re , if y o u d o n o t c o n s is te n tly
b rin g th e re c e iv e r in to th e la s e r b e a m fro m o n e d ire c tio n , y o u m a y in a d v e rte n tly in tro d u c e a 1 /1 6 th o f a n
in c h e rro r in y o u r fin is h e d g ra d e le v e l. It s h o u ld a ls o b e n o te d th a t in c o a rs e m o d e , th e d e a d b a n d is
la rg e r, s o n e v e r u s e th e h a n d -h e ld re c e iv e r in c o a rs e m o d e . If n e c e s s a ry , a d ju s t th e h e ig h t o f th e re c e iv e r
o n th e g ra d e s tic k s o th a t th e b o tto m o f th e g ra d e s tic k h its th e g ra d e re fe re n c e p o in t a t e x a c tly th e s a m e
tim e th e re c e iv e r a u d io a le rt in d ic a te s th a t th e la s e r re fe re n c e h a s b e e n re c e iv e d . R e p e a t th is h e ig h t
a d ju s tm e n t a s o fte n a s n e c e s s a ry u n til th e g ra d e ro d m a tc h e s th e g ra d e re fe re n c e p o in t. T h e ro d is n o w
o n g ra d e a n d y o u b e n c h m a rk is s e t.

N o w m a k e s u re th e C o p p e rh e a d G ra d e R o d is lo c k e d a n d m a rk th e ro d w ith a p e n c il. D u rin g th e c o u rs e

o f t h e d a y , i t 's a g o o d i d e a t o c h e c k t h i s p e n c i l m a r k p e r i o d i c a l l y t o a s s u r e y o u r s e l f t h a t t h e s t i c k h a s n o t
s lip p e d in o n e d ire c tio n o r a n o th e r.

N o w th a t th e C o p p e rh e a d G ra d e R o d h a s b e e n s e t a g a in s t th e g ra d e re fe re n c e p o in t, y o u s h o u ld w a lk th e
C o p p e rh e a d G ra d e R o d a ro u n d th e p la c e m e n t a re a , c h e c k in g th a t a ll fo rm s a n d o th e r g ra d e re fe re n c e s
h a v e b e e n p ro p e rly s e t.

6 /0 2 B .4 .9
T h e w a lk a ro u n d in s p e c tio n is e x tre m e ly im p o rta n t. N o t o n ly a re y o u v e rify in g th a t a ll p e rim e te r fo rm s ,
p lu m b in g , d o c k le v e le rs , d o o r w a y s , a n d p re v io u s ly p o u re d c o n c re te a re a t th e d e s ire d e le v a tio n , b u t y o u
a re a ls o v e rify in g th a t th e tra n s m itte r is s e n d in g o u t a la s e r b e a m th a t is p e rfe c tly le v e l a n d th a t th e
re c e iv e r its e lf is o p e ra tin g p ro p e rly .

T h e e n d g o a l o f a c o m p le te w a lk -a ro u n d is to c o n firm th a t th e C o p p e rh e a d G ra d e R o d is s e t c o rre c tly ,

th a t th e la s e r b e a m is fo llo w in g th e d e s ire d g r a d e o f th e flo o r, a n d to fin d e le v a tio n e rro rs a t re fe re n c e
p o in ts s o th a t th e y c a n b e c o rre c te d b e f o re th e p o u r b e g in s . A ls o , w h ile d o in g th e w a lk a ro u n d , y o u
s h o u ld m a k e a n o te o f th e lo c a tio n o f p lu m b in g o r o th e r o b s tru c tio n s t h a t y o u 'l l n e e d to a v o id w h ile
s c re e d in g .

F in a lly , o n c e th e b e n c h m a rk is p ro p e rly s e t, y o u s h o u ld a lw a y s u s e th e s a m e b e n c h m a rk fo r e v e ry
p la c e m e n t in th e b u ild in g . If y o u n e e d to tra n s fe r th e b e n c h m a rk d u e to o b s tru c tio n s o r e x c e s s iv e
d is ta n c e , ta k e e x tre m e c a re . U se a v e ry a c c u ra te tra n s it o r o p tic a l le v e l to h e lp to e lim in a te a n y v a ria n c e
in e le v a tio n c a u se d b y th e tra n s f e r .

T R A N S F E R IN G T H E B E N C H M A R K
N o w w e n e e d to tra n s fe r th e b e n c h m a rk h e ig h t to th e C o p p e rh e a d . In d o in g s o , w e 'l l b e s e ttin g th e
d is ta n c e b e tw e e n th e C o p p e r h e a d 's p l o w a n d i t s l a s e r re c e iv e rs to e x a c tly m a tc h th e d is ta n c e b e tw e e n
th e o rig in a l g ra d e re fe re n c e a n d th e " s trik e p o in t" o n th e C o p p e rh e a d G r a d e R o d 's la s e r re c e iv e r. T h is
p ro c e ss m u st b e d o n e c a r e fu lly a n d a c c u ra te ly b e c a u s e s e ttin g th e w ro n g h e ig h t o n th e C o p p e rh e a d w ill
re s u lt in th e e n tire flo o r b e in g s c re e d e d a b o v e o r b e lo w th e d e s ire d e le v a tio n .

T o s ta rt th e p ro c e s s , v e rify th a t th e la s e r re c e iv e rs h a v e p o w e r a n d m a k e su re th e le ft a n d rig h t
A u to /M a n u a l s w itc h e s a re s e t to A u to . T h e n p o s itio n th e m a c h in e in th e p la c e m e n t a re a w ith th e s c re e d
h e a d s ittin g o n th e firs t p o u r o f c o n c re te a n d c o n firm th a t th e la s e r re c e iv e rs h a v e a c le a r fie ld o f v ie w to
th e tra n s m itte r. U s in g th e le v e l in d ic a to r o n th e C o p p e r h e a d , le v e l th e m a c h in e w ith th e H e a d L ift
c o n tro l.

N o w s e t th e e d g e o f th e C o p p e rh e a d G ra d e R o d R in g o n th e to p o f th e p lo w o n o n e s id e o f th e s c re e d
h e a d a n d to th e s id e o f th e n e a re s t lin e a r a c tu a to r. T h e n m a n u a lly ra is e o r lo w e r th e la s e r re c e iv e r o n th a t
s id e o f th e p lo w u n til th e h a n d -h e ld re c e iv e r o n th e C o p p e rh e a d G ra d e R o d s ig n a ls th a t th e s c re e d h e a d
is o n g ra d e . T h e in d ic a to r o n th a t s id e o f th e m a c h in e s h o u ld n o w sh o w a g re e n , o n -g ra d e lig h t. R e p e a t
th is p ro c e s s o n th e o p p o s ite s id e o f th e s c re e d h e a d . F in a lly , d o u b le c h e c k e a c h s id e o n e m o re tim e .

A fte r th e s e tu p is c o m p le te , s e t th e E le v a tio n A u to /M a n u a l S w itc h to A u to a n d s c re e d a b o u t s ix (6 ) fe e t

o f c o n c re te a s a te s t. T h e n c h e c k th e a c tu a l g ra d e o f th e c o n c re te o n b o th s id e s o f th e n e w ly s c re e d e d
s e c tio n a n d m a k e a d ju s tm e n ts to th e C o p p e r h e a d 's r e c e i v e r s a s n e e d e d . I f th e C o p p e rh e a d G ra d e R o d
in d ic a te s th a t th e c o n c re te is to o lo w o n o n e s id e , th e re c e iv e r o n th a t s id e is lo w e re d in o rd e r to ra is e th e
g ra d e . If th e C o p p e rh e a d G ra d e R o d in d ic a te s th e c o n c re te is to o h ig h th e n th e re c e iv e r o n th a t s id e is
r a i s e d . L e t 's g o o v e r h o w t h a t w o r k s .

L o w e rin g th e re c e iv e r m o v e s th e re c e iv e r 's " s t r i k e p o in t" d o w n c lo s e r to th e p lo w w h ic h c a u s e s th e

O p e ra tio n s B o x to ra is e th e s c re e d h e a d b a c k u p so th a t th e " s trik e p o in t" a g a in s its rig h t o n ta rg e t w ith
th e re fe r e n c e s ig n a l fro m th e la s e r tra n s m itte r. F o r e x a m p le , lo w e rin g th e re c e iv e r b y 1 /8 o f a n in c h w ill
ra is e th e sc re e d h e a d b y 1 /8 o f a n in c h . R a is in g th e re c e iv e r d o e s th e o p p o s ite . S o , o n m o re tim e .
M o v in g a re c e iv e r d o w n w ill ra is e th e g ra d e a n d m o v in g a re c e iv e r u p w ill lo w e r th e g ra d e .

6 /0 2 B .4 .1 0
 If y o u d o m a k e a d ju s tm e n ts a fte r th is
b re a k o u t th e C o p p e rh e a d G ra d e R o d
re p e a t th e p ro c e s s u n til a m e a s u re m e n
s c re e d in g rig h t o n g ra d e . N o w ta k e a n
c h e c k th e o v e rla p lin e le ft b e h in d fro m
n e w p a s s , th e o v e rla p s h o u ld c re a te a
s id e is s lig h tly h ig h c o m p a re d to th e o
s lig h tly lo w e r th a n th e o th e r s id e .
firs t p a s s , re s c re e d th e s a m e s e c tio n , b u t a t th e n e w e le v a tio n . T h e n
a n d c h e c k th e fin is h e d h e ig h t o f th e c o n c re te a g a in . Y o u s h o u ld
t w ith th e C o p p e rh e a d G ra d e R o d c o n firm s th a t th e m a c h in e is
o th e r p a s s o v e rla p p in g th e firs t p a s s b y a b o u t tw o (2 ) fe e t. T h e n
th e v ib ra to r a n d m a k e a d ju s tm e n ts if n e e d e d . A s y o u s c re e d e a c h
rid g e o f a b o u t 1 /8 o f a n in c h . N o rid g e m e a n s th a t th e o v e rla p p in g
th e r s id e . If th e rid g e is to o p ro n o u n c e d , th e o v e rla p p in g s id e is

In e ith e r c a se , y o u w ill n e e d to a d ju s t th e la s e r re c e iv e r s a n d th e n u se th e C o p p e rh e a d G ra d e R o d to
c h e c k b o th s id e s o f th e s c re e d h e a d a g a in . If th e C o p p e rh e a d G ra d e R o d in d ic a te s th a t b o th s id e s o f th e
sc re e d h e a d a re rig h t o n g ra d e , b u t th e o v e rla p is n o t a t th e rig h t h e ig h t, t h e n y o u 'l l n e e d to s p lit th e
d iffe re n c e o n e ith e r s id e , m o v in g e a c h re c e iv e r b y h a lf th e a m o u n t o f th e c h a n g e y o u 'r e se e k in g to
a c h ie v e .

F o r in s ta n c e , if th e o v e rla p is to o h ig h b y 1 /8 o f a n in c h , y o u w o u ld m o v e o n re c e iv e r u p b y 1 /1 6 o f a n
in c h a n d th e o th e r re c e iv e r d o w n b y 1 /1 6 o f a n in c h to s p lit th e d iffe re n c e . If n e c e s s a ry , re p e a t th is
p r o c e s s u n t i l t h e o v e r l a p i s c o r r e c t a n d y o u 'r e s c r e e d i n g c o n s i s t e n t l y a t t h e p r o p e r e l e v a t i o n .

O n c e th e re c e iv e rs a re c o rr e c te d a n d y o u 'r e s a t i s f i e d w ith t h e o v e r l a p , i t 's a g o o d i d e a t o u s e t h e

h a n d h e ld re c e iv e r a n d re c h e c k th a t y o u 'r e o n g r a d e . W ith th e la s e r tra n s m itte r s e n d in g a s te a d y b e a m o f
lig h t p a ra lle l to th e d e s ire d s lo p e , o u r g ra d e re fe re n c e s c h e c k e d , a n d b e n c h m a rk s e t o n th e C o p p e rh e a d -
y o u 'r e j u s t a b o u t re a d y to b e g in fu ll s c r e e d in g o p e r a tio n s .

S C R E E D IN G O P E R A T IO N S
B e fo re y o u s ta rt a c tu a l s c re e d in g o p e ra tio n s , m a k e s u re y o u h a v e a s c re e d in g p a tte rn in m in d a n d s h a re
th a t p la n w ith th e e n tire c re w . T h a t w a y th e y c a n w o rk w ith y o u to a c h ie v e th e b e s t re s u lts .

In te rm s o f g o o d p la n n in g , a g o o d , d a ily a v e ra g e sp e e d to s e t fo r y o u rs e lf w h e n w o rk in g w ith th e
C o p p e rh e a d is 3 ,0 0 0 - 4 ,0 0 0 s q u a re fe e t p e r h o u r. B u t d o n 't e x p e c t t o h i t t h a t t a r g e t c o n s i s t e n t l y
th ro u g h o u t th e jo b . A n u m b e r o f fa c to rs o n th e s ite c o u ld re d u c e y o u r s p e e d , in c lu d in g c o ld w e a th e r, lo w
s lu m p c o n c re te , o r a re q u ire m e n t fo r h ig h -to le ra n c e flo o rs .

A s th e c o n c re te is d e liv e re d to th e p la c e m e n t a re a , it s h o u ld b e ra k e d o u t in fro n t o f th e s c re e d h e a d so
th a t is to p s o ff a t b e tw e e n o n e -e ig h th to o n e -q u a rte r o f a n in c h a b o v e fin is h flo o r h e ig h t. B y h a v in g th e
c re w p ro v id e th is s te a d y , s l i g h t o v e r s u p p l y , y o u 'l l h a v e e n o u g h c o n c re te to fill a n y u n e x p e c te d lo w
sp o ts . T h is is im p o rta n t b e c a u s e if th e y c o n s is te n tly p la c e th e c o n c re te to o h ig h , y o u 'l l e x p e n d a lo t o f
tim e a n d e n e rg y d e a lin g w ith e x c e s s c o n c re te .

A s s o o n a s th e firs t c o n c re te c o m e s in , th e fin is h e rs c a n s ta rt tro w e lin g th e e d g e s o f th e p la c e m e n t. T h is

w ill e lim in a te th e n e e d to re sc re e d th e e d g e s b y h a n d if th e y a re n o t a c c e s s ib le a fte r th e C o p p e rh e a d h a s
c o m p le te d its p a s s . H o w e v e r, if th e e d g e s o f th e p la c e m e n t a re a c c e s s ib le a fte r th e C o p p e rh e a d h a s
s c re e d e d , th e y s h o u ld b e re - sc re e d e d b y h a n d to b le n d th e e d g e s in to th e p e rim e te r fo rm o r e x is tin g flo o r
e d g e s.

A fte r y o u m a k e th e firs t c o m p le te p a s s , a n d re g u la rly th e re a fte r, y o u s h o u ld c h e c k th e n e w ly s c re e d e d

c o n c r e t e f o r p r o p e r e l e v a t i o n . R e m e m b e r , w h e n e v e r y o u 'r e c h e c k i n g t h e g r a d e , k e e p t h e C o p p e r h e a d
G ra d e R o d p lu m b a n d lo w e r it in to th e la s e r b e a m .

6 /0 2 B .4 .1 1
W h e n y o u 'r e r e a d y to s c re e d th e n e x t s e c tio n , d riv e s tra ig h t u p to th e p o in t y o u 'l l b e g i n s c r e e d i n g w i t h
th e s c re e d h e a d o v e rla p p in g th e p re v io u s p a s s b y o n e o r tw o fe e t. T h e e x a c t a m o u n t o f o v e rla p w ill b e
d e te rm in e d b y th e s lu m p o f th e c o n c re te . T h e w e tte r th e c o n c re te , th e m o re y o u 'l l n e e d t o o v e r l a p .
R e m e m b e r, th e s c re e d h e a d w ill b e c o m in g d o w n o v e r s c re e d e d c o n c re te , s o i t 's e s p e c i a l l y c r i t i c a l t h a t
y o u b rin g it in fo r a s m o o th la n d in g . A ls o , s in c e th e d e p th o f th e c o n c re te o f th e p la c e m e n t its e lf w ill
d e te rm in e th e h e ig h t re la tio n s h ip b e tw e e n th e s c re e d h e a d a n d th e re s t o f th e m a c h in e , h e a d lift
a d ju s tm e n ts m u s t b e m a d e fo r e a c h s p e c ific s c re e d in g s itu a tio n .
D u rin g th e c o u rse o f a jo b , th e le v e l s h o u ld b e c h e c k e d a t th e b e g in n in g o f e a c h p a s s to in s u re th a t th e
m a c h in e a n d th e s c re e d h e a d a re c o rre c tly a lig n e d . A s th e p ro c e s s m o v e s a lo n g , y o u 'l l g e t a f e e l f o r t h e
rh y th m a n d p a c e o f s c re e d in g w ith th e C o p p e rh e a d . T h e g ra d e -le v e l in d ic a to rs o n th e c h a s s is c o v e r w ill
b e sh o w in g m o s tly g re e n lig h ts w ith n o m o re th a n a n o c c a s io n a l h ig h o r lo w lig h t. T h a t k in d o f p a tte rn
is a g o o d in d ic a to r th a t y o u 'r e h ittin g th e o p tim u m s c re e d in g s p e e d .

A s m e n tio n e d e a rlie r, th e C o p p e rh e a d c o m e s e q u ip p e d w ith fo u r (4 ) c o u n te rw e ig h ts . W h e n n o t n e e d e d ,

th e s e c o u n te rw e ig h ts a re s to re d a lo n g s id e th e h y d ra u lic ta n k , d ire c tly o v e r th e a x le , w h e re th e y w ill n o t
a f f e c t t h e m a c h i n e 's b a l a n c e . H o w e v e r, d e p e n d i n g o n t h e s l u m p o f t h e c o n c r e t e y o u 'r e s c r e e d i n g , o n e o r
m o re c o u n te rw e ig h ts m a y n e e d to b e m o u n te d a t th e fro n t o r re a r o f th e m a c h in e . If th e c o n c re te is
re la tiv e ly w e t, c o u n te rw e ig h ts c a n b e h u n g h e r e a t th e re a r o f th e m a c h in e to re d u c e d o w n -p re s s u re o n
th e s c re e d h e a d . T h is w ill h e lp p re v e n t th e s c re e d h e a d fro m s in k in g in to th e c o n c re te .

O n th e o th e r h a n d , re la tiv e ly d ry c o n c re te m a y re q u ire m o re w e ig h t o n th e s c re e d h e a d , in w h ic h c a s e
th e c o u n te rw e ig h ts c a n b e p u t o n th e fro n t o f th e m a c h in e .

A s y o u c o n tin u e t o s c r e e d , y o u 'l l n o d o u b t e n c o u n t e r s o m e sh a d o w a re a s w h e re o n e o f th e re c e iv e rs is
b lo c k e d fro m s e e in g th e la s e r tra n s m itte r. In c a s e s w h e re a re c e iv e r is b lo c k e d fro m th e la s e r tra n s m itte r,
y o u 'l l h a v e t o s w itc h o v e r to m a n u a l m o d e to c o n tin u e s c re e d in g . In th e m a n u a l m o r e y o u 'l l h a v e to p a y
v e ry c a re fu l a tte n tio n to m a k e s u re th a t th e s c re e d h e a d d o e s n o t d ro p to o lo w . W a tc h th e rid g e o n th e
o v e rla p p in g s e c tio n a s a n in d ic a tio n o f y o u r p ro g re s s .

A t t h e e n d o f t h e p l a c e m e n t , w h i l e y o u 'r e w o r k i n g y o u r w a y t o w a r d t h e e x i t , r e m e m b e r t o t h i n k a h e a d .
S tic k to th e ro u te y o u d e c id e d o n d u rin g p la n n in g a n d p a rtic u la rly , a s y o u g e t c lo s e to th e e n d , m a k e
s u re th a t th e re s t o f th e p la c e m e n t c re w a lw a y s k n o w s w h e re to d u m p c o n c re te b e fo re y o u r n e x t p a s s .

6 /0 2 B .4 .1 2
 C o p p e r h e a d G C R L a se r S y ste m S e tu p L is t
1 .) B e g in b y s e ttin g th e tr a n s m itte r u p in th e b e g in n in g o f th e p la c e m e n t in th e b e s t p o s s ib le lo c a tio n s
(e lim in a tin g a s m a n y c o lu m n b lo c k s a s p o s s ib le ) a p p ro x . 6 fe e t a b o v e flo o r e le v a tio n .
2 .) A tta c h th e s c r e e d h e a d to th e lif t a r m .
3 .) S e e p a g e s B .3 .2 - B .3 .4 f o r w a r m u p p ro c e d u re .
4 .) S lid e th e 2 r e c e iv e r p o le s in to th e s c r e e d h e a d a s s e m b ly .
5 . ) A t t a c h t h e 2 r e c e i v e r s o n t o t h e r e c e i v e r p o l e s , r e c e i v e r L E D 's s h o u l d b e p o i n t e d t o w a r d t h e c o n t r o l
p a n e l.
6 .) A tta c h th e r e c e iv e r c o r d f r o m th e re c e iv e r to th e c o n tro l b o x o n b o th s id e s .
7 .) V e r if y th a t th e la s e r s y s te m is tu r n e d o n a n d w o r k in g p r o p e r ly .
T u rn th e a u to /m a n u a l s w itc h to m a n u a l.
R a is e a n d lo w e r b o th s id e s u s in g th e m a n u a l s w itc h e s to v e rify th e s y s te m is w o rk in g p ro p e rly .
8 .) S e t th e g r a d e s tic k to th e b e n c h m a r k , d o y o u w a lk a r o u n d in s p e c tio n o f th e p la c e m e n t v e r if y in g th a t
th e g ra d e s tic k is m a tc h in g u p to a ll fo rm s , p re v io u s s c re e d e d c o n c re te , d ia m o n d s , a n d a n y th in g th a t w ill
b e o n g ra d e .
9 .) S ta rt p la c in g th e c o n c re te in th e b e s t k n o w n lo c a tio n . W h e re v e r th e C o p p e rh e a d w ill s ta rt s c re e d in g
n e e d s to b e o n g ra d e . E x a m p le : If th e firs t p a s s o f th e C o p p e rh e a d w ill b e a g a in s t a n e x te rio r w a ll e d g e
th is w a ll e d g e n e e d s to b e tro w e le d /m a g g e d to th e p ro p e r e le v a tio n ) th is p ro c e d u re w ill m a k e th e s e tu p
o f th e C o p p e rh e a d e a s ie r a n d m o re a c c u ra te .
1 0 .) D r iv e th e C o p p e r h e a d in to th e f ir s t p a s s p o s itio n .
1 1 .) L e v e l th e m a c h in e u s in g th e h e a d lif t s w itc h .
1 2 .) M a k e s u r e th e la s e r c o n tr o l s y s te m is in th e m a n u a l p o s itio n .
1 3 .) I n s tr u c t a c o w o r k e r to h o ld th e g r a d e s tic k o n th e p lo w f a c in g th e la s e r tr a n s m itte r .
1 4 .) A t th e o p e r a to r c o n s o le r a is e o r lo w e r th e p lo w u s in g th e m a n u a l s w itc h f o r th a t s id e u n til th e g r a d e
s tic k /h a n d h e ld re c e iv e r in d ic a te th a t th e p lo w is a t th e p ro p e r e le v a tio n . R e p e a t th is s a m e p ro c e s s fo r th e
o p p o s ite s id e . R e c h e c k b o th s id e s .
1 5 .) O n c e th e p lo w is o n - g r a d e , m a n u a lly lo w e r th e la s e r r e c e iv e r ( f r o m t h e t o p d o w n ) u n t i l t h e L E D 's
in d ic a te th e o n -g ra d e s ig n a l, re p e a t th e p ro c e s s fo r th e o p p o s ite s id e .
1 6 .) T u r n th e la s e r c o n tr o l s y s te m in to th e a u to m o d e .
1 7 .) P r o c e e d to s c r e e d th e f ir s t 3 f e e t o f th e p a s s .
1 8 .) C h e c k th e a c tu a l s c r e e d e d s u r f a c e o f th e c o n c r e te o n b o th s id e s o f th e p a s s .
1 9 .) M a k e th e n e c e s s a ry a d ju s tm e n ts to e ith e r re c e iv e rs , if th e g ra d e s tic k is s h o w in g th a t th e g ra d e is
h ig h o n o n e s id e o f th e p a s s , ra is e th e re c e iv e r to lo w e r th e g ra d e . D o th e s a m e fo r th e o p p o s ite s id e . If
th e g ra d e s tic k is s h o w in g th a t th e s c re e d e d p a s s n e e d s to b e ra is e d u p , lo w e r th e re c e iv e r to o b ta in th e
p ro p e r h e ig h t.
2 0 .) R e s c r e e d th e p a s s a t th e n e w e le v a tio n a n d r e c h e c k th e e le v a tio n w ith th e g r a d e s tic k . I f c h a n g e s a r e
n e e d e d o n c e a g a in , fo llo w th e s a m e p ro c e s s a s a b o v e .

6 /0 2 B .4 .1 3
 C L E A N U P P R O C E D U R E S

E v e n t h o u g h t h e c o n c r e t e i s i n a n d t h e f l o o r i s w i t h i n t o l e r a n c e s , y o u r d a y i s n 't d o n e u n t i l y o u
c o m p le te ly c le a n y o u r C o p p e rh e a d .

1 . B e fo re y o u m o v e to th e w a s h in g a re a , s w itc h th e la s e r c o n tro l o v e r to th e
m a n u a l m o d e a n d d riv e b o th a c tu a to rs to th e to p o f th e ir tra v e l.

2 . T h e n e n g a g e th e S id e L o c k S w itc h . F in a lly , lo w e r th e re c e iv e r m a s ts , d is c o n n e c t
th e la s e r re c e iv e rs , re m o v e th e m fro m th e m a s ts , a n d c o il th e ir c o n n e c tin g c o rd s .

3 . N o w y o u c a n d riv e to w h e re th e m a c h in e w ill b e w a s h e d .

4 . O n c e y o u 'r e i n p o s i t i o n , t u r n o f f t h e M a s t e r S w i t c h a n d s h u t o f f t h e f u e l
s u p p ly to th e e n g in e .

5 . K e e p in g w a te r a w a y fro m th e e le c tro n ic e q u ip m e n t a n d th e b re a th e r filte r o n th e

v ib r a to r g e a r b o x ( s e e 4 0 .1 0 ) , w a s h th e e n tir e C o p p e r h e a d w ith a r e g u la r h o s e a n d w a te r .

6 . O n c e e v e ry tw o o r th re e d a y s y o u s h o u ld th o ro u g h ly c le a n th e C o p p e rh e a d u s in g a
p re ss u re w a sh in g sy s te m c a p a b le o f p ro v id in g 3 0 0 0 p o u n d p e r s q u a re in c h . W h e n y o u
d o th is , b e v e r y c a re fu l b e c a u se a tig h t h ig h p re s s u re s tre a m o f w a te r is s o m e tim e s
p o w e rfu l e n o u g h to re m o v e p a in t a n d s a fe ty d e c a ls .

6 /0 2 B .4 .1 4
 C O P P E R H E A D T R O U B L E S H O O T I N G G U I D E

P R O B L E M C H E C K
L in e a r a c tu a to rs w ill n o t m o v e M a n u a l/A u to S w itc h is w h e re y o u w a n t it
A ll c o rd s fo r la s e r c o n tro l a re p lu g g e d in a n d tig h t
T ra n s m itte r is o n & ro ta tin g
M a s te r s w itc h is o n
B a tte ry is c h a rg e d
L in e a r a c tu a to r p a c k a rd c o n n e c to rs a re p lu g g e d in
T u rn o n L a s e r R e c e iv e rs

M a c h in e w ill n o t h o ld g ra d e S id e -S id e o s c illa tio n is lo c k e d

T o o c lo s e to la s e r tra n s m itte r
L a s e r is re fle c tin g o f f o f g la s s a n d b o u n c in g b a c k
L a s e r re c e iv e r is s lip p in g d o w n
R e -s e t u p th e p lo w
M a c h in e le v e l
S u b g ra d e b a d
P u llin g to o m u c h c o n c re te w ith p lo w

M a c h in e is n o t s e a lin g th e c o n c re te C h e c k v ib ra to r s p e e d
A tta c k a n g le o f h e a d (T u rn b u c k le le n g th )

H a rd to tu rn tra v e lin g in th e fo rw a rd d ire c tio n D iffe re n tia l lo c k o n

V ib ra to r d o e s n o t tu rn o n w h ile s c re e d in g M a s te r s w itc h o n
V ib ra to r s w itc h o n

M a c h in e d o e s n o t s to p w h e n o p e ra to r O p e ra to r p re s e n c e s w itc h o n le ft
re le a s e s h a n d le s h a n d le b a r w o rk in g

6 /0 2 B .5 .1
 T R O U B L E S H O O T I N G - S C R E E D I N G O P E R A T I O N S
C O N D I T I O N S T H A T M A Y A F F E C T T H E L A S E R C O N T R O L S Y S T E M
1 ) T h e fo llo w in g m a y c a u s e in te rfe re n c e b e tw e e n th e la s e r tra n s m itte r
a n d th e re c e iv e rs :

a ) F o g .
b ) D u s t.
c ) D ie s e l E x h a u s t.
d ) U n e v e n ly h e a te d a ir.
e ) U s in g a c o lu m n c la m p o n a b u ild in g c o lu m n . W in d o r o th e r d is tu rb a n c e s m a y c a u s e th e b u ild in g to
ro c k . T h is m o v e m e n t w ill n o t b e d is c e rn ib le b y e y e , b u t c a n e a s ily b e e n o u g h to c a u s e e rra tic
s ig n a ls . U s e o f a trip o d m a y e lim in a te th e p ro b le m .
f) H e a v y e q u ip m e n t s u c h a s a b u lld o z e r o r a v ib ra to ry ro lle r o p e ra tin g n e a rb y . T h is c a n c a u s e g ro u n d
to v ib ra te e n o u g h to a ffe c t th e tra n s m itte r. If e q u ip m e n t c a n n o t b e s h u t o ff, try re lo c a tin g th e
tra n s m itte r fu rth e r fro m th e s o u rc e o f v ib ra tio n a n d m o u n t th e tra n s m itte r o n a trip o d ra th e r th a n
a b u ild in g c o lu m n .
g ) W in d m a y c a u s e th e tra n s m itte r trip o d to ro c k . T ry h a n g in g w e ig h ts , s u c h a s s e v e ra l c o n c re te
b lo c k s , fro m th e c e n te r o f th e trip o d , o r p la c e a w in d b re a k , s u c h a s a v e h ic le , u p w in d .

2 ) F lu o re s c e n t lig h ts m a y c a u s e a s o lid re d h ig h s ig n a l.
P o s s ib le s o lu tio n s :
a ) S h u t o ff lig h ts .
b ) In s ta ll s h ie ld s a b o v e th e re c e iv e rs .
3 ) W e a k b a tte rie s in th e tra n s m itte r w ill c a u s e :
a ) W e a k e rra tic s ig n a ls .
b ) N o s ig n a l if fa r e n o u g h a w a y .

4 ) R e fle c tiv e s u rfa c e s s u c h a s g la s s o r g a lv a n iz e d s h e e t m e ta l, lo c a te d a t th e s a m e h e ig h t a s th e

tra n s m itte r, c a n c a u s e fa ls e b e a m re fle c tio n s to s trik e th e re c e iv e rs a n d re s u lt in e rra tic h ig h
o r lo w s ig n a ls .

S o lu tio n s :
a ) P la c e a n o n re fle c tiv e m a te ria l a t tra n sm itte r h e ig h t o n th e re fle c tiv e s u rfa c e s .
b ) T a p e u p th e s id e o f th e re c e iv e r th a t is p ic k in g u p th e re fle c te d s ig n a l.
c ) P la c e n o n re fle c tiv e s h ie ld b e tw e e n tra n s m itte r a n d s o u rc e o f re fle c tio n .
d ) T a p e th e w in d o w o f th e tra n s m itte r o n th e re fle c tio n s o u rc e s id e .
5 ) If is o la te d a re a s o f rip p le d c o n c re te fin is h a re n o tic e d , it m a y b e d u e to in te rfe re n c e o f th e la s e r b e a m
b y th e s u p p o rt le g s a t th e c o rn e rs o f th e tra n s m itte r ro ta tin g b e a c o n h o u s in g . R o ta te th e tra n s m itte r a s
n e c e s s a ry to e lim in a te th e b lo c k a g e b y th e s u p p o rt le g s .

6 /0 2 B .6 .1
 S E R V IC E A N D M A IN T E N A N C E

O B S E R V E S E R V IC E IN T E R V A L S
U s in g th e h o u r m e te r a s a g u id e , p e r fo r m a ll
S E R V IC E
r e c o m m e n d e d s e r v ic e s a t h o u r ly in te r v a ls in d ic a te d o n
th e fo llo w in g p a g e s . Y o u s h o u ld k e e p a s e r v ic e r e c o r d .
O IL C H A N G E
U s e th e c o r r e c t fu e ls a n d lu b r ic a n ts

F A N B E L T

H Y D . F IL T E R

D IS P O S E O F W A S T E P R O P E R L Y
U s e le a k p r o o f c o n ta in e r s w h e n d r a in in g h a z a r d o u s
flu id s . D o n o t u s e fo o d o r b e v e r a g e c o n ta in e r s th a t m a y
m is le a d s o m e o n e in to d r in k in g fr o m th e m .
D O N O T p o u r w a s te o n to th e g r o u n d , d o w n a d r a in , o r
in to a n y w a te r s o u r c e .

A V O ID H IG H -P R E S S U R E F L U ID S
E s c a p in g flu id u n d e r p r e s s u r e c a n p e n e tr a te th e s k in
a n d c a u s e s e r io u s in ju r y .
R e lie v e p r e s s u r e b e fo r e d is c o n n e c tin g h y d r a u lic o r
o th e r lin e s . T ig h te n a ll c o n n e c tio n s b e fo r e a p p ly in g
p r e ssu r e .
IF A N A C C ID E N T O C C U R S , S E E A D O C T O R
IM M E D I A T E L Y . A n y flu id in je c te d in to th e s k in m u s t
b e s u r g ic a lly r e m o v e d w ith in a fe w h o u r s o r g a n g r e n e
m a y r e s u lt.

6 /0 2 C .1 .1
 S E R V IC E A N D M A IN T E N A N C E

S H U T T H E E N G IN E O F F
A L W A Y S sh u t th e C o p p e r h e a d 's e n g in e O F F
B E F O R E a tte m p tin g a n y r e p a ir s o r w o r k in g
o n a n y m o v in g p a r ts o n o r in s id e th e m a c h in e ,
in c lu d in g a n y p a r t o f th e h y d r a u lic sy ste m .

N E V E R w o r k o n a n y p a r t o f th e h y d r a u lic
s y s te m o r th e e n g in e w h e n th e m a c h in e is h o t.

T U R N T H E M A S T E R S W IT C H O F F
A L W A Y S tu r n th e M a s te r S w itc h O F F w h e n
w o r k in g o n th e e le c tr ic a l s y s te m .

U S E P R O P E R T O O L S
A L W A Y S s e r v ic e y o u r C o p p e r h e a d w ith th e
p r o p e r to o ls a n d b e p a r tic u la r ly c a r e fu l w h e n
c h a n g in g p r e c is io n c o m p o n e n ts .

6 /0 2 C .1 .1
 C O P P E R H E A D S C H E D U L E D
L U B R IC A T IO N & M A IN T E N A N C E

S E R V IC E IN T E R V A L IN E E
S E R V IC E IT E M M A C H IN E H O U R S AP G NE C N T
CI A
P e r fo r m a t e v e r y in d ic a te d F irs t E V E R Y E V E R Y E V E R Y E V E R Y E R R
m o n th o r o p e r a tin g h o u r in te r v a l, E A C H
m o n th 3 m o n th s 6 m o n th s y e a r 2 0 0 0
R E F UL B
w h ic h e v e r c o m e s f ir s t. U S E
o r o r o r o r H R S .
2 0 5 0 1 0 0 3 0 0
H R S . H R S . H R S . H R S .
C h e c k e n g in e o il le v e l
ü E N G IN E
M A N U A L E O
C h a n g e e n g in e o il
ü ü E N G
M A N
IN E
U A L E O

ü
E N G IN E
C h e c k tra n s m is s io n o il le v e l M A N U A L E O
C h a n g e tra n s m is s io n o il
ü ü E N G I
M A N U
N E
A L E O

ü
E N G I N E
C h e c k a ir filte r M A N U A L

ü
E N G I N E
C le a n a ir filte r M A N U A L

ü
E N G I N E
R e p la c e a ir filte r M A N U A L

ü
E N G IN E
C le a n s e d im e n t c u p M A N U A L

ü
E N G IN E
C le a n -re a d ju s t s p a rk p lu g M A N U A L

ü
E N G IN E
R e p la c e s p a rk p lu g M A N U A L

ü
E N G IN E
C h e c k -a d ju s t id le s p e e d M A N U A L

ü
E N G IN E
C h e c k /re a d ju s t v a lv e c le a ra n c e M A N U A L

C le a n fu e l ta n k a n d s tra in e r
C h e c k fu e l lin e E v e r y 2 y e a r s ( R e p la c e
ü
if n e c e s s a r y )
E N G IN E
M A N U A L
E N G IN E
M A N U A L

C h e c k fu e l le v e l
ü E N G IN E
M A N U A L

C h e c k b a tte ry e le c tro ly te le v e l
ü
C h e c k e le c tric a l fu s e c o n n e c tio n s
ü
In s p e c t e le c tric a l w irin g
ü
C h a rg e re m o te s
ü

D E F IN IT IO N S :
E O - E N G IN E C R A N K C A S E O IL
H Y D O - H Y D R A U L IC O IL
M P G M - M U L T IP U R P O S E T Y P E G R E A S E W IT H M O L Y B D E N U M D IS U L F ID E

6 /0 2 C .1 .2
 C O P P E R H E A D S C H E D U L E D
L U B R IC A T IO N & M A IN T E N A N C E

S E R V IC E IN T E R V A L IN E E
S E R V IC E IT E M M A C H IN E H O U R S AP G NE C N T
CI A
P e r fo r m a t e v e r y in d ic a te d F irs t E V E R Y E V E R Y E V E R Y E V E R Y E R R
m o n th o r o p e r a tin g h o u r in te r v a l, E A C H
m o n th 3 m o n th s 6 m o n th s y e a r 2 0 0 0
R E F UL B
w h ic h e v e r c o m e s f ir s t. U S E
o r o r o r o r H R S .
2 0 5 0 1 0 0 3 0 0
H R S . H R S . H R S . H R S .
C le a n o il c o o le r c o re e x te rio r
ü C .3 .1
C h e c k o il c o o le r h o s e s
ü C .3 .1

C h e c k h y d ra u lic o il le v e l ü C .3 .1 H Y D O
C h e c k h y d . o il filte r re s tric tio n in d ic a to r
(p re s s u re lin e ) ü C .3 .2
C h e c k h y d . o il filte r re s tric tio n in d ic a to r
(re tu rn lin e )
C h a n g e h y d . o il filte r (p re s s u re lin e ) P E R
ü
R E S T R IC T IO N IN D IC A T O R
C .3 .2
C .3 .2
C h a n g e h y d . o il filte r (re tu rn lin e ) P E R R E S T R IC T IO N IN D IC A T O R C .3 .2
C h a n g e h y d . o il in re s e rv o ir
ü C .3 .3 H Y D O
C h e c k h y d ra u lic h o s e s
ü
C h e c k w h e e l lu g n u t tig h tn e s s
ü
V ib ra to r G e a r B o x O il
ü C .3 .4 E O

D E F IN IT IO N S :
E O - E N G IN E C R A N K C A S E O IL
H Y D O - H Y D R A U L IC O IL
M P G M - M U L T IP U R P O S E T Y P E G R E A S E W IT H M O L Y B D E N U M D IS U L F ID E

6 /0 2 C .1 .3
 L U B R IC A N T S P E C IF IC A T IO N S

L u b ric a n t a b b re v ia tio n s u s e d a re in a c c o rd a n c e w ith S A E J 7 5 4 a . O il c la s s ific a tio n s a re in a c c o rd a n c e w ith

S A E J1 8 3 .

E N G IN E O IL S : U s e e n g in e o ils w ith a n A P I c la s s ific a tio n o f S F o r S D . N e w m a c h in e s a re s u p p lie d w ith ,

a n d w e re c o m m e n d th e u s e o f, e n g in e o il e q u iv a le n t to S A E 1 0 W 3 0 .

R e fe r to y o u r e n g in e m a n u a l fo r a d d itio n a l e n g in e o il in fo rm a tio n a n d re q u ire m e n ts .

H Y D R A U L IC O IL S : (H Y D O ) U s e h y d ra u lic o ils c e rtifie d b y s u p p lie r to h a v e a n tiw e a r, a n tiru s t, a n tifo a m

a n d a n tio x id a tio n a d d itiv e s fo r h e a v y d u ty u s e . N e w m a c h in e s a re e q u ip p e d w ith , a n d w e re c o m m e n d th e
u s e o f, h y d ra u lic o il w ith a v is c o s ity e q u iv a le n t to IS O 3 2 .
V IS C O S IT Y T E M P E R A T U R E R A N G E
IS O 3 2 A b o v e 0 d e g re e s F (-1 8 d e g .C )
IS O 6 8 A b o v e 2 2 d e g re e s F (3 d e g . C )
IS O 1 0 0 A b o v e 4 5 d e g re e s F (7 d e g .C )

L U B R IC A T IN G G R E A S E : (M P G M ) U s e g re a s e w h ic h c o n ta in s 3 -5 % m o ly b d e n u m d is u lfid e fo r a ll
g re a s e p o in ts .

C A P A C IT IE S

A P P R O X IM A T E F L U ID C A P A C IT IE S :

S y s te m C a p a c ity
E n g in e c ra n k c a s e :
H o n d a G X 2 7 0 9 h p E n g in e 1 .1 6 U S q u a r ts ( 1 .1 L )
H y d ra u lic ta n k 4 .8 7 U S g a llo n s ( 1 8 .5 1 L )
F u e l ta n k 1 .5 9 U S g a llo n s ( 6 .0 L )

6 /0 2 C .2 .1
 S E R V IC E IN S T R U C T IO N S

C H E C K IN G B A T T E R Y E L E C T R O L Y T E L E V E L
E v e ry 1 0 0 h o u rs (o r 6 m o n th s ) th e e le c tro ly te le v e l in th e b a tte ry sh o u ld b e c h e c k e d . T h is is
e s p e c ia lly im p o rta n t in h o t w e a th e r. T h e e le c tro ly te (w a te r) le v e l is c h e c k e d b y re m o v in g th e
c a p s fro m th e to p o f th e b a tte ry a n d in s p e c tin g th e le v e l in e a c h o f th e 6 b a tte ry c e lls . It w ill b e
n e c e ssa ry to re m o v e th e b a tte ry -h o ld d o w n s tra p to g a in a c c e s s to th e c e ll c a p s . T h e e le c tro ly te
le v e l s h o u ld b e e v e n w ith th e b o tto m o f th e tu b e s in e a c h fille r h o le . A d d o n ly c le a n d is tille d
w a te r to a n y b a tte ry c e ll w h ic h m a y b e lo w .

C L E A N IN G T H E O IL C O O L E R C O R E E X T E R IO R
If th e a ir flo w th ro u g h th e o il c o o le r b e c o m e s re s tric te d th e h y d ra u lic o il m a y b e g in to o p e ra te a t
to o h ig h a te m p e ra tu re w h ic h w ill s h o rte n th e life o f th e h y d ra u lic p u m p . C le a n th e o il c o o le r
d a ily to p re v e n t th e b u ild u p a n d h a rd e n in g o f c o n c re te d u s t. If th e o il c o o le r b e c o m e s b lo c k e d
d u e to la c k o f c le a n in g it w ill e v e n tu a lly n e e d to b e re p la c e d . C le a n th e ra d ia to r w ith c o m p re s s e d
a ir o r u s e a p r e ssu re w a sh e r b e fo re d u s ty m a te ria l h a rd e n s to th e ra d ia to r.

C H E C K IN G O IL C O O L E R H O S E S
P e rio d ic a lly c h e c k a ll h o s e s o f th e c o o lin g s y s te m fo r le a k s o r d e te rio ra tio n . R e p la c e a n y
q u e s tio n a b le -a p p e a rin g h o s e s w ith n e w o n e s .

C H E C K IN G H Y D R A U L IC O IL L E V E L
T h e h y d ra u lic o il le v e l is c h e c k e d b y lo o k in g a t th e h y d ra u lic o il le v e l s ig h t g u a g e lo c a te d o n th e
le ft s id e o f th e h y d ra u lic ta n k . C h e c k th e o il le v e l w ith th e m a c h in e p a rk e d o n le v e l g ro u n d , th e
o il a t n o rm a l o p e ra tin g te m p e ra tu re . T h e o il le v e l s h o u ld b e v is ib le in s id e th e s ig h t g a u g e a n d n e a r
th e " o il le v e l" m a rk o n th e ta n k . A d d o il a s re q u ire d to m a in ta in c o rre c t o il le v e l.

1 2 /0 3 C .3 .1
C H E C K IN G T H E H Y D R A U L IC O IL F IL T E R R E S T R IC T IO N IN D IC A T O R
A c lo g g e d filte r w ill c a u s e a n o tic e a b le d e c re a s e in p e rfo rm a n c e . C h e c k th e h y d ra u lic o il filte r
re s tric tio n in d ic a to rs a s fo llo w s :
R e tu rn L in e
S e t th e e n g in e a t fu ll th ro ttle . C h e c k th e filte r re s tric tio n in d ic a to r (g a u g e ) lo c a te d o n th e
h y d ra u lic o il filte r m o u n tin g a s s e m b ly . If th e g a u g e re g is te rs o v e r 2 b a r (s ta rt o f th e y e llo w a re a
o n th e g a u g e ), th e filte r e le m e n t s h o u ld b e c h a n g e d .

H Y D R A U L IC O IL F IL T E R E L E M E N T S :
C h a n g e th e h y d ra u lic o il filte r o n th e re tu rn lin e a s fo llo w s :
W ith th e m a c h in e tu rn e d o ff, re m o v e th e to p o f th e filte r h o u s in g a n d re p la c e filte r e le m e n t. D o
n o t a llo w a n y d irt a n d d e b ris to e n te r th e h y d ra u lic ta n k .
C h a n g e th e h y d ra u lic o il filte r o n th e p re s s u re lin e a s fo llo w s :
U n s c re w th e lo w e r p o rtio n o f th e filte r h o u s in g , a n d re p la c e filte r e le m e n t. D o n o t a llo w a n y d irt
a n d d e b ris to e n te r th e filte r h o u s in g .

H Y D R A U L IC O IL
R E S T R IC T IO N F IL T E R E L E M E N T
IN D IC A T O R R E T U R N L IN E

1 2 /0 3 C .3 .2
C H A N G IN G H Y D R A U L IC O IL
R e f e r to f ig u r e o n p a g e C .3 .2 .
P e rio d ic a lly it w ill b e n e c e s s a ry to c h a n g e th e h y d ra u lic o il to p re v e n t d e te rio ra tio n o f th e s y s te m s
c o m p o n e n ts . A s o il a g e s w ith u s e th e s p e c ia l c h e m ic a l a d d itiv e s in th e o il, w h ic h r e s is t c o rro s io n ,
b re a k d o w n a n d b e c o m e le ss e ffe c tiv e . T h e r e fo re it is im p o rta n t to p e rio d ic a lly re p la c e a s m u c h o f th e
o il a s p o s s ib le w ith fre s h o il. It is im p ra c tic a l to c h a n g e a ll th e o il in th e s y s te m d u e to o il b e in g
tra p p e d in th e v a rio u s c o m p o n e n ts o f th e s y s te m .
T o c h a n g e h y d ra u lic o il:
1 ) P re ssu re w a s h th e m a c h in e . P a y s p e c ia l a tte n tio n to c le a n in g th e to p o f th e h y d ra u lic
ta n k in th e a re a o f th e h y d ra u lic re s e rv o ir a c c e s s c o v e rs . T h e to p o f th e ta n k s h o u ld b e
a s c le a n a s p o s s ib le s o th a t n o d irt c a n fa ll in to th e ta n k w h e n th e o il filte r a s s e m b ly is
re m o v e d .
2 ) D ra in th e o il fro m th e h y d ra u lic ta n k b y o p e n in g th e d ra in p lu g a t th e b o tto m o f th e
ta n k . D ra in th e o ld o il in to a la rg e d ra in p a n o f c a p a c ity e q u a l to o r g re a te r th a n th e o il
c a p a c ity o f th e r e s e r v o ir ( 4 .8 7 g a llo n s /1 8 .5 1 L ) .
3 ) O n c e a ll th e o il h a s d ra in e d fro m th e ta n k , it m a y b e b e s t to re m o v e th e o il filte r
a s s e m b ly fo r a n in s p e c tio n a n d c le a n in g o f th e in s id e o f th e re s e rv o ir.
4 ) T h e h y d ra u lic o il filte r a s s e m b ly is re m o v e d b y re m o v in g th e h e x b o lts in th e b a s e p la te
o f th e o il filte r a s s e m b ly .
5 ) T h e filte r e le m e n t is lo c a te d u n d e r th e c o v e r o f th e o il filte r a s s e m b ly .
6 ) W ith th e o il filte r a s s e m b ly re m o v e d , th e in te rio r o f th e h y d ra u lic re s e rv o ir c a n b e
in s p e c te d a n d c le a n e d . A fte r c le a n in g , re p la c e th e o il filte r a s s e m b ly w ith th e s e a lin g
g a s k e t in p ro p e r p o s itio n .
7 ) R e p la c e th e d ra in p lu g a n d re fill th e h y d ra u lic ta n k to th e c o rre c t le v e l w ith n e w
h y d ra u lic o il.

C H E C K IN G W H E E L L U G N U T T IG H T N E S S
P e rio d ic a lly c h e c k th e tig h tn e s s o f th e w h e e l lu g n u ts .

1 2 /0 3 C .3 .3
 V IB R A T O R G E A R B O X

C A U T IO N : D O N O T A T T E M P T T O L U B R IC A T E O R P E R F O R M A N Y O T H E R
M A IN T E N A N C E O N A N Y F U N C T IO N W H IL E IT IS IN O P E R A T IO N .

A p p ro x im a te ly 3 o z . o f 1 0 -3 0 m o to r o il is u s e d in th e V ib ra to r G e a r B o x .

C h e c k o il le v e l in th e v ib ra to r g e a r b o x b e fo re e a c h u s e o f th e C o p p e rh e a d .
R e m o v e p lu g o n th e b o tto m d ra in h o le .
O il s h o u ld b e le v e l w ith th e b o tto m o f th e d ra in h o le .
If o il is lo w re m o v e th e p lu g fro m th e fill h o le o n to p o f th e V ib ra to r G e a r B o x .
P o u r o il in th ro u g h th e fill h o le u n til o il c o m e s o u t o f th e b o tto m d ra in h o le .
R e p la c e p lu g s .

N O T E : It is e x tre m e ly im p o rta n t th a t th e re is th e p ro p e r le v e l o f o il in th e V ib ra to r
G e a r B o x . D a m a g e w ill o c c u r to th e V ib ra to r G e a r B o x if it is ru n w ith o u t o il.

O il F ill H o le

O il L e v e l

1 2 /0 3 C .3 .4
 P L O W A N D V IB R A T O R P L A T E

Q : H o w s h o u ld I d e te rm in e it is tim e to re p la c e th e P lo w ?

A : 1 . I t is n o lo n g e r s tr a ig h t in th e u p -d o w n p o s itio n .
(F o r-A ft w a v e s a re a ll r ig h t b u t if th e re a re d ip s
a n d v a lle y s it w ill n o t w o r k r ig h t.)
2 . T h e p lo w is n o lo n g e r a b le to h o ld
th e la s e r r e c e iv e r m a s ts v e rtic a l.

Q : H o w s h o u ld I d e te rm in e it is tim e to re p la c e th e V ib ra to r P la te ?

A : 1 . T h e b o tto m p la te is w o r n th ro u g h .
2 . It su ffe re d so m e so rt o f c a ta s tro p h ic fa ilu re .
3 . W h e n s trin g -lin in g it, it h a s a fro w n o f m o re th a t 1 /4 " .
(L e a d in g a n d tra ilin g e d g e s sh o u ld b e c h e c k e d .)
4 . W h e n s trin g -lin in g it, it h a s a s m ile o f 1 /8 " o r m o re
fro m e n d to e n d . (L e a d in g a n d tra ilin g e d g e s
s h o u ld b e c h e c k e d .)

1 2 /0 3 C .3 .5
 C O P P E R H E A D O P E R A T IN G S P E E D S & P R E S S U R E S
E n g in e a t fu ll 3 6 0 0 R P M , th e H y d ra u lic O il a t O p e ra tin g T e m p e ra tu re 9 0 -1 0 0 d e g re e F

H E A D L IF T 1 0 S E C O N D C Y C L E (U P /D O W N ) 2 5 0 0 P S I M A X

V IB R A T O R F A C T O R Y S E T T I N G 4 5 0 0 R P M 's @ 9 5 0 P S I

P R O P E L F W D /R E V L E V E L D R IV E 4 0 0 -5 0 0 P S I

S P E E D 0 R P M to 7 5 R P M O N K IC K S T A N D W IT H O N E
W H E E L B L O C K E D (W IT H T R A C T IO N A S S IS T O F F )

L IN E A R A C T U A T O R S 5 - 6 S E C 'S F O R F U L L S T R O K E ( R A B B I T M O D E )

7 - 8 S E C 'S F O R F U L L S T R O K E ( T U R T L E M O D E )

C O U N T E R B A L A N C E S E T T IN G P R O P E L 1 1 /2 T U R N S O U T

M A X S Y S T E M P R E S S U R E P R O P E L S ID E 3 4 0 0 P S I
H E A D L IF T /V IB R A T O R 3 0 0 0 P S I

1 0 /0 2 C .4 .1
 R E C O M M E N D E D T O R Q U E V A L U E S F O R B O L T S
M O S T B O L T S S U P P L IE D O N T H E L A S E R S C R E E D A R E G R A D E 8 .
G R A D E 8 B O L T S H A V E 6 M A R K S /L IN E S O N T H E H E A D S .
G R A D E 5 B O L T S H A V E 3 M A R K S /L IN E S O N T H E H E A D S .
G R A D E 8 G R A D E 5
T H R E A D H E X S I Z E D R Y O R P L A T E D O R D R Y O R P L A T E D O R
S IZ E (D IS T A N C E P L A IN L U B R IC A T E D P L A IN L U B R IC A T E D
A C R O S S F L A T S ) * *
(IN C H E S )
F T L B F T L B F T L B F T L B
(N -m ) (N -m ) (N -m ) (N -m )
1 /4 -2 0 7 /1 6 1 2 9 8 6
(1 6 ) (1 2 ) (1 1 ) (8 )
5 /1 6 -1 8 1 /2 2 5 2 0 1 7 1 3
(3 4 ) (2 7 ) (2 3 ) (1 8 )
3 /8 -1 6 9 /1 6 4 5 3 5 3 0 2 3
(6 1 ) (4 7 ) (4 1 ) (3 1 )
1 /2 -1 3 3 /4 1 1 0 8 0 7 5 5 5
(1 4 9 ) (1 0 8 ) (1 0 2 ) (7 5 )
5 /8 -1 1 1 5 /1 6 2 2 0 1 7 0 1 5 0 1 1 0
(2 9 8 ) (2 3 0 ) (2 0 3 ) (1 4 9 )
3 /4 -1 0 1 1 /8 3 8 0 2 8 0 2 6 0 2 0 0
(5 1 5 ) (3 7 9 ) (3 5 2 ) (2 7 1 )
1 -8 1 1 /2 9 0 0 6 8 0 6 4 0 4 8 0
(1 2 2 0 ) (9 2 1 ) (8 6 7 ) (6 5 0 )

* T H E V A L U E S F O R P L A T E D O R L U B R IC A T E D B O L T S S H O U L D A L S O B E U S E D IF T H E B O L T
IS C O A T E D W IT H A T H R E A D L O C K IN G C O M P O U N D S U C H A S L O C -T IT E O R IF A H A R D E N E D
S T E E L W A S H E R IS U S E D U N D E R T H E H E A D O F T H E B O L T .
R E F E R T O Y O U R E N G IN E O P E R A T IO N M A N U A L F O R T O R Q U E V A L U E S T H A T A P P L Y T O T H E
M E T R IC N U T S A N D B O L T S F U R N IS H E D O N T H E E N G IN E .

3 /0 2 C .5 .1
 R E C O M M E N D E D T O R Q U E V A L U E S F O R P L A T E D L O C K N U T S
A P P L IC A B L E W H E N T H E Y A R E U S E D W IT H C O M P A R A B L E H E X H E A D B O L T S W IT H
H A R D E N E D F L A T W A S H E R S U N D E R T H E N U T A N D B O L T H E A D A N D T O R Q U E IS
A P P L IE D T O T H E N U T O N L Y .
M O S T L O C K N U T S S U P P L IE D O N T H E L A S E R S C R E E D A R E G R A D E 8 .
G R A D E 8 N U T S H A V E 6 ID E N T IF Y IN G M A R K S O N T H E M .
G R A D E 5 N U T S H A V E 3 ID E N T IF Y IN G M A R K S O N T H E M .

G R A D E 8 G R A D E 5
T H R E A D H E X S I Z E F T L B F T L B
S IZ E (D IS T A N C E (N -m ) (N -m )
A C R O S S F L A T S )
(IN C H E S )
1 /4 -2 0 7 /1 6 8 6
(1 1 ) (8 )

5 /1 6 -1 8 1 /2 1 3 1 1
(1 8 ) (1 5 )

3 /8 -1 6 9 /1 6 2 4 1 7
(3 3 ) (2 3 )

1 /2 -1 3 3 /4 5 5 4 2
(7 5 ) (5 7 )

5 /8 -1 1 1 5 /1 6 1 0 0 8 2
(1 3 6 ) (1 1 1 )

3 /4 -1 0 1 1 /8 1 6 5 1 3 7
(2 2 4 ) (1 8 6 )

1 -8 1 1 /2 4 0 9 3 3 2
5 5 4 ) (4 5 0 )

3 /0 2 C .5 .2
 R E C O M M E N D E D T O O L S & S P A R E P A R T S

R E C O M M E N D E D T O O L S T O K E E P W IT H E A C H C O P P E R H E A D M A C H IN E

1 ) S e t o f s ta n d a rd o p e n /b o x e n d w re n c h e s th ru 1 "
2 ) S ta n d a rd s o c k e t s e t to 1 "
3 ) P re ssu re w a sh e r
4 ) P re s s u re c a n to s p ra y o n fo rm re le a s e o il

G E N E R A L P A R T S & S U P P L IE S

1 ) B la c k e le c tric a l ta p e 6 ) E n g in e o il

2 ) N y lo n tie w ra p s 7 ) F o rm re le a s e o il

3 ) C a rb u re to r C le a n e r fo r c le a n in g p a rts 8 ) S p a re tra n s m itte r b a tte rie s

4 ) L u b ric a n t s u c h a s W D -4 0
5 ) T w o J IC c a p s a n d p lu g s fo r e a c h h y d ra u lic h o s e
s iz e .

S P E C IF IC P A R T S
W e re c o m m e n d th a t th e p a rts lis te d o n th e fo llo w in g p a g e s b e k e p t o n h a n d w ith e a c h C o p p e rh e a d
m a c h in e .
If th e C o p p e rh e a d is b e in g u s e d c lo s e to y o u r y a rd /s h o p , y o u m a y c h o o s e to k e e p s o m e o f th e d a ily
m a in te n a n c e a n d " e m e rg e n c y re p a ir" ty p e ite m s w ith th e m a c h in e w h ile k e e p in g th e la rg e r ite m s a t
y o u r sh o p .
If th e C o p p e rh e a d is g o in g to b e u s e d o n a jo b s ite a g re a t d is ta n c e fro m y o u r y a rd /s h o p , y o u s h o u ld
k e e p m o s t o f th e s p a re p a rts lis te d a t th e jo b s ite .

5 /0 3 C .6 .1
 R E C O M M E N D E D S P A R E P A R T S T O K E E P W IT H E A C H C O P P E R H E A D M A C H IN E

R E F E R E N C E P A G E
P A R T N U M B E R D E S C R IP T IO N Q U A N T IT Y IN P A R T S B O O K

7 5 0 7 0 1 0 5 2 -0 0 H y d a c R e tu rn F ilte r - R e p la c e m e n t, 0 0 7 5 R 0 1 0 B N 3 H C 1 2 0 .2 0

7 4 0 8 0 1 2 1 6 -0 0 H a ir p in C lip s , 7 /1 6 " -3 /4 " s h a f t, .1 2 5 w ir e d ia . * 3 4 0 .2 0 , 4 0 .3 0

7 2 0 5 0 1 6 5 7 -0 1 P in - H e a d to T u rn b u c k le * 1 4 0 .2 0 , 4 0 .3 0

7 2 0 5 0 1 3 1 9 -0 1 B u s h in g , U p p e r L ift * 1 4 0 .2 0 , 4 0 .3 0

7 2 0 5 0 1 6 5 6 -0 0 P in - H e a d to L ift A rm * 1 4 0 .2 0 , 4 0 .3 0

7 4 0 8 0 1 2 0 8 -0 0 Is o la to rs , V ib ra to r * 2 4 0 .2 0 , 4 0 .3 0

2 0 2 7 1 -1 5 F u se , 1 5 a m p * 5 2 0 .3 0

2 0 0 6 5 -0 0 0 6 3 /8 " O R B p lu g 1 U se w h e re n e e d e d

7 4 0 8 0 1 2 1 9 -0 0 O -R in g 3 /3 2 " D ia 1 U se w h e re n e e d e d

7 1 1 6 0 1 0 2 2 -0 0 R o c k e r S w itc h , 2 p o s itio n * 1 2 0 .3 0

7 1 1 6 0 1 0 2 3 -0 0 R o c k e r S w itc h , 3 p o s itio n m o m e n t * 1 2 0 .3 0

7 1 0 6 0 1 0 7 4 -0 0 S p a re G C R 4 N o n c o ile d C o rd 7 ft. * 1 5 0 .3 0

7 5 0 7 0 1 0 5 5 -0 0 5 0 0 0 p si g a u g e a ssy , F S C 2 0 1 1 1 1 2 0 3 -6 2 1 U se w h e re n e e d e d

2 0 5 0 9 V ib ra to r M o to r S h a ft S e a l * 1 4 0 .1 0

7 7 0 4 0 1 0 0 6 -C 0 H o n d a F u e l F ilte r, 9 & 1 3 H P 1 H o n d a E n g in e

7 7 0 4 0 1 0 0 7 -C 0 H o n d a A ir F ilte r, 9 H P 1 H o n d a E n g in e

7 7 0 4 0 1 0 0 9 -C 0 H o n d a , S h o p M a n u a l 1 H o n d a E n g in e

7 1 0 6 0 1 0 7 2 -0 0 C o rd , A c t to G C R b o x * 1 5 0 .3 0

* In c lu d e d in S p a re P a rts k it.

5 /0 3 C .6 .2
 H Y D R A U L IC O P E R A T IO N

S e e f ig . ( D .1 .2 ) a n d h y d r a u lic d ia g r a m fo r ite m s re fe re n c e d b e lo w .
D U A L P U M P
O n e s id e o f th is p u m p is fo r d riv e p ro p u ls io n a n d h e a d lift a n d th e o th e r s id e is fo r th e s c re e d h e a d
v ib ra to r.
H Y D R A U L IC T A N K
T h is is th e re s e rv o ir fro m w h ic h th e p u m p s d ra w th e ir h y d ra u lic o il s u p p ly . T h e o il is filte re d a s it re tu rn s
to th e ta n k .
W H E E L M O T O R S
T w o s e p a r a t e h y d r a u l i c m o t o r s . E a c h d r i v e o n e o f t h e m a c h i n e 's t w o w h e e l s .
V IB R A T O R M O T O R
T h is m o to r tu rn s tw o e c c e n tric w e ig h ts in s id e th e v ib ra to r g e a r b o x w h ic h p ro v id e s v ib ra tio n to th e
v ib ra to r s h o e .

L IF T C Y L IN D E R
T h e c y lin d e r lifts a n d lo w e rs th e s c re e d h e a d .

S ID E L O C K C Y L IN D E R S
T h e s e tw o c y lin d e rs a llo w th e u p p e r a n d lo w e r fra m e s o f th e m a c h in e to b e lo c k e d to g e th e r.

C O U N T E R B A L A N C E B Y P A S S V A L V E
W h e n th e e n g in e is tu rn e d o ff, h y d ra u lic p re s s u re th ro u g h th e c o u n te rb a la n c e v a lv e w ill m a k e it d iffic u lt
to m o v e th e m a c h in e a ro u n d . In th a t c a s e , th is b y p a s s v a lv e c a n b e o p e n e d , th e re b y re le a s in g p re s s u re in
th e d riv e s y s te m a n d a llo w in g th e w h e e ls to tu rn m o re e a s ily .

V IB R A T O R S P E E D A D J U S T M E N T V A L V E
T h is v a lv e a d ju s ts th e s p e e d o f th e v ib ra to r to m a tc h th e s lu m p o f th e c o n c re te b e in g le v e le d .
S -9 2 1 0 V ib r a to r M o to r

2 -1 /2 tu rn s in * O 5 1 0 0 rp m

3 tu rn s in * O 3 7 5 0 rp m

2 -3 /4 tu rn s in * O 4 5 0 0 rp m - F a c to r y S e ttin g

R e c o m m e n d e d m a x im u m s p e e d o f 5 5 0 0 rp m , w h ic h is O 2 1 /4 tu rn s in * .
* T u r n in C lo c k w is e fr o m th e to p .

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6 /0 2

C O P P E R H E A D M A N IF O L D
H Y D R A U L IC M A N IF O L D
P R O P E L T E S T P O R T H E A D
T E S T P O R T F U N C T IO N P U M P
P R O P E L C O U N T E R B A L A N C E
P U M P H E A D F U N C T IO N H E A D L IF T
P R O P E L F L O W P U M P R E L IE F C A R T R ID G E
P R O P E L P R E S S U R E D IV ID E R
C O M P E N S A T O R
H E A D L IF T
F L O W
C O N T R O L
P R O P E L
C O U N T E R - P R O P E L
B A L A N C E B Y -P A S S V IB R A T O R
B Y -P A S S C A R T R ID G E
V IB R A T O R
P R O P U L S IO N S P E E D
C A R T R ID G E

P R O P E L P R O P E L V IB . S P E E D S ID E L O C K
P U M P C O U N T E R B A L A N C E C O N T R O L C A R T R ID G E
R E L IE F H E A D L IF T
T R A C T IO N A S S IS T C O U N T E R -
C A R T R ID G E B A L A N C E
D .1 .2
 C O P P E R H E A D H Y D R A U L IC S C H E M A T IC
6 /0 2 D .2 .1
T R O U B L E S H O O T IN G H Y D R A U L IC S Y S T E M P R O B L E M S

T h e m o s t c o m m o n p ro b le m s e n c o u n te re d w ith th e h y d ra u lic s y s te m a re c a u s e d b y d irt a n d d e b ris th a t

g e t in to th e s y s te m . IT IS V E R Y IM P O R T A N T T O K E E P T H E H Y D R A U L IC S Y S T E M C L E A N .
F o llo w in g th e s e s im p le m a in te n a n c e p ra c tic e s c a n h e lp p re v e n t u n n e c e s s a ry d o w n -tim e :
1 ) R e p la c e th e h y d ra u lic s y s te m filte r e le m e n t a s s p e c ifie d in th e S e rv ic e s e c tio n o f th is m a n u a l w ith
th e p ro p e r re p la c e m e n t e le m e n t.
2 ) If th e h y d ra u lic s y s te m h a s to b e w o rk e d o n , s u c h a s to c h a n g e a fa ile d h o s e o r o th e r c o m p o n e n t o f
th e s y s te m , ta k e s p e c ia l c a re to k e e p d irt o u t o f th e s y s te m b y c a p p in g a n d p lu g g in g a ll b ro k e n
c o n n e c tio n s , p re fe ra b ly w ith s te e l J I C c a p s a n d p lu g s . B e fo re d is c o n n e c tin g a h o s e , c le a n th e h o s e
e n d a re a th o ro u g h ly (a to o th b ru sh w o rk s w e ll).
3 ) C le a n n e w h o s e a s s e m b lie s th o ro u g h ly b e fo re in s ta llin g th e m ; b lo w in g c o m p re s s e d a ir th ro u g h
th e m w o rk s w e ll. O n c e th e y a re c le a n e d , p lu g th e e n d s o f n e w h o s e a s s e m b lie s u n til th e y a re
a c tu a lly in s ta lle d .
4 ) B e s u re th a t a n y o il a d d e d to th e s y s te m is c le a n . Id e a lly , a n y o il a d d e d to th e s y s te m s h o u ld b e
p u m p e d th ro u g h a filte r b e fo re it is p o u re d in to th e h y d ra u lic ta n k . B e s u re a n y fu n n e ls o r c o n ta in e rs
th a t c o m e in to c o n ta c t w ith th e flu id a re th o ro u g h ly c le a n e d b e fo re u s e .

G E N E R A L IN F O R M A T IO N
T y p ic a lly , h y d ra u lic s y s te m p ro b le m s c a u s e d b y d irt c a n b e re c o g n iz e d a s fo llo w s : A fu n c tio n fa ils to
o p e ra te in o n e o r b o th d ire c tio n s . In th is c a s e , th e p ro b le m is m o s t lik e ly d u e to d irt a ffe c tin g th e lo a d
s e n s in g c irc u it o f th e fu n c tio n , o r e ls e th e a c tu a to r (c y lin d e r o r m o to r) is a llo w in g th e o il to le a k b y .
If, a fte r re m o v in g a n d p lu g g in g th e lin e s a t th e a c tu a to r, fu ll s y s te m p re s s u re b u ild s u p w h e n y o u s h ift
t h a t f u n c t i o n 's c o n t r o l v a l v e , t h e n t h e p r o b l e m p r o b a b l y l i e s w i t h i n t h e a c t u a t o r . I f , a f t e r r e m o v i n g
a n d p lu g g in g th e lin e s a t th e a c tu a to r, fu ll s y s te m p re s s u re s till c a n n o t b e o b ta in e d , th e n d irt a ffe c tin g
th e lo a d s e n s in g s y s te m is p ro b a b ly th e c a u s e . T h e m o s t lik e ly p la c e fo r th is to o c c u r is a t th e lo a d
s e n s e c h e c k b a ll lo c a te d in e a c h h y d ra u lic m a n ifo ld .

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 C O P P E R H E A D W IR IN G D IA G R A M
6 /0 2 E .1 .1
 C O P P E R H E A D W IR IN G D IA G R A M
6 /0 2
 C O P P E R H E A D W IR IN G D IA G R A M
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 C O P P E R H E A D W IR IN G D IA G R A M
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T R O U B L E S H O O T IN G E L E C T R IC A L S Y S T E M P R O B L E M S

S P E C IF IC P R O B L E M S A N D S O L U T IO N S
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
P R O B L E M : E le c tric a l c o m p o n e n t o n m a c h in e is n o t w o rk in g .
P O S S IB L E C A U S E : L o o s e c o n n e c tio n o n m a c h in e (s u c h a s g ro u n d c a b le ), b ro k e n w ire , o r b ro k e n
c o n n e c tio n .
A C T IO N : U s e a v o lt m e te r to c h e c k th e a m o u n t o f v o lta g e a c o m p o n e n t is g e ttin g , it s h o u ld b e g e ttin g
1 2 v o lts . If n o t, c h e c k th a t c irc u it fo r a n y o f th e p o s s ib le c a u s e s lis te d . D is c o n n e c t th e b a tte r y b e fo re
a tte m p tin g to c o rre c t th e p ro b le m .

6 /0 2 E .2 .1