NOTICE NOTICE. Section 06 Maintenance. Change Hydraulic Charge & Return Drop-In Tank Filters. DO NOT operate engine without oil in the reservoir.

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1 Change Hydraulic Charge & Return Drop-In Tank Filters Section 06 Maintenance NOTICE DO NOT operate engine without oil in the reservoir Park machine on level surface. Lower Cutter-head to ground. Push hydraulic tank bleed screw to relieve pressure to the hydraulic system. Remove four (4) capscrews. Remove filter cover. Remove hydraulic filter element and discard. Remove gasket and discard. Install new filter element onto cover. NOTICE Hydraulic oil filters cannot be cleaned. Figure 6-15, Analog Dirty Hydraulic Filters Gauges Position new gasket into place and reinstall filter cover and secure with four (4) capscrews. Check for leaks. GT-60 Rev: 0 Feb

2 Section 06 Maintenance Track Sag General Information Properly adjusted tracks prolong chain life. To get the maximum life out of track bushings, keep the track sag properly adjusted. Improperly adjusted track wears at a more rapid rate. A tight track causes higher loading which will increase wear on the pins, bushings, links, sprocket and front idler. Also, a tight track requires more horsepower, increasing fuel consumption and decreasing productivity. Periodically check track sag. In some applications, tracks may require adjustment several times during a working day. This is especially true when working in different conditions on the same job site, as moisture content of the soil changes. Tracks should always be adjusted in the actual operating conditions. If material packs in the undercarriage, the tracks should be adjusted with the material packed in the components. When packing occurs, track sag is taken up and must be loosened to extend wear life. The track spring will recoil and the machine will continue to operate with tight track. However, continued operation without loosening the tracks will result in excessive pin and bushing wear, sprocket popping, tooth tip wear, and excessive loads on the entire undercarriage and final drive system. Maintaining track sag is very important. Adjust Track Sag Grease or oil coming out of the relief valve under pressure can penetrate the skin causing severe injury or death. DO NOT watch the relief valve to see if grease is escaping. Watch the track or track adjustment cylinder to see if the track is being loosened. Loosen the relief valve slowly and at one turn at a time only! Figure 6-17, Track Sag Too Tight If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Figure 6-18, Properly Adjusted Track Sag Adjust The sprocket and track pins must be clean. Remove accumulated mud and debris before measuring the sag. Operate the machine toward the idler ends of the tracks. Stop with one track pin directly over the front carrier roller. Correct adjustment allows for 13mm to 19mm (1/2 to 3/4 inches) of sag midway between the front carrier roller and the idler. 62 GT-60 Rev: 0 Feb 2009

3 If the Track is Too Loose: A special adapter is required to add grease to the track adjustment cylinder. The adapter (refer to your parts catalog) is available from your Gyro-Trac dealer Remove two(2) capscrews and open cover to access fill/relief fitting. (Refer to Fig. 6-20). Apply grease to lubrication fitting (B) using a kpa (552 bar) (8000 psi) capacity grease gun and special fitting from tool kit. (See Fuels and Lubricants chapter for grease specifications.) Drive machine slowly in forward and reverse directions to allow track adjuster cylinder to fully adjust. Check track sag again. If Track is Too Tight Remove two (2) capscrews and open cover to access lubrication fitting. Figure 6-19, Adjust Track Sag Section 06 Maintenance 2. Using a 1-1/16 inch deep socket and a ratchet loosen the fill/relief valve one turn at a time ONLY to allow grease to escape. Tighten the valve when adjustment is correct. 3. Drive machine slowly in forward and reverse directions to allow track adjuster cylinder to fully adjust. 4. Check track sag again. Consult your Gyro-Trac dealer if correct adjustment cannot be obtained. Figure 6-20, Track Tensioner Grease Fitting Cleaning Track Components NOTICE DO NOT allow mud, rocks, etc. collect on track components. Debris in track components could cause serious damage to machine if operated. To prevent machine damage, DO NOT use force to break a machine loose from frozen ground. At the end of day, complete undercarriage should be checked and cleaned or repaired, if necessary. If temperatures are below freezing, park the machine on planks or concrete to prevent the tracks from freezing to the ground. GT-60 Rev: 0 Feb

4 Section 06 Maintenance Checking Track Shoe Capscrew Torque Track Shoe Capscrews Track shoe capscrew torque should be periodically checked. If the capscrews do not meet the torque specifications, remove the shoes and clean the mating surfaces of the shoes and links before tightening the capscrews. If machine is operated with loose track shoes, the capscrew holes in the shoes and links will wallow out and it may be difficult to keep the track shoes tight. Loose shoes can also cause hardware failure and loss of track shoes. Figure 6-21, Tarck Shoe Bolts IMPORTANT Tighten hexhead capscrews to torque specification using a criss-cross pattern. Then repeat torque pattern again. 1 4 NOTE: Replacement track shoe hardware should be lubricated when torquing to specification. Tighten hexhead capscrews using a torque-turn-torque method. 3 2 Figure 6-22, Track Shoe Bolt Tightening Pattern Specification 5/8 in Capscrew 180 N m (133 lb ft) Torque Turn 120 3/4-inch Capscrew 320 N m (235 lb ft) Torque Turn GT-60 Rev: 0 Feb 2009

5 Lubricate Cutter-head Bearings, Linkage and Cylinder Pivots. Section 06 Maintenance With grease gun, inject grease that is able to withstand high temperatures (at least 550 F, 288 C) [refer to Appendix for grease type] and extreme pressure. Use good quality grease that cannot be washed out by water. Lubricate Hood Cylinder Pivots as required. Lube every 50 hours or weekly Lubricate Cab Door Hinges as required. Lubricate Cutter-head Linkage and Cylinder Pivots weekly or every 50 hours whichever comes first. Lubricate Cutter-head bearing twice daily. Using grease gun lubricate each Cutter-head bearing with 1-shot of grease for every hour of operation. (Example: for a 10 hour day apply 5 shots of grease every 5 hours) Lubricate Hood Hinges as required. LEFT SIDE SHOWN RIGHT SIDE SIMILAR GT-60 Rev: 0 Feb

6 Section 06 Maintenance Cutter-head Belt Tensioning and Pulley Alignment Figure 6-22, Unbolt and Raise Cutter-head Side Cover Remove or Disconnect Remove four (4) bolts from Cutter-head's side cover and open hinged cover. Inspect Pulley Alignment Position a straight edge between the two pulley's outer face, making a 2-point contact on one pulley and check their alignment. The alignment should be within 1/8" (3mm). Adjust If adjustment is required, perform the following: a. b. c. d. Loosen taper locks on pulley. Install a puller onto the pulley. Adjust upper and lower pulley to within the 1/8" (3mm) spec. Remove puller and retighten taper locks. Inspect Belt Tension Measure belt tension at center between Pulley #1 and Pulley #2. Belt flex should be 3/4" (19mm) with 10 lbf (5 kgf) of side force. If adjustment is required proceed with the following: Figure 6-23, Measure Drive Belt Tension by Amount of Sag 2. Remove or Disconnect Remove bolts from drum motor's access cover and remove cover. (Not shown) Loosen four (4) drum motor attaching bolts. Figure 6-24, Adjust Belt Tension 66 GT-60 Rev: 0 Feb 2009

7 2. 2. Adjust Loosen lock-nut on belt tensioner and adjust belt tension to within specification. Tighten Re-tighten belt tensioner lock-nut. Re-tighten the four (4) drum motor's attaching bolts. Install or Connect Close Cutter-head side cover and secure with four (4) bolts. Reinstall Cutter-head drive motor cover and tighten bolts to secure. Belt Tensioner Lock-nut Belt Tensioner Section 06 Maintenance Figure 6-25, Cutter-head Drive Belt tensioner & Locknut Cutter-head Drive Motor Oil Level Check IMPORTANT It is critical that the oil level in the Cutter-head Hydraulic Motor be maintained at proper levels at all times. To check the oil level perform the following: Remove top and back covers from the Cutterhead. Inspect oil level at sight gauge. If you can see a oil level line then oil level is too low! Remove oil fill plug and add oil (refer to Appendix A). Fill oil to within first knuckle of your index finger. Oil Fill Oil Level Sight Gauge Cleaning the Cutter-head Figure 6-26, Rotor Pump Motor Oil Fill NOTICE Gyro Trac recommends using a dry cleaning method to clean the Cutter-head whenever possible. DO NOT use a metallic brush to clean the Cutter-head. GT-60 Rev: 0 Feb

8 Section 06 Maintenance Non-Routine Maintenance Non-routine maintenance repair work should only be performed by qualified personnel. If the Cutterhead maintenance repair requires a skill level and tools that you do not have then contact your nearest authorized dealer for a qualified service technician. If your Cutter-head is experiencing unusual vibrations caused by something other than bad bearings, debris in drum, or uneven tooth wear, then more than likely the drum is out-of-balance. Rebalancing of the Cutter-head must be performed by a qualified Gyro Trac service facility in possession of necessary equipment. Cutter-head Teeth (Planar type teeth only) Cutter-head teeth must be replaced only when they can no longer be sharpened for their intended work. This generally happens when tooth shape has become completely rounded and they no longer are able to cut efficiently. NOTICE DO NOT try to repair teeth by adding weld material to the tooth, it will increase weight and cause drum imbalance. 68 GT-60 Rev: 0 Feb 2009

9 ENGINE Crankcase Inspect Daily First 50 hours Every 50 hours Check Oil Level Check at dipstick. Check for Leaks Repair. Change Oil and Filter Every 250 hours Every 500 hours Every 1000 hours COMMENTS Section 06 Maintenance Schedule Chart See Manufacturer's Maintenance manual. Take an Oil Sample and inspect for metal shavings. Cooling System Check Cooling Fins Blow out accumulated debris with water spray or compressed air, as required. Check Drive Belts Inspect for proper tension and pulley mis-alignment. Check Engine Coolant Inspect for proper fill level, add if necessary. Replace Engine Coolant Fuel System Drain and replace engine coolant. Check Fuel Tank Level Fill at end of the day. Change Primary Fuel Filter See Manufacturer's Maintenance manual. Change Secondary Fuel Filter See Manufacturer's Maintenance manual. Air Filters Check Engine Intake Air Filter at Plus +1 Digital Input Screen GEARBOX Check Oil Level Change Oil HYDRAULIC SYSTEM Check Hydraulic Oil Level Check for Clogged Charge and Return Filters Change Charge & Return Filters Both Drop in and Spin On. Check for Leaks Check & Drain Hydraulic Tank Press Button 3 on the Plus +1 System and Check Digital Inputs Screen for an ON Circuit or Change Air Filter when Analog Indicator is in the Yellow. Press Button 3 on the Plus +1 System and Check Digital Inputs Screen for an ON Circuit or Inspect Fluid Level Sight Gauge under Hood. Press Button 3 on the Plus +1 System and Check Digital Inputs Screen for an ON Circuit or Change Dirty Hydraulic Filter when Analog Indicator is in the Yellow. Perform a Walk Around inspection of entire machine, repair as required. Take a Hydraulic Oil sample. Drain, clean, and refill as required. See Capacities & Specifications Chart. GT-60 Rev: 0 Feb

10 Section 06 Maintenance Schedule Chart TRAVEL/TRACKS Check/Adjust Track Tension Check Planetarys for Leaks Check Planetary Oil Level Inspect Undercarrage Tracks Inspect Track Shoe Bolts Cutter-head Check all Fasteners for Tightness Comments Rotate Plugs To 3:00 & 6:00 O'clock Position And Remove Top Plug To Check Oil Level Check All Components For Wear Or Damage Repair Or Replace As Required Check All Components For Wear Or Damage Repair Or Replace As Required Check Hydraulic Hoses for Leaks Repair Or Replace As Required Check for Unusual Vibrations Note Any Unusual Vibrations Repair As Required Check Bearing Play Inspect Daily First 50 hours Every 50 hours Every 250 hours Every 500 hours Every 1000 hours Check Bearings For Up/down Play (No Movement Allowed) Repair Or Replace As Required Check Drive Belts for Proper Tension No More Than 3/4" (19 Mm) Of Play With 10 Lbf (5 Kgf) Of Side Force. Adjust As Required Check Belt Pulleys Check Belt Pulleys For Unusual Wear Check Rotor for Cracks Check Rotor For Crack Damage Repair Or Replace As Required Sharpen Teeth Sharpen All Teeth As Required (Planar Type Only) Grease Drum Bearings Grease Bearings One (1) Shot Of Grease For Every Hour Of Operation No More Than Four (4) Hours Of Operation Without Re-greasing Grease Hydraulic Cylinder Pivots Apply Grease To Cylinder Pivot Bushings Check Drum Motor's Seal for Leaks Check Drum Motor's Attaching Bolts for Tightness GENERAL MAINTENANCE Check Drum Motor's Seal For Leaks Replace As Required Torque Should Be (320 Ft Lbs [434 N m]) Grease all Door Hinges Apply Grease To Engine And Cab Door Hinges 70 GT-60 Rev: 0 Feb 2009

11 APPENDIX Section Contents Page Appendix A (Capacities & Specifications)...74 Appendix B (Technical Specifications)...75 Appendix C (Overall Dimensions)...77 Appendix D (Torque Values)...78 GT-25XP Rev: 0 Jan 2009

12 APPENDIX A: Capacities & Specifications! 72 GT-60 Rev: 0 Jan 2009

13 APPENDIX B: Technical Specifications Engine Make... 6 cyl. Cummins Diesel Model... QSX 15L Tier III 2100 RPM Torque FT LBS (987 N 2100 RPM Cooling System...Ethylene Glycol/Water Capacity US gal. (21 liters) Mixture (Antifreeze/Water)...60/40 Radiator Normal Operating Temperature F (85 C) Pressure...16 psi (110 kpa atmosphere) Fuel Tank Capacity US gal. (1162 liters) Hydraulic Drive System Hydraulic Tank US gal. (605 liters) Traction (2) Planetary Transmittal...Sauer Danfoss (1) Hydrostatic Tandem Pump...Sauer Danfoss Series...H1 Ratio...Variable Infinite Gear Box...Durst Ratio... 38:1 Brake & Parking Brake Positive Hydraulic Multi-disc...Integral to each Planetary Auxiliary Hydraulic System Hydraulic Pump (Bolted to Engine)...Sauer Danfoss Type...Piston Pump Load Sensing Maximum...13 US gpm ( RPM Operating Pressure psi (20684 kpa) Cutter-head Maximum rpm rpm Number of Teeth...30 Fixed (2) Motors... Rexroth (2) Pumps... Rexroth Operating Pressure psi (41369 kpa) GT-60 Rev: 0 Jan

14 APPENDIX B: Technical Specifications (Cont'd) Track System Steel Track...Berco D5 Track Tension...Greased Filled 8000 psi (55158 kpa) Frame Water Tight Luge Type... CHT 100 Welded Steel Tub Cab/Hood Hydraulic Tilt Mechanism VDC Pump Windows... Lexan MR-10 Seat... Air Suspension w/armrest & Seat Belt Heater...3-Speed Backup Alarm Rear View Mirror Electrical System Battery Type...12 volts Power range amps (CCA x 4) Voltage...12 volts Amps amps Alternator... Delco Model SI Power amps per hour replenish Belt... Gates Starter... Delco Series...38 MT-HD Tension...12 Volts 74 GT-60 Rev: 0 Jan 2009

15 Vehicle Dimensions APPENDIX C: Overall Dimensions Overall Length " (803 cm) Overall Width " (274 cm) Overall Height " (327 cm) Operating Weight... 46,000 lbs (20865 kg) Ground Pressure psi (29 kpa) Ground Clearance... 18½" (37 cm) Maximum Speed mph (12 kmh) TOP VIEW 113" 316" 1325" SIDE VIEW REAR VIEW FRONT VIEW BOTTOM VIEW GT-60 Rev: 0 Jan

16 APPENDIX D: Torque Values BOLT SIZE (INCHES) 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 THDS PER INCH DRY LBS. FT. GRADE 5 - HEX HEAD BOLT TORQUE LUB. LBS. FT DRY Nm LUB. Nm DRY LBS. FT. GRADE 8 - HEX HEAD BOLT TORQUE LUB. LBS. FT DRY Nm LUB. Nm Above is a list of bolt torques. In general the proper torque spec is usually around 65-70% of the bolt failure torque rate. The above chart refers to usage in steel. Proper torque spec varies depending on the material, bolt grade, or wether lubrication is used such as oil, wax, or anti-seize. Always refer to the equipment manufacturer for proper torques specs if needed. Lubrication added to dry bolts will typically reduce the torque value 15-25%. Gyro Trac, Inc. reserves the right to make changes at any time without notice or obligation. 76 GT-25XP Rev: 0 Jan 2009

17 Single Purpose Built Mulching Machines t t t t t t t Low ground pressure (LGP)! Does not damage feeder roots! No more erosion and runoff! No more chipping, hauling, or dumping! No more burning needed! Clear land FASTER & CHEAPER! Easier, sometimes NO permitting! Site Prep Real Estate Improvements Slash Removal (Post Harvest or Storm Debris) Survey, Fence & Utility Lines Right of Way Vegetation Control Railroad Line of Sight Clearing Hub & Spoke Fire Lanes (Hunting) Re-forestation Hazardous Fuels Reduction Wildland Urban Interface (Defensible Space) Pre-fire Suppression (Breaks, Access Lanes) Initial Attack Wildfire Low Flow Cutter-head High Flow 500HF Cutter-head GT 13XP (140HP) GT 13XP (260HP) Gyro Trac, Inc. (USA) 10 Flying Cloud Drive Summerville, SC w w w. g y r o t r a c. c o m GT 60 (600HP) Copyright MMVIII Gyro Trac, Inc. All rights reserved.