Tigercat 1065 1075 FORWARDER SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL Tigercat 1065/1075 FORWARDER Issue 1.1, FEBRUARY, 2009

TABLE OF CONTENTS SECTION INTRODUCTION .............................................................................................................. iii SAFETY ............................................................................................................................ 1 CONTROLS AND OPERATION ........................................... SEE OPERATOR'S MANUAL LUBRICATION AND MAINTENANCE ............................................................................... 3 ELECTRICAL AND COMPUTERS .................................................................................... 6 ENGINE START & STOP .................................................................................................. 7 DRIVE ............................................................................................................................... 8 BRAKES ............................................................................................................................ 9 OIL COOLER/RADIATOR, FAN AND HYDRAULIC RESERVOIR .................................. 10 CENTER JOINT, STEERING, GATE AND SNOW BLADE ............................................. 11 CRANE, GRAPPLE AND MAIN PUMP ........................................................................... 12

1065/1075-SM00

1065/1075 Available Literature Operator's Manual ..............................

Service Manual (This Manual) ............

Parts Catalog ......................................

Hydraulic Adapters Book ....................

Hose Assemblies Book ......................

Part No. 25791A Part No. 25792A Part No. 25793A Part No. 1472A Part No. 3707A

Tigercat

®

Tigercat Industries Inc. P.O. Box 544 Paris, Ontario Canada N3L 3T6 Tel: (519) 442-1000

Fax: (519) 442-1855

ii

Tigercat 1065/1075 Forwarder

Introduction

Tigercat 1065/1075 FORWARDER

INTRODUCTION An Operator's manual, Service manual and a Parts catalog are made available by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the 1065/1075 Forwarder.

Serial numbers:10650101 and up.

10750101 and up.

The operator's manual will assist the operator with the techniques of proper and safe operation of the Forwarder. There is also important information regarding the safe operation of optional equipment and attachments. The service manual contains safety and servicing procedures and a preventive maintenance schedule to ensure optimum machine performance.

Section 1 in both the operator's manual and the service manual contains safety information that must be followed. As well, throughout the rest of the manuals, WARNING and CAUTION notices are displayed where necessary, drawing attention to possible hazards when performing certain procedures.

Only trained personnel should be allowed to operate or work on the machine.

The information contained in this manual is current at time of printing. Improvements to the machine are on-going and may not be covered, therefore in these cases contact your Tigercat dealer for the appropriate information.

The phrase “and up” appearing in this manual after the serial number implies that the related information is current for any machine serial number HIGHER than the serial number preceding the “and up”.

Tigercat reserves the right to make changes to the machine after this manual release date that may not immediately appear in this manual.

Every effort is made to send out updates on a regular basis. If the machine in question was built after the release date of this manual and there is a discrepancy, call Tigercat service department. The release date appears on the first page.

The Company reserves the right to change information contained herein at any time without prior notice.

Tigercat Industries Inc.

1065-001

iii

Tigercat 1065/1075 Forwarder

Introduction

NON-APPROVED FIELD PRODUCT CHANGES The installation of any unauthorized attachment or changes made of any kind to this Tigercat product could affect the product's ability to perform as originally intended. The product's integrity, stability and safety could be at serious risk.

IT IS Tigercat POLICY THAT NO CHANGES ARE TO BE MADE TO ITS PRODUCTS INCLUDING DELETIONS OR ADDITIONS OTHER THAN A Tigercat APPROVED OPTION FITTED IN THE FACTORY APPROVED MANNER. Official approval to make changes or install options is only as follows: i) The relevant options for that product must be shown or listed on current Tigercat documentation or literature such as a printed specification sheet, price list, parts manual, or product literature issued by Tigercat. ii) Approved options or product changes authorized in writing by the Tigercat Engineering Manager.

Authorization by any other person is unacceptable.

Unauthorized changes made or contributed to by a person or organization may result in creating a dangerous situation and therefore the person or organization will be considered to have assumed the risk involved or be negligent in creating this situation.

Weight is an important factor when considering the addition of options or an attachment, Refer to your Tigercat distributor for information on maximum permissible operating weight and the effect the addition of various options may have on your machine.

Tigercat will not be held responsible for any situation that may arise resulting from Non-approved Field Product Changes to its product.

Should Tigercat become involved in a suit resulting from changes made to the product without proper authorization by Tigercat as stated above, Tigercat will take whatever action is appropriate to protect its interests.

The product warranty policy and the certification on any safety items installed on the modified product will become NULL and VOID if the above policy is not adhered to as specified.

Non-approved product changes also nullify warranties given to Tigercat by its component manufacturers.

Tigercat Industries Inc.

iv

Tigercat 1065/1075 Forwarder SECTION 1 - SAFETY APRIL, 2007

Read and understand this Safety section prior to operating any equipment.

Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 1 ARTICULATION LOCK .................................................................................. 1.11 BATTERY DISCONNECT SWITCH .................................................................. 1.7 CAB TILT SUPPORT BRACE ........................................................................ 1.10 COOLING SYSTEM ........................................................................................ 1.9 EXHAUST FUMES ........................................................................................ 1.11 FIRE PREVENTION ...................................................................................... 1.12 FIRE PREVENTION GUIDELINES ............................................................. 1.12 WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE ...................... 1.13 WHAT TO DO AFTER A FIRE ................................................................... 1.14 WHAT TO DO IN CASE OF A MACHINE FIRE .......................................... 1.13 FIRST AID ....................................................................................................... 1.4 FLUID LEAKS ................................................................................................. 1.9 HYDRAULIC PRESSURE HAZARD ................................................................ 1.9 LOOSE CLOTHING HAZARD ........................................................................ 1.10 PARKING THE MACHINE ............................................................................... 1.7 PROTECTIVE CLOTHING ............................................................................... 1.3 SAFETY INTERLOCK SWITCHES ON DOORS .............................................. 1.8 SAFETY PRECAUTIONS, GENERAL ............................................. 1.3, 1.4, 1.5 SAFETY PRECAUTIONS, OPERATING .......................................... 1.6, 1.7, 1.8 SAFETY PRECAUTIONS, SERVICING ....................................... 1.9, 1.10, 1.11 SAFETY SYMBOLS ....................................................................................... 1.2 SIGNAL WORDS ............................................................................................ 1.2

Tigercat 1065/1075 Forwarder

Safety

SAFETY SYMBOLS

This safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! The safety alert symbol identifies important safety messages on machines, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death.

Follow the instructions in the safety message.

Understanding Signal Words

DANGER DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

1.2

Tigercat 1065/1075 Forwarder

Safety

GENERAL SAFETY PRECAUTIONS Remember that safety is a prime responsibility of all.

To minimize the risks and promote safety at all times, this section of the operator’s manual details a number of safety rules which should always be followed and obeyed.

Always read the operator's manual before operating the machine. Pay close attention to WARNINGS and HAZARD identifications

Follow all instructions from safety inspector and supervisors.

You must be fully trained to operate this piece of equipment. Know the capabilities and the limitations of the equipment. Learn the most efficient operating techniques.

Do not let an untrained person operate the machine.

Wear suitable hearing protective device such as earmuffs or earplugs to protect against noise.

Prolonged exposure to loud noise can cause permanent hearing loss.

Use the handrails and steps provided when mounting and dismounting from the machine.

Do not climb onto or jump off the machine at any time.

Do not try to climb onto or off a moving machine.

Do not use the joysticks as a handle when entering or leaving the cab.

Do not use machine foot controls as a step.

When mounting or dismounting the machine always use the 3 point technique - Use one hand with 2 feet or 2 hands with one foot.

Use recommended protective clothing and safety devices such as gloves, safety boots, safety hat, goggles, and ear protection when necessary. These safety rules highlight both general and specific measures the operator should be familiar with and adhere to. More specific measures are illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message. Keep safety labels in good condition.

Repair or replace damaged labels.

1.3

Avoid mounting or dismounting the machine in areas with slippery surfaces. If this is not possible clean up or cover slippery surfaces with a nonslip material.

Tigercat 1065/1075 Forwarder

Safety Safety Hazards - Viton Seals O-rings and other seals manufactured of Viton material (fluofine rubber) produce a highly corrosive acid (Hydofluoric) when subjected to temperatures above. 600°f (315°c).

GENERAL SAFETY PRECAUTIONS continued Machines should be completely cleaned of debris at least daily, particularly around the engine exhaust components. Hydraulic oil leaks, excess grease, fuel and oil accumulation (including spillage) should be eliminated immediately.

This contamination can have extreme consequences on human tissue since it is almost impossible to remove after contact.

The following procedures are recommended when inspecting equipment that has been subjected to high temperatures such as fire:

Maintain a clean cab interior, clear away trash or debris.

Machine should be washed completely at every major service.

•

Visually inspect any seals or gaskets which have suffered from heat; they will appear black and sticky.

•

If these are found, Do Not Touch!!!

•

Determine the material composition of any seals or gaskets, If fluro-elastomer seals (Viton, fluorel, or tecmoflon) have been used, the affected area must be decontaminated before undertaking further work. Natural rubber and nitrile materials are not hazardous.

•

Disposable heavy duty gloves (neoprene) must be worn and the affected area decontaminated by washing thoroughly with limewater (Calcium Hydroxide solution).

Do not operate the machine with any defective or inoperable components.

•

Any cloths, residue and gloves must be safely discarded after use.

Check all fluid levels.

NOTE:

Do not operate the machine with any of the exhaust system, safety covers, or other devices removed.

Burning discarded items is not recommended except in an approved incineration process where the dangerous products are treated by alkaline scrubbing.

Inspect the machine daily for signs of damage or unusual wear, to ROPS, FOPS, OPS structures.

The machine should be inspected daily for signs of fluid leaks, damage, unusual wear, or faulty operation. Repair or replace malfunctioning parts and systems immediately.

Check window and door guards for damage.

Check protective windows for cracks, a damaged window has reduced strength to stop flying objects.

Check windows for scratching, crazing and cloudiness that could impair clear visibility all round the machine.

Do not operate the machine with the cab retaining pins removed. Always install retaining pins after lowering the cab.

Keep a first aid kit in an easily accessible location on the vehicle at all times.

1.4

Tigercat 1065/1075 Forwarder

Safety

GENERAL SAFETY PRECAUTIONS continued

WARNING Engine exhaust, some of its constituents, and certain vehicle components contain or emit chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Maintain a charged fire extinguisher on the vehicle at all times and KNOW HOW TO USE IT. Do not carry passengers either in the cab or anywhere else on the machine. The vehicle seating accommodation is for one operator only.

WARNING

Do not allow anyone to operate the machine who may not be physically fit or who may be under the influence of alcohol or drugs.

Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

When operating the machine, ensure there is adequate clearance on both sides and above the machine or any of its attachments. Additional clearance may be necessary where the ground is uneven.

Extreme caution should be exercised when approaching any area where overhanging electrical powerlines are present. Serious injury or death by electrocution can result if the machine or any of its attachments are not kept a safe distance from these lines.

Maintain a distance of 10 ft. (3m) between any part of the machine or boom and any power line carrying up to 50,000 volts or less plus 1/2 inch (10mm) for each additional 1,000 volts above the 50,000 volt level.

If State/Provincial, local or job site regulations require even greater safety distances than stated above, adhere strictly to these regulations for your own protection.

If the machine must be transported, make sure that it is adequately secured to the transporting vehicle.

Even though the brakes are fully engaged, block the wheels to prevent movement during transport.

Install articulation lock whenever the machine is to be transported.

Comply with instructions in this manual and also your company’s regulations for the operation of this machine.

Read, understand and follow all general safety precautions specified by crane, rotator and grapple manufacturer.

Access to a cell phone or radio to call for assistance in an emergency is advised. Be aware that signal strength for cell phones and radios changes with terrain and location.

1.5

Tigercat 1065/1075 Forwarder

Safety Secure loose items in the cab.

OPERATING SAFETY PRECAUTIONS

Prior to commencing work, check all equipment controls to ensure that the machine responds correctly.

Make sure that all safety screens and guards are installed and properly secured.

Do not open an escape hatch or the cab doors to increase ventilation when operating the machine.

Shut off engine when refuelling - DO NOT refuel the engine while smoking or near open flame or sparks.

Check that no other personnel have moved into a hazardous area before starting the machine.

Keep the cab doors closed when driving or steering the machine to prevent accidental entry of branches and debris into the cab.

Sound the machine horn before starting the machine.

Keep the cab doors closed and use seat belt when driving or steering the machine to prevent being thrown from the operator's cab.

• BRAKE

STEERING

••

The operator's seat is equipped with a lap belt.

Use this restraint system at all times when operating the machine.

1014-D153

Never use the emergency brake to slow down or stop the machine except in an emergency.

Keep the brakes properly adjusted at all times.

Always place the crane in the park position, or rest it on the ground when operation is stopped, regardless if the engine is running or shut off.

Start the engine by following the instructions in this manual. Refer to OPERATING MACHINE in SECTION 2 of the OPERATOR'S MANUAL.

Always rest the snow blade on the ground when operation is stopped, regardless if the engine is running or shut off.

Before moving the machine to the worksite, check to ensure that all doors, panels, and access covers are installed properly and secured.

Never work alone. Regularly inform other crew members of your intentions, location and length of time to perform duties.

Forwarder operations should only be performed from the operator’s seat.

Park machine at least 50 feet (15 meters) away from other equipment and in a cleared area. In the event of a fire, this distance will minimize the chance of the fire spreading to other equipment.

1.6

Tigercat 1065/1075 Forwarder

Safety

OPERATING SAFETY PRECAUTIONS continued Before leaving operator's cab, place the crane in the park position or on the ground and lower the snow blade (if equipped) to the ground.

If out of the operator's cab for an extended period shut the machine off.

Maintain a safe operating distance between the machine and workers and all other personnel. It is the duty of the operator to ensure that no person approach the machine while in use, the risk zone is 60 m (200 feet).

When parking the machine: •

Park on level ground ONLY.

•

Do not park on a hillside or incline.

•

Place the crane in the park position or on the ground and lower the snow blade (if equipped) to the ground.

•

Stop the engine and release pilot system pressure by performing the following steps:

Use only prearranged and approved signalling practices.

1. Close both doors. Turn key switch to the ON position. Do not start the engine.

Press pilot reset switch.

Obey flagger's signal and signs

2. Fully apply brake foot pedal 50 times or more.

Do not carry passengers either in the cab or anywhere else on the machine.

3. Pressure may remain in the system after completing all of the above steps.

Use caution when loosening hydraulic connections.

If vision is limited by dust, smoke, fog or snow, stop the machine until visibility is restored.

Never operate the crane or grapple over the heads of bystanders.

Operate the machine only from a seated position in the operator’s seat.

Do not work below or behind a forwarder parked on a grade.

When working on slopes, travel straight up or down the slope to prevent roll-over.

NEVER travel across a STEEP slope or side hill:

ON OFF

If you travel across a MODERATE slope, NEVER make an uphill turn as this could cause a tip-over situation.

•

When loading, keep load in grapple low and close to the forwarder for best stability.

•

A load of logs will change the handling and stability of the forwarder.

•

Always be prepared to dump the load in the grapple in case of emergency.

•

Never approach an unstable log from the downhill side.

•

Do not overload your forwarder as this can create an unstable condition and cause a roll-over.

• BATTERY DISCONNECT SWITCH

1014-D001

•

•

Turn the battery disconnect switch off if the vehicle is to be parked for an extended period of time (Example - overnight).

CAUTION Do not open cab doors or window screens (if equipped) when machine is on a slope.

The doors and screens are heavy and could swing out with considerable force.

When the engine is running, DO NOT allow anyone in areas of the machine where they may be crushed by moving components.

1.7

Tigercat 1065/1075 Forwarder

Safety

OPERATING SAFETY PRECAUTIONS continued Before moving the machine, place the crane in the park position, and lift the snow blade (if equipped) off the ground high enough to clear obstacles such as stumps.

•• SWITCH

Check for correct tire air pressure (refer to tire manufacturers specifications for correct tire air pressure). If the pressure is too low it will result in swaying. If the pressure is too high it will result in bouncing.

1014-D002

INTERLOCK SWITCH (L.H. DOOR SHOWN)

SAFETY INTERLOCK SWITCHES ON DOORS:

If the machine is to travel on public roads, use accessory lights (when installed) and other caution devices to alert operators of other vehicles of your presence. Ensure your machine meets all regulatory requirements.

Both doors are equipped with safety interlock switches to prevent the machine from being operated while either of the doors are open (pilot system is shut off).

When transporting the machine, ensure that enough clearance is available on both sides and above the machine or any of its attachments to avoid contact with power or telephone lines, bridge structures, etc.

DO NOT use the joystick, steering control lever or armrest to assist entering or leaving the cab.

Before transporting the machine check to ensure that all doors, panels and access covers are installed properly and secured.

NOTE: The engine can be started but the machine functions cannot be operated with a door open.

Read, understand and follow all general safety precautions specified by the crane, rotator, and grapple manufacturer.

To operate:

CAUTION

Close both doors, start the engine and press the PILOT RESET switch to activate the MDM computer. Press the PILOT RESET switch again to enable operation of machine functions.

NOTE: The PILOT RESET only needs to be reset twice at engine start-up. Only once is needed after the MDM computer has been turned on.

CAUTION All functions on the machine can now be operated, either as intended or by accidentally touching them.

Once the safety interlock system has been activated, the safety of both the operator and all persons outside the cab becomes the responsibility of the operator.

The door safety interlock switches and the pilot reset switch are a safety feature and their function must not be defeated in any way.

1.8

Tigercat 1065/1075 Forwarder

Safety

SERVICING SAFETY PRECAUTIONS

WARNING Diesel fuel or hydraulic fluid under pressure can penetrate the skin and cause serious personal injury, blindness, or death. If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar with treating this type of injury.

Conduct maintenance inspections at least as frequently as recommended in section 3 of the operator's manual.

Never use bare hand to check for fluid leaks.

When servicing or repairing equipment, shut the engine down, and disconnect the positive (+) battery cable from both batteries.

Fluid leaks under pressure may not be visible.

When searching for leaks, wear work gloves and use a wrench or piece of wood to move hydraulic hoses. Do not grab hold of hydraulic hoses. Wear safety goggles for eye protection.

Install a “DO NOT START ENGINE” sign on the operator’s cab door and in the engine compartment when making repairs to the machine.

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower grapple and snow blade (if equipped) to the ground and relieve trapped pressure from brake accumulator before performing work on components, or disconnecting any hoses. For the procedure on how to RELIEVE PRESSURE, refer to PARKING THE MACHINE in THIS SECTION.

Before performing maintenance or repair work on any equipment, consult the manufacturer’s instruction manual and follow recommended procedures.

The radiator and the engine cooling system should be cleaned and serviced daily to maintain moderate engine temperatures.

Prior to welding on any part of the machine, it should be cleaned and a fire extinguisher should be made available at the welding location. Care must be taken in attaching the welding machine grounding clamp so current does not pass through bearings, especially the center joint bearings. Also, turn off the battery disconnect switch and disconnect the engine computer plug from the computer module on the engine and the engine ground connection from the chassis.

Explosive release of fluids from pressurized cooling system can cause serious burns.

1.9

Tigercat 1065/1075 Forwarder

Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING CLOSE cab doors before tilting cab. The doors are heavy and will swing out or closed with considerable force.

Shut off engine. Only remove filler cap when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.

Do not change any pressure or relief setting unless authorized instruction has been obtained.

Use the proper tool for the job. Repair or replace worn or damaged tools including lifting equipment immediately.

1014-D003

CAB TILT CYLINDER FULLY EXTENDED

Before working under cab, machine must be parked on level ground. Cab must be fully tilted with tilt cylinder fully extended, to prevent injury.

Never stand under an object supported with hydraulics. Always use safety stands or a locking device.

Keep your hands, feet, head, and loose clothing away from power driven parts. Tie long hair behind your head. Remove rings and other jewellery to prevent electrical shorts and entanglement in moving parts.

CAB SUPPORT BRACE

•

CAB SUPPORT BRACE STORAGE NOTE: If partial tilt is required for an operator assistant to be in cab while service work is performed under cab, locate CAB SUPPORT BRACE mounted on the front left side of the gate.

Remove from gate and install under cab as follows: 1055-025

CAB LOCKING LUGS

SAFETY7

CAB SUPPORT BRACE

Always be aware of machine pinch points that could cause injury. Never place body parts within the range of motion of the working parts of the machine.

CAB LOCKING PIN TURN 90° TO SECURE BRACE

Always wear your safety gloves when handling cables, chains or logs.

• •• •

• ••

1055-022 CAB SUPPORT BRACE - INSTALLED For partial tilt, install CAB SUPPORT BRACE .

With cab tilted, insert brace in cab locking lugs, lower cab and secure lower end of brace with the cab locking pin turned 90°.

1.10

Tigercat 1065/1075 Forwarder

Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING DO NOT work below or behind a machine that is parked on a grade.

WARNING

CAUTION Do not open cab doors or window screens (if equipped) when machine cab is tilted . The doors and screens are heavy and will swing out with considerable force.

WARNING, HOT FLUIDS AND HOT MACHINE SURFACES CAN CAUSE SERIOUS BURNS! •

Before servicing the machine, allow the engine cooling system, fuel system, exhaust system, hydraulic system and machine surfaces to cool down.

•

Use a thermometer to check surface and system temperatures to ensure it is safe to begin service work.

•

DO NOT begin service work until the surface or system temperature has cooled down to below 100°F (38°C)!

WARNING Failure to follow all of the above instructions could result in serious injury or death from crushing.

RETAINING PIN ARTICULATION LOCK BAR

••

If the engine is running inside a building, ensure that sufficient ventilation is available to prevent a build-up of toxic exhaust fumes. Run the engine only when it is necessary for testing or adjustments.

•• 1014-D005

Work in a ventilated area. If it is necessary to run an engine in an enclosed area, use an exhaust pipe extension to remove toxic exhaust fumes.

ARTICULATION LOCK BAR IN LOCKED POSITION

If you don't have an exhaust pipe extension, either work outside, or open the shop doors.

• ARTICULATION LOCK BAR

1014-D004

ARTICULATION LOCK BAR IN STORAGE POSITION

Before working in the center joint area, install the chassis articulation lock bar between the chassis and center joint to prevent accidental articulation and injury. Always replace the lock bar in its storage position after use.

Dispose of fluids properly.

Never stand under an object supported with hydraulics. Always use safety stands or a locking device.

Do not pour fluids into the ground, stream, pond.

Before draining any fluids, know the proper way to dispose of them.

1.11

Tigercat 1065/1075 Forwarder

Safety 5. Remove debris and blow out dust regularly from the air intake doors, engine radiator, hydraulic oil cooler and A/C condenser core to prevent overheating of the engine and hydraulics. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL.

FIRE PREVENTION

6. Blow off all debris and dust accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently depending on logging conditions. Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smolder. If dislodged by vibration this smoldering debris can fall into other areas of the machine and thereby spread a fire.

When working in a forest environment, it is impossible to prevent combustible debris from collecting in tight corners of the machine. This debris, in itself, may cause a fire; however, when mixed with fuel, oil or grease in a hot or confined place, the danger of fire is greatly increased.

The following fire prevention guidelines should be used to supplement the operator’s fire prevention efforts. In no case should the guidelines be used, or assumed, as replacements for diligent operator efforts at preventing fires.

The following guidelines will help to keep your equipment up and running efficiently and keep the risk of fire damage to a minimum.

7. Clean out all accumulated forest debris (twigs, pine needles, branches, bark, leaves, saw dust, small wood chips) and any other combustible materials from inside the machine belly pans or lower machine structures as well as from areas in proximity to the engine, fuel and hydraulic oil systems no less frequently than at the completion of each work shift.

1. Maintain a CHARGED fire extinguisher on the machine at all times and KNOW HOW TO USE IT. 2. Inspect the machine for any signs of fuel or hydraulic system leakage and check for worn or eroded fuel or hydraulic lines before starting up any equipment.

8. AFTER transporting (trucking) a machine from one job sight to the next, open all doors and access panels and blow off any debris that may have repositioned itself onto the engine and exhaust parts due to wind turbulence caused by the journey.

3. Inspect the EXHAUST SYSTEM DAILY for any signs of LEAKAGE. Check for worn, cracked, broken, or damaged pipes or muffler. Also check for missing or damaged bolts or clamps. Should any exhaust leaks or defective parts be found, repairs must be made immediately. Engine exhaust leaks can cause fires, DO NOT OPERATE the machine until the exhaust leak is repaired.

9. Clean up any grease, diesel fuel, hydraulic and lubricating oil accumulation and spillage immediately.

10. Steam clean the engine, transmission, brake, fuel and hydraulic tank compartments of all equipment at least once a month or more frequently depending on logging conditions.

4. During daily operation of the machine, the occurrence of exhaust leaks are usually accompanied by a change or increase in engine exhaust noise levels. These audible warnings cannot be ignored. Should any exhaust leaks occur during operation, the machine must be shut down immediately and not put back to work until the necessary repairs have been completed.

11. Be cautious when smoking. An open flame, a lighted cigarette, etc., should not be permitted around any vehicle, especially during fuelling operations and/or when the fuel system is open to the atmosphere, and/or when servicing batteries.

1.12

Tigercat 1065/1075 Forwarder

Safety

FIRE PREVENTION continued

•

Ensure that any stored water systems on the machine are charged and functional.

•

Ensure that the nozzle of any hand held extinguishers available at the work site fits within the access holes in the doors of the machine.

•

Ensure that you have the proper fire extinguishers on site. Most fires involving mobile equipment will be of the A or B type.

You should have a dry chemical extinguisher rated ABC and a pressurized water extinguisher rated A.

•

Prevent the fire from happening by ensuring that the machine is cleaned regularly and all systems are well maintained.

12. Shut down equipment immediately when a problem is suspected or smoke is detected.

13. Park the machine at least 50 feet away from other equipment at the end of each shift.

14. Turn the battery disconnect switch to OFF at shut down to avoid loss by electrical short.

15. Remain with the machine for at least 45 minutes at the end of operations while the machine cools.

16. Once a fire has started on a machine hoses will quickly burn through causing pressurized fluids (diesel fuel, hydraulic oil, etc.) to fuel the fire. NEVER leave the machine parked with booms or arches suspended off the ground, as they will inject hydraulic oil into the fire if a supporting hose burns through.

*NOTE: Dry chemical fire suppression systems are offered by Tigercat as an optional installation on some of the Tigercat product lines. Please disregard any references made to fire suppression systems if not installed on your machine.

17. Remove all keys, lock equipment and fuel cap at the end of operations to reduce the risk of vandalism.

WHAT TO DO IN CASE OF A MACHINE FIRE •

At all times ensure your own personal safety and the safety of anyone that may be in the area. Approach any fire with extreme caution.

•

If the machine is in a dangerous position, attempt to move to a safe position. Lower working attachment to the ground.

20. Store rags and other combustible materials in a safe, fireproof location.

•

Shut the engine off.

•

Activate the fire suppression system

21. Do not use the machine on top of or to push piles of burning timber. A machine fire will result.

•

Radio or call for help (as appropriate).

•

Exit the machine taking fire extinguisher or water hose (if applicable) with you.

EQUIPMENT FIRES ADVERSELY EFFECT YOUR ABILITY TO LOG, MAY INCREASE YOUR INSURANCE PREMIUMS DRAMATICALLY OR PREVENT YOU FROM OBTAINING INSURANCE COVERAGE AT ALL.

•

If you can safely do so, turn OFF battery disconnect switch.

•

If you can safely open the access panels to the machine, in the area of the fire, do so.

•

If you can safely do so, attempt to extinguish the fire.

•

A dry chemical fire extinguisher should be used first, if available.

18. Before starting repair work, such as welding, the surrounding area should be cleaned and a fire extinguisher should be close by.

19. Use only nonflammable solutions for cleaning the machine or components.

WHAT ELSE TO DO BEFORE YOU EXPERIENCE A FIRE •

Ensure that you are familiar with emergency procedure in the event of a fire.

•

Ensure that your fire suppression system is charged and functional.

•

Ensure that any hand held fire extinguishers are charged and functional.

*

1.13

*

Tigercat 1065/1075 Forwarder

Safety

FIRE PREVENTION continued •

•

Remain with the machine until help arrives to ensure that the fire does not re-ignite.

•

Ensure that the machine and all components have cooled down sufficiently after a fire has occurred. Beware of the possibility of coolant or hydraulic hoses rupturing after a fire spraying hot oil or coolant which may result in severe burns.

Use the PASS method with most extinguishers.

•

Pull the pin. This will allow you to discharge the extinguisher.

•

Aim at the base of the fire. If you aim at the flames (which is frequently the temptation), the extinguishing agent will fly right through and do no good. You want to hit the fuel.

•

Squeeze the top handle or lever. This depresses a button that releases the pressurized extinguishing agent in the extinguisher.

•

Sweep from side to side until the fire is completely out. Once the fire is out, keep an eye on the area in case it re-ignites.

WHAT TO DO AFTER A FIRE •

Notify your equipment dealer and or Tigercat Industries Inc. by completing an incident report, Tigercat form number 5101.

•

Ensure that the cause of the fire is determined and all appropriate repairs are completed before returning the machine to work.

•

Ensure that the fire suppression system is properly serviced and returned to a functional state (if applicable).

•

Ensure that all extinguishers used in fighting the fire are replaced or recharged as appropriate.

*

*NOTE: Dry chemical fire suppression systems are offered by Tigercat as an optional installation on some of the Tigercat product lines. Please disregard any references made to fire suppression systems if not installed on your machine.

20229A

TYPICAL FIRE EXTINGUISHER ACCESS HOLE

•

Place the nozzle of the fire extinguisher into the appropriate fire extinguisher access hole and discharge the extinguisher.

•

Failing all attempts to access the machine compartment, attempt to discharge the extinguisher through the mesh or any available openings on the machine.

•

Use the pressurized water hose supplied with the machine (if applicable) or a pressurized water extinguisher (if available) after the discharge of a dry chemical extinguisher or suppression system* to remove heat build up from the area. A fire suppressed by a dry chemical powder may re-ignite with the latent heat of any debris in the area.

1.14

Tigercat 1065/1075 Forwarder

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

SECTION 3 - LUBRICATION & MAINTENANCE FEBRUARY, 2009

Read and understand the entire manual including Safety section prior to operating any equipment.

Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 3 AIR CLEANER CHANGING FILTER ELEMENTS ................................................................... 3.17 MAINTENANCE .............................................................................................. 3.16 SERVICING ..................................................................................................... 3.17 UNLOADER VALVE ........................................................................................ 3.16 AIR CONDITIONING ........................................................................................... 3.18 ARTICULATION JOINT ....................................................................................... 3.15 AXLE LUBRICATION .......................................................................................... 3.24 BELT - ENGINE SERPENTINE .......................................................................... 3.25 CAB LOWERING THE CAB .................................................................................... 3.21 RAISING THE CAB ......................................................................................... 3.20 CAB AIR FILTERS FRESH AIR ..................................................................................................... 3.19 RECIRCULATING AIR - A/C UNIT .................................................................. 3.19 CENTRE JOINT .................................................................................................. 3.15 CHARGE PRESSURE FILTER-DRIVE PUMP ................................................... 3.13 CRANE, ROTATOR AND GRAPPLE MAINTENANCE ....................................... 3.26 DRAINING AND REFILLING BOGIE HOUSING ................................................. 3.25 DRAINING AND REFILLING DIFFERENTIAL .................................................... 3.24 EMERGENCY EXITS, CHECK MONTHLY ........................................................... 3.4 ENGINE HOOD ................................................................................................... 3.21 ENGINE SERPENTINE BELT ............................................................................. 3.25 FILTERS CHARGE PRESSURE .................................................................................... 3.13 FUEL FILTER/WATER SEPARATOR ............................................................. 3.10 HYDRAULIC OIL ............................................................................................. 3.12 REMOVE AND REPLACE ............................................................................... 3.10 RETURN OIL STRAINER ................................................................................ 3.14 SERVICING GUIDELINES FOR OIL FILTERS ............................................... 3.13 FIRE PREVENTION .............................................................................................. 3.4 FUEL TANK STRAINER ..................................................................................... 3.11 GENERAL ............................................................................................................. 3.4 GENERAL TORQUE SPECIFICATIONS ............................................................ 3.28 HOT WATER SHUT OFF VALVE ....................................................................... 3.18 HYDRAULIC OILS ................................................................................................ 3.7 INITIAL PRE-DELIVERY INSPECTION ................................................................ 3.3 LINK SNUBBER MAINTENANCE ....................................................................... 3.26 MACHINE STARTUP .......................................................................................... 3.23 NEW MACHINE MAINTENANCE ......................................................................... 3.3

continued...

3.1

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

SECTION 3 - LUBRICATION & MAINTENANCE OSCILLATION JOINT ......................................................................................... 3.15 PREVENTIVE MAINTENANCE SCHEDULE ........................................................ 3.3 REAR (BOGIE) AXLE PLANETARY DRIVES (4 FILLING POINTS) ................................................... 3.24 SCHEDULED MAINTENANCE 1000 HOURS .................................................................................................... 3.6 125 HOURS ...................................................................................................... 3.5 250 HOURS ...................................................................................................... 3.6 500 HOURS ...................................................................................................... 3.6 8 HOURS .......................................................................................................... 3.5 SEASONAL ....................................................................................................... 3.6 SERVICE AND LUBRICATION POINTS .............................................................. 3.9 SNUBBER TENSION ADJUSTING ..................................................................... 3.26 STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE ............. 3.22 TEMPERATURE CONTROL - CAB HEATER/AC ............................................... 3.19 TILTING THE CAB .............................................................................................. 3.20 TORQUE CHART ................................................................................................ 3.27 TORQUE, FLUID CONNECTIONS ........................................................... 3.30, 3.32 TORQUE SPECIFICATIONS - GENERAL .......................................................... 3.28 UNLOADER VALVE ............................................................................................ 3.16

3.2

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR 1065/1075 FORWARDER _______________________________________________________________________________________

NEW MACHINE MAINTENANCE *INITIAL PRE-DELIVERY INSPECTION:PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBER 5296; “PDI AND 50-100 HOUR INSPECTION REPORT”

*FIRST 50-100 HOUR INSPECTION AND SERVICE REPORT:WITH THE OWNER’S MECHANIC PRESENT, PERFORM AN INSPECTION AND SERVICE ACCORDING TO THE Tigercat FORM NUMBER 5296; “PDI AND 50-100 HOUR INSPECTION REPORT” THIS MUST BE COMPLETED WITHIN THE FIRST 50-100 HOUR TIME FRAME. *IMPORTANT: TO QUALIFY FOR CONTINUED WARRANTY, THIS REPORT MUST BE COMPLETED AND RETURNED TO Tigercat Industries Inc. WARRANTY DEPARTMENT.

TIGHTENING POINTS FOR:-

IMPORTANT!

THE FIRST 50-100 HOUR INSPECTION REPORT:~

__________________________________________

All hydraulic connections Hose clamps Center joint pin securing bolts Transmission securing bolts Engine mounting bolts Pump securing bolts Axle mounting bolts Wheel retaining bolts Cab securing bolts Pin retainers Any other loose nut, bolt or fitting NOTE: Use of filters other than the Tigercat brand could lead to severe wear and rapid failure of system components.

WHEELS: When installing wheels, ensure that all paint has been removed from the mating surfaces of both the wheel disc and the flange of the axle to ensure metal to metal contact.

For more complete instructions also refer to section 8 of the service manual. __________________________________________

HOUR METER ~ MAINTENANCE: Check the hour meter (on the MDM Display terminal) on a regular basis to determine your scheduled maintenance times.

The intervals and times on the scheduled maintenance chart in this manual are for normal operating conditions.

If your machine is being operated in difficult or severe conditions, you should service your machine at shorter intervals.

*OIL LOST FROM LEAKAGE

Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

LEAKAGE RATE ONE DROP IN 10 SECONDS ONE DROP IN 5 SECONDS ONE DROP PER SECOND THREE DROP PER SECOND DROPS BREAK INTO STREAM

_______________________________________________________________________________________

3.3

LOST OIL (GALLONS) PER PER PER DAY MONTH YEAR 0.112 3.36 40.0 0.225 6.75 81.0 1.125 33.75 405.0 3.75 112.5 1,350.0 24.00 720.0 8,640.0

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

GENERAL Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires

CAUTION All handles, steps and platforms must be kept free of grease, oil, fuel, mud, snow and ice

Always have a fire extinguisher at hand and know how to use it For safety; when leaving the cab or leaving machine unattended or during service, always place the crane in the park position or other SECURE position, and lower the blade (if equipped). Turn the ignition switch off. Turn the battery disconnect switch off.

Clean around filler caps before checking or adding fluids.

Release hydraulic pressure and clean around hydraulic fittings before breaking connection.

Plug or cap immediately.

For safety, always block or support the crane and blade (if equipped) when working under them.

Clean up ALL spills immediately.

Always use clean oil and containers.

_______________________________________________________________________________________

Drain dirty oil while still warm.

Do not exceed recommended fluid levels.

FIRE PREVENTION Maintaining your machine properly will greatly extend its life and reduce your operating costs.

Service all hydraulic filters, and return strainer after the failure of a pump, motor, cylinder or valve. Failures of this nature could contaminate the entire hydraulic system.

Fire can result in a machine loss which can be financially devastating.

Top up diesel fuel at end of each shift to reduce contamination by condensation.

1. Pine needles and bark when allowed to accumulate, form a fuel source that when ignited is extremely difficult to extinguish. A thorough program of regular cleaning and washing will reduce the possibility of a fire starting. In the event a fire does start, the regular cleaning program will improve the chances of successfully extinguishing a fire.

Inspect the EXHAUST SYSTEM DAILY for any signs of LEAKAGE. Check for worn, cracked, broken, or damaged pipes or muffler.

Also check for missing or damaged bolts or clamps. Should any exhaust leaks or defective parts be found, repairs must be made immediately. Engine exhaust leaks can cause fires, DO NOT OPERATE the machine until the exhaust leak is repaired.

During daily operation of the machine, the occurrence of exhaust leaks are usually accompanied by a change or increase in engine exhaust noise levels. These audible warnings cannot be ignored. Should any exhaust leaks occur during operation, the machine must be shut down immediately and not put back to work until the necessary repairs have been completed.

2. Pay close attention to wiring and plumbing routings during maintenance, ensure that ALL wiring harnesses or hydraulic hoses are properly restrained and clamped to prevent damage from chaffing.

3. If equipped, read the fire suppression system manual and have the system serviced regularly by qualified personnel.

4. In case of fire lower the boom system to the ground and shut off the engine before discharging the fire suppression system.

Also refer to FIRE PREVENTION in SECTION 1 of THIS MANUAL for additional information.

Before welding on machine be sure master switch is disconnected and disconnect multi pin connectors on engine CPU and engine wiring harness.

When welding, secure ground connection as close to working position as possible to prevent arcing across machined surfaces or through bearings

3.4

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 8 HOURS (EVERY SHIFT):~

EVERY 125 HOURS:~

• • • • • • • •

• Perform 8 hour maintenance

Check engine coolant level Check engine oil level Drain fuel/water separator Check air cleaner unloader valve Check engine air filter restriction indicator Check hydraulic oil level in hydraulic tank Check transmission oil level with dipstick Lubricate mid drive shaft 1-fitting, purge Note: Lubrication of mid drive shaft slip joint should be done with machine fully articulated.

• Lubricate fixed center joint drive shaft, 1-fittings, purge • Lubricate rear drive shaft bearing, 2-fittings, purge • Lubricate center joint articulation bearings, 2-fittings, purge • Lubricate center joint oscillation bearings, 2-fittings, purge • Lubricate center joint oscillation lock cylinder ends, 4-fittings, purge • Lubricate steering cylinder ends, 4-fittings, purge • Lubricate load gate cylinder ends, 2-fittings, purge • Lubricate ladder pivots (if equipped), 1-fitting, purge • Lubricate snow blade cylinders and pivots (if equipped), 6-fittings, purge • Lubricate and adjust link snubber, 4-fittings, purge Clean:~ • Potentially damaging limbs or sticks from machine • A/C condenser, oil cooler, radiator and charge air cooler - refer to CLEANING A/C CONDENSER, OIL COOLER, RADIATOR AND CHARGE AIR COOLER in SECTION 2 of the OPERATOR’S MANUAL. Check:~ • For leakage around hydraulic components and flexible hoses. * See “Oil lost from leakage” chart.

• For loose nuts, bolts and fittings.

• Condition and tension of engine belt.

• Exhaust system for leaks.

• Conduct an overall visual inspection.

• Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period. ______________________________________________

And in addition:~ • Lubricate axles – slew bearings*, 12-fitting; 4-places, purge * Remove plugs on slew bearings prior to lubrication, then lubricate, and replace plugs.

• Lubricate axles – shaft bearings, 1-fitting; 8places, purge • Lubricate front drive shaft, 1-fitting, purge • Lubricate rear drive shaft, 1-fitting, purge Check:~ • Check fuel tank filler screen • Fluid level in batteries unless maintenance free • Engine rpm • All hydraulic pressures • Hydraulic pump and motor securing bolts • Torque tightening points as per new machine maintenance Visually check for damage to:~ • Bunks and load gate • Front and rear frame • Center joint area • Crane, link, rotator, and grapple Make repairs immediately Visually inspect for:~ • Frayed electrical wiring and hydraulic hose • Wear in any other components Clean/replace:~ • Air conditioner re-circulation filter • Cab fresh air filter • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period. ______________________________________________

3.5

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 250 HOURS:~

EVERY 1000 HOURS:~

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 125 hour maintenance

• Perform 125 hour maintenance

And in addition:~

• Perform 250 hour maintenance

• Replace engine oil and change oil filter

• Perform 500 hour maintenance

• Replace engine fuel filter

And in addition:~

• Replace fuel/water separator

• Replace air cleaner unloader valve

• Replace air intake primary element

• Drain and refill front and rear axle differentials, planetaries and bogie housings with SAE 90/ API-GL-5 gear oil. Refer to AXLE LUBRICATION in THIS SECTION and SECTION 8 of the SERVICE MANUAL for axle draining procedure.

• Check oil level in bogie axle differentials, 2-places • Check oil level in bogie axle housings, 4-places • Check oil level in planetary axles, 8-places • Check the center joint for looseness. Refer to CENTER JOINT MAINTENANCE in THIS SECTION for instructions. If a problem is found corrective action should be taken immediately. Refer also to CENTER JOINT in SECTION 11 of the SERVICE MANUAL for more detailed checking and adjustment procedures.

• Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period. ______________________________________________

SEASONAL:~ • Drain and refill hydraulic oil reservoir with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION.

• Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period.

• Drain and refill cab tilt reservoir with recommended hydraulic oil. Refer to APPROVED HYDRAULIC OILS in THIS SECTION.

______________________________________________

EVERY 500 HOURS:~ • Perform 8 hour maintenance

______________________________________________

• Perform 125 hour maintenance • Perform 250 hour maintenance And in addition:~ • Replace air intake safety element • Replace all hydraulic oil double element filters (4 elements) † 3 white, high performance element.

1 blue, water absorbing element.

• Replace charge pressure filter † • Replace pilot system filter † • Replace oil in transmission • Refer to diesel engine service manual and attachment manual for additional required maintenance at this scheduled time period. † Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components. ______________________________________________

3.6

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

APPROVED HYDRAULIC OILS In addition to providing the vehicle with its normal operational functions, hydraulic oil is also used to fill the cab tilt pump reservoir, apply brakes and operate differential locks.

Use only one of the following oils to fill or replenish the hydraulic system. ®

Tigercat

HYDRAULIC OIL OPERATING RANGE (Not suitable for axle applications)

OPERATING TEMP. RANGE LOWEST START-UP TEMP.

HYDRAULIC OIL TEMPERATURE -40

OIL TYPE

-40

-30 -20

-20 0

-10

0 20

10 40

20 60

30 80

40

50

60

70

100

120

140

160

80 180

90 200

100

˚C 220˚F

CITGO MYSTICK HVI 32 MYSTICK HVI 46 MYSTICK HVI 68 CHEVRON RYKON PREMIUM 32 RYKON PREMIUM 46 RYKON PREMIUM 68 ESSO / EXXON UNIVIS N22 UNIVIS N32 UNIVIS N46 UNIVIS N68 IRVING OIL HYDRAULIC LP 22 HYDRAULIC LP 32 HYDRAULIC LP 46 HYDRAULIC LP 68 MOBIL MOBIL DTE 12M (ISO 22) MOBIL DTE 13M (ISO 32) MOBIL DTE 15M (ISO 46) MOBIL DTE 16M (ISO 68) PETRO-CANADA HYDREX MV 22 HYDREX MV 36 HYDREX MV 60 SHELL TELLUS T22 TELLUS T32 TELLUS T46 TELLUS T68 TEXACO RANDO HDZ 22 RANDO HDZ 32 RANDO HDZ 46 RANDO HDZ 68

CAUTION

OPERATING MACHINE OUTSIDE LIMITS SHOWN WILL RESULT IN FAILURE OF HYDRAULIC COMPONENTS

5168AR03

3.7

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

•

3.8

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance Tigercat® Model 1065/1075

1

COOLING SYSTEM

CHK

2

ENGINE OIL/FILTER

CHK

3 4 5 6

FUEL FILTER (ENGINE) FUEL/WATER SEPARATOR FUEL TANK FILLER SCREEN AIR INTAKE AIR INTAKE PRIMARY ELEMENT AIR INTAKE SAFETY ELEMENT AIR CLEANER UNLOADER VALVE HYDRAULIC OIL RESERVOIR (LEVEL INDICATOR ON TANK)

7 8 9

10

11 12 13 14 15 16 17 18

19

20 21 22 23 24 25

HYDRAULIC FILTER, FULL FLOW, INCLUDES:1 BLUE WATER ABSORBING ELEMENT* 3 WHITE HIGH PERFORMANCE ELEMENTS CHARGE PRESSURE FILTER (DRIVE PUMP) PILOT SYSTEM FILTER TRANSMISSION (2 SPEED) AXLES - DIFFERENTIAL AXLES - BOGIE HOUSINGS AXLES - PLANETARY DRIVES AXLES - SLEW BEARINGS AXLES - INPUT SHAFT BEARINGS DRIVE SHAFT, MID SHAFT DRIVE SHAFT, CENTER JOINT DRIVE SHAFT, FRONT SHAFT DRIVE SHAFT, REAR SHAFT DRIVE SHAFT, REAR BEARING HANGERS CENTER JOINT ARTICULATION CENTER JOINT OSCILLATION CENTER JOINT BEARING PRELOAD STEERING CYLINDERS SNOW BLADE CYLINDER & PIVOTS (IF EQUIPPED) LADDER PIVOT (IF EQUIPPED) CRANE/ROTATOR/GRAPPLE LINK SNUBBER DOOR HINGES

CHANGE COOLANT EVERY 2 YEARS REP

28

7.4

60% ANTIFREEZE/40% DISTILLED WATER

29

7.6

SEE ENGINE MANUFACTURERS MAINTENANCE MANUAL

REP REP

DRN CHK CHK

REP REP CHK CHK

REP 120

CHK

4

REP + REP + D/R

1

LUB *** LUB LUB LUB LUB LUB LUB

LUB LUB

1.5

1 1

14 3.7 30 7.9 5 1.3 PURGE PURGE PURGE

2 4 8 48 2 2

PURGE PURGE PURGE PURGE PURGE PURGE

1 1 1 2 2 2

5.5 D/R D/R D/R

LUB LUB

CHK

32

1 1 1 1 1 1 1 1

REP +

CHK CHK CHK

LUB LUB

DESCRIPTION Qty

USG

Liters

1000

500

250

8

ITEM

125

SERVICE POINT NO.

SERVICE AND LUBRICATION POINTS REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION CAPACITY SERVICE EVERY

CLEAN AS REQUIRED CHECK FILTER RESTRICTION INDICATOR WITH ENGINE RUNNING REFER TO SECTION 3 OF MANUAL DRAIN AND REFILL AS REQUIRED BY SEASONAL OIL CHANGE (SEE HYDRAULIC OIL CHART) CHECK FILTER RESTRICTION INDICATOR ON FILTER WITH ENGINE RUNNING AT FULL AND WITH OIL FLOW

FILL WITH MIL-L-2105 OR API-GL-4 OR GL-5 USE SAE 80/90 REFER TO BOGIE AXLE SERVICE IN SECTION 3 OF THE OPERATORS MANUAL FOR PROCEDURE ~ USE SAE 90/API-GL-5 LITHIUM BASE EP2 GREASE LITHIUM BASE EP2 GREASE

LITHIUM BASE EP2 GREASE

LITHIUM BASE EP2 GREASE

REFER TO SECTION 3 OF THE MANUAL PURGE 4 LITHIUM BASE EP2 GREASE PURGE 6 LITHIUM BASE EP2 GREASE PURGE 1 LITHIUM BASE EP2 GREASE SEE MANUFACTURER'S MAINTENANCE SCHEDULE PURGE 4 LITHIUM BASE EP2 GREASE PURGE LUB 17 LITHIUM BASE EP2 GREASE

1065 LUBE REV 1.XLS

3.9

Tigercat 1065/1075 Forwarder FILTERS - REMOVE AND REPLACE

Lubrication and Maintenance PRIMER PUMP

IMPORTANT

• ••

Failure to service and replace filters at the proper intervals specified in the manufacturer’s manuals, could cause damage to the machine and result in the product warranty becoming NULL and VOID. Check Tigercat parts catalog for replacement filters.

FUEL WATER SEPARATOR

•• GASKET WATER SEPARATOR BOWL

FUEL FILTER/WATER SEPARATOR This is a combination unit, with a replaceable fuel filter and a removable water sediment bowl on the bottom of the unit. The water sediment bowl is only replaced if it becomes damaged or nonfunctional. For service and replacement intervals refer to SERVICE AND LUBRICATION POINTS in THIS SECTION. PRIMER PUMP

••

••

VENT PLUG

1014-D073

•• ••

FUEL/WATER SEPARATOR

6. Remove and discard the gasket the filter head.

7. Remove the water sediment bowl from the bottom of the old filter. Discard this gasket also. Dispose of old filter and any fuel properly.

9. Lubricate gasket for bottom of filter and water sediment bowl with clean engine oil and carefully hand tighten the water sediment bowl onto the new filter. It is plastic and will break if over tightened. Close the water drain valve.

•• BOWL DRAIN

••

10. Lubricate the gasket on top of the new filter with clean engine oil and prefill the filter with clean fuel.

•• 1014-D072

BOWL DRAIN

•

8. Clean the water sediment bowl, seating area for the gaskets on the filter head and the sediment bowl and close bowl drain.

FUEL WATER SEPARATOR

WATER SEPARATOR BOWL

GASKET

11. Screw the new filter on to the filter head until the gasket makes contact with the seat and then hand tighten an additional 3/4 turn only.

FUEL/WATER SEPARATOR

Changing the filter:

12. Use primer pump to refill filter until fuel free of air flows from vent on top of filter head, then tighten vent plug.

1. Park machine on level ground, install articulation lock bar, lower the snow blade (if equipped) and place the crane in the park position, stop engine, remove key, open hood, then switch battery disconnect off, and block wheels.

13. Start the engine and check for leaks.

2. Wipe clean the area around the filter and head.

3. Attach a hose to the spout on the bowl drain and place a suitable drain pan under separator bowl drain hose.

4. Loosen vent plug on filter head, open drain on separator bowl and drain fuel into pan.

5. Remove the water separator filter and bowl from the filter head.

3.10

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

IMPORTANT

• •

FILL CAP & TUBE

Filters that are an integral part of the engine (fuel and lubricating oil) should be serviced and replaced according to the engine manufacturer’s operation and maintenance manual.

Tier II engine fuel injection systems require cleaner fuel than Tier I engines. To accomplish this, Tier II engines typically use filters with a finer micron rating. If the fuel supply is dirty, the fuel filter must be replaced more frequently than recommended in the owner’s manual.

Operating the machine with a clogged fuel filter will result in low engine power. It is also recommended that the fuel/water separator bowl be drained daily.

FUEL TANK DRAIN PLUG

•• 1014-D016

FUEL TANK DRAIN PLUG DIPSTICK

•• ••

When installing a new fuel filter, DO NOT pre-fill with diesel fuel, or engine fuel pump damage will result. This type of failure is not warrantable by the engine manufacturer.

•

FILL CAP

•• FILLER SCREEN

FUEL TANK FILL SPOUT

••

FUEL SHUT-OFF TURNED ON (UP)

To prolong the operating life of the fuel filter, ensure that the fuel supply storage tank is clean and free of water and that the fuel is pre-filtered prior to adding it to the machine.

• ••

1014-D064

FUEL TANK COVER

FUEL TANK LOCATION

FUEL TANK STRAINER This is a stainless steel fuel strainer, screwed on to the inlet pipe of the engine fuel feed line inside at the bottom of the fuel tank.

7. Reinstall the strainer using the hex on end.

Changing or cleaning the strainer:

9. Reinstall drain plug.

1. Park machine on level ground, install articulation lock bar, lower the blade (if equipped) and place the crane in the park position, stop engine, remove key, then switch battery disconnect off, and block wheels.

10. Refuel and check for leaks. Start the engine and check for leaks again.

8. Reinstall fuel tank cover plate with new “O” ring.

2. Remove filler cap. Install a suitable container below fuel tank, remove drain plug and drain the fuel tank.

3. Remove the cover from the fuel tank and “O” ring from the access hole.

4. Clean any debris from the bottom of the tank and wipe it clean.

5. Remove the fuel strainer using the hex on the end of strainer. Carefully clean the strainer (it may be damaged by rough handling).

6. Check for a buildup of foreign materials where the strainer threads on to the pipe and elbow.

3.11

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance SECTION. Changing the filters:

BLUE ELEMENT CHARGE PUMP FILTER

•

1. Park machine on level ground, install articulation lock bar, lower the blade (if equipped) and place the crane in the park position, stop engine, remove key, then switch battery disconnect off, and block wheels.

• •• • •

FULL FLOW FILTER ELEMENTS

FULL FLOW FILTER ELEMENT

2. Wipe clean the area around the filter and head.

•

3. Place rags below to catch the spillage of oil.

HYDRAULIC RESERVOIR

1014-D015

4. Wearing face protection (in case of an oil spray), unscrew the old filter. Dispose of old filter and any oil properly.

HYDRAULIC RESERVOIR AND FILTER LOCATION

5. Check the seating area for the gasket on the filter head and wipe it clean.

HYDRAULIC OIL FILTERS The hydraulic return line contains a double filter head with a built in restriction indicator and a 1.7 bar (25 psi) bypass valve. The oil cooling circuit contains another double filter head with the same restriction indicator and bypass valve. In the event of a clogged filter element or thicker oil on cold starts, this bypass filter will open and redirect oil around the filter element. When the filter elements become restricted, the Red pop-up indicator will show RED, indicating that the elements must be changed. It is recommended that all machines use the following different filter elements:

6. The Tigercat spin-on filter element is supplied with two gaskets. A round ('O' ring style) section gasket is used for all four return filters.

FILTER HEAD

• • GASKET

•

FILTER ELEMENT

FILTR_SEALS

ROUND SECTION GASKET INSTALLATION

3 white, Tigercat high performance, full flow hydraulic oil filter elements

Discard the square section gasket.

1 blue, Tigercat water absorbing, full flow hydraulic oil filter element (installed in first location on return filter head).

7. Remove used gasket and clean gasket seat in head.

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION POINTS in THIS

9. Install new gasket on inside lip of filter.

8. Apply clean oil to new gasket surfaces.

10. Screw on new filter until gasket makes contact.

11. Tighten filter until top edge makes metal to metal contact with filter head. (approximately 1 1/2 additional turns after gasket contact) 12. Start the engine and check for leaks.

IMPORTANT Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals. Refer to SCHEDULED MAINTENANCE in THIS SECTION OF THIS MANUAL. Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

3.12

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

CHARGE PRESSURE FILTER-DRIVE PUMP

HYDRAULIC FILTER SERVICING GUIDELINES FOR 1014/1018C FORWARDERS

CHARGE PUMP FILTER

•• •

IMPORTANT HYDRAULIC RESERVOIR

HYDRAULIC RESERVOIR AND FILTER LOCATION The drive pump charge circuit contains a single element, full flow Tigercat hydraulic filter with a restriction indicator sending unit and a 3.4 bar (50 psi) third port bypass valve. The restriction indicator sending unit turns on the filter bypass warning light in the cab when an oil flow restriction in excess of 3.4 bar (50 psi) is encountered at the filter head. When a restriction is encountered, the bypass valve diverts oil back to tank via the third port to prevent unfiltered oil from entering the drive circuit.

1014-D015

NEVER PRE-FILL ANY HYDRAULIC FILTERS ON FORWARDERS Tigercat generally does not recommend the prefilling of spin-on filters due to the risk of damage to the hydraulic system caused by unfiltered oil.

Unfiltered oil used to pre-fill filters enters directly into the hydraulic circuit. Contaminants in unfiltered oil can cause significant and costly damage to hydraulic valves, pumps and motors.

The cleanliness of hydraulic oil cannot be guaranteed unless it is always prefiltered before use.

IMPORTANT Changing a pressure filter:

Direct contact with oil implies a risk of skin complaints. Oil on skin should be washed off immediately with soap and water. Refer also to WORKING WITH OIL in SECTION 1 of THIS MANUAL.

1. Park machine on level ground, install articulation lock bar, lower the snow blade (if equipped) and place the crane in the park position, stop engine, remove key, then switch battery disconnect off, and block wheels.

2. Wipe clean the area around the filter and head.

3. Place rags below to catch the spillage of oil.

4. Wearing face protection (in case of an oil spray), unscrew the old filter. Dispose of old filter and any oil properly.

5. Check the seating area for the gasket on the filter head and wipe it clean.

6. The new filter has an attached gasket. Apply hydraulic oil to the gasket surface.

7. Screw on the new filter until the gasket makes contact with the seat in the filter head.

8. Hand tighten filter an additional 1/2 turn only.

9. Start the engine and check for leaks.

3.13

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

IMPORTANT Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals, Refer to SCHEDULED MAINTENANCE in THIS SECTION. Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

1

• 1014-D169

RETURN OIL STRAINER

HYDRAULIC RETURN OIL STRAINER This strainer (1) is located beside the hydraulic pumps in the front chassis. The strainer is provided as a safety device to trap contaminants in the event of a pump failure.

The strainer only requires replacement if it is damaged or a pump failure has occurred.

3.14

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

CENTER JOINT

REAR CHASSIS

FRONT CHASSIS

MAINTENANCE OF ARTICULATION JOINT

CENTER JOINT

Maintenance in this area is usually limited to: a) Regular lubrication of the two center joint articulation grease fittings to purge the articulation pivot bearings of debris and water.

Refer to SERVICE AND LUBRICATION POINTS in SECTION 3 for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide. b) Visually checking the center joint articulation for looseness every 250 hours. With an observer on the ground, keeping well clear of the center joint area, perform the following test to check for looseness of center joint articulation.

1. Have operator lift the crane out of the park position, and maneuver it 90 degrees to one side of the machine. Fold the stick boom down, and rapidly raise and lower the main boom several times to “bounce” machine (it may be necessary to adjust the boom up and boom down parameters using the MDM Display Terminal).

2. As the machine bounces, check for motion between the front chassis and center joint lugs. Also check for a “clunking” sound at the center joint area.

CHECK FOR MOVEMENT IN THIS JOINT AREA

1014-D071

••

CENTER JOINT

MAINTENANCE OF OSCILLATION JOINT Maintenance in this area is usually limited to: a) Regular lubrication of the two center joint oscillation grease fittings to purge the oscillation pivot bearings of debris and water.

Refer to SERVICE AND LUBRICATION POINTS in SECTION 3 for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide. b) Visually checking the center joint oscillation for looseness every 250 hours. With an observer on the ground, keeping well clear of the center joint area, perform the following test to check for looseness of center joint.

1. Have operator place the crane into the park position. Drive the machine in forward and reverse rapidly several times.

3. Have operator place the crane back into the park position.

4. Movement between front chassis and center joint lugs or clunking of the pivot indicates a loose articulation joint and articulation joint preload must be checked.

Refer to CHECKING ARTICULATION PRELOAD in SECTION 11 of the SERVICE MANUAL.

2. Check for motion between the center joint and rear chassis. Also check for a “clunking” sound at the center joint area.

3. Movement between center joint and rear chassis or clunking indicates a loose oscillation joint and oscillation joint preload must be checked. Refer to CHECKING/ ADJUSTING OSCILLATION PRELOAD in SECTION 11 of the SERVICE MANUAL.

3.15

Tigercat 1065/1075 Forwarder AIR CLEANER MAINTENANCE

Lubrication and Maintenance

AIR CLEANER

SENDING UNIT FOR WARNING ALARM

•• ••

ENGINE AIR INTAKE

FILTER RESTRICTION INDICATOR

•

UNLOADER VALVE

••

••

1014-D056

ENGINE AIR CLEANER

1014-D055

AIR CLEANER The air cleaner on this machine uses two filter elements, a primary element and a safety element accessible from the left side of the engine compartment.

SAFETY ELEMENT PRIMARY ELEMENT

• • OUTLET TUBE 1018-D068

AIR CLEANER UNLOADER VALVE

AIR CLEANER UNLOADER VALVE This rubber valve on the tube of the air cleaner housing should be checked at the beginning of every shift. (8 hours) If this valve is missing, damaged or has become hard, it will cause the air cleaner to become ineffective. The valve should suck closed at 1/3 throttle.

This valve should be replaced every 1000 hours.

Remove the unloader valve from the tube of the air cleaner housing. Check and clean the valve. A good valve should be soft and flexible. If it is plugged, be sure to check the filter elements as they may need replacing as well. Reattach the valve to the tube.

When operating in high dust conditions, the unloader valve should be checked and squeezed every 2 hours to release dust buildup.

AIR FILTER ELEMENTS

To ensure maximum engine protection, it is important that the elements be serviced correctly and at proper servicing intervals.

Warning lights in the cab will come ON when the elements in the engine air cleaner become excessively clogged with dust causing air intake restriction.

In addition, a filter restriction indicator is mounted on the engine intake tube side of the filter, this should show green when the engine is running at high RPM. Service is required if the indicator shows red.

1014-D065

ENGINE AIR INTAKE HOSES

AIR INTAKE AND EXHAUST HOSES Inspect air intake and exhaust hoses and pipes for leaks wear or loose connections.

3.16

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

In addition to the SCHEDULED MAINTENANCE, the following instructions should also be noted.

IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS

The most common and damaging servicing problems are:

1. Thoroughly clean the air cleaner housing and surrounding area before opening air cleaner.

OVER SERVICING

2. Release the cover latch gently to reduce the amount of dust dislodged.

Filter elements increase in dust cleaning efficiency as dust builds up on the media. Looks can be deceiving. A filter that looks dirty is actually more efficient than one that is clean. A filter with dust build up on the media reaches nearly 100% dust cleaning efficiency. Only when a filter is so clogged with dirt that air restriction goes beyond engine manufacturer’s guidelines, should a filter be replaced.

NOTE: This does not apply to oil filters.

IMPROPER SERVICING

3. Avoid dislodging dust from filter element(s) by gently pulling the element off the outlet tube.

4. Always clean the sealing surface of the outlet tube before inserting a new filter element.

5. Always clean the inside of the outlet tube and filter housing.

6. Check your old filter, It can help you detect foreign material on the sealing surface that is causing leakage.

NOTE: Filter elements should never be cleaned and reused. Cleaning causes dust to bypass the filter and be deposited on the inner surface of the filter media. The dust is then drawn directly into the engine.

Engine exposure to dust during servicing is the largest single reason for engine damage due to dust.

Abrasive dust can easily enter the intake system once the air cleaner cover and protective filter element is removed for replacement. The safety element does reduce this risk but it should also be replaced at every third primary element change.

7. Inspect the new filter for damage.

8. Insert the new filter properly. Apply pressure to the outer rim of the filter not the flexible centre.

9. Check connections and ducts for air tight fit.

Ensure that all clamps, bolts and connections are tight. Check rubber elbows for splits or wear points. Leaks here send dust directly to the engine.

3.17

Tigercat 1065/1075 Forwarder CHECKING THE AIR CONDITIONING SYSTEM

Lubrication and Maintenance IMPORTANT

Any service work must be performed by authorized A/C technicians. The system should be charged with R134a refrigerant only. PAG (polyalkeylene glycol) oil should be present in the system and must be used on ‘O’ ring fittings during assembly.

It is recommended that during cold weather when the A/C system is not in use, that it be run for a period of 5 minutes every 2 weeks.

This will circulate oil to all components of the A/C system.

A/C SYSTEM TOTAL CAPACITIES PAG OIL R134a REFRIGERANT (polyalkylene glycol) 3 LBS. 8 OZ.

CAUTION • If using compressed air for cleaning, use at 30 psi or less.

2 OZ.

• Always use personal protective equipment to guard against flying debris.

The compressor and charge valves are accessible from the left side engine compartment. The receiver drier is accessible from the front of the engine compartment, on the front of the charge air cooler. The evaporator core is accessible from behind the operator’s seat inside the cab.

•• •

WINGNUT

Use this checklist to maintain system between service intervals.

A/C CONDENSER

a. Check and adjust compressor drive belt tension.

•

b. Check air intake filters and clean as required. c.

Check the condenser core for dirt and debris.

Clean as required. Refer to CLEANING A/C CONDENSER, AND COOLER PACKAGE in SECTION 2 of this manual.

1014-D068

d. Check the evaporator core and the inside of the A/C housing for dirt and debris. Clean as required.

A/C CONDENSER AND COOLER PACKAGE

NOTE: Cooler package shown above with front screen removed.

e. Run air conditioning system for 3 - 5 minutes. f.

COOLER PACKAGE

HOSE TO A/C HEATER UNIT

Check to see that compressor clutch will engage.

••

1014-152

HOT WATER SHUT OFF VALVE

HOT WATER SHUT OFF VALVE (ENGINE) During times when cab heating is not required the HOT WATER SHUT OFF VALVE, on the heater hose from the engine, can be closed to prevent hot water from seeping through the A/C unit, thereby reducing the cooling system effect.

3.18

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

CAB AIR FILTERS

FRESH AIR FILTER

CAP SCREWS

•••

•• ••

•

RECIRCULATING AIR FILTER

CAP SCREWS

• •• 1014-D196

Remove the four hex head cap screws and remove the cover panel to gain access to the filter in the cab roof.

R.H. SIDE OF CAB FILTER, RECIRCULATING AIR - A/C UNIT 1014-D074

Air in the cab is drawn into the A/C-HEATER unit via this filter and recirculated. The filter is located on the front face of the A/C unit. It should be cleaned or replaced every 125 hours. This is done by removing two threaded knobs on the front cover and lift out the filter.

CAP SCREWS

Remove four cap screws, two brackets and lift the filter out. It should be cleaned or replaced every 125 hours.

WARNING These filters may require cleaning or replacement more frequently under extreme operating conditions.

FRESH AIR FILTER

••

FREASH AIR FILTER LOCATION

CAP SCREWS

•• • • 1014-D199

•

FREASH AIR FILTER

TEMPERATURE CONTROL

FILTER - FRESH AIR When the Heater/AC Blower control switch is in the ON position, outside air is drawn into the cab air conditioning unit through the air filter and mixed with interior air from the cab. To reduce dust in the cab area, use the Heater/AC Blower control option with the A/C on. This pressurizes the cab, forcing dust out and reducing dust coming in. The FRESH AIR filter is accessible from outside of the cab, at the left side of the cab roof.

1014-D075

A/C AND FAN CONTROLS

HEAT - VARIABLE/TEMPERATURE CONTROL This electronic temperature control automatically adjusts the temperature of air in the cab for both heating and air conditioning. The blue area of the scale indicates cooler temperatures the red area indicates warmer temperatures.

This control will automatically regulate cooling or heating to maintain the requested temperature

3.19

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

TILTING THE CAB CAUTION WARNING

Keep hands away from the locking pin area.

Before tilting the cab, ensure that the machine is parked on level ground with the cab facing forward. Lower the snow blade (if equipped) and place the crane in the park position. Turn the ignition switch off.

Close all cab doors.

RAISING THE CAB 1. Position the forwarder on level ground.

8. Place tilt pump control lever in RAISE position.

Pump the lever until the cab weight is just off the locking pins.

9. Lift the locking plate out of the slots in the pins and turn the cab locking pins so the flat surfaces are vertical and in line with the slots on the cab locking lugs.

2. Lower the snow blade (if equipped) and place the crane in the park position.

CYLINDER FULLY EXTENDED

3. Turn ignition off and secure all loose articles in cab. Close all cab doors.

4. Check to be sure that the area above the tires on the right hand side of the cab and cab path is clear of all personnel and obstacles.

CAB TILT RESTRAINT CABLE

••

••

PIN LOCK PLATES

••••

•• • CAB LOCKING PINS

LEFT SIDE BELOW CAB

1014-D078

5. Loosen the pin lock plate cap screws (located above the cab locking pins).

1014-D080

CAB TILT CYLINDER FULLY EXTENDED

10. Operate pump until the cab tilt is just at over centre position and stop pumping. Use the RAISE/LOWER CONTROL LEVER to meter the hydraulic flow at the cab tilt cylinder, slowly tilting the cab all the way over fully extending cylinder.

WARNING LEFT SIDE HYDRAULIC TANK ACCESS DOOR

PUMP LEVER

CAB TILT LEVER

•• 1014-D079

Before working under cab;

•• •• •

CAB TILT PUMP

CAB TILT PUMP

Machine must be parked on level ground.

Cab must be fully tilted with tilt cylinders fully extended.

NOTE: If partial tilt is required for an operator assistant to be in cab while service work is performed under cab, locate CAB SUPPORT BRACE mounted on the front left side of the gate. Remove from gate and install under cab as outlined in step 11.

CAB SUPPORT BRACE

6. Locate the cab tilt pump inside the left side hydraulic tank access door.

7. Locate the cab tilt pump handle inside the cab and insert handle in pump lever.

1055-025

3.20

••

CAB SUPPORT BRACE STORAGE

Tigercat 1065/1075 Forwarder CAB LOCKING LUGS

Lubrication and Maintenance OPENING ENGINE HOOD

• •• •

CAB SUPPORT BRACE

ENGINE HOOD LATCH

••

CAB LOCKING PIN TURN 90° TO SECURE BRACE

•• ••

CAB SUPPORT BRACE - INSTALLED 11. For partial tilt, install CAB SUPPORT BRACE .

With cab tilted, insert brace in cab locking lugs, lower cab and secure lower end of brace with the cab locking pin turned 90°.

1055-022

OPENING ENGINE HOOD

1014-D011

TO OPEN: Release the over center latch on left side of the engine hood. Pull down on latch handle, lift latch ring off retainer lug on frame.

LOWERING THE CAB 1. Clear the area under the cab and cab path of obstructions and secure all lines and wires.

PULL ON HANDLE

2. Place tilt pump control lever in LOWER position.

3. Operate pump until the cab is all the way over in the ride position onto the locking pins.

••

CAUTION Keep hands away from the locking pin area as the cab is being lowered.

NOTE: When the cab locking lugs are just over the locking pins, rotate the pins so the flat surfaces of the locking pins are horizontal.

ILLY-D012

PULL HOOD OPEN

Locate handle on front of engine hood. Pull on handle and tip engine hood forward to open hood.

PIN LOCK PLATES

••• •

Reverse this procedure to close engine hood.

•• • CAB LOCKING PINS

1014-D078

LEFT SIDE BELOW CAB

4. Place the locking plates back in the slots on the locking pins and tighten the cap screws.

5. Place the cab tilt control lever in the LOWER position and remove tilt pump handle.

6. Place the pump handle back in the storage location in the cab.

7. Close the left side hydraulic tank access door.

3.21

Tigercat 1065/1075 Forwarder STARTUP PROCEDURE AFTER MAJOR MACHINE MAINTENANCE

Lubrication and Maintenance

This procedure should be followed: •

after major service or a rebuild.

•

whenever the machine has been drained of hydraulic oil.

•

when any major component has been removed, repaired or replaced.

LOOSEN HOSE ON TOP OF DRIVE MOTOR

•

PRE-STARTUP AND FILLING 1. Ensure all filters are in place. Do not pre-fill the filters.

1014-D081

2. Check oil levels in the engine, the transmission, and both front and rear axles.

DRIVE MOTOR

•

Loosen hose on top of drive motor.

•

Operate the hydraulic oil fill pump by turning the switch on the pump ON.

4. Do a final inspection of all fittings and clamps to make sure they are tight and will not leak.

•

5. Install the articulation lock (pinned at both ends) and switch the FWD./NEUTRAL/REV. to NEUTRAL.

Watch for oil leaking from each hose fitting previously loosened and tighten each when oil leaks out.

•

Continue running the hydraulic oil fill pump and watch the oil sight gauge on the reservoir.

Allow the hydraulic oil fill pump to run until the hydraulic tank is full. The hydraulic oil sight gauge will indicate FULL.

3. Check coolant level in the radiator.

6. Do not start engine. Purge air from hydraulic system by adding oil as follows; •

Prepare the hydraulic oil fill pump on the machine to add hydraulic oil. Clean and install the fill line, remove cap on end of pipe and insert pipe into oil supply drum.

•

Pre-fill the cases of the hydrostatic pump and any other components that have been drained of oil.

LOOSEN HOSE ON TOP OF DRIVE PUMP

LOOSEN HOSE ON TOP OF MAIN PUMP

• •

1014-D081

MAIN AND DRIVE PUMPS

•

Loosen hose on the top of hydrostatic drive pump.

•

Loosen hose on the top of the main pump.

3.22

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

MACHINE STARTUP CHARGE PRESSURE TEST PORT

Before beginning this procedure, perform the PRESTARTUP AND FILLING steps.

1. Ensure the articulation lock is installed and pinned at each end.

••

CAUTION Machine operator must ONLY take directions from the person doing the set-up.

1014-D085

STOP BUTTON

hydraulic oil reservoir with clean hydraulic oil.

••

1014-D017

CHARGE PRESSURE TEST

NOTE: The steer and drive functions may not be properly purged or flushed. Remove the articulation lock pin and at LOW IDLE, slowly operate the steer function right and left a few times. With the emergency brake released, slowly operate the drive function forward and reverse a few times.

ENGINE STOP BUTTON

2. Hold the STOP button on the left side of the engine cover and have an assistant crank NOTE: If possible, allow the machine to stand for engine using the key switch in the cab for 10 seconds, wait for 10 seconds. Repeat 6 times 4 to 6 hours before setting any of the operating pressures. This will allow any air bubbles in the oil to pump oil into pumps. Do not start engine. to escape and is a good time to check for leaks.

3. Install a 0-1000 psi. gauge on the 'CHARGE' test port to check charge pressure. Watch gauge closely during startup.

4. Start engine. If charge pressure does not rise within 5 to 10 seconds, TURN ENGINE OFF. Refer to CHARGE PUMP in SECTION 8 of THE SERVICE MANUAL. 5. If charge pressure is between 18-31 bar (260450 psi), run engine at IDLE for 20 minutes.

Check engine oil pressure in cab. Do not operate any functions. Remove gauge from 'CHARGE' test port.

6. With engine at IDLE, emergency brake ON, hold foot brake down, bleed service brake and parking brake release line in the front and rear axles.

7. With engine speed at IDLE run each function for 2 minutes to purge air from circuit.

8. Set engine speed to 1400 rpm and run each function again for 2 minutes to flush circuit.

9. Top up the radiator with clean coolant.

10. With cylinders fully retracted, top up the

3.23

Tigercat 1065/1075 Forwarder AXLE LUBRICATION

Lubrication and Maintenance

Each bogie axle has seven separate oil reservoirs that require individual draining/filling, there are nine drain points and seven fill points. The axle must be level when draining/filling lubricant. Perform scheduled oil change in the axles when doing the seasonal hydraulic oil change. Refill the axle differentials and bogie housings with SAE 90/API-GL-5 gear oil.

FILL PLUG DIFFERENTIAL OIL LEVEL PLUG (1 PLACE)

BOGIE HOUSING LEVEL PLUG (4 PLACES)

• •

••

• ••

BREATHER

BOGIE HOUSING FILL PLUG (2 PLACES)

•• •

DIP STICK (1 PLACE) BOGIE HOUSING DRAIN PLUG (4 PLACES)

PLANETARY FILL PLUG (4 PLACES)

BOGIE HOUSING CONTAMINATED DRAIN PLUG (4 PLACES - LOWER)

•

WHEEL HUB IN PLANETARY DRAIN POSITION

PLANETARY LEVEL/DRAIN PLUG (4 PLACES)

• •

BM041A

DIFFERENTIAL DRAIN PLUG (1 PLACE)

WHEEL HUB IN PLANETARY FILL POSITION

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS 8. Refill the differential by pumping oil through the fill plug location on the differential. Stop adding oil when the oil level reaches the bottom of the differential oil level plug.

DRAINING AND REFILLING DIFFERENTIAL: (1 PER AXLE) 1. Park machine on level ground, install articulation lock bar, lower the snow blade (if equipped) and place the crane in the park position, stop engine, remove key, then switch battery disconnect off, and block wheels.

9. Replace the differential fill and level plugs.

PLANETARY DRIVES (4 FILLING POINTS) 10. Position the wheel hub for draining the planetary, with the drain plug in the lowest possible position as shown.

2. The axle must be level in order to drain and refill it properly.

11. Remove the PLANETARY FILL PLUG.

3. Clean around all fill, level and drain plugs before removing them.

12. Remove the PLANETARY DRAIN/LEVEL PLUG and drain the oil into a suitable container for disposal.

4. Remove the differential oil level plug located opposite the input yoke on the differential housing.

13. Reposition the wheel hub for filling the planetary, with the PLANETARY DRAIN/ LEVEL PLUG at 9 o’clock and the fill plug at 1 o’clock as shown.

5. Remove the differential housing drain plug located on the bottom of the differential, and drain the oil into a suitable container for disposal.

6. Clean any filings from the magnetic drain plug.

7. Replace the differential housing drain plug.

3.24

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance REPLACING THE ENGINE SERPENTINE BELT

14. Refill the planetary with new oil until the level reaches the bottom of the PLANETARY DRAIN/LEVEL PLUG. (Note: To get a correct filling level the wheel hub must be in the planetary fill position as shown.)

Replace the engine serpentine belt as follows:.

1. Park the machine on level ground. Place the crane in the park position, lower the blade (if equipped) and turn engine off.

15. Repeat steps 10 to 14 for each of the four planetary drives.

DRAINING AND REFILLING BOGIE HOUSING: (2 PER AXLE) 16. Remove the bogie housing fill plugs located on the top of the bogie housing.

• ••

17. Remove the bogie housing level plugs located on the inside of the housing.

FAN GUARD FASTENERS

••

Note: There are two bogie housing level plugs to be removed per axle.

18. Remove the bogie housing drain plugs on the inside of the bogie housings, towards the bottom. Note, there are four plugs in total to be removed per axle to drain the bogie housings. Drain the oil into a suitable container for disposal.

•• 1014-D086

ENGINE FAN GUARD

2. Remove the six fasteners that attach the R.H. fan guard to the rad shroud and remove the fan guard.

19. Clean any filings from the magnetic drain plugs.

3. Install a 1/2" Johnson bar with a 15mm socket on the hex head bolt of the belt tensioner.

20. Replace the bogie housing drain plugs in all locations.

4. Rotate the tensioner away from the belt to release belt tension. This will provide enough clearance to replace the serpentine belt.

21. Refill the bogie housings by pumping oil into the fill plug on the bogie housings. Stop adding oil when the oil level reaches the bottom of the bogie housing level plug. Note, each of the bogie housings must be filled separately.

22. Replace the bogie housing level plugs.

23. Replace the bogie housing fill plugs.

Note: There are 9 drain points and 7 fill points CAPACITIES For front and rear axle oil fill capacities, refer to the table: SERVICE AND LUBRICATION in THIS SECTION of THIS MANUAL.

1014-071

SERPENTINE BELT INSTALLATION

5. Reverse removal procedure to replace the belt.

6. Ensure that all of the ribs on the serpentine belt align with the grooves on the engine pulleys.

3.25

Tigercat 1065/1075 Forwarder CRANE, ROTATOR AND GRAPPLE MAINTENANCE Refer to the manufacturer’s maintenance and service manual for information on your crane, rotator and grapple.

Lubrication and Maintenance LINK SNUBBER MAINTENANCE

IMPORTANT All service points on link must be greased every shift (8 hours) to ensure a long service life.

CRANE LUBRICATION PROCEDURE NOTE: This procedure will allow grease to flow to the normally 'loaded' side of the pin/bearing surfaces.

The link provides a double direction snubbing action. There are 4 grease fittings on the link, for daily lubrication of the sleeves, bushings and housing.

NUT

COLLAR

•• •• 1014-D082

1. Fully extend booms and place opened grapple on the ground.

2. While in this position, lubricate all cylinder retaining pins and joints daily.

LINK SNUBBER (CY049) MAINTENANCE ADJUSTING SNUBBER TENSION Tension is adjusted by turning the adjusting nut.

Turn the adjusting nut only 1/2 turn at a time against the tension collar until the desired tension is achieved. Over-tightening may result in grapple stiffness and reduced friction sleeve life.

3.26

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

TORQUE CHART LOCATION

THREAD

TORQUE (LUBRICATED) Nm

lbf-ft

Steer Cylinders Pin keeper plate bolts Piston nut Gland

M20 x 2.5 1 3/4" UNF -

530 2370 745

400 1750 550

Snow Blade Cylinders (if equipped) Pin keeper plate bolts Piston nut, arc/boom cylinder Gland keeper plate bolts

M20 x 2.5 2" UNF M16 x 2.0

530 3050 275

400 2250 200

Cab pin keeper plate bolts

M20 x 2.5

530

400

Center joint bearing Articulation bearing retaining bolts Articulation pin retaining bolts Oscillation end cap bolts

M16 x 2.0 M20 x 2.5 M20 x 2.5

275 530 530

200 400 400

Engine mounting Rear Bolts Front Bolt

M20 x 2.5 M20 x 2.5

530 530

400 400

Main/Drive Pump mounting Drive plate to flywheel Bell housing Rear engine mounting brackets Front engine mounting brackets

M10 x 1.5 M10 x 1.5 M16 x 2.0 M16 x 1.5

43 43 275 275

32 32 200 200

1 1/4" x 18 UNEF M12 x 1.75 M20 x 2.5 1/2" UNF

640-711 110 530 163-179

475-525 80 400 120-132

Axle mounting bolts Front/Rear Bridge mounting bolts front/rear

M30 x 3.5 M24 x 3.0

1850 925

1350 675

Wheel nuts

M22 x 1.5

800

600

Transmission Housing to Mounting Bracket Mounting Bracket to Frame

M16 x 2.0 M20 x 2.5

275 530

200 400

Drive shafts Yoke retaining nut, rear shaft Hanger bearing retaining bolts Hanger bearing mount bolts Universal joint bolts

REV 1 04/2004

Torque values pertaining to the engine and attachments are provided in the appropriate manuals.

3.27

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

GENERAL TORQUE SPECIFICATIONS The torque values listed below are for general use only.

DO NOT use these values if a different torque value or tightening procedure is shown for a specific application.

IMPERIAL GRADE 8 BOLTS

GRADE 5 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 8 BOLTS GRADE 5 BOLTS COARSE THREAD 1/4" - 20 5/16" - 18 3/8" - 16 7/16" - 14 1/2" - 13 9/16" - 12 5/8" - 11 3/4" - 10 7/8" - 9 1" - 8 1 1/8" - 7 1 1/4" - 7 FINE THREAD 1/4" - 28 5/16" - 24 3/8" - 24 7/16" - 20 1/2" - 20 9/16" - 18 5/8" - 18 3/4" - 16 7/8" - 14 1" - 14 1 1/8" - 12 1 1/4" - 12

DRY LUBRICATED lbf-ft Nm lbf-ft Nm 11 - 12 15 - 16 8 - 10 11 - 13 20 - 28 27 - 38 26 - 30 35 - 40 44 -48 60 - 65 33 - 36 45 - 49 70 - 77 95 - 104 52 - 57 71 - 77 106 - 117 144 - 158 80 - 88 109 - 119 153 - 168 208 - 228 115 - 127 156 - 172 212 - 233 288 - 316 159 - 175 216 - 237 376 - 414 510 - 561 282 - 310 393 - 420 606 - 667 822 - 904 455 - 501 617 - 679 909 - 1000 1233 - 1355 682 - 750 925 - 1016 1288 - 1417 1746 - 1921 966 - 1062 1310 - 1441 1817 - 1999 2464 - 2710 1360 - 1496 1844 - 2027 DRY LUBRICATED lbf-ft Nm lbf-ft Nm 13 - 14 18 - 19 10 - 13 14 - 17 23 - 28 31 - 38 18 - 25 25 - 33 49 - 54 67 - 73 37 - 41 50 - 55 78 - 86 106 - 116 58 - 64 79 - 86 120 - 132 163 - 179 90 - 99 122 - 134 171 - 188 232 - 255 128 - 141 174 - 191 240 - 264 326 - 358 180 - 198 244 - 268 420 - 462 570 - 626 315 - 347 427 - 470 668 - 735 906 - 996 501 - 550 679 - 745 995 - 1096 1359 - 1486 746 - 821 1012 - 1113 1445 - 1590 1960 - 2155 1083 - 1191 1469 - 1613 2012 - 2213 2728 - 2997 1509 - 1660 2046 - 2250

D RY COARSE lbf-ft Nm THREAD 1/4" - 20 7- 8 10 - 11 5/16" - 18 14 - 18 19 - 24 3/8" - 16 31 - 34 42 - 46 7/16" - 14 49 - 54 66 - 73 1/2" - 13 75 - 83 102 - 112 9/16" - 12 109 - 120 148 - 162 5/8" - 11 150 - 165 204 - 223 3/4" - 10 266 - 293 360 - 397 7/8" - 9 394 - 433 535 - 586 1" - 8 591 - 649 802 - 879 1 1/8" - 7 794 - 873 1077 - 1183 1 1/4" - 7 1120 - 1232 1519 - 1670 FINE D RY THREAD lbf-ft Nm 1/4" - 28 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 3/8" - 24 35 - 39 48 - 53 7/16" - 20 55 - 61 75 - 83 1/2" - 20 85 - 94 116 - 127 9/16" - 18 121 - 133 164 - 180 5/8" - 18 170 - 187 231 - 253 3/4" - 16 297 - 327 403 - 443 7/8" - 14 434 - 477 589 - 646 1" - 14 646 - 711 876 - 965 1 1/8" - 12 891 - 980 1208 - 1328 1 1/4" - 12 1240 - 1364 1682 - 1849

LU BRICATED lbf-ft Nm 8 - 10 11 - 13 10 - 15 13 - 20 23 - 25 31 - 34 37 - 41 50 - 55 57 - 63 77 - 85 82 - 90 111 - 122 113 - 124 152 - 168 200 - 220 271 - 298 296 - 326 402 - 441 443 - 489 601 - 663 596 - 656 808 - 889 840 - 924 1139 - 1252 LU BRICATED lbf-ft Nm 9 - 10 12 - 13 16 - 20 21 - 27 26 - 29 35 - 39 41 - 45 56 - 61 64 - 70 87 - 95 91 - 100 124 - 135 128 - 141 174 - 191 223 - 245 303 - 332 326 - 359 442 - 486 484 - 534 657 - 724 668 - 735 906 - 996 931 - 1024 1262 - 1387

METRIC

METRIC BOLT TORQUE SPECIFICATIONS SIZE

CLASS 4.8 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

CLASS 8.8 OR 9.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

CLASS 10.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

CLASS 12.9 LUBRICATED DRY Nm lbf-ft Nm lbf-ft

M6 M8 M10

4.8 12.0 23.0

3.5 8.5 17.0

6.0 15.0 29.0

4.5 11.0 21.0

9.0 22.0 43.0

6.5 16.0 32.0

11.0 28.0 55.0

8.5 20.0 40.0

13.0 32.0 63.0

9.5 24.0 47.0

17.0 40.0 80.0

12.0 30.0 60.0

15.0 37.0 75.0

11.5 28.0 55.0

19.0 47.0 95.0

14.5 35.0 70.0

M12 M14 M16

40.0 63.0 100.0

29.0 47.0 73.0

50.0 80.0 125.0

37.0 60.0 92.0

75.0 120.0 190.0

55.0 88.0 140.0

95.0 150.0 240.0

70.0 110.0 175.0

110.0 175.0 275.0

80.0 130.0 200.0

140.0 225.0 350.0

105.0 165.0 225.0

130.0 205.0 320.0

95.0 150.0 240.0

165.0 260.0 400.0

120.0 190.0 300.0

M18 M20 M22

135.0 190.0 260.0

100.0 140.0 190.0

175.0 240.0 330.0

125.0 180.0 250.0

260.0 375.0 510.0

195.0 275.0 375.0

330.0 475.0 650.0

250.0 350.0 475.0

375.0 530.0 725.0

275.0 400.0 540.0

475.0 675.0 925.0

350.0 500.0 675.0

440.0 625.0 850.0

325.0 560.0 460.0 800.0 625.0 1,075.0

410.0 580.0 800.0

M24 M27 M30

330.0 490.0 675.0

250.0 360.0 490.0

425.0 625.0 850.0

310.0 650.0 450.0 950.0 625.0 1,300.0

M33 900.0 M36 1,150.0

475.0 825.0 600.0 925.0 675.0 1,150.0 850.0 1,075.0 800.0 1,350.0 1,000.0 700.0 1,200.0 875.0 1,350.0 1,000.0 1,700.0 1,250.0 1,600.0 1,150.0 2,000.0 1,500.0 950.0 1,650.0 1,200.0 1,850.0 1,350.0 2,300.0 1,700.0 2,150.0 1,600.0 2,700.0 2,000.0

675.0 1,150.0 850.0 1,750.0 1,300.0 2,200.0 1,650.0 2,500.0 1,850.0 3,150.0 2,350.0 2,900.0 2,150.0 3,700.0 2,750.0 850.0 1,450.0 1,075.0 2,250.0 1,650.0 2,850.0 2,100.0 3,200.0 2,350.0 4,050.0 3,000.0 3,750.0 2,750.0 4,750.0 3,500.0

TORQUECHARTGENERAL.XLS GENERAL TORQUE SPECIFICATIONS

3.28

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

Vibration Level - Whole-body As per Tigercat test ETR037 Measured in accordance with ISO 2631-1 Weighted rms acceleration (m/s2) Seat Seat-back Health Comfort Driving max speed (High) x-axis (back-to-chest) 0.7440 0.2120 y-axis (right-to-left) 0.4700 0.4630 z-axis (buttocks-to-head) 0.7580 1.3500 Σ 1.5300 1.4428 0.7110 Driving max speed (Low) x-axis (back-to-chest) 0.3290 0.1110 y-axis (right-to-left) 0.4560 0.3030 z-axis (buttocks-to-head) 0.4050 0.5210 Σ 0.6870 0.6128 0.4160 Boom operation 1400 rpm x-axis (back-to-chest) 0.0232 0.0344 y-axis (right-to-left) 0.1550 0.1090 z-axis (buttocks-to-head) 0.0992 0.0391 Σ 0.1650 0.1208 0.1110

Feet 0.0388 0.0699 0.1310 0.0561 0.0187 0.0455 0.0657 0.0290 0.0096 0.0190 0.0179 0.0089

Vibration Level - Hand/Arm As per Tigercat test ETR037 Weighted rms acceleration (m/s2) Driving max speed (High) Σ 1.250 Driving max speed (Low) Σ 0.543 Boom operation 1400 rpm Σ 0.083 *Note for hand/arm, all weighted RMS acceleration values are below 2.5 m/s 2 as per clause 3.6.3 Machinery Directive 98/37/EC Annex 1.

Noise Level in Cab As per Tigercat test ETR035 Measured in accordance with ISO 5131:1996(E) Annex D Driving max speed (High) Σ 80.7 dB(A) Driving max speed (Low) Σ 79.2 dB(A) Boom operation 1400 rpm Σ 73.3 dB(A)

3.29

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

Par ker ark

Assemb que Assemblly Tor orque

3.30

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

Par ker ark

Assemb que Assemblly Tor orque

JIC 37 Degree Flare SAE Dash Size -2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

Thread Size 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12 3-12

Tube Connection FFWR

NPTF Swivel or Hose Connection FFWR

NA NA 2 2 1 1/2 1 1/2 1 1/2 1 1/4 1 1 1 1 1 1

SAE Dash Size

NA NA 2 2 1 1/4 1 1 1 1 1 1 1 1 1

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

1/8-27 NA 1/4-18 NA 3/8-18 1/2-14 7/8-14 3/4-14 NA 1-11 1/2 1 1/4-11 1/2 1 1/2-11 1/2 2-11 1/2 NA

SAE Dash Size -2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

Thread Size NA NA 9/16-18 NA 11/16-16 13/16-16 1-14 1 3/16-12 NA 1 7/16-12 1 11/16-12 2-12 NA NA

NA NA 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA 1/4 TO 1/2 1/4 TO 1/2 1/4 TO 1/2 NA NA

F.F.W.R : Flats From Wrench Resistance All values are for Steel, Stainless Steel and Brass

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

Swivel or Hose Connection TFFT

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

O'ring Face Seal / Seal-Lok Tube Connection FFWR

Tube Connection TFFT

Thread Size

BSPT

Swivel or Hose Connection FFWR

SAE Dash Size

NA NA 1/2 TO 3/4 NA 1/2 TO 3/4 1/2 TO 3/4 1/2 TO 3/4 1/3 TO 1/2 NA 1/3 TO 1/2 1/3 TO 1/2 1/3 TO 1/2 NA NA

-2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -40

Thread Size 1/8-28 NA 1/4-19 NA 3/8-19 1/2-14 NA 3/4-14 NA 1-11 1 1/4-11 1 1/2-11 2-11 NA

Tube Connection TFFT 2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

T.F.F.T. : Turns from finger tight All pipe values are for Steel, Stainless Steel and Brass

3.31

Swivel or Hose Connection TFFT

2-3 NA 2-3 NA 2-3 2-3 NA 2-3 NA 1.5-2.5 1.5-2.5 1.5-2.5 1.5-2.5 NA

Tigercat 1065/1075 Forwarder

Lubrication and Maintenance

Assemb que Assemblly Tor orque

EATON Aeroquip Recommended Parallel Connection Assembly torque

Eaton recommends that a

The values listed are for

Torque wrench be used to

steel connections. Contact

assure proper fitting

Eaton Aeroquip for torques values for

assembly of these

other materials

connections.

Straight Thread O-Ring Boss Low Pressure with 37º (SAEJ514)

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24 -32

Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Straight Thread O-Ring Boss High Pressure with ORS (J1453)

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-9 12-13 13-15 18-20 14-15 19-21 23-24 32-33 40-43 55-57 43-48 59-64 68-75 93-101 83-90 113-122 112-123 152-166 146-161 198-218 154-170 209-230 218-240 296-325

Dash Size -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24

ORS

Dash Size -04 -06 -08 -10 -12 -16 -20 -24

Jam Nut or Jam Nut or Straight Straight Fitting Torque Fitting Torque lb.-ft.

Newton Meters 8-10 11-16 14-16 20-22 18-20 24-27 24-26 33-35 50-60 68-78 72-80 98-110 125-135 170-183 160-180 215-245 200-220 270-300 210-280 285-380 270-360 370-490

SAE 37º (JIC)

Thread Size (inches) 9/16-18 11/16-20 13/16-16 1-14 1 3/16-12 1 7/16-12 1 11/16-12 2-12

Swivel Nut Torque lb.-ft.

10-12 18-20 32-35 46-50 65-70 92-100 125-140 150-165

Swivel Nut Torque Newton Meters 14-16 24-27 43-47 62-68 88-95 125-136 170-190 204-224

Dash Size -04 -05 -06 -08 -10 -12 -16 -20 -24 -32

Metric Thread Size mm M10x1 M12x1.5 M14x1.5 M16x1.5 M18x1.5 M20x1.5 M22x1.5 M26x1.5 M27x2 M33x2 M42x2 M48x2

Thread Size (inches) 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 3/16-12 1 5/16-12 1 5/8-12 1 7/8-12

Thread Size (inches) 7/16-20 1/2-20 9/16-18 3/4-16 7/8-14 1 1/16-12 1 5/16-12 1 5/8-12 1 7/8-12 2 1/2-12

Swivel Nut Torque lb.-ft.

11-12 15-16 18-20 38-42 57-62 79-87 108-113 127-133 158-167 245-258

Swivel Nut Torque Newton Meters 15-16 20-22 24-28 52-58 77-85 108-119 148-154 173-182 216-227 334-352

BSPP Straight Adapter or Locknut Torque lb.-ft.

Newton Meters 13-15 18-20 15-19 20-25 19-23 25-30 33-40 45-55 37-44 50-60 52-66 70-90 55-70 75-95 81-96 110-130 96-111 130-150 162-184 220-250 170-192 230-260 258-347 350-470

Nominal Thread Size Straight Adapter or Locknut Torque inches** lb.-ft.

Newton Meters G1/8-28 13-15 18-20 G1/4-19 19-23 25-30 G3/8-19 33-40 45-55 G1/2-14 55-70 75-95 G3/4-14 103-118 140-160 G1-11 162-184 220-250 G1 1/4-11 170-192 230-260 G1 1/2-11 258-347 350-470 ** "G" denotes parallel threads, other than ISO 6149 (Port connection only)

Eaton Aeroquip Fluid Conveyance Products A-HOOV-MC001-E January 2005

3.32

Tigercat 1065/1075 Forwarder SECTION 6 - ELECTRICAL & COMPUTERS MAY, 2005

CONTENTS - SECTION 6 AIR FILTER RESTRICTION WARNING ..................... 6.39 BRAKE PRESSURE WARNING ............................. 6.39 CAB FUSE AND RELAY PANEL ............................. 6.46 CAB MODULE ......................................................... 6.10 COMPUTER CONTROL SYSTEM ............................................ 6.2 COMPUTER SYSTEM COMPONENTS .................. 6.20 CONDITIONAL MESSAGES ................................... 6.37 COOLANT LEVEL WARNING ................................. 6.40 CRANE MODULE.................................................... 6.16 CRANE START (CM) .............................................. 6.37 CURRENT OUTPUT SETTINGS ............................ 6.27 DATE TIME SETTINGS .......................................... 6.26 DIAGNOSTICS ADJUSTMENT MENUS ................. 6.21 DRIVE START (CM) ................................................ 6.37 ENGINE COOLANT LEVEL WARNING ............................. 6.40 OIL PRESSURE WARNING ................................ 6.39 OVERSPEED (CM) .............................................. 6.38 TEMPERATURE WARNING ............................... 6.35 ENGINE MODULE .................................................. 6.12 ERROR MESSAGES AND ALARMS MAIN SYSTEM ERRORS .................................... 6.41 FINE CONTROL ...................................................... 6.28 FOOT PEDAL CONTROLS ..................................... 6.8 FRAME MODULE.................................................... 6.14 FUEL LEVEL WARNING ............................................... 6.40 FUNCTION PARAMETERS SETTINGS ................. 6.33 FUSE AND RELAY PANELS ...................................

6.46, 6.47 GRAPPLE MODULE ............................................... 6.18 HYDRAULIC OIL LEVEL WARNING ........................................ 6.39 OIL TEMPERATURE WARNING ......................... 6.35 INFORMATION MENU ............................................ 6.22 INFORMATION MENU DESCRIPTION .................. 6.22 IQAN MDM COMPUTER DISPLAY WARNING MESSAGES MODULE IS OFFLINE ..................................... 6.41

L.H. JOYSTICKS & COMPUTER DISPLAY ............ 6.4 LOW BRAKE PRESSURE WARNING .................... 6.39 MAIN SYSTEM ERRORS ....................................... 6.41 LX-A0 MODULE OFFLINE ERROR .................... 6.43 MDM MODULE BLANK SCREEN ........................ 6.41 MODULE IS OFFLINE ......................................... 6.41 XP2-A0 MODULE OFFLINE ERRORS ................ 6.45 XS-A0 MODULE OFFLINE ERROR ................... 6.42 XT2-A0 MODULE OFFLINE ERROR ................. 6.44 MAXIMUM TRAVEL SPEED (CM) .......................... 6.38 MEASURE MENU DESCRIPTION .......................... 6.22 MINIMUM CURRENT .............................................. 6.27 MODE MENU .......................................................... 6.21 MODE MENU DESCRIPTION ................................. 6.21 MODE MENU OPERATION .................................... 6.22 MODULE IS OFFLINE ............................................. 6.41 NO GEAR ENGAGED WARNING ........................... 6.36 NO MOTOR SPEED (CM) ....................................... 6.38 PARK BRAKE/LADDER DOWN WARNING ........... 6.35 PROPERTIES MENU .............................................. 6.27 PROPERTIES MENU OPERATION ........................ 6.27 SCHEMATIC L.H. JOYSTICK AND POD .................................. 6.5 R.H. JOYSTICK AND POD .................................. 6.7 XP2-A0 FRONT FRAME MODULE ..................... 6.15 XP2-A1 CRANE MODULE ................................... 6.17 XP2-A2 GRAPPLE MODULE .............................. 6.19 XT2-A0 ENGINE MODULE .................................. 6.13 SELECTING A FUNCTION TO ADJUST ................ 6.28 SETTINGS MENU ................................................... 6.24 SETTINGS MENU OPERATION ............................. 6.24 START/STOP SLOPE ............................................. 6.28 STEER CHECK ERROR (CM) ................................ 6.38 SYSTEM BYPASSED WARNING ........................... 6.37 SYSTEM COMPONENTS ....................................... 6.20 SYSTEM WARNING MESSAGES .......................... 6.35 THROTTLE AND BRAKE FOOT PEDALS .............. 6.8 TIRE ROLLING CIRCUMFERENCE ....................... 6.34 VOLTAGE WARNING ............................................. 6.40 WIRE COLOUR CODE CHART .............................. 6.48 WORKING RPM ...................................................... 6.33

Tigercat 1065/1075 Forwarder

Electrical & Computers

MDM COMPUTER DISPLAY AND CONTROL SYSTEM XS MODULE

••

JOYSTICK MODULES

• ••

DISPLAY MODULE

••

1014-i01.ai

Machine operation is controlled electronically by the MDM computer system. During operation of the electronic joysticks, foot pedals or control switches, the computer system provides integrated control of the engine, main pump, hydrostatic drive and all of the proportional valve functions.

The MDM display and control module (1) located in the L.H. Joystick Pod is connected in series to the L.H. Joystick (2), through the L.H. Joystick to the R.H. Joystick (3), through the R.H. Joystick to the CAN 1 terminal on the cab module (4 located in the R.H. upper cab roof compartment), the cab module is connected via the CAN 2 terminal to the engine module (5), frame and crane modules (6, 7 and 8).

The operator can view input and output information and enter function parameter settings for the engine, transmission and crane modules using the MDM Display Terminal.

SYSTEM COMPONENTS 5 1014-D018

The computer monitors and analyzes engine and transmission inputs and produces outputs (as defined in its program) to control the engine and drive functions.

4 6

The computer also monitors and analyzes inputs and produces outputs (as defined in its program) to control the machine proportional valve functions.

Proportional valve functions are:

3

7 2

8

•

Steering

•

Blade (if equipped)

•

Crane Rotate

•

Main Boom

•

Stick Boom

•

Telescope Boom

•

Grapple Rotate

•

Grapple Open/Close

•

Gate Up/Down

Inputs:

1

The computer monitors analogue, digital, and frequency inputs (CAN Bus inputs). CAN Bus is a data bus system that allows several input signals to be sent to the MDM through a reduced number of wires.

Outputs:

1. MDM Display/Control Module 2. L.H. Joystick 3. R.H. Joystick 4. (XS-A0) Cab Module

The computer directs a proportional output (24 Volt electrical current) to the solenoids on the steer valve, boom valve, main pump, drive pump, brake valve and controls engine RPM by sending appropriate signals to the engine’s control computer.

5. (XT2-A0) Engine Module 6. (XP2-A0) Front Frame Module 7. (XP2-A1) Crane Module 8. (XP2-A2) Grapple Module 6.2

Tigercat 1065/1075 Forwarder

Electrical & Computers

The IQAN MDM computer display is the operator interface with the IQAN control system. The IQAN MDM (master display module) is the central unit in the IQAN control system which works as both a master and a display unit. It has a backlit graphic LCD display. Three function buttons (F1, F2 and F3), a scrolling up/down button and an escape button are used by the operator to move through menus and adjust the settings of the IQAN control system.

GAUGES SWITCH

DISPLAY

F1

F2

F3

SCROLL UP/DOWN

MDM DISPLAY MODULE

••

1014-140

L.H. JOYSTICKS & COMPUTER DISPLAY

ESCAPE SWITCH

•

SYSTEM COMPONENT LOCATIONS

•

1065-003 1014-002

FUSE & RELAY COMPARTMENT IN CAB

L.H. JOYSTICKS & COMPUTER DISPLAY The GAUGES switch to the left of the IQAN-MDM display is used to select between the gauge menus and the diagnostic and function adjustment menus.

XT2-A0 ENGINE MODULE

••

Press the top of the GAUGES switch to display the gauge menus.

Press the bottom of the GAUGES switch to display the IQAN-MDM diagnostic and function adjustment menus.

Note: Whenever an alarm is activated, the gauge display menus are replaced with the alarm warning message. When the alarm function is cleared, diagnostic and function adjustment menus appear.

Press the top of the GAUGES switch to display the gauge menus.

Refer to IQAN MDM COMPUTER DISPLAY in SECTION 2 of the OPERATOR’S MANUAL for more information.

1014-137

L.H. SIDE ENGINE COMPARTMENT

XP2-A0 FRONT FRAME MODULE

XP2-A1 CRANE MODULE

••

••

XP2-A2 GRAPPLE MODULE

••

1014-139

REAR CHASSIS HYDRAULIC COMPARTMENT 6.3

Tigercat 1065/1075 Forwarder

Electrical & Computers MDM MODULE WIRING PIN ASSIGNMENT

COMPONENT REPLACEMENT MDM DISPLAY MODULE

•

••

RELEASE TABS

MDM MODULE REPLACEMENT

1014-035

1. Turn battery disconnect switch OFF. 2. Remove the bottom panel on the joystick pod to access the wiring and back of the MDM module.

3. Disconnect the wiring harness at the module.

4. Press the four tabs on the module (snap on attachment) and lift the module out of the control pod.

5. Install module in reverse order as removed.

NOTE: Refer to Tigercat Product Support Bulletin 1443 for procedure to Update the Application in an MDM Module.

REAR OF MDM MODULE 1014-031

6

5

2

5

3

1. CAN LOW

••

••

•• •

2. ALARM OUT

••

3. BATTERY GROUND 4. CAN HIGH 5. POWER SUPPLY - Real Time Clock

•• •• 1014-032

1

• 5

4

6. POWER SUPPLY

••

NOTE: Refer to the L.H. JOYSTICK and MDM MODULE wiring schematic and Electrical schematics in this section for detailed pin and wiring assignment.

5

The back of the MDM Module consists of the following:

DISPLAY MODULE

GAUGES SWITCH

1. Tag with serial number and part number.

2. RS-232 serial port, 8 pin for PC connection.

•

3. Voltage supply indicator. LED with green light ON indicates supply voltage is activated. LED light OUT indicates supply voltage is OFF.

•

•

STEERING JOYSTICK

• CRANE JOYSTICK

4. Main connector for voltage supply, CAN communication and alarm output.

5. Snap on attachment for mounting in panel.

1014-002

6. Membrane valve for condensation prevention inside unit.

L.H. JOYSTICKS & COMPUTER DISPLAY 6.4

Tigercat 1065/1075 Forwarder

Electrical & Computers

L.H. JOYSTICK and POD SCHEMATIC

TO R.H. JOYSTICK

TO R.H. JOYSTICK

1014-001.AI

STEERING JOYSTICK

1014-009

6.5

Tigercat 1065/1075 Forwarder

Electrical & Computers I.

COMPONENT REPLACEMENT CONT’D JOYSTICK MODULES XS MODULE

•

JOYSTICK MODULES

•• •

Status indicator LED. LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows:

DISPLAY MODULE

••

•

One flash indicates fault on inputs/outputs or that supply voltage is to low or to high.

•

Two flashes in a row indicates that the internal temperature of the unit is to high or to low.

•

Three flashes in a row indicates that the fault is related to the CAN-bus.

•

Four flashes in a row indicates an internal fault on the hardware of the unit.

•

Five flashes in a row indicates that the fault is related to the address.

•

Continuous flashing indicates the fault is related to software.

1014-IA1.AI

The R.H. and L.H. joystick module components are as follows:

Error code

Blink (red light)

I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

JOYSTICK MODULE WIRING PIN ASSIGNMENT

1014-039

A. Handle B. Rocker Switch C. Bellows D. Mounting Flange

•

E. Lower Body F.

C2 INPUT/OUTPUT CONNECTOR

C1 CAN-BUS CONNECTOR

••

C1 CAN-bus connector

G. C2 Input/Output connector H. Supply Voltage LED. LED with green light ON indicates supply voltage is ON. LED OFF indicates supply voltage is OFF.

1014-040

NOTE: Refer to the R.H. and L.H. JOYSTICK and MODULE Wiring Schematics and Electrical Schematics in this section for detailed pin and wiring assignment.

6.6

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Electrical & Computers

R.H. JOYSTICK and POD SCHEMATIC

TO L.H. JOYSTICK TO L.H. JOYSTICK TO XS-A0 CAB MODULE CAN 1 CONNECTOR TO XS-A0 CAB MODULE CAN 1 CONNECTOR

1014-010

6.7

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Electrical & Computers

THROTTLE AND BRAKE FOOT PEDALS 2

2

1

1

•

•

••

••

Pressing down on the foot pedal (1) activates the lever (2) connected to a potentiometer (3) which sends out a voltage signal (0 to 3.2 volts) to the cab module then to the MDM Display and Control Module that is proportional to pedal position.

Depending on which pedal is being operated the MDM Display and Control Module will activate or deactivate the service brakes or increase/decrease engine and travel speed.

1014-D007

FRONT FOOT PEDAL CONTROLS

1014-D008

REAR FOOT PEDAL CONTROLS

FOOT PEDAL CONTROLS The machine is equipped with two sets of electronic foot pedal controls. Front foot pedal controls and rear foot pedal controls. The operator’s seat can be rotated 225° from a forward facing position to a rearward facing position. The two sets of foot pedal controls provide the operator with throttle control (1) and brake control (2) with the seat in either position.

The seat position is monitored by a sensor located in the seat frame. The sensor provides the computer control with the seat position signal. The computer control activates or deactivates the foot pedal controls relative to the seat position. Refer to COMPUTER CONTROL FUNCTIONS in SECTION 2 for more detail.

AH082

FOOT PEDAL PIN ASSIGNMENT 1. PEDAL SS SIGNAL 2. POWER INPUT 3. OUTPUT SIGNAL

Note: The front and rear foot pedal controls operate 4. GROUND the same function, THROTTLE FOOT PEDAL (1) 5. POWER AND BRAKE FOOT PEDAL (2).

6. NOT USED

1

••

2

• 3

•• 4

1014-D154

•• FOOT PEDAL CONTROL

The foot pedal control consists of foot pedal (1), lever (2), potentiometer (3) and mounting plate (4).

The resistance of the potentiometer (3) in the neutral position (58° to 62°) is 1.4 kΩ and fully depressed (0°) is o.5 kΩ.

6.8

DT04-6P.AI

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Electrical & Computers

THROTTLE AND BRAKE FOOT CONTROL SCHEMATIC

1014-061.PLT

6.9

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Electrical & Computers

XS-A0 CAB MODULE COMPONENTS

XS-A0 CAB MODULE REPLACEMENT

XS-A0 CAB MODULE

••

1065-002

1014-038

A. Supply Voltage LED. LED OFF indicates supply voltage is OFF. LED ON solid green light indicates supply voltage is ON.

XS-A0 CAB MODULE

1. Turn battery disconnect switch OFF. 2. Open the top front compartment door.

3. Disconnect the wiring harness connectors on the module.

B. Arrow and Heart Status Indicator LEDs. LED for Heart and Arrow flash alternately (solid green) indicates Status is Correct.

When LED for Heart is out and LED for arrow flashes, this indicates the following errors: •

One flash indicates fault on inputs/outputs or that supply voltage is to low or to high.

•

Two flashes in a row indicates that the internal temperature of the unit is to high or to low.

•

Three flashes in a row indicates that the fault is related to the CAN-bus.

•

Four flashes in a row indicates an internal fault on the hardware of the unit.

1014-037

•

Five flashes in a row indicates that the fault is related to the address.

•

Continuous flashing indicates the fault is related to software.

Error code

4. Remove the two hex nuts and lift the module out.

Blink (red light)

I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

C. Connectors CAN1 and CAN2 for CAN-bus.

D. C1 connector for inputs and outputs.

1014-036

E. Module assembly.

NOTE: Refer to the XS-A0 CAB MODULE wiring schematic and Electrical schematics in this section for detailed pin and wiring assignment.

5. Reverse procedure to install module.

6.10

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Electrical & Computers

XS-A0 CAB MODULE SCHEMATIC

CAN HIGH TO R.H. JOYSTICK

CAN LOW TO ENGINE MODULE CAN HIGH TO ENGINE MODULE 1014-013

6.11

CAN LOW TO R.H. JOYSTICK

Tigercat 1065/1075 Forwarder

Electrical & Computers

XT2-A0 ENGINE MODULE

XT2-A0 MODULE WIRING PIN ASSIGNMENT

XT2-A0 ENGINE MODULE

••

1014-041

L.H. SIDE ENGINE COMPARTMENT

1014-137

XT2-A0 ENGINE MODULE LED INDICATORS 2 1

•• • XT2-AO MODULE LED INDICATORS

1014-042

1014-043

1. Supply Voltage LED. LED with green light ON indicates supply voltage is ON. LED OFF indicates supply voltage is OFF.

NOTE: Refer to the XT2-A0 ENGINE MODULE Wiring Schematic and Electrical Schematics in this section for detailed pin and wiring assignment.

2. Status indicator LED. LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows: •

One flash indicates fault on inputs/outputs or that supply voltage is to low or to high.

•

Two flashes in a row indicates that the internal temperature of the unit is to high or to low.

•

Three flashes in a row indicates that the fault is related to the CAN-bus.

•

Four flashes in a row indicates an internal fault on the hardware of the unit.

•

Five flashes in a row indicates that the fault is related to the address.

•

Continuous flashing indicates the fault is related to software.

Error code

Blink (red light)

I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

6.12

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Electrical & Computers

XT2-A0 ENGINE MODULE SCHEMATIC

1014-008

6.13

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Electrical & Computers

XP2-A0 FRAME MODULE XP2-A0 FRONT FRAME MODULE

XP2-A0 MODULE WIRING PIN ASSIGNMENT

XP2-A1 CRANE MODULE

•

•

XP2-A2 GRAPPLE MODULE

••

1014-041 1014-139

REAR CHASSIS HYDRAULIC COMPARTMENT XP2-A0 FRAME MODULE LED INDICATORS 2 1

• • 1014-043

XP2-AO MODULE LED INDICATORS

1014-042

NOTE: Refer to the XP2-A0 FRAME MODULE Wiring Schematic and Electrical Schematics in this section for detailed pin and wiring assignment.

1. Supply Voltage LED. LED with green light ON indicates supply voltage is ON. LED OFF indicates supply voltage is OFF. 2. Status indicator LED. LED yellow flashing light indicates status is correct. .

LED flashing red light indicates error status as follows: •

One flash indicates fault on inputs/outputs or that supply voltage is to low or to high.

•

Two flashes in a row indicates that the internal temperature of the unit is to high or to low.

•

Three flashes in a row indicates that the fault is related to the CAN-bus.

•

Four flashes in a row indicates an internal fault on the hardware of the unit.

•

Five flashes in a row indicates that the fault is related to the address.

•

Continuous flashing indicates the fault is related to software.

Error code

Blink (red light)

I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

6.14

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Electrical & Computers

XP2-A0 FRONT FRAME MODULE SCHEMATIC

1014-014

6.15

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Electrical & Computers

XP2-A1 CRANE MODULE XP2-A0 FRONT FRAME MODULE

XP2-A1 MODULE WIRING PIN ASSIGNMENT

XP2-A1 CRANE MODULE

•

•

XP2-A2 GRAPPLE MODULE

••

1014-041 1014-139

REAR CHASSIS HYDRAULIC COMPARTMENT XP2-A1 CRANE MODULE LED INDICATORS 2 1

• • 1014-043

XP2-A1 MODULE LED INDICATORS

1014-042

NOTE: Refer to the XP2-A1 CRANE MODULE Wiring Schematic and Electrical Schematics in this section for detailed pin and wiring assignment.

1. Supply Voltage LED. LED with green light ON indicates supply voltage is ON. LED OFF indicates supply voltage is OFF. 2. Status indicator LED. LED yellow flashing light indicates status is correct. .

LED flashing red light indicates error status as follows: •

One flash indicates fault on inputs/outputs or that supply voltage is to low or to high.

•

Two flashes in a row indicates that the internal temperature of the unit is to high or to low.

•

Three flashes in a row indicates that the fault is related to the CAN-bus.

•

Four flashes in a row indicates an internal fault on the hardware of the unit.

•

Five flashes in a row indicates that the fault is related to the address.

•

Continuous flashing indicates the fault is related to software.

Error code

Blink (red light)

I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

6.16

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Electrical & Computers

XP2-A1 CRANE MODULE SCHEMATIC

1014-011

6.17

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Electrical & Computers

XP2-A2 GRAPPLE MODULE XP2-A0 FRONT FRAME MODULE

XP2-A2 MODULE WIRING PIN ASSIGNMENT

XP2-A1 CRANE MODULE

•

•

XP2-A2 GRAPPLE MODULE

••

1014-041 1014-139

REAR CHASSIS HYDRAULIC COMPARTMENT XP2-A2 GRAPPLE MODULE LED INDICATORS 2 1

• • 1014-043

XP2-A2 MODULE LED INDICATORS

1014-042

NOTE: Refer to the XP2-A2 GRAPPLE MODULE Wiring Schematic and Electrical Schematics in this section for detailed pin and wiring assignment.

1. Supply Voltage LED. LED with green light ON indicates supply voltage is ON. LED OFF indicates supply voltage is OFF. 2. Status indicator LED. LED yellow flashing light indicates status is correct. .

LED flashing red light indicates error status as follows: •

One flash indicates fault on inputs/outputs or that supply voltage is to low or to high.

•

Two flashes in a row indicates that the internal temperature of the unit is to high or to low.

•

Three flashes in a row indicates that the fault is related to the CAN-bus.

•

Four flashes in a row indicates an internal fault on the hardware of the unit.

•

Five flashes in a row indicates that the fault is related to the address.

•

Continuous flashing indicates the fault is related to software.

Error code

Blink (red light)

I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

6.18

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Electrical & Computers

XP2-A2 GRAPPLE MODULE SCHEMATIC

1014-012

6.19

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Electrical & Computers

COMPUTER DISPLAY AND CONTROL SYSTEM COMPONENTS

2 1

3 10

4

9

8 7

1. Display Module

6

2. XT2-A0 Engine Module

5

3. XS-A0 Cab Module 4. R.H. Joystick 5. XP2-A0 Frame Module 6. XP2-A1 Crane Module 7. XP2-A2 Grapple Module 8. Foot Pedals 9. L.H. Joystick 10. Steering Joystick

1014-01 PLT. DWGPB

COMPUTER DISPLAY AND CONTROL SYSTEM COMPONENT LOCATION

6.20

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Electrical & Computers

SYSTEM DIAGNOSTICS AND FUNCTION ADJUSTMENT MENUS DISPLAY GAUGES SWITCH

•

•

1014-002

1014-D001B

L.H. JOYSTICKS & COMPUTER DISPLAY

Press the ESCAPE button to display one of 5 menus (MODE, INFORMATION, SETTINGS, MEASURE AND PROPERTIES) that access system diagnostics and function adjustment menus. Use the up and down arrow buttons to scroll through the menus. Use the “F1, F2, and F3 buttons to select the highlighted boxes located above the buttons in the LCD display.

Press the bottom of the GAUGES switch to display the IQAN-MDM system diagnostics and function adjustment menus.

TIME

MACHINE MODEL AND SOFTWARE VERSION

•

• •• •• F1 BUTTON

1014-D157

OPERATOR MODE

DATE

•• •• F2 BUTTON

•

SCROLL BUTTON

•• ••

F3 BUTTON

ESCAPE BUTTON

MDM COMPUTER MODULE

The display should show the current date, time, operator mode, machine model number and software version identification.

1014-D94

1. MODE MENU DESCRIPTION A. One of 4 operator modes can be selected.

Each operator mode can be djusted by the individual operator.

B. Operator modes can be copied from one mode to another.

C. Operator modes can also be reset to factory defaults in this menu.

6.21

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Electrical & Computers

1014-D097

1014-D095

2. INFORMATION MENU DESCRIPTION

4. MEASURE MENU DESCRIPTION

This menu is for trained service technicians only. See Service Manual for detailed information.

A. Input and output VOLTAGE and CURRENT can be measured.

B. J1939 CANBUS DATA can be viewed.

See Service Manual for detailed information.

WARNING Do not make adjustments in this menu.

Machine warning alarms can be disabled in this menu.

1014-D098

5. PROPERTIES MENU DESCRIPTION Adjustable machine functions can be changed for the current operator mode.

1014-D096

3. SETTINGS MENU DESCRIPTION

••

A. Display CONTRAST and BRIGHTNESS can be adjusted.

CURRENT OPERATOR MODE (1)

B. Computer SOUND volumes can be adjusted.

C. Computer DATE and TIME can be adjusted.

1014-D094

D. The LANGUAGE that the text is displayed in can be selected.

1. MODE MENU OPERATION The crane, steering, gate and blade function speeds and start/stop ramps can be adjusted by the operator. The settings can be saved for up to 4 different operators. These are called modes.

The settings in one mode can be copied to another mode. A mode can also be reset to factory default settings.

The machine is shipped from the factory with default settings in modes 1 through 4.

6.22

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Electrical & Computers

SELECTING AN OPERATOR MODE DESIRED OPERATOR MODE (4)

• 1014-D103

Press the F1 button located under the “OK” box in the LCD display. The current mode settings have now been copied to the selected mode number.

1014-D099

Press the F1 button located under the “SELECT” box in the LCD display.

Press the UP or DOWN arrow button to change the mode number to the desired mode number.

RESETTING THE CURRENT OPERATOR MODE

Press the F1 button located under the “OK” box in the LCD display.

••

CURRENT OPERATOR MODE (4)

1014-D104

Press the F3 button located under the RESET box in the LCD display.

1014-D101

The current forwarder operator mode number in the upper right corner of the display should now show the new mode number (4). The settings in the displayed mode number will now control the crane, steering, gate and blade functions.

COPYING THE CURRENT OPERATOR MODE 1014-D105

Press the F1 button located under the “OK” box in the LCD display. The current mode (1) settings have now been RESET to the preset factory default settings.

1014-D102

Press the F2 button located under the COPY box in the LCD display.

Press the UP or DOWN arrow button to select the mode that the current mode will be copied to.

6.23

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Electrical & Computers

2. SETTINGS MENU OPERATION

CHANGE LIGHT

The computer sound volume, display contrast, light, date, time and language can be adjusted in this menu.

CHANGE CONTRAST

1014-D106

Press LIGHT (F2) to select the function LCD LIGHT. 1014-D096

Press LCD (F1) to select LCD SETTINGS.

1014-D108

Change to desired BRIGHTNESS using UP/ DN and press OK (F1) to save setting and return to previous menu.

1014-D106

Cancel (F2) or ESC returns the character window to the previous window without saving any new setting.

Press CONTRAST (F1) to select the function LCD CONTRAST.

Reset Light RESET (F3) resets the character window’s light to the preset factory value which corresponds to 100.

1014-D107

Change to desired CONTRAST using UP/DN and press OK (F1) to save setting and return to previous menu.

Cancel (F2) or ESC returns the character window to the previous window without saving any new setting.

Reset Contrast RESET (F3) resets the character window’s contrast to the preset factory value which corresponds to 30.

6.24

Tigercat 1065/1075 Forwarder

Electrical & Computers CHANGE ALARM VOLUME

LANGUAGE SETTINGS

•

Change LANGUAGE on Menu Text.

1014-D112

Press ALARM (F1) to select the function for setting the volume for the alarm signal.

1014-D096

CHANGE LANGUAGE Press LANGUAGE (F2) to select the function LANGUAGE.

1014-D111

Change to desired VOLUME using UP/DN. There are Ten volume levels. 0 implies that sound is turned OFF. 100 is the loudest.

Thereafter, press OK (F1) to save setting and return to previous menu.

1014-D109

Change to desired LANGUAGE using UP/ DN and press OK (F1) to save setting and return to previous menu.

Cancel (F2) or ESC returns the character window to the previous menu without saving any new setting.

Cancel (F2) or ESC returns the character window to the previous window without saving any new setting.

Reset the Volume RESET (F3) resets the alarm volume to the preset factory value which corresponds to 50.

SOUND SETTINGS •

Adjusting BUZZER VOLUME and change BUTTON SOUND.

CHANGE BUTTON SOUND

1014-D110

1014-D110

To shift to the tab SOUND, press MORE (F3).

Press SOUND (F1) to select the function SOUND SETTINGS.

Press SOUND (F1) to select the function SOUND SETTINGS.

6.25

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Electrical & Computers

CHANGE BUTTON SOUND CONT’D

1014-D110

Press SET CLOCK (F2) to select the function for setting the DATE and TIME.

1014-D112

Press BUTTON (F2) to select the function to change the button sound.

1014-D114

Browse using UP/DN and thereafter press SELECT (F1) to select alternative from list.

1014-D113

Change to desired BUTTON SOUND using UP/DN. There are Ten button beep levels. 0 implies that the button beep is turned OFF. 100 is the loudest. Thereafter, press OK (F1) to save setting and return to previous menu.

YEAR - MONTH - DAY - HOUR - MINUTE

Cancel (F2) or ESC returns the character window to the previous menu without saving any new setting.

Reset the Button Sound Level RESET (F3) resets the button sound level to the preset factory value which corresponds to 50.

1014-D115

Change to desired value using UP/DN and press OK (F1) to save setting and return to previous menu.

DATE TIME SETTINGS •

Setting DATE and TIME.

Cancel (F2) or ESC returns the character window to the previous menu without saving any new setting.

1014-D096

To shift to the tab SET CLOCK, press MORE (F3).

6.26

Tigercat 1065/1075 Forwarder

Electrical & Computers CURRENT OUTPUT SETTINGS DESCRIPTION There are five different settings of minimum and maximum current for a current output. These settings (defined below) fine tune the operating speeds and start/stop ramps for the crane, steering, gate and blade functions.

MINIMUM CURRENT

1014-D098

3. PROPERTIES MENU OPERATION Changes can be made to the settings for adjustable machine functions. Adjustments will only affect the settings in the current operator mode.

Press F2 OUTPUTS to select CURRENT OUTPUT menu. Adjustments in this menu are:

1014-DMIN

•

STEERING FORWARD

•

STEERING REVERSE

•

BLADE

•

CRANE SLEW

•

MAIN BOOM

•

STICK BOOM

•

TELESCOPE

•

GRAPPLE ROTATE

•

GRAPPLE OPEN/CLOSE

•

GATE UP/DOWN

•

CRANE TILT

•

PUMP (+) FORWARD BEGIN OF REG

•

PUMP (-) REVERSE BEGIN OF REG

•

MOTOR MIN CURRENT BEGIN OF REG

•

MOTOR MAX CURRENT END OF REG

Minimum current settings control function start speed. Coils on hydraulic valves require a certain amount of current before they begin to operate the valve. The Min current value is the current that will be sent to the hydraulic valve coil when the joystick is moved a very small amount.

The min current is adjusted to a value that causes the function to just begin to move.

MAXIMUM CURRENT

Press F3 OTHER to select FUNCTION PARAMETERS menu. Adjustments in this menu are: •

WORKING RPM

•

CRANE MAXIMUM SPEED

•

TIRE ROLLING CIRCUMFERENCE

•

MOTOR SPEED BYPASS

•

GEAR CHANGE OUTPUT

•

BLADE ON/OFF

1014-DMAX

Maximum current settings control the maximum speed the function will operate.

NOTE: See CURRENT OUTPUT, START/STOP SLOPE AND FINE CONTROL DEFAULT SETTING VALUES at the end of this section.

Select scroll UP button to view PWM OUTPUT. There are no adjustable functions in this menu.

6.27

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Electrical & Computers

CURRENT OUTPUT SETTINGS DESCRIPTION

SELECTING A FUNCTION TO ADJUST

START/STOP SLOPE

There are two methods of selecting a function for adjustment: 1) Manual Selection or 2) Direct Selection 1. MANUAL SELECTION

1014-DSTOP

Start and stop slope is the time it will take for the current to rise from minimum to maximum and maximum to minimum respectively.

1014-D098

Press F2 OUTPUTS to choose CURRENT OUT menu.

FINE CONTROL

CURRENT OUT

1014-D121

Press F1 SELECT to display SELECT FUNCTION menu.

1014-DFINE

SELECT FUNCTION

Fine Control changes the current output to joystick position curve from being a straight line to being close to a type of curved line. Lower numbers make the first 50% of joystick movement create more output. Higher numbers make the first 50% of joystick movement create less output.

MANUAL

1014-D121

CURRENT OUT ADJUSTMENTS

Press F3 MANUAL to display the adjustable functions.

With the seat facing the crane, start the engine and set the CRANE/BLADE switch to WORKING RPM. The hydraulic system must be warmed up before making any adjustments. See SYSTEM TEST AND WARM-UP procedure in this section.

All functions in this menu adjust in the same way.

MAIN BOOM UP function has been chosen as an example.

These functions can be reset to the factory defaults using the reset feature in the MODE menu.

1014-D133

Use UP/DN buttons to scroll to desired function.

6.28

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Electrical & Computers

CURRENT OUT

1014-D121

1014-D121

Press F1 SELECT to display SELECT FUNCTION menu.

Press F1 SELECT (+) to select the BOOM UP function for adjustment. (NOTE: Pressing the F2 SELECT (-) selects the BOOM DOWN function.)

MIN CURRENT (+) MAIN BOOM OK

MANUAL

360

mA

CANCEL

1014-D187

Operate the BOOM UP joystick to select it for adjustment.

1014-D121

Use the UP/DN buttons to select desired adjustment, Min Current, Max Current, Start Slope, Stop Slope or Fine Controls. See CURRENT OUTPUT SETTINGS DESCRIPTION in this Section.

Shown above MIN CURRENT (+) MAIN BOOM UP function has been selected.

1014-D186

2. DIRECT SELECTION

(+) Main Boom appears in the display. Press F1 “SELECT” to confirm selection of boom up.

1014-D098

Press F2 OUTPUTS to choose CURRENT OUT menu.

1014-D134

Use the UP/DN buttons to select desired adjustment, Min Current, Max Current, Start Slope, Stop Slope or Fine Controls. See CURRENT OUTPUT SETTINGS DESCRIPTION in this Section.

Shown above MIN CURRENT (+) MAIN BOOM UP function has been selected.

6.29

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Electrical & Computers

MIN CURRENT SETTING

MIN CURRENT (+) MAIN BOOM OK

365

mA

CANCEL

1014-D121 1014-D134

1. Use the UP/DN buttons to scroll to the MIN CURRENT adjustment menu. Press F1 SELECT.

5. While holding the BOOM UP function ON, use the UP/DN button to decrease the MIN CURRENT value until the Boom function just stops moving.

6. Press OK (F1) to save and return to previous menu.

MIN CURRENT (+) MAIN BOOM OK

Pressing CANCEL (F2) or ESC returns the display to the previous menu without saving any changed value.

250

mA

CANCEL

The MIN CURRENT value has now been saved.

1014-D121

2. Use UP/DN buttons to adjust the MIN CURRENT to a value of 250ma.

3. Slowly operate BOOM UP joystick to full on position. The boom should not move.

MIN CURRENT (+) MAIN BOOM OK

370

mA

CANCEL

1014-D121

4. While holding the BOOM UP function ON, use the UP/DN button to increase the MIN CURRENT value until the Boom function just begins moving.

6.30

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Electrical & Computers

MAX CURRENT SETTING

MAX CURRENT (+) MAIN BOOM

START SLOPE SETTING

STARTSLOPE

625

mA

(+) MAIN BOOM

SELECT

1014-D121

ms

1014-D121

1. Scroll using UP/DN buttons to select MAX CURRENT menu. Press F1 SELECT.

MAX CURRENT (+) MAIN BOOM OK

450

SELECT

1. Scroll using UP/DN buttons to select START SLOPE menu. Press F1 SELECT.

STARTSLOPE

625

(+) MAIN BOOM

mA

OK

CANCEL

450

ms

CANCEL

1014-D121

1014-D121

2. Shown above MAX CURRENT (+) MAIN BOOM UP function has been selected.

2. Shown above START SLOPE (+) MAIN BOOM UP function has been selected.

3. With the engine running at Working RPM, adjust the MAX CURRENT value using the UP/DN buttons to increase (speed up boom speed) or decrease (slow down boom speed) value. Pull the Boom Up joystick back to its maximum position to test boom speed.

3. With the engine running at Working RPM, adjust the START SLOPE value using the UP/ DN buttons to adjust acceleration rate by increasing or decreasing value. Pull the Boom Up joystick back to test ACCELERATION speed.

4. Continue to adjust the MAX CURRENT value using the UP/DN buttons until the desired speed is obtained.

4. Continue to adjust the START SLOPE value using the UP/DN buttons until the desired ACCELERATION is obtained.

5. Press OK (F1) to save and return to previous menu.

5. Press OK (F1) to save and return to previous menu.

Pressing CANCEL (F2) or ESC returns the display to the previous menu without saving any changed value.

Pressing CANCEL (F2) or ESC returns the display to the previous menu without saving any changed value.

The MAX CURRENT value has now been saved.

The START SLOPE value has now been saved.

6.31

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Electrical & Computers

STOP SLOPE SETTING

FINE CONTROL SETTING

1014-D188

1014-D189

1. Scroll using UP/DN buttons to select STOP SLOPE menu and press F1 to select (+) MAIN BOOM.

STOPSLOPE (+) MAIN BOOM OK

1. Scroll using UP/DN buttons to select FINE CONTROL menu and press F1 to select (+) MAIN BOOM.

FINE CONTROL

600

(+) MAIN BOOM

ms

OK

CANCEL

60

%

CANCEL

1014-D121

1014-D121

2. Shown above STOP SLOPE (+) MAIN BOOM UP function has been selected.

2. Shown above FINE CONTROL (+) MAIN BOOM UP function has been selected.

3. With the engine running at Working RPM, adjust the STOP SLOPE value using the UP/ DN buttons to adjust deceleration rate by increasing or decreasing value. Pull the Boom Up joystick back and release to test DECELERATION speed.

3. With the engine running at Working RPM, adjust the FINE CONTROL value using the UP/DN buttons to adjust CONTROL by increasing or decreasing value. Pull the Boom Up joystick back to test CONTROL. 4. Continue to adjust the FINE CONTROL value using the UP/DN buttons until the desired CONTROL is obtained.

4. Continue to adjust the STOP SLOPE value using the UP/DN buttons until the desired DECELERATION is obtained.

5. Press OK (F1) to save and return to previous menu.

5. Press OK (F1) to save and return to previous menu.

Pressing CANCEL (F2) or ESC returns the display to the previous menu without saving any changed value.

Pressing CANCEL (F2) or ESC returns the display to the previous menu without saving any changed value.

The FINE CONTROL value has now been saved.

The STOP SLOPE value has now been saved.

6.32

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Electrical & Computers

FUNCTION PARAMETERS SETTINGS

BLADE ON/OFF

1014-D098

From the PROPERTIES main menu, press F3 OTHER to select FUNCTION PARAMETERS menu.

Blade On/Off is used to allow the blade to function when the optional blade is installed.

When the value is 0, the blade outputs won’t operate. This is done to provide a common program for machines with or without blades.

If the blade on/off is left on (value of 1) when no blade is installed, and the operator tries to operate the blade, alarms and messages will activate to indicate there is a problem with the blade (even though there isn’t one). Use the UP/Down buttons to change value to 0 to avoid unnecessary alarms.

1014-D122

WORKING RPM

Press F1 SELECT to display SELECT FUNCTION menu.

WORKING RPM is the constant engine speed setting that will occur when crane WORKING RPM is selected and operator is facing the crane.

Use the UP/DN buttons to scroll through the menu. Press F1 SELECT to select function.

1014-D127

Use the UP/DN buttons to scroll to the WORKING RPM menu. Press F1 SELECT to select function.

MOTOR SPEED BYPASS The Motor Speed Bypass value has a default value of 1. The only valid values are 1 and 0.

1 means the drive motor speed sensor functions as normal. When the value is changed to 0, the drive system bypasses the motor speed sensor value. This makes the drive very slow to respond. It is intended to be used only when there is a failure of the motor speed sensor. Motor Speed Bypass is displayed when there is a possible failure of the motor sensor. Use the UP/Down buttons to change the parameter to 0.

continued on next page

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Tigercat 1065/1075 Forwarder

Electrical & Computers GEAR CHANGE OUTPUT %

1014-D128

Use the UP/DN buttons to scroll to the desired idle speed. Range is 1250 rpm to 1800 rpm, factory default setting is 1450 rpm.

1014-D190

When a gear change is taking place, the drive motor is rotated forward and reverse to allow the transmission gears for the selected speed range to engage. The gear change output is the percent of maximum pump flow that is used to rotate the drive motor during the gear change.

Press OK (F1) to save and return to previous menu.

CRANE SPEED

TIRE ROLLING CIRCUMFERENCE

1014-D132

CRANE SPEED PERCENT is a single adjustment that will reduce the maximum crane speeds of all the crane functions (except grapple open or close). The new speeds will be the maximum speed setting of each crane function multiplied by the percentage displayed.

1014-D129

For accurate reading of speed and distance, use the UP/DN buttons to scroll to the TIRE ROLLING CIRCUMFERENCE menu. Press F1 SELECT to select function.

Use the UP/DN buttons to scroll to the CRANE SPEED menu. Press F1 SELECT to select function.

Use the UP/DN buttons to scroll to the desired % of MAX CRANE SPEED. Press OK (F1) to save and return to previous menu.

1014-D130

Use the UP/DN buttons to scroll to the desired TIRE ROLLING CIRCUMFERENCE. TIRE ROLLING CIRCUMFERENCE SPECIFICATIONS TIRE SIZE

6.34

CIRCUMFERENCE

600/55-26.5

3995

650/65-26.5

4398

700/50-26.5

4036

750/55-26.5

4398

Tigercat 1065/1075 Forwarder

Electrical & Computers

SYSTEM WARNING MESSAGES

1014-D039

3. PILOT RESET WARNING

1014-D032

1. ENGINE TEMPERATURE WARNING

This warning will be displayed and Pilot Reset Indicator Light will turn on if an attempt is made to drive or operate the machine with no pilot reset. The alarm, warning lights and message will be displayed.

This warning will be displayed and warning light will activate when engine temperature exceeds 101°C (214°F). The WARNING MESSAGE will be displayed, WARNING LIGHT will activate and ALARM will sound when engine temperature exceeds 105°C (221°F).

If doors are open or the ladder down/park brake switch “ON” position is selected, the pilot can’t be reset (proximity switches sense doors are open) and machine won’t operate.

When this alarm is activated check for plugged air intake access panel screens or plugged radiator. DO NOT continue to operate machine. Refer to CLEANING A/C CONDENSER, OIL COOLER, RADIATOR and AIR CHARGE COOLER in THIS SECTION.

If door opens while machine is moving (or switch fails), the alarm, warning lights and message will be displayed but functions are allowed to continue until machine stops, then outputs are shut-off.

Close the doors and press Pilot Reset Switch to resume machine operation.

1014-D033

2. HYDRAULIC OIL TEMPERATURE WARNING

1014-D198

This warning will be displayed, warning light will activate and alarm will sound when the oil temperature exceeds normal operating temperatures 84°C (183°F).

4. PARK BRAKE/LADDER DOWN WARNING This warning will be displayed, and warning alarm will sound when the ladder is down and/ or parking brakes are on and the pilot system is on.

If the temperature goes above 84°C (183°F) check the following:

Check that the LADDER is fully UP and the PARK BRAKE LEVER is fully OFF to deactivate this warning.

• Plugged oil cooler • Malfunction in a hydraulic system • High loads on the hydraulic system • Low hydraulic oil level Operation above 84°C (183°F) will shorten hydraulic component life. If the temperature reaches 84°C (183°F) DO NOT continue to operate the machine.

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Electrical & Computers

1014-D030

1014-D045

7. WARNING

5. GEAR NOT ENGAGED WARNING

When an alarm is displayed and “BYPASS” is selected this message will be displayed.

Pressing “OK” when this message is displayed will remove the message from the display. The warning lights will stay on until the alarm condition is corrected.

This warning will be displayed, warning light will activate and alarm will sound when the transmission is not in the requested gear range.

When this alarm ocurrs, the transmission gear switch may be in second gear but second gear is not engaged, or the switch may be in first gear but first gear is not engaged.

When this alarm is activated, change gear selection to engage another drive gear and stop alarm. If bypass is selected, warning lights will remain on and gear selected will be assumed by computer.

If this alarm continues investigate cause, refer to DRIVE SECTION of the Service Manual.

1014-D116

6. GEAR CHANGE WARNING This warning will be displayed, the warning and alarm will sound when transmission gear change is attempted.

STOP machine travel to complete the gear change.

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CONDITIONAL MESSAGES (CM) Conditional messages give the operator information regarding an event or problem condition while the event or problem exists. If the event or condition disappears, so will the message and alarm.

1014-D164

2. CRANE START (CM) If any crane joystick input is high (joystick activated) when crane switch is turned on, Crane Input Is Active message is displayed.

Release the joystick to deactivate the input to operate the crane.

1014-D031

If the operator presses “OK” on the MDM, the message will disappear even if the problem still exists. When this alarm is activated investigate the cause. Refer to ELECTRICAL AND COMPUTER SECTION of Service Manual.

1014-D040

3. DRIVE START (CM) If the drive pedal input is high (pedal activated) before pilot is reset, Drive Pedal Input Is Active message is displayed. Drive is prevented until the pedal is released.

1014-D030

Release the pedal to deactivate the input to enable the drive function.

1. SYSTEM BYPASSED WARNING When an alarm is bypassed, as long as the fault is still active, this warning will be displayed, alarm warning light will flash and horn will sound every 30 seconds.

When this alarm is activated investigate the cause immediately. Once the fault is fixed, warning deactivates and bypass is stopped.

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Electrical & Computers

CONDITIONAL MESSAGES (CM) CONTINUED

1014-D050

7. ENGINE OVERSPEED (CM) 1014-D048

This warning will be displayed, warning light will activate and alarm will sound if the engine speed exceeds the maximum desired speed.

5. STEER CHECK ERROR (CM) This warning will be displayed, warning light will activate and alarm will sound if dual steering joystick outputs don’t match.

When this alarm is activated apply the brakes to slow the machine down.

This condition has no bypass option. Alarm and message will remain on display and steering function will be disabled until fault is fixed.

When this alarm is activated investigate the cause immediately. Refer to the Electrical and Computer Section of the Service Manual.

8. MAXIMUM TRAVEL SPEED (CM) When adjusting the maximum travel speed of the machine, a bar graph appears indicating the current percent of maximum travel speed setting.

This adjustment is used for Travel Crawl Speed setting to control maximum travel speed when travelling over uneven and rough terrain.

1014-D165

6. NO MOTOR SPEED (CM) This warning will be displayed, warning light will activate and alarm will sound when the drive pump has an output, but the drive motor speed measures 0 RPM.

Note: Refer to TRAVEL SPEED SETTING in THIS SECTION.

If the machine is in motion, this condition can be bypassed by holding the pilot reset switch on momentarily to allow machine to be driven temporarily so fault can be fixed. See FUNCTION PARAMETERS SETTINGS earlier in this section to turn alarm OFF. When this alarm is activated investigate the cause immediately. Refer to the Service Manual Drive Section.

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Electrical & Computers

1014-D158

1014-D160

11. HYDRAULIC OIL LEVEL WARNING (CM)

9. BRAKE PRESSURE WARNING (CM)

This warning will be displayed, warning light will activate and alarm will sound when the main hydraulic tank oil level is low.

This warning will be displayed, warning light will activate and alarm will sound when brake pressure falls below 40bar (580 psi). Stop the engine when this alarm is activated. Check brake system. See OPERATING MACHINE in this SECTION for more information.

Stop the engine immediately when this alarm is activated. Operating machine with a low hydraulic oil level can cause hydraulic pumps to fail.

When this alarm is activated stop the engine and look for signs of broken hoses or other leaks. Repair leaks and refill the main hydraulic tank to FULL mark on the sight gauge. Restart engine and inspect for leaks.

1014-D159

10. ENGINE OIL PRESSURE WARNING (CM) This warning will be displayed, warning light will activate and alarm will sound when engine oil pressure falls below 1.03 bar (15 psi) at Low Idle or 2.07 bar (30 psi) at High Idle. Stop the engine when this alarm is activated.

Check engine oil levels. See OPERATING MACHINE in this SECTION for more information.

1014-D162

12. AIR FILTER RESTRICTION WARNING (CM) This warning will be displayed, warning light will activate and alarm will sound when the engine air filter restriction exceeds 6.2 kPa (25” H2O).

Stop the engine immediately when this alarm is activated and service the air cleaner. See AIR CLEANER MAINTENANCE in Section 3 of this manual.

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Electrical & Computers

CONDITIONAL MESSAGES (CM) CONTINUED WARNING DO NOT remove the radiator cap when the engine is hot, release of pressurized coolant can cause serious burns.

Shut off engine. Only remove engine radiator filler cap when cool enough to touch with bare hands.

Slowly loosen cap to first stop to relieve pressure before removing completely.

1014-D163

14. FUEL LEVEL WARNING (CM) This warning will be displayed, warning light will activate and alarm will sound when fuel level drops below 10%.

When this alarm is activated it can be bypassed, alarm and warning lights will remain on until machine is refuelled and fuel level is above 10%.

1014-D161

13. COOLANT LEVEL WARNING (CM) This warning will be displayed, warning light will activate and alarm will sound when the coolant level drops below a safe operating level. The sensor is located in the radiator surge tank. If this light comes on when the engine is running, stop the engine immediately and correct the fault. With engine running, top up radiator using correct solution of coolant antifreeze.

1014-D158

15. VOLTAGE WARNING (CM) This warning will be displayed, warning light will activate and alarm will sound when voltage readings of less than 20 volts or greater than 28 volts are detected.

When this alarm is activated investigate the cause immediately.

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Electrical & Computers

MAIN SYSTEM ERRORS

MODULE IS OFFLINE

MDM MODULE BLANK SCREEN

The MODULE IS OFFLINE warning message indicates a loss of communication with or power to an IQAN module. The offline module is identified on the display screen.

The MDM module is the central unit in the IQAN control system, which works as both a master and a display unit. Faults or failure in this unit will affect all other IQAN components.

Likely causes are: • Power - Fuse (MDM BATTERY or MDM CLOCK) • Ground • LCD display settings too light to read • Faulty MDM module

When a module goes offline all machine functions controlled by that module cease and all alarms and warnings associated with that module are triggered. If the problem is with the CAN wires all modules beyond the problem module will also be affected.

NOTE: It is possible for an operator or service technician to disable this warning message. If the MODULE IS OFFLINE warning function is disabled for a module the first indication of a loss of communication or power to a module will be the loss of all machine functions controlled by the module and the triggering of all alarms and warnings associated with that module. This may cause problems in identifying the source of a control problem, as it will not be immediately obvious that a loss of communication or power to the module is the source of the problem.

To greatly reduce the time required to diagnose a MODULE IS OFFLINE warning, it is recommended that all available modules ALWAYS be set to ENABLED as shown. This screen is accessed through the INFORMATION MENU, which should normally be accessed by Tigercat service technicians only. Refer to INFORMATION CENTER~SYSTEM DIAGNOSTICS MENUS~DIAGNOSTICS MENU OPERATION inTHIS SECTION.

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Electrical & Computers

XS-A0 MODULE OFFLINE ERROR Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN

1014-038

2. CHECK MODULE STATUS INDICATORS

Press OK to acknowledge each error message. Note that module offline errors will be followed by other alarm messages associated with the module(s) which is(are) offline.

Status lights can also give an immediate indication of the nature of the error.

Supply Voltage LED. LED ON solid green light indicates supply voltage is ON.

If XS-A0 MODULE IS OFFLINE is the only module is offline error message the likely causes are:

LED OFF indicates supply voltage is OFF. Arrow and Heart Status Indicator LEDs.

• Power - Fuse (XS MODULE)

LED for Heart and Arrow flash alternately (solid green) indicates Status is Correct.

• Ground

When Heart LED is off and LED for arrow flashes (green), this indicates the following errors:

• Address (ID-Tag) If the XS-A0 MODULE IS OFFLINE is followed by LX-A0, XT2-A0 and XP2-A0 MODULE IS OFFLINE errors the likely cause is: • CAN wire connection

•

One flash indicates fault on inputs/outputs or that supply voltage is to low or to high.

•

Two flashes in a row indicates that the internal temperature of the unit is to high or to low.

•

Three flashes in a row indicates that the fault is related to the CAN-bus.

•

Four flashes in a row indicates an internal fault on the hardware of the unit.

XS Module Error code I/O and voltage errors Low/High temperature CAN error VREF error

6.42

Blink (Arrow only green light)

Tigercat 1065/1075 Forwarder

Electrical & Computers

LX MODULE OFFLINE ERROR Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN Press OK to acknowledge each error message. Note that module offline errors will be followed by other alarm messages associated with the module(s) which is(are) offline.

1014-039

LX-, XP2- and XT2- module

If LX-A0 MODULE IS OFFLINE is the only module is offline error message the likely causes are:

Error code

• Power - Fuse (JOYSTICK)

CAN error

Low/High temperature

Hardware error

• Ground

Address error

• Address (ID-Tag)

Software error

If the XS-A0 MODULE IS OFFLINE is followed by XT2-A0 and XP2-A0 MODULE IS OFFLINE errors the likely cause is:

• •

• CAN wire connection •

2. CHECK MODULE STATUS INDICATORS Status lights can also give an immediate indication of the nature of the error.

•

(1) Supply Voltage LED. LED ON solid green light indicates supply voltage is ON. LED OFF indicates supply voltage is OFF. (2) Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows: • •

Blink (red light)

I/O and voltage errors

One flash indicates fault on inputs/outputs or that supply voltage is to low or to high.

Two flashes in a row indicates that the internal temperature of the unit is to high or to low.

6.43

Three flashes in a row indicates that the fault is related to the CAN-bus.

Four flashes in a row indicates an internal fault on the hardware of the unit.

Five flashes in a row indicates that the fault is related to the address.

Continuous flashing indicates the fault is related to software.

Tigercat 1065/1075 Forwarder

Electrical & Computers 2 1

•• •• XT2-A0 MODULE LED INDICATORS

1014-042

2. CHECK MODULE STATUS INDICATORS XT2 MODULE OFFLINE ERROR

Status lights can also give an immediate indication of the nature of the error.

Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

(1) Supply Voltage LED. LED ON solid green light indicates supply voltage is ON.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN

LED OFF indicates supply voltage is OFF.

Press OK to acknowledge each error message. Note that module offline errors will be followed by other alarm messages associated with the module(s) which is(are) offline.

(2) Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows:

If XT2-A0 MODULE IS OFFLINE is the only module is offline error message the likely causes are:

•

• Power - Fuse (XT2 MODULE)

•

• Ground • Address (ID-Tag)

•

If the XT2-A0 MODULE IS OFFLINE is followed by the XP2-A0 MODULE IS OFFLINE error the likely cause is:

•

• CAN wire connection

• •

One flash indicates fault on inputs/outputs or that supply voltage is to low or to high.

Two flashes in a row indicates that the internal temperature of the unit is to high or to low.

Three flashes in a row indicates that the fault is related to the CAN-bus.

Four flashes in a row indicates an internal fault on the hardware of the unit.

Five flashes in a row indicates that the fault is related to the address.

Continuous flashing indicates the fault is related to software.

LX-, XP2- and XT2- module Error code I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

6.44

Blink (red light)

Tigercat 1065/1075 Forwarder

Electrical & Computers 2 1

•• •• 1014-042 XP2-A0 MODULE LED INDICATORS 2. CHECK MODULE STATUS INDICATORS

XP2 MODULE OFFLINE ERRORS

Status lights can also give an immediate indication of the nature of the error.

Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

(1) Supply Voltage LED. LED ON solid green light indicates supply voltage is ON.

1. CHECK FOR OTHER ERROR/ALARM MESSAGES ON SCREEN

LED OFF indicates supply voltage is OFF.

Press OK to acknowledge each error message. Note that module offline errors will be followed by other alarm messages associated with the module(s) which is(are) offline.

(2) Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows:

Note also that the XP2-A0 module is the terminal module in the series connection.

Therefore failure of this module alone will not affect any other modules in the series.

• •

If the XT2-A0 MODULE IS OFFLINE is the only module is offline error message the likely causes are:

•

• Power - Fuse (XP2 MODULE) •

• Ground • Address (ID-Tag)

•

• CAN wire connection If the XT2-A0 MODULE IS OFFLINE error is not the only module is offline error message check other affected modules in order from the MDM connection (XS-A0, LX-A0, XT2-A0).

Refer to MODULE IS OFFLINE ERROR for each module for more detailed information.

•

One flash indicates fault on inputs/outputs or that supply voltage is to low or to high.

Two flashes in a row indicates that the internal temperature of the unit is to high or to low.

Three flashes in a row indicates that the fault is related to the CAN-bus.

Four flashes in a row indicates an internal fault on the hardware of the unit.

Five flashes in a row indicates that the fault is related to the address.

Continuous flashing indicates the fault is related to software.

LX-, XP2- and XT2- module Error code I/O and voltage errors Low/High temperature CAN error Hardware error Address error Software error

6.45

Blink (red light)

Tigercat 1065/1075 Forwarder

Electrical & Computers

FUSE AND RELAY PANELS

SPARE

COMPUTER 1

SPARE

ACCESSORIES 1

RELAY 1

RELAY 3

RELAY 5

RELAY 7

SPARE

RELAY 2

COMPUTER 2

SPARE

RELAY 4

RELAY 6

ACCESSORIES 2 RELAY 8

SERIAL NUMBER 10650101 TO 10650150

15A

3A

5A

2A

INTAKE AIR HEATER

CHASSIS COMPUTER

ENGINE START

PROXIMITY SWITCHES

15A

10A

5A

10A

REAR WIPER

XS MODULE

INTERIOR LIGHTS

HIGH BEAM RELAY

3A

3A

10A

7.5A

SWITCH ILLUMINATION

L.H. JOYSTICK

HORN

LIGHT SWITCHES / MARKER LIGHTS

10A

3A

15A

7.5A

CHASSIS RELAYS

MDM CLOCK

12V CONVERTER

HAZARD LIGHTS

15A

3A

10A

7.5A

FRONT WIPER

MDM MODULE

24V OUTLET 1

TURN SIGNAL

3A

3A

10A

30A

SWITCHES / RELAYS

R.H. JOYSTICK

24V OUTLET 2

LIGHT MODULE 1

10A

25A

30A

SEAT COMPRESSOR

COMPUTER POWER

LIGHT MODULE 2

FUSE AND RELAY PANEL LABEL - CAB

1. FUSE AND RELAY PANEL - CAB

22054B R1

FUSE AND RELAY PANEL LABEL - ENGINE COMP’T 25A

SPARE

A/C COMPRESSER CLUTCH

RELAY 2

RELAY 1

INTAKE AIR HEATER

ECM GROUND

RELAY 4

RELAY 3

BRAKE LIGHTS

CHASSIS LIGHTS

RELAY 6

RELAY 5

FUEL HEATER

LIFT PUMP

RELAY 8

RELAY 7

A/C

SPARE

RELAY 10

RELAY 9

COMPUTER 1

COMPUTER 2

RELAY 12

RELAY 11

COMPUTER

30A A/C COMPRESSER CLUTCH

2A LADDER SENSOR

1014-135

10A

Fuses and relays for the cab electrical controls and computer are located inside the top right compartment in the cab roof.

BRAKE LIGHTS

25A INTAKE AIR HEATER

30A

2. FUSE AND RELAY PANEL - ENGINE COMPARTMENT

CHASSIS LIGHTS

10A FUEL HEATER

25A LIFT / VACUUM PUMP

20A PLD - MR

20A A/C

20A XT2

20A XP2 - 2

20A XP2 - 1

20A

1014-136

XP2 - 0

Fuses and relays for the engine, hydraulic and machine electrical controls are located in the electrical box in the engine compartment.

22055B R1

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Electrical & Computers

FUSE AND RELAY PANELS

SERIAL NUMBER 10650151 AND UP, AND 10750101 AND UP

FUSE AND RELAY PANEL LABEL - CAB

1. FUSE AND RELAY PANEL - CAB

2. FUSE AND RELAY PANEL - UNDER CAB

1065-003

FUSE & RELAY COMPARTMENT IN CAB Fuses and relays for the cab electrical controls and computer are located inside the top right compartment in the cab roof.

1065-001

Fuses and relays for the engine, hydraulic and machine electrical controls are located in the electrical box under the cab.

FUSE AND RELAY PANEL LABEL- UNDER CAB

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Electrical & Computers

Tigercat wire colour code chart applicable to all products manufactured by Tigercat Industries Inc. COLOUR Red Black White Blue Purple Tan Yellow Grey Brown Green Orange

FUNCTION EXAMPLE Power ........................................ (fused and unfused) Ground Engine control ........................... (fuel shut-off, start aid) Propulsion Control .................... (transmission/reverser solenoids) Monitor, electrical and mechanical systems ................. (air cleaner, alternator, wheel speed, engine speed) Electrical and electromechanical control ......... (park brake, alternator excitation) (power door motor, backup alarm) Monitors .................................... (flow, pressure, temperature, level) Standard monitor system .......... (logic module to monitor) Lights Electro-hydraulic control ........... (pilot solenoids) Accessories .............................. (horn, A/C, heater)

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Tigercat 1065/1075 Forwarder

Electrical & Computers

CURRENT OUTPUT, START/STOP SLOPE AND FINE CONTROL DEFAULT SETTINGS FUNCTION

MIN CUR mA

MAX CUR mA Start Slope ms Stop Slope ms Fine C%

• STEERING FORWARD (+)

340

550

300

500

60

• STEERING FORWARD (-)

340

550

300

500

60

• STEERING REVERSE (+)

340

550

300

550

60

• STEERING REVERSE (-)

340

550

300

500

60

• BLADE UP (+)

200

500

250

250

0

• BLADE DOWN (-)

200

500

250

250

0

• CRANE SLEW (+)

380

550

200

200

0

• CRANE SLEW (-)

340

500

200

200

0

• MAIN BOOM (+)

360

575

600

560

30

• MAIN BOOM (-)

360

610

300

600

0

• STICK BOOM (+)

355

600

200

200

0

• STICK BOOM (-)

335

625

300

200

0

• TELESCOPE (+)

380

670

300

400

0

• TELESCOPE (-)

375

575

250

370

0

• GRAPPLE ROTATE (+)

330

520

250

400

0

• GRAPPLE ROTATE (-)

360

545

250

400

0

• GRAPPLE OPEN (+)

340

600

0

0

0

• GRAPPLE CLOSE (-)

380

650

0

0

0

• GATE UP (+)

425

480

1000

200

50

• GATE DOWN (-)

400

450

1000

200

50

• CRANE TILT (+)

200

500

250

250

0

• CRANE TILT (-)

200

500

250

250

0

• PUMP (+) B of R & Max Dis

225

555

0

0

0

• PUMP (-) B of R & Max Dis

275

600

0

0

0

• MOTOR (+) B of R & Min Dis 225

580

0

0

0

FUNCTION PARAMETERS SETTING • WORKING RPM

Min 1200 rpm

Max 1800 rpm

Default 1400 rpm

• CRANE MAXIMUM SPEED

Min 60%

Max 100%

Default 90%

• TIRE ROLLING CIRCUMFERENCE

Min 1

Max 6000

See chart in Section 2

• MOTOR SPEED BYPASS

Min 0

Max 1

Default 1

• GEAR CHANGE OUTPUT

Min 5

Max 10

Default 5

• BLADE ON/OFF

Min 0

Max 1

Default 0

NOTE: The actual values may vary from factory settings due to operator preference adjustment.

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Electrical & Computers

LOADING IQAN PROGRAMS 1. Using your laptop and IQAN develop, first get the current program from the machine and save it. The machine serial number and date are good idea for the name. You will be required to enter in a password to get the program (and load the new one). Contact Tigercat service for the password.

Save the old program so if anything goes wrong with the new program, you still have the old one as a backup. It also saves all the operator adjustments in case they are accidentally overwriten in a later step.

2. Check and write down the current engine hours and transmission hours from the machine using the MDM display.

3.

Open the new program for the machine. Same password may be required.

4. Send the new program to the MDM in the machine. When you start to send the new program, a popup menu will come up in IQAN develop. On the left side of this screen are 3 windows which you can ignore. On the right however there are 3 different sections of check boxes that are very important.

The first window is about “Factory Default Values” The options are “Leave values in master unchanged” and “Use values from IQAN develop application”. “Use values from IQANdevelop application” should already be checked and this is how we want it.

The second window is about “Adjustable values”. The options are the same - “Leave values in master unchanged” and “Use values from IQAN develop application”. This one should have “Leave values in master unchanged” selected. This allows the operators adjustment to remain the same.

The last window is about “Stored values”. The options are “Leave values in master unchanged”, “Use values from IQANdevelop application” and “Reset all values in master to zero”. This one should have “Leave values in master unchanged” selected.

5. Once you make sure all windows have the correct selection, then press the send button.

6. Another window should pop up telling you that the you are trying to send a new program that has a different description. This is correct and is ok. Press the YES button to continue sending the new program.

7. Once the program is sent, then check the engine and transmission hours to make sure they haven’t changed. You can view them using the MDM through the Tigercat Display switch beside the MDM or by finding them using the laptop and IQAN develop. They are under the MDM tab, and under the Other tab within the MDM tab. On the bottom left side you will find the hour counters. To read the values, single click the grey box associated with the engine and transmission counters. Then start measuring.

8. To adjust this value if it is incorrect, double click the counter channel and under the properties tab, press the “change value” button. Type in the correct time and press send. Select OK to complete the change.

6.50

Tigercat 1065/1075 FORWARDER

Tigercat 1065/1075 Forwarder

Engine Start & Stop

SECTION 7 - ENGINE START & STOP MAY, 2005

CONTENTS - SECTION 7 ADM2 ADAPTION MODULE .......................................................................... 7.3 CIRCUIT DESCRIPTION ............................................................................... 7.2 ELECTRICAL CIRCUIT SCHEMATIC ........................................................... 7.4 ENGINE CONTROL MODULES .................................................................... 7.3 ENGINE ELECTRONIC CONTROLS LOCATIONS ....................................... 7.5 ENGINE START CIRCUIT ............................................................................. 7.2 MERCEDES ENGINE .................................................................................... 7.2 PLD-MR ENGINE CONTROL MODULE ........................................................ 7.3

7.1

Tigercat 1065/1075 FORWARDER

Engine Start & Stop

MERCEDES ENGINE ENGINE START CIRCUIT For detailed engine information refer to the engine manufacturer’s manual.

For engine starting and stopping procedures refer to OPERATING MACHINE: STARTING ENGINE and STOPPING ENGINE in SECTION 2 of the OPERATOR’S MANUAL. The engine is started by turning the ignition switch to the START position and then releasing it to the RUN position after the engine starts. Once the engine has started no functions will operate until both cab doors are closed and the PILOT RESET SWITCH is pressed to turn on the computer, allow machine functions to operate. Refer to PILOT RESET SWITCH and PILOT SYSTEM SHUT OFF in SECTION 2 of the OPERATOR’S MANUAL for more information.

PILOT OFF INDICATOR LIGHT

1014-136

FUSE AND RELAY POWER DISTRIBUTION EARLIER MACHINES

PILOT RESET SWITCH

••

1065-001

••

FUSE AND RELAY POWER DISTRIBUTION LATER MACHINES Power for the ignition switch is supplied from a 20 amp fuse in the fuse and relay power distribution box. Power from the 20 amp fuse is supplied through circuit 10A to the emergency shut off switch. When the switch is turned ON power flows through the switch circuit 10C to the ignition switch.

1014-001

R.H. JOYSTICK & CONTROL SWITCHES If the engine stalls during operation of the vehicle, the ignition must be turned to the OFF position to reset before the engine can be restarted.

CIRCUIT DESCRIPTION

ADM2 ADAPTION MODULE

Refer to schematic diagrams showing the ENGINE START CIRCUIT in THIS SECTION.

•

ENGINE HOOD

•

ON OFF

1014-138

FUSE & RELAY COMPARTMENT IN CAB When the ignition switch is turned to the START position, voltage is supplied through the ignition switch start terminal to wires 178 and 178B. Wire 178B is the engine start signal for the ADM2 Engine Adaption Control Module located in the fuse and relay compartment in the cab.

• BATTERY DISCONNECT SWITCH

1014-D001

With the battery disconnect switch ON, power is able to flow to all constant power circuits.

7.2

Tigercat 1065/1075 FORWARDER XT2-A0 MODULE

PLD-MR MODULE

•

Engine Start & Stop The data is evaluated together with the data from the sensors on the engine such as oil pressure, fuel temperature, coolant temperature, air intake temperature, fuel charge pressure, crankshaft speed etc is compared to the data stored in the PLD-MR control module.

POWER DISTRIBUTION BOX

•• ••

From this data, commencement and duration of fuel injection is calculated and the unit pumps are actuated accordingly via solenoid valves.

•• 1014-142

L.H. SIDE ENGINE COMPARTMENT ADM2 ADAPTION MODULE

Wire 178 is the engine start signal for the PLD-MR Engine Control Module that supplies voltage to the starter solenoid to close the starter solenoid contacts and supply battery power to the starter motor to start the engine.

•

STARTER SOLENOID STARTER MOTOR

1014-138

FUSE & RELAY COMPARTMENT IN CAB

•

ADM2 ADAPTION MODULE

•

The ADM2 Adaption Module is used to adapt the engine to the machine application-specific requirements. The control module is programmed with diverse sets of data for specific applications such as idle speed, maximum working speed or speed limitation.

1014-144

R.H. SIDE OF ENGINE COMPARTMENT

ENGINE CONTROL MODULES Communication between the MDM Control and Display Module, the XS-A0 System Interface, and the XT2-A0 Engine Module to the engine is conducted via a CAN-Bus link to the ADM2 Engine Adaption Module and the PLD-MR Engine Control Module.

ENGINE WIRING HARNESS PLUG CONNECTOR

PLD-MR MODULE

••

APPLIANCE WIRING HARNESS PLUG CONNECTOR

••

From this data, instructions are computed for the engine control and are transmitted to the PLD-MR control module via the CAN-Bus link.

Refer to the engine manufacturers manuals for more detailed service, troubleshooting procedures and operational information on the ADM2 and PLD-MR control modules.

••

1014-145

The ADM2 Module receives data from the operator via the throttle pedal potentiometer, engine speed control, engine start/stop etc, and the PLD-MR control module (e.g. oil pressure and coolant temperature).

L.H. SIDE ENGINE COMPARTMENT

PLD-MR ENGINE CONTROL MODULE The PLD-MR control module processes the data received from the ADM2 control module such as the throttle pedal position, engine speed control, and engine start/stop etc.

7.3

Tigercat 1065/1075 FORWARDER

Engine Start & Stop

ENGINE ELECTRICAL CIRCUIT SCHEMATIC

1014-072

7.4

Tigercat 1065/1075 FORWARDER

Engine Start & Stop

ENGINE ELECTRONIC CONTROLS LOCATIONS

XT2-A0 ENGINE MODULE PLD-MR MODULE

XS-A0 CAB MODULE

• ••

•• MDM DISPLAY MODULE

FRONT DRIVE PEDAL

••

••

L.H. JOYSTICK MODULE

• •• ADM2 ADAPTION MODULE

• REAR DRIVE PEDAL

1014-062.DWG

7.5

Tigercat 1065/1075 FORWARDER

Engine Start & Stop

7.6

Tigercat 1065/1075 FORWARDER

Tigercat 1065/1075 FORWARDER

DRIVE

SECTION 8 - DRIVE MAY, 2005

CONTENTS - SECTION 8 AUXILIARY FUNCTION VALVE .................................................................... 8.7 AXLES .......................................................................................................... 8.19 AXLE LUBRICATION ............................................................................... 8.20 DIFFERENTIAL AND DIFFERENTIAL LOCKS ........................................ 8.19 DRAINING AND REFILLING DIFFERENTIAL:(1 PER AXLE) .................. 8.20 SERVICE/PARKING BRAKES ................................................................. 8.27 WHEEL INSTALLATION .......................................................................... 8.22 CHARGE & COOLING PUMP CIRCUITS ...................................................... 8.5 CHARGE PUMP ............................................................................................. 8.5 DRAINING AND REFILLING BOGIE HOUSING ......................................... 8.21 DRIVE MOTOR .............................................................................................. 8.6 DRIVE MOTOR CONTROLLER SOLENOID ................................................. 8.4 DRIVE MOTOR SCHEMATIC ........................................................................ 8.6 DRIVE PUMP ................................................................................................. 8.3 DRIVE PUMP CONTROLLER SOLENOIDS ......................................... 8.4, 8.8 HYDRAULIC OIL HEATING PROCEDURE ................................................... 8.8 HYDROSTATIC DRIVE MOTOR BEGIN OF REGULATION ....................... 8.15 HYDROSTATIC DRIVE PUMP HYDRAULIC NEUTRAL ........................................................................... 8.13 HYDROSTATIC DRIVE PUMP BEGIN OF REGULATION .......................... 8.14 HYDROSTATIC DRIVE SYSTEM .................................................................. 8.2 MOTOR BEGIN OF REGULATION ............................................................. 8.12 PRESSURE AND SPEED SETTINGS ......................................................... 8.30 PUMP BEGIN OF REGULATION ................................................................ 8.10 PUMP SCHEMATIC ....................................................................................... 8.3 REAR (BOGIE) AXLE PLANETARY DRIVES (4 FILLING POINTS) ............................................ 8.20 TRANSMISSION .......................................................................................... 8.19

8.1

Tigercat 1065/1075 FORWARDER

DRIVE

HYDROSTATIC DRIVE SYSTEM The primary components of the hydrostatic drive system are a hydraulic pump and hydraulic motors connected together by hoses. The pump converts the mechanical power of the diesel engine into hydraulic power. This hydraulic power is then provided as high pressure flow of hydraulic oil and is then transmitted to the hydraulic motors through a supply hose. The motors then reconvert the hydraulic power back into the mechanical power used to propel the machine. Low pressure hydraulic oil flow then returns from the motors to the pump through the return hose thereby completing a continuous closed loop hydraulic circuit.

A hydraulic system is termed closed loop when the hydraulic oil returning from the motor is fed straight back to the pump without first returning to tank.

When the machine is travelling forward, one side of the closed loop is a high pressure supply while the other side is a low pressure return. The supply and return will alternate from side to side of the closed loop as the direction of travel of the vehicle goes from forward to reverse.

LOW PRESSURE RETURN

SWASHPLATE AXIAL PISTON PUMP

FROM DIESEL ENGINE

TWIN DRIVE MOTOR TO TRANSMISSION

P

S

HIGH PRESSURE SUPPLY 1014-052

SWASHPLATE AXIAL PISTON PUMP

TWIN DRIVE MOTOR

P

Return

S

Flow

1014-048

CLOSED LOOP HYDRAULIC CIRCUIT 8.2

TRANSMISSION

Tigercat 1065/1075 FORWARDER

DRIVE

DRIVE PUMP

maximum flow in one direction in the closed loop.

As the swashplate is de-stroked the flow smoothly decreases until there is no flow at an angle of zero (0°). Continuing to angle the swashplate past this neutral position steplessly reverses the direction of flow from the piston pump.

The hydrostatic drive pump is mounted on the engine flywheel housing and is driven directly by the diesel engine through a flexible plate coupling.

A splined through shaft in the pump connects the driveshaft of the hydrostatic pump directly to the input of the main pump.

DRIVE PUMP

SWASHPLATE CONTROL VALVE SOLENOID

MAIN PUMP DRIVESHAFT

• •

•

•

Å FRONT

• PUMPS 1014-146 The hydrostatic drive pump is a variable displacement, swashplate, axial piston pump. This pump is made variable by slipping the pump pistons against a tiltable swashplate cradle. The volume and direction of oil flow from the piston pump is determined by the angle of this swashplate.

• SWASHPLATE AP131-DRIVE

• PISTON

DRIVE PUMP

When the swashplate is stroked to a maximum displacement angle, the piston pump will produce HYDRAULIC RESERVOIR

RETURN STRAINER HYDRAULIC FILTERS

FORWARD “Z” CONTROL SOLENOID REVERSE “Y” CONTROL SOLENOID

SWASHPLATE CONTROL VALVE

CHARGE PUMP

OIL COOLER REV CHARGE PRESSURE FILTER FWD

CHARGE PRESSURE RELIEF VALVE 1014-051

HIGH PRESSURE RELIEF VALVES

CONTROL CYLINDER

DRIVE PUMP SCHEMATIC 8.3

Tigercat 1065/1075 FORWARDER

DRIVE

When the throttle pedal is activated the XT2-AO Engine Module sends an electrical current output to the proportional solenoids installed on the drive pump controller and the drive motor controller.

The angle and direction that the swashplate moves is directly proportional to the current being sent from the XT2-AO Module. When no current is supplied, pilot oil is not supplied to the drive pump swashplate. The swashplate therefore remains in the neutral position and no oil is pumped by the piston pump.

XT2-AO ENGINE MODULE

DRIVE MOTOR CONTROLLER SOLENOID

DRIVE MOTOR CONTROLLER SOLENOID

•• 1014-148

DRIVE MOTOR CONTROLLER SOLENOID

DRIVE PUMP FWD/REV CONTROLLER SOLENOIDS 1014-054

DRIVE PUMP CONTROLLER CIRCUITS To propel the machine forward, a proportional current is sent from terminal 19 on the XT2-AO Module, through wire 371A to the forward solenoid on the pump. To propel the machine in reverse, a proportional current is sent from terminal 33 on the XT2-AO, through wire 371B to the reverse solenoid on the pump.

“Y” REVERSE SOLENOID

The motor proportional solenoid shifts the actuation piston. The actuation piston in turn shifts the swashplate control cylinder, which is directly connected to the swashplate of the drive motors. The angle that the swashplate moves determines the motor speed. Increasing throttle speed decreases swashplate angle which increases motor speed.

There are two high pressure relief valves at the ‘P’ and ‘S’ ports on the pump. These are intended only to act as pressure limiting safety devices in the event that the system does not respond quickly enough to high pressure surges. The high pressure relief valves always dump oil from the high pressure to the low pressure side of the closed loop thereby keeping the hydraulic oil within the closed loop.

REVERSE RELIEF VALVE

•• “Z” FORWARD SOLENOID

••

•• 1014-147

DRIVE PUMP CONTROLLER SOLENOIDS The controller solenoids shift the actuation piston.

The actuation piston in turn shifts the swashplate control valve spool. This changes the position of the control cylinder, which is directly connected to the swashplate of the piston pump. The angle and direction that the swashplate moves determines the speed and direction of travel of the vehicle.

FORWARD RELIEF VALVE

• 1014-149

DRIVE PUMP RELIEF VALVES

For pressure setting procedures refer to DRIVE PUMP PRESSURE SETTINGS AND ADJUSTMENTS in THIS SECTION. 8.4

Tigercat 1065/1075 FORWARDER

DRIVE

CHARGE PUMP CHARGE PUMP FILTER

The charge pump is a gear pump mounted in tandem with the cooling circulation pump. This tandem gear pump is mounted on the back of the main pump.

• •• HYDRAULIC RESERVOIR

CHARGE PUMP

••

HYDRAULIC RESERVOIR AND FILTER LOCATION The charge pressure filter ensures that only clean charge pump oil is introduced into the closed loop hydrostatic circuit and the swashplate control system. Should this pressure filter become clogged with debris, charge pump flow is diverted to tank thus preventing the entry of unfiltered charge pump oil into the closed loop.

1014-D015

1014-D013

CHARGE PUMP

The charge pump is a fixed displacement internal gear pump that is fed from the hydraulic oil reservoir. The charge pump continuously introduces oil from the hydraulic tank back into the hydrostatic drive system. The charge pump relief valve maintains a constant pilot pressure for use by the swashplate control system. In addition, the charge pump oil is used as make up oil to the low pressure side of the closed loop to replenish losses due to internal leakage in the hydrostatic pump and motor. This same flow acts as a cooling fluid for the drive pump and drive motor to ensure peak hydrostatic drive performance and long service life.

HYDRAULIC RESERVOIR

STRAINER

FILTERS

OIL COOLER

Excess charge pump oil is relieved by the charge pressure relief valve into the case of the drive pump. Charge pressure is set at 20 BAR (290 psi).

CHARGE PUMP

CHARGE PRESSURE TEST PORT

COOLING PUMP

CHARGE PUMP FILTER

• 1014-053

CHARGE & COOLING PUMP CIRCUITS

1014-D085

CHARGE PRESSURE TEST

8.5

Tigercat 1065/1075 FORWARDER

DRIVE

HYDROSTATIC DRIVE MOTOR A variable displacement, axial piston double motor is used to drive the forwarder. It is mounted to the input side of the transmission. A splined connection transmits the torque from the motor shaft to the transmission input.

DISPLACEMENT CONTROL CYLINDER

DISPLACEMENT CONTROL SPOOLS

DISPLACEMENT CONTROL CYLINDER

FROM PUMP “P” PORT

DRIVE MOTORS

••

DRIVE MOTOR CONTROLLER 1014-055

1014-D013

DOUBLE DRIVE MOTOR

High pressure oil from the drive pump enters the drive motor via port ‘A’ or port ‘B’, depending on the direction of travel. The oil is directed to the back of a set of pistons in the motor’s rotary group.

The pistons push against the back of the output shaft at an angle causing it to rotate.

The angle of the pistons relative to the drive shaft determine the speed and available torque .

Reducing the piston angle provides increased speed with less torque. Increasing the piston angle provides reduce speed with more torque.

When the throttle pedal is activated the XT2-AO Engine Module sends an electrical current output to the proportional solenoids on the drive pump controller and the drive motor controller.

FLUSHING VALVE

FROM PUMP “S” PORT

DRIVE MOTOR SCHEMATIC

The drive motor controller directs pressure from the charge pump to the displacement control spools. When sufficient pressure from the pump is directed to the spools, the spools shift against a spring and direct oil to the displacement control cylinders thus decreasing the displacement of the motors increasing the motor speed.

Removal of the pressure signal from the drive motor causes the displacement control spools to return to the neutral position, shutting off the pressure to the displacement control cylinders thus increasing displacement to maximum decreasing motor speed.

A flushing valve is incorporated into the motor. This valve provides a regulated flow of oil from the low pressure side of the loop into the motor case. This action reduces the possibility of particle build up in the loop by providing a continuous change of oil, it also assists with cooling. This valve is factory set and requires no adjustment.

1014-003.AI

1014-065.DWG

AQ080 (HMV135D-02) DRIVE MOTOR 8.6

1014-064.DWG

Tigercat 1065/1075 FORWARDER

DRIVE

AUXILIARY FUNCTION VALVES

HIGH PRESSURE MANIFOLD

BRAKE VALVE MANIFOLD

•• RP3

••

C6

••

•• 1014-150

C5 PU

HYDRAULIC VALVE COMPARTMENT

PR3

The Brake Valve Manifold and High Pressure Manifold provide reduced pressure for the operation of brake release, parking brake, front and rear differential locks, accumulator and ladder cylinder circuits. These manifolds are located in the hydraulic valve compartment and contain the following components: SV

PR1

• P1

RV

PR2

• • ••

C3 C4

C1

BRAKE VALVE MANIFOLD BRAKE VALVE MANIFOLD COMPONENTS 1014-059

C1 ................................ Solenoid 1 ~ Service Brakes C3 .................................... Solenoid 2 ~ Park Brakes C4 ............................... Solenoid 3 ~ Front Diff Locks C5 ................................. Solenoid 4 ~ Rear Diff Lock C6 ............................................. Solenoid 5 ~ Ladder PR3 .... Pressure Reducer – Diff Lock/Brake/Ladder PU ........................ Overpressure Pressure Shut-Off RP3 .. Pressure Test (Diff Locks/Park Brake/Ladder

SW2

••

STEERING

••

• ••

•• SW1

•• •• •• •• •• •

•

••

RP2 BRAKE

1014-D006B

ACC1 1014-057

Auxilary Steering and Secondary Brake system are operated via an auxilary steering valve and a secondary brake valve located in the cab.

HIGH PRESSURE MANIFOLD

HIGH PRESSURE MANIFOLD COMPONENTS ACC1 ............................ Accumulator Pressure Test P1 .................................. Pump Outlet Pressure Test PR1 ....................... Pressure Reducer 1 (*190 BAR) PR2 ................. Pressure Reducer Brakes 100 BAR RP2 .......................... Pressure Test Service Brakes RV .......................................... Relief Valve 105 BAR SW1 .. Low Pressure Switch 69 BAR (Start Charge) SW2 High Pressure Switch 124 BAR (Stop Charge) SV ............................... To LS Signal on Main Pump

8.7

Gear Shift and Rear Drive Disconnect solenoid control valves are located in a manifold block mounted on the front chassis beside the transmission

Tigercat 1065/1075 FORWARDER

DRIVE

HYDRAULIC OIL HEATING PROCEDURE

DRIVE SYSTEM SET UP

This procedure is used to heat up the hydraulic oil in the machine in preparation for setting up hydraulic pressures.

1. Pump Begin of Regulation and Max Displacement adjustment and control pressure.

These tests will verify the following:

1. Park machine on level ground, place a sheet of cardboard in front of the oil cooler portion of the heat exchanger. The radiator must remain uncovered to prevent engine overheating. Start the engine, depress the PILOT RESET switch, place the WORKING RPM switch in the ON position, and set engine to max throttle using the L.H. joystick thumb switch.

2. Motor Begin of Regulation and Min Displacement adjustment and control pressure.

3. Steering check; slow and fast.

4. Front and rear differential lock functions.

5. Service braking check.

CONTROL ‘Y’ PRESSURE TEST PORT

WARNING DRIVE ‘MP’ REVERSE PRESSURE TEST PORT

DO NOT leave the machine while heating the oil, as overheating of engine or hydraulic oil can cause serious damage.

2. Operate the TELESCOPE OUT function, while at the same time operating the GRAPPLE CLOSE function. Hold both joystick thumb switches to their maximum position. Release after 5 seconds, wait 5 seconds, then repeat.

This will cause oil to pass over the telescope out port relief, which will generate heat.

Monitor ENGINE COOLANT TEMPERATURE and HYDRAULIC OIL TEMPERATURE on the display module.

WARNING

DRIVE ‘MS’ FORWARD PRESSURE TEST PORT

1014-D085

••

DRIVE PUMP

CHARGE PRESSURE TEST PORT

••

•• • •

PRESSURE TEST PORTS

INSTALL PRESSURE TEST GAUGES Install two 0-10,000 psi gauges on ‘MP’, ‘MS’ and two 0-500 psi gauges on the pump controller ‘Y’ and ‘Z’ test ports on the DRIVE PUMP and a 0-500 psi gauge on the motor controller ‘Y’ test port.

Install a 0-500 psi gauge on ‘CHARGE PRESSURE’ test port on the DRIVE PUMP. “Y” REVERSE TEST PORT

Hydraulic oil temperature rises quickly when passing over relief valves. Remove the cardboard blocking the oil cooler if necessary to maintain the proper temperature. Do not pass oil over the relief valves for longer than 5 seconds at a time.

Damage to valves can occur from excessive heat.

•• “Z” FORWARD TEST PORT

• 1014-147

DRIVE PUMP CONTROLLER TEST PORTS

3. Ensure that the hydraulic oil temperature is between 48C and 60C (120F and 140F).

4. Once the hydraulic oil is up to operating temperature, proceed to required hydraulic set-up procedure.

Y 1014-069

DRIVE MOTOR

Z

NOTE: Fasten the gauges so they can be easily viewed from the operator’s seat and will not be damaged during the test.

8.8

Tigercat 1065/1075 FORWARDER

DRIVE

CONNECT A PDA (PERSONAL DIGITAL ASSISTANT) The following procedure instructs how to connect a PDA (Personal Digital Assistant) device to the MDM module. The PDA will be used as a second display unit required when performing test procedures outlined later in this section.

To perform this procedure you will require: • • •

PDA IQAN data cable for PDA PDA serial port adapter cable (for the PDA being used).

A. Ensure the Ignition key switch is OFF. Remove the lower cover on the L.H. joystick pod.

B. Locate the ‘round’ RS232 port connection on the back of the MDM. Do not disconnect the rectangular 6-pin connector.

1014-191

C. Remove the rubber dust seal from the RS232 port and connect IQAN data cable for PDA.

G. Select the ‘CHANNELS’ icon from the bottom right corner of the PDA screen.

This will display a drop down menu showing channels to chose from.

WARNING

NOTE: In this instance we will be selecting Frequency In then motor speed rpm.

Damage may occur to the PDA if the wrong data cable is used. Ensure the appropriate cable is selected when using a PDA; DO NOT USE AN ADAPTER TO MATCH UP SERIAL PORTS. IQAN DATA CABLE FOR PDA

PDA MAIN IQAN WINDOW

0 selected Voltage In Digital In Frequency In J1939 analog In Current Out Digital Out Conditional Message Alarm

PDA SERIAL PORT ADAPTER CABLE

IQAN - MDM PALM OS PDA

CONNECTING MDM TO PDA D. Connect the other end of the cable to the serial port adapter cable for the PDA being used.

E. Turn on power to the PDA. F. Turn the key switch to ‘RUN’. DO NOT START THE MACHINE.

1014-192

PDA DROP DOWN MENU DISPLAY H. Select frequency in, and select motor speed then select measure menu.

8.9

Tigercat 1065/1075 FORWARDER

DRIVE

PUMP BEGIN OF REGULATION & MAX DISPLACEMENT ADJUSTMENT The pump begin of regulation is the point at which an electrical signal to the pump control solenoid will result in rotary motion of the wheels.

NOTE: Prior to performing this adjustment the drive motor begin of regulation Min Current and Max Current must be set to 0.0 mA. See MOTOR BEGIN OF REGULATION & MIN DISPLACEMENT ADJUSTMENT for setting Motor Min Current/Max Current and adjust the values to 0.0 mA.

8. Use the UP or DOWN arrow buttons if necessary to locate the “Current Out” menu.

1. Start the engine and depress the pilot reset switch to activate the computer.

9. Press the F1 button to enter the function selection menu.

2. Reset the pilot.

3. Use the switch to the left of the display to select the Iqan display screen.

4. Turn Maximum Travel speed switch OFF.

10. Press the F3 button to activate manual function selection.

5. Press the ESCAPE button to display the menu selection screen.

11. Using the UP or DOWN arrow buttons, scroll through the adjustable functions until “Drive Pump COUT” is displayed.

12. Press F1 “SELECT (+)” to enter the forward begin of regulation adjustment menu.

6. Using the UP or DOWN arrow buttons, scroll through the 5 different menus until the “Properties” menu is found.

7. Press the F2 button to enter the output property menu.

8.10

Tigercat 1065/1075 FORWARDER

DRIVE

13. Using the UP or DOWN arrow buttons, scroll through the adjustable values until “MIN CURRENT” is displayed.

19. Using the UP or DOWN arrow buttons, scroll through the adjustable values until “MAX CURRENT” is displayed.

14. Press F1 and select FWD travel direction to start adjusting the pump begin of regulation.

20. Press F1 to start adjusting the pump maximum displacement.

15. Engage the front differential locks and depress the drive pedal to max.

21. Depress the drive pedal to max.

16. Using the UP/DOWN arrow buttons, adjust the “MIN CURRENT” to the point at which the wheels just begin rotating or until drive pressure is sensed on the appropriate work port. Round this value to the nearest 5mA. 17. Observe the current and pressure, should be 225mA @ 4 BAR (58 psi). (if the values are out of range, refer to HYDROSTATIC DRIVE PUMP HYDRAULIC NEUTRAL procedure in this section for adjustment)

22. Using the UP/DOWN arrow buttons, adjust the “MAX CURRENT” to the point at which the motor speed stops increasing. Round this value up to the nearest 5mA and add 20mA to this value 23. Observe the current and pressure, should be 555mA @ 15 BAR (218 psi).

24. When the forward max displacement has been established release the drive pedal and press F1 “OK”.

18. When the forward begin of regulation has been established release the drive pedal and press F1 “OK”.

25. Press the escape button once to return to step 13 and repeat steps 14-25 for the reverse direction by pressing F2 “SELECT (-)” and selecting REV travel direction.

8.11

Tigercat 1065/1075 FORWARDER

DRIVE

MOTOR BEGIN OF REGULATION & MIN DISPLACEMENT ADJUSTMENT The motor begin of regulation is the point at which an electrical signal to the motor control solenoid will result in an increase in wheel speed.

8. When the motor begin of regulation has been established release the drive pedal and press F1 “OK”.

9. Observe the current and pressure readings, should be 225mA @ 10 BAR (145 psi).

1. Follow steps 1-11 as in pump set-up

2. Use the UP or DOWN arrow buttons, scroll through the adjustable functions until “Drive Motor COUT” is displayed.

10. Using the UP or DOWN arrow buttons, scroll through the adjustable values until “MAX CURRENT” is displayed.

3. Press F1 “SELECT (+)” to enter the motor begin of regulation adjustment menu.

11. Press F1 to start adjusting the motor end of regulation.

12. Depress the drive pedal to max.

4. Using the UP or DOWN arrow buttons, scroll through the adjustable values until “MIN CURRENT” is displayed.

13. Using the UP/DOWN arrow buttons, adjust the “MAX CURRENT” until a motor speed of 3150rpm ± 50 is achieved. Round this value to the nearest 5mA.

5. Press F1 to start adjusting the motor begin of regulation.

14. When the motor end of regulation has been established release the drive pedal and press F1 “OK”.

6. Depress the drive pedal to max.

15. Observe the current and pressure readings, should be 580mA @ 16 BAR (232 psi).

7. Using the UP/DOWN arrow buttons, adjust the “MIN CURRENT” to the point at which the wheel speed increases. Round this value to the nearest 5mA. 8.12

Tigercat 1065/1075 FORWARDER

DRIVE

HYDROSTATIC DRIVE PUMP HYDRAULIC NEUTRAL (LINDE)

Mp

Hydraulic neutral should be checked and adjusted (if required) to ensure the pump does not produce pressure in either direction when provided with no input.

P

1. Park the machine on level ground, place the crane in its parked position, place the blade on the ground (if equipped) and turn off the engine.

S

2. Install 10000psi gauges on ‘MP’ and ‘MS’ test ports located on the drive pump.

Ms

3. Start the engine and set to a speed of 2000rpm, monitor the gauges: ·

·

If both gauges are reading less than 1000psi, turn off the engine, remove the 10000psi gauges from ‘MP’ and ‘MS’ and replace with 1000psi gauges.

DRIVE PUMP

1014-067

If either gauge is reading over 1000psi skip to step 6.

4. Start the engine and set to a speed of 2000rpm, if the difference between the two gauges is less than 29psi, no adjustment is required.

5. If the difference between the two gauges is greater than 29psi, loosen the spanner nut.

6. Using a 16mm wrench and a digital caliper, adjust the hydraulic neutral adjustment screw to a height of 14.75mm.

7. Continue making small adjustments to the hydraulic neutral adjustment until the difference between the two gauge readings is less than 29psi.

SPANNER NUT

8. Once neutral has been established (gauges less than 29psi different) secure the spanner nut on the hydraulic neutral adjustment.

1014-068

8.13

NEUTRAL ADJUSTMENT 14.75mm

DRIVE PUMP CONTROLLER

Tigercat 1065/1075 FORWARDER

DRIVE

HYDROSTATIC DRIVE PUMP BEGIN OF REGULATION

10. To Adjust the Regulation Begin Pressure:

TOOLS REQUIRED:

b. Use the 13mm wrench on “Locking Nut 1” to adjust “Regulation Begin Cup 1”. Turn it IN to increase the regulation begin pressure or turn it OUT to decrease it.

1 - Hammer 1 - Punch 1 - 13 mm offset closed end wrench 2 - 0-600 psi gauges 1 - 0-6000 psi gauge

c. Use the hammer and punch to tighten (rotate CW) “Spanner Nut 1”.

Hydraulic neutral should be checked and adjusted (if required) prior to performing this procedure.

d. Repeat steps 8 and 9 to verify that the regulation begin pressure is 3.7-4.3 bar (54-62 psi) @ full throttle.

1. Install the 0-600 psi delta p-gauge into ports “Y” and “Z” (“HI” side into “Y” and “LO” side into “Z”).

2.

a. Use the hammer and punch to loosen (rotate CCW) “Spanner Nut 1”.

Install the 0-6000 psi gauge into gauge port “Mp”.

3. Place the Travel Direction Switch in the OFF position and set the input speed to high idle.

4. While simultaneously monitoring both gauges, slowly energize solenoid “My”. Note the pressure on the delta p-gauge when you first see pressure at port “Mp”. This is the regulation begin pressure for workport “P”.

5. To Adjust the Regulation Begin Pressure: a. Use the hammer and punch to loosen (rotate CCW) “Spanner Nut 2”. b. Use the 13mm wrench on “Locking Nut 2” to adjust “Regulation Begin Cup 2”. Turn it IN to increase the regulation begin pressure or turn it OUT to decrease it. c. Use the hammer and punch to tighten (rotate CW) “Spanner Nut 2”. d. Repeat steps 3 and 4 to verify that the regulation begin pressure is 3.7-4.3 bar (54-62 psi) @ full throttle..

6. Install the 0-600 psi delta p-gauge into ports “Z” and “Y” (“HI” side into “Z” and “LO” side into “Y”).

7. Install the 0-6000 psi gauge into gauge port “Ms”.

8. Set the input speed to high idle.

9. While simultaneously monitoring both gauges, slowly energize solenoid “Mz”. Note the pressure on the delta p-gauge when you first see pressure at port “Ms”. This is the regulation begin pressure for workport “S”.

8.14

Tigercat 1065/1075 FORWARDER

DRIVE

HYDROSTATIC DRIVE MOTOR BEGIN OF REGULATION TOOLS REQUIRED: 1 - Hammer 1 - Punch 1 - 13 mm offset closed end wrench 1 - multi meter (0-1000 mA) 1 - 4mm Allen wrench 1 - digital calipers (0.1 mm increments) MOTOR #1 ADJUSTMENT This procedure should only be performed if the begin of regulation adjustment has been tampered with or if one or both motor controls have been replaced.

1. On the Motor #2 Regulation Begin Adjustment, hold the Min. Displacement Stud stationary with the 4mm Allen wrench and loosen the Locking Nut with the 13mm wrench.

2. Slowly turn the Min. Displacement Stud IN until it just touches the spool in the motor control then tighten the Locking Nut. Record the number of turns (to the nearest 1/8 turn) of the stud.

7. For a 24VDC Solenoid, the regulation begin setting should be 225 ± 2.5 mA. To adjust the regulation begin setting, use the following steps for the control on Motor #1: a. Use the hammer and punch to loosen the Spanner Nut. b. Use the 13mm wrench on the Locking Nut to turn the Regulation Begin Cup IN to increase the regulation begin setting or OUT to decrease it.

Number of Turns Stud #2 _____ = turns 3. As illustrated above, measure from the edge of the Regulation Begin Cup to the edge of the motor control for Motor #1. Use the following steps to adjust the Regulation Begin Cup:

c. Once a regulation begin setting of 225 ± 2.5 mA (24VDC Solenoid) is acquired, use the hammer and punch to tighten the Spanner Nut.

a. Use the hammer and punch to loosen the Spanner Nut.

8. On the Motor #2 Regulation Begin Adjustment, hold the Min. Displacement Stud stationary and loosen the Locking Nut.

b. Use the 13mm wrench on the Locking Nut to turn the Regulation Begin Cup either IN or OUT until the dimension of 15.6mm is acquired.

9. Turn the Min. Displacement StudOUT by the number of turns recorded in Step #2 above.

Tighten the Locking Nut. The proper torque for the Locking Nut is 10 ft-lb.

c. Use the hammer and punch to tighten the Spanner Nut. 4. Connect the multi-meter to measure the current to the motor solenoid.

10. Perform Motor #2 Adjustment, outlined on the following page.

5. Supply a constant flow to the motor (It is important to maintain a constant flow since changes in motor rotational speed are used as an indicator).

6. While monitoring both the multi-meter and the motor rotational speed, slowly supply current to the motor solenoid. When the motor rotational speed changes (increases), record the current on the multi-meter – This is the regulation begin setting for Motor #1.

8.15

Tigercat 1065/1075 FORWARDER

DRIVE

HYDROSTATIC DRIVE MOTOR BEGIN OF REGULATION CONT’D MOTOR #2 ADJUSTMENT This procedure should only be performed if the begin of regulation adjustment has been tampered with or if one or both motor controls have been replaced.

1. On the Motor #1 Regulation Begin Adjustment, hold the Min. Displacement Stud stationary with the 4mm Allen wrench and loosen the Locking Nut with the 13mm wrench.

2. Slowly turn the Min. Displacement Stud IN until it just touches the spool in the motor control then tighten the Locking Nut. Record the number of turns (to the nearest 1/8 turn) of the stud.

Number of Turns Stud #1 _____ = turns 3. As illustrated above, measure from the edge of the Regulation Begin Cup to the edge of the motor control for Motor #2. Use the following steps to adjust the Regulation Begin Cup:

7. For a 24VDC Solenoid, the regulation begin setting should be 225 ± 2.5 mA. To adjust the regulation begin setting, use the following steps for the control on Motor #2: a. Use the hammer and punch to loosen the Spanner Nut. b. Use the 13mm wrench on the Locking Nut to turn the Regulation Begin Cup IN to increase the regulation begin setting or OUT to decrease it.

a. Use the hammer and punch to loosen the Spanner Nut. b. Use the 13mm wrench on the Locking Nut to turn the Regulation Begin Cup either IN or OUT until the dimension of 15.6mm is acquired.

c. Once a regulation begin setting of 225 ± 2.5 mA (24VDC Solenoid) is acquired, use the hammer and punch to tighten the Spanner Nut.

c. Use the hammer and punch to tighten the Spanner Nut. 4. Connect the multi-meter to measure the current to the motor solenoid.

8. On the Motor #1 Regulation Begin Adjustment, hold the Min. Displacement Stud stationary and loosen the Locking Nut.

5. Supply a constant flow to the motor (It is important to maintain a constant flow since changes in motor rotational speed are used as an indicator).

9. Turn the Min. Displacement Stud OUT by the number of turns recorded in Step #2 above.

Tighten the Locking Nut. The proper torque for the Locking Nut is 10 ft-lb.

6. While monitoring both the multi-meter and the motor rotational speed, slowly supply current to the motor solenoid. When the motor rotational speed changes (increases), record the current on the multi-meter – This is the regulation begin setting for Motor #1.

8.16

Tigercat 1065/1075 FORWARDER

DRIVE

STEERING OPERATION

STEERING CURRENT OUTPUT ADJUSTMENTS

TRAVEL DIRECTION SWITCH

1. With the seat facing forward, start the engine and depress the pilot reset switch to activate the computer.

••

2. Reset the pilot.

3. Use the switch to the left of the display to select the Iqan display screen.

R.H. JOYSTICK & CONTROL SWITCHES

1014-001

A. Set the TRAVEL DIRECTION switch to either the FWD. or REV. position. Press the DRIVE PEDAL slightly to disengage the parking brake (note that the machine may creep slightly).

Operate the STEERING JOYSTICK slightly in one direction until it hits the stop.

4. Disable the limited travel speed function.

5. Press the ESCAPE button to display the menu selection screen.

STEERING JOYSTICK

•

1014-002

L.H. JOYSTICKS &CONTROLS B. Operate the STEERING JOYSTICK slightly in the opposite direction, as SLOWLY as possible, until it hits the end stop. This should result in slow, gentle articulation of the machine.

C. Operate the STEERING JOYSTICK back to the other end stop, as FAST as possible (control moved to its extent). This should result in quick, severe articulation of the machine.

6. Using the UP or DOWN arrow buttons, scroll through the 5 different menus until the “Properties” menu is found.

7. Press the F2 button to enter the output property menu.

D. If this condition is not obtained, check the CURRENT OUTPUT parameters.

For additional information on the steering system refer to SECTION 11 of THIS MANUAL.

8. Use the UP or DOWN arrow buttons if necessary to locate the “Current Out” menu.

8.17

Tigercat 1065/1075 FORWARDER

DRIVE 2 1 6 5 7

9. Press the F1 button to enter the function selection menu.

CRANE/BLADE SWITCH

4

•• •

3

8

• •• •• ••

9

TRAVEL SPEED SWITCH

1014-001

R.H. JOYSTICK & CONTROL SWITCHES NOTE: The CRANE/BLADE switch is a three position switch. Selecting the OFF position enables the R.H. Joystick (1) to ENGAGE or DISENGAGE the differential locks as follows:

10. Press the F3 button to activate manual function selection.

11. Using the UP or DOWN arrow buttons, scroll through the adjustable functions until “Steer COUT” is displayed.

Joystick Left (2) - Rear Differential Lock OFF Joystick Right (3) - Rear Differential Lock ON Joystick Forward (4) - Front Differential Lock ON Joystick Back (5) - Front Differential Lock OFF

The differential locks will remain in the selected condition regardless of how the CRANE/BLADE switch is operated afterwards. The differential locks are only controllable when the CRANE/ BLADE switch is in the OFF position.

B. Release the drive pedal 12. Press F1 “SELECT (+)” to enter the Steering Forward adjustment menu.

C. Set the DIFF. LOCK SELECTOR switch to FRONT , then press and hold the DIFF. LOCK switch ON. Press the drive pedal slightly to disengage the parking brake. While steering the machine and driving slowly, engage and disengage the front differential locks. There should be a noticable difference in the turn radius of the machine and the rotation speed of the LH and RH wheels on the front bogie when the differential locks turn off and on.

13. Using the UP or DOWN arrow buttons, scroll through the adjustable values until “MIN CURRENT” is displayed.

14. Press F1 to start adjusting the output.

15. Engage steering joystick and use the UP or DOWN arrow buttons to adjust the “MIN CURRENT” to obtain desired steering response.

D. Release the drive pedal.

16. When desired steering response is achieved release joystick and press F1 “OK”.

DIFFERENTIAL LOCKS OPERATIONAL TEST A. Bring the machine to a full stop, ensure that both front and rear differential locks are turned OFF. Set the TRAVEL DIRECTION switch to either the FWD. or REV. position. Press the drive pedal slightly to disengage the parking brake (note that the machine may creep slightly). Steer the machine.

All wheels should rotate as machine is being steered. Steer several times, check all wheels.

E. Set the DIFF. LOCK SELECTOR switch to REAR, then press and hold the DIFF.LOCK switch ON. Press the drive pedal slightly to disengage the parking brake. While steering the machine and driving slowly, engage and disengage the rear differential locks. There should be a noticable difference in the turn radius of the machine and the rotation speed of the LH and RH wheels on the rear bogie when the differential locks turn off and on.

F.

8.18

Release the drive pedal.

Tigercat 1065/1075 FORWARDER

DRIVE

TRANSMISSION

AXLES

1014-3600

1014-048

DRIVE TRAIN

TRANSMISSION & DRIVE MOTOR The transmission transmits power to both the front and rear axles unless pilot pressure is supplied to the rear drive disconnect to de-clutch the all wheel drive function. When the declutch is operated, drive power is directed to the front axle only.

Power is supplied to the transmission by the hydraulic motor mounted to the input side of the transmission. The output shafts transmit the power to the front and rear axles through the driveshafts.

Power from the drive motor is transmitted to the front and rear axles via the transmission and the front and rear drive shafts.

Shifting gears in the transmission is accomplished with pilot pressure from the gear select manifold valve. When a gear is engaged, a feed back signal from the shifting sensor is sent back to the MDM. If the MDM sends an electrical signal to the solenoid on the gear change valve and does not receive the proper feedback, a “Transmission Gear Not Engaged” warning will display on the MDM to alert the operator of the condition. When this alarm is activated, change gear selection to engage another drive gear and disable alarm.

Each axle assembly consists of an input yoke, differential with hydraulic differential lock, Inboard multiple wet disk brakes, slew bearings bogie housings and gear sets, axle housings and shafts.

The gears and bearings in the transmission are lubricated by splash lubrication inside the case.

The oil level in the transmission must always be kept up to the proper level as indicated on the dipstick. Add oil to the transmission as required using dipstick fill tube. Refer to SERVICE AND LUBRICATION POINTS chart in SECTION 3 of THIS MANUAL for recommended lubricant information.

The differentials distribute the power to each side of the axle while allowing the wheels on each side of the differential to turn at different speeds. The differential locks, in the front and rear axle assemblies, are hydraulically controlled and can be independently turned ON or OFF by switches in the cab.

DIPSTICK

1014-D062

••

Both axles are bolted directly to their respective frames. The centre joint is pivot mounted to the rear frame allowing it to oscillate.

Both front and rear axle assemblies are configured in an identical manner, but are installed in opposing directions.

The gear oil in the differentials and bogie housings is separated within the axle by internal seals. This results in the need to individually drain and fill these components. Refer also to AXLE LUBRICATION in THIS SECTION. DIFFERENTIAL AND DIFFERENTIAL LOCKS

Differential locks provide positive drive to both sides of the axle (all 4 wheels) when tractive conditions might otherwise allow one side to spin.

By using the R.H. joystick, one or both of the axles can have the differential lock activated. This function energizes the differential lock control valve solenoids (C4 & C5, located on the auxiliary function valve) and directs pilot oil to the corresponding differential lock engagement pistons to lock the differential(s). Refer to AUXILIARY FUNCTION VALVE in THIS SECTION for additional information on the differential lock hydraulic circuit.

TRANSMISSION OIL LEVEL 8.19

Tigercat 1065/1075 FORWARDER

DRIVE

AXLE LUBRICATION

6. Clean any filings from the magnetic drain plug.

Each bogie axle has seven separate oil reservoirs that require individual draining/filling, there are nine drain points and seven fill points. The axle must be level when draining/filling lubricant.

Perform scheduled oil change in the axles when doing the seasonal hydraulic oil change. Refill the axle differentials and bogie housings with SAE 90/ API-GL-5 gear oil.

7. Replace the differential housing drain plug.

DRAINING AND REFILLING DIFFERENTIAL: (1 PER AXLE) 1. Park machine on level ground, install articulation lock bar, lower the snow blade (if equipped) and place the crane in the park position, stop engine, remove key, then switch battery disconnect off, and block wheels.

10. Position the wheel hub for draining the planetary, with the drain plug in the lowest possible position as shown.

8. Refill the differential by pumping oil into the fill/ level plug on the differential. Stop adding oil when the oil level reaches the bottom of the differential level fill/level plug.

9. Replace the differential fill/level plug.

PLANETARY DRIVES (4 FILLING POINTS)

11. Remove the PLANETARY FILL PLUG. 12. Remove the PLANETARY DRAIN/LEVEL PLUG and drain the oil into a suitable container for disposal.

2. The axle must be level in order to drain and refill it properly.

13. Reposition the wheel hub for filling the planetary, with the PLANETARY DRAIN/LEVEL PLUG at 9 o’clock and the fill plug at 1 o’clock as shown.

3. Clean around all fill, level and drain plugs before removing them.

4. Remove the differential fill/level plug located opposite the input yoke on the differential housing.

14. Refill the planetary with new oil until the level reaches the bottom of the PLANETARY DRAIN/LEVEL PLUG. (Note: To get a correct filling level the wheel hub must be in the planetary fill position as shown.)

5. Remove the differential housing drain plug located on the bottom of the differential, and drain the oil into a suitable container for disposal.

15. Repeat steps 10 to 14 for each of the four planetary drives.

BREATHER DIFFERENTIAL FILL PLUG (1 PLACE)

BOGIE HOUSING LEVEL PLUG (4 PLACES)

• (DIPSTICK 1 PLACE)

•

BOGIE HOUSING FILL PLUG (2 PLACES)

••

•

•

•• BOGIE HOUSING DRAIN PLUG (4 PLACES)

PLANETARY FILL PLUG (4 PLACES)

BOGIE HOUSING CONTAMINATED DRAIN PLUG (4 PLACES - LOWER)

WHEEL HUB IN PLANETARY FILL POSITION

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS 8.20

•

WHEEL HUB IN PLANETARY DRAIN POSITION

PLANETARY LEVEL/DRAIN PLUG (4 PLACES)

• •

BM041

DIFFERENTIAL DRAIN PLUG (1 PLACE)

Tigercat 1065/1075 FORWARDER

DRIVE BREATHER DIFFERENTIAL FILL PLUG (1 PLACE)

BOGIE HOUSING LEVEL PLUG (4 PLACES)

• (DIPSTICK 1 PLACE)

•

BOGIE HOUSING FILL PLUG (2 PLACES)

•

•

•

•• BOGIE HOUSING DRAIN PLUG (4 PLACES)

PLANETARY FILL PLUG (4 PLACES)

BOGIE HOUSING CONTAMINATED DRAIN PLUG (4 PLACES - LOWER)

•

WHEEL HUB IN PLANETARY DRAIN POSITION

PLANETARY LEVEL/DRAIN PLUG (4 PLACES)

• •

BM041

DIFFERENTIAL DRAIN PLUG (1 PLACE)

WHEEL HUB IN PLANETARY FILL POSITION

BOGIE AXLE FILL, DRAIN AND LEVEL PLUGS

DRAINING AND REFILLING BOGIE HOUSING: (2 PER AXLE) 16. Remove the bogie housing fill plugs located on the top of the bogie housing.

17. Remove the bogie housing level plugs located on the inside of the housing.

Note: There are two bogie housing level plugs to be removed per axle.

18. Remove the bogie housing drain plugs on the inside of the bogie housings, towards the bottom. Note, there are four plugs in total to be removed per axle to drain the bogie housings. Drain the oil into a suitable container for disposal.

19. Clean any filings from the magnetic drain plugs.

20. Replace the bogie housing drain plugs in all locations.

IMPORTANT To prevent serious damage, care should be taken to refill the axle(s) before moving the machine after draining.

21. Refill the bogie housings by pumping oil into the fill plug on the bogie housings. Stop adding oil when the oil level reaches the bottom of the bogie housing level plug. Note, each of the bogie housings must be filled separately.

22. Replace the bogie housing level plugs.

23. Replace the bogie housing fill plugs.

Note: There are 9 drain points and 7 fill points CAPACITIES For front and rear axle oil fill capacities, refer to the table: SERVICE AND LUBRICATION in SECTION 3 of THIS MANUAL.

8.21

Tigercat 1065/1075 FORWARDER

DRIVE

WHEEL INSTALLATION NOTE: All wheel installation joints and surfaces should be clean, flat surfaces (free of paint, grease and oil etc.) using grade 10 nuts, hardened washers and standard torque practices.

•

1

2

••

Thoroughly clean the wheel studs (1) in the axle flange, as well as the nuts and washers (2). When cleaning studs in the axle flange, double check and be sure to use the proper size die for the threads (M22x1.5).

WARNING If a power wrench is used to install wheel nuts, be sure that the nuts are first handengaged to prevent stripping. Operate the wrench slowly to prevent damage to the threads.

•

Install wheel nuts by hand to insure bolts are not cross threaded.

•

Torque the M22x1.5 wheel nuts to 545Nm (400 lbf/ft).

8.22

••

Tigercat 1065/1075 FORWARDER

1014.NAF.TC14

DRIVE

DIFFERENTIAL ASSEMBLY AND DIFF LOCK COMPONENTS

8.23

Tigercat 1065/1075 FORWARDER

1014-003.TIF

DRIVE

DIFFERENTIAL ASSEMBLY AND DIFF LOCK CROSS SECTION

8.24

Tigercat 1065/1075 FORWARDER

DRIVE

DIFFERENTIAL ASSEMBLY AND DIFF LOCK COMPONENT LIST 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

Screw for locking plate Locking plate for groove nut Groove nut Crown gear side Allen screw for Diff.-flange O-ring Axle beam, Diff.

Diff.-flange Crown gear side O-ring Diff.-flange Diff.-cage bearing Crown gear side Crown wheel screw HV washer crown wheel Diff.-cage Dowel pin for crown wheel Crown wheel / pinion Butting ring for compensating gear Compensating gear Cross bolt Bushing Differential gear Thrust washer for Differential gear Screw for compression spring by MDDL Compression spring Allen screw Diff.-cage Multi disc support Diff.-cage bearing (at lock) Shaft seal for piston Driven disc Piston Diff.-lock Axial bearing Adjusting washers for Diff.-cage (gear gap) Drive disc Piston Diff.-lock Butting ring Multi disc support Allen screw Piston seal Diff.-lock Diff. flange (lock)

37. Seal ring to control plug 38. Oil control plug Diff.

39. 40. Butting ring 41. Allen screw 42. Differential housing 43. Pinion head bearing 44. Print pattern adjusting washer Diff.-housing 45. Pinion bearing adjusting washer 46. Spacer sleeve Pinion bearing 47. Spacer sleeve Pinion bearing 48. Outer Pinion bearing 49. O-ring Drive shaft flange 50. Drive shaft flange nut 51. Drive shaft flange 52. Washer 53. O-ring in Drive shaft flange cover 54. Gasket 55. Drive shaft flange cover 56. Grease nipple 57. Lock washer 58. Screw for cover 59. V-ring 60. Flange 61. Butting ring 62. Driven disk 63. Screw 64. Washer 65. Oil drain plug Diff 66. Axial bearing 67. Butting ring 89. Seal ring for Drive shaft flange 90. Lock ring 91. Seal ring for Drive shaft flange 106. Split spring for axle housing

8.25

Tigercat 1065/1075 FORWARDER

BM070.TIF

DRIVE

DIFFERENTIAL ASSEMBLY AND DIFF LOCK COMPONENTS

8.26

Tigercat 1065/1075 FORWARDER

DRIVE

SERVICE/PARKING BRAKES The disk type brake assembly consists of a operating disk, a series of steel and friction disks and a brake cylinder. One brake assembly is located on each side of the differential case inside the slew bearings.

The disk brake assembly (5) is mounted on the differential housing with locking dowels (6) that prevent rotation of the steel disks. The friction disks are splined to the gear shaft which connects the differential to the centre gear in the bogie housing.

flow through the service brake port on the brake cylinder to move the piston against the operating disk lugs applying pressure to the steel and friction disks applying the brakes. For information on the hydraulic brake circuit refer to SECTION 9 of THIS MANUAL. The brake cylinder assemblies are equipped with brake bleed screws. Brakes must be bled whenever there has been potential for air to enter the system, such as removal of hydraulic line. All passages must be bled one at a time. Refer to BRAKE BLEEDING in SECTION 9 of THIS MANUAL for brake bleeding procedure.

Brake operation is accomplished by the use of a brake cylinder (1) applying force against the operating disk lugs (2) forcing the operating disk to spread apart and apply pressure against the friction disks (3) and steel disks (4).

2

•

6

3

• •

6

•

The brake cylinder (1) is activated in three ways:

•

1. Spring applied for Parking Brakes.

5

2. Hydraulic applied Service Brakes.

4

•

3. Hydraulic applied Secondary Brakes When the brake pedal control in the cab is depressed, an electronic signal is sent to the computer. The computer then sends the proportional signal to the brake valve solenoids.

The brake valve then allows brake pressure oil to

•

6

•

6

1014-002.TIF

1

DISK BRAKE ASSEMBLY

5

•

•

2

•

1

1014-001.PDF

•

•

BRAKE INSTALLATION CROSS SECTION 8.27

1014-002.PDF

Tigercat 1065/1075 FORWARDER

1014-002.PDF

DRIVE

BRAKE INSTALLATION AND DIFFERENTIAL GEAR SHAFT CROSS SECTION 8.28

Tigercat 1065/1075 FORWARDER

DRIVE

DISK BRAKE CYLINDER COMPONENTS

BMO.O7O-2.TIF

1014-001.PDF

1014.002.TIF

DISK BRAKE ASSEMBLY

Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 8.29

Part Description Screw Plug Protective cap Hex bolt O-ring Housing Plate spring Piston Allen screw Locking ring Allen screw Hex nut Guide ring Cylinder (upper part) Gasket Piston seal Breather valve with dust hood Guide ring O-ring Cylinder (lower part) Piston seal Stud O-ring Pressure piston

Qty. 1 1 1 1 1 26 1 2 2 1 1 1 1 1 1 2 1 1 1 2 1 1 1

Ring Piston seal Piston seal Allen screw Locking clip Wedge

1 2 1 4 4 1

Tigercat 1065/1075 FORWARDER

DRIVE

PRESSURE AND SPEED SETTINGS (@ 48-60°C) Engine RPM (Full Throttle)

2200 rpm

Engine RPM (Low Idle with pilot reset) Engine RPM (Low Idle without pilot reset)

825 - 875 rpm 800 rpm

Hydrostatics Charge Pressure Parker Tandem Pump

19.7-20.3 bar @ 1100 rpm 285-295 psi @ 1100 rpm 19.7-20.3 bar @ full throttle 285-295 psi @ full throttle

Parker Tandem Pump

Main Reliefs Forward Reverse Overload Protection functions correctly Drive Pump Forward - Drive Pump Begin of Regulation Control

Forward - Drive Pump End of Regulation Control

Reverse - Drive Pump Begin of Regulation Control

Reverse - Drive Pump End of Regulation Control

Drive Motor Drive Motor Begin of Displacement Control

418.2-421.6 bar @ full throttle 6065-6115 psi @ full throttle 418.2-421.6 bar @ full throttle 6065-6115 psi @ full throttle after 5 secs.

3.7-4.3 bar @ full throttle 54-62 psi @ full throttle Min Current 15.3-16.7 bar @ full throttle 222-242 psi @ full throttle Max Current 3.7-4.3 bar @ full throttle 54-62 psi @ full throttle Min Current 15.3-16.7 bar @ full throttle 222-242 psi @ full throttle Max Current 3.7-4.3 bar @ full throttle 54-62 psi @ full throttle Min Current

Drive Motor Min Displacement Control

3100-3200 rpm Max Current

Main Pump Pump LS Margin Pressure

24.5-25.5 bar @ full throttle 355-370 psi @ full throttle 215-220 bar @ full throttle 3118-3190 psi @ full throttle

Pump Pressure Compensator

8.30

Tigercat 1065/1075 FORWARDER

DRIVE

PRESSURE AND SPEED SETTINGS (@ 48-60°C) High Pressure Manifold Pressure Reducing Valve 1

137-139 bar @ full throttle 1980-2020 psi @ full throttle 98-102 bar @ full throttle 1421-1479 psi @ full throttle 105 bar @ full throttle 1523 psi @ full throttle 124 bar @ full throttle 1800 psi @ full throttle 70 bar @ full throttle 1015 psi @ full throttle

Pressure Reducing Valve 2 Pressure Relief Valve Pressure Switch High Pressure Switch Low Low Pressure Manifold Pressure Reducing Valve

43-44 bar @ full throttle 624-638 psi @ full throttle 55-56 bar @ full throttle 798-812 psi @ full throttle

Pressure Shut-Off Valve Differential locks Front axle

43-44 bar @ full throttle 624-638 psi @ full throttle 43-44 bar @ full throttle 624-638 psi @ full throttle

Rear axle

Steer Valve * Assume limits of plus/minus 1bar (14.5psi) for non-adjustable relief valve settings Winch P.O.R. Pressure (A) 195-200 bar @ full throttle 2828-2900 psi @ full throttle Winch Relief Pressure (A) 230 bar @ full throttle 3335 psi @ full throttle Winch P.O.R. Pressure (B) 195-200 bar @ full throttle 2828-2900 psi @ full throttle Winch Relief Pressure (B) 230 bar @ full throttle 3335 psi @ full throttle Gate P.O.R. Pressure (A) FULL @ full throttle Gate Relief Pressure (A) 230 bar @ full throttle 3335 psi @ full throttle Gate P.O.R. Pressure (B) FULL @ full throttle Gate Relief Pressure (B) 230 bar @ full throttle 3335 psi @ full throttle Steer P.O.R. Pressure (A) FULL @ full throttle Steer Relief Pressure (A) 230 bar @ full throttle 3335 psi @ full throttle Steer P.O.R. Pressure (B) FULL @ full throttle Steer Relief Pressure (B) 230 bar @ full throttle 3335 psi @ full throttle Blade P.O.R. Pressure (A) TBA bar @ full throttle TBA psi @ full throttle Blade Relief Pressure (A) 230 bar @ full throttle 3335 psi @ full throttle Blade P.O.R. Pressure (B) TBA bar @ full throttle TBA psi @ full throttle Blade Relief Pressure (B) 230 bar @ full throttle 3335 psi @ full throttle

8.31

Tigercat 1065/1075 FORWARDER

DRIVE

PRESSURE AND SPEED SETTINGS (@ 48-60°C) Crane Functions Valve * Assume limits of plus/minus 1bar (14.5psi) for non-adjustable relief valve settings Stick Boom P.O.R. Pressure (A) N/A Stick Boom Relief Pressure (A) 230 bar @ full throttle 2320 psi @ full throttle Stick Boom P.O.R. Pressure (B) N/A Stick Boom Relief Pressure (B) 230 bar @ full throttle 3335 psi @ full throttle Main Boom P.O.R. Pressure (A) N/A Main Boom Relief Pressure (A) 230 bar @ full throttle 3335 psi @ full throttle Main Boom P.O.R. Pressure (B) N/A Main Boom Relief Pressure (B) N/A Swing Rotate P.O.R. Pressure (A) N/A Swing Rotate Relief Pressure (A) 210 bar @ full throttle 3045 psi @ full throttle Swing Rotate P.O.R. Pressure (B) N/A Swing Rotate Relief Pressure (B) 210 bar @ full throttle 3045 psi @ full throttle Telescope Boom P.O.R. Pressure (A) FULL @ full throttle Telescope Boom Relief Pressure (A) 80 bar @ full throttle 1160 psi @ full throttle Telescope Boom P.O.R. Pressure (B) FULL @ full throttle Telescope Boom Relief Pressure (B) 230 bar @ full throttle 3335 psi @ full throttle Grapple Rotate P.O.R. Pressure (A) N/A Grapple Rotate Relief Pressure (A) 230 bar @ full throttle 3335 psi @ full throttle Grapple Rotate P.O.R. Pressure (B) N/A Grapple Rotate Relief Pressure (B) 230 bar @ full throttle 3335 psi @ full throttle Grapple Open/Close P.O.R. Pressure (A) 195-200 bar @ full throttle 2828-2900 psi @ full throttle Grapple Open/Close Relief Pressure (A) 230 bar @ full throttle 3335 psi @ full throttle Grapple Open/Close P.O.R. Pressure (B) 195-200 bar @ full throttle 2828-2900 psi @ full throttle Grapple Open/Close Relief Pressure (B) 230 bar @ full throttle 3335 psi @ full throttle

8.32

Tigercat 1065/1075 Forwarder SECTION 9 - BRAKES FEBRUARY , 2009

CONTENTS - SECTION 9 ACCUMULATOR ............................................................................................ 9.6 CHARGING AND TESTING DEVICE ......................................................... 9.6 CHARGING THE ACCUMULATOR ............................................................ 9.6 CHECKING THE GAS PRE-CHARGE PRESSURE ................................... 9.6 ACCUMULATOR CHARGE VALVE ............................................................... 9.2 AXLES SERVICE/PARKING BRAKES .................................................................... 9.8 BRAKE ADJUSTMENT ............................................................ 9.11, 9.12, 9.13 BRAKE BLEEDING ...................................................................................... 9.10 BRAKE PEDAL CONTROL ............................................................................ 9.2 EMERGENCY BRAKE VALVE ....................................................................... 9.9 TEST DRIVE SERVICE BRAKE OPERATION ............................................................... 9.12

Tigercat 1065/1075 Forwarder

Brakes

BRAKE PEDAL CONTROL 1

••

1014-D007

2

1

•

•

FRONT FOOT PEDAL CONTROLS

ACCUMULATOR CHARGE The main pump supplies oil directly to the boom valve. From the boom valve, pilot oil is directed to the high pressure manifold when the low pressure switch detects pressure below 70 Bar (1015 psi) and is turned off at 124 Bar (1798 psi). These switches regulate the pressure in the accumulator and braking systems. When no flow or pressure is required by the accumulator charge valve, the main pump stands by. In this state, the brake system remains responsive because the reserve has been built up in the accumulator. When flow and pressure are required by the accumulator charge circuit, a pilot signal is sent to the main pump (via the ‘LS’ port) which causes the pump to stroke. Refer to LOAD SENSING in SECTION 12 of THIS MANUAL for more information on load sense systems.

2

•• ••

1014-D008

REAR FOOT PEDAL CONTROLS

The brake pedal (1) is manually operated and communicates with the MDM Display and Control Module electronically. The pedal has a precision potentiometer (2) built into it, and will vary the voltage signal (0 to 3.2 volts) to the brake control valve proportionally as it is depressed. The brakes are spring applied and hydraulicly released.

NOTE: The accumulator will hold sufficient pressure, after the engine is turned off, for up to 5 brake applications, beyond this the pressure drops substantially and the brakes will no longer release.

Refer to BRAKE VALVE and ACCUMULATOR in THIS SECTION for further information on the brake valve and the accumulator.

BRAKE CYLINDER COVERS

•

1014-D090

••

REAR CHASSIS BRAKE CYLINDERS 1014-D202

1014-056.PLT

REAR CHASSIS ~ ACCUMULATOR

BRAKE VALVE AND HIGH PRESSURE MANIFOLDS 9.2

Tigercat 1065/1075 Forwarder

6. There will be a slow drop in pressure as the accumulator drains, through valve leakage in the system. The pressure should not drop below 70bar (1015 psi) in the first 5 minutes.

Leakage rate will be rapid at first and will slow down as the pressure drops.

HIGH PRESSURE MANIFOLD

BRAKE VALVE MANIFOLD

• 1014-203

Brakes

••

7. Start and run the engine for a further 20 seconds and shut engine off, to recharge the accumulator. Turn the ignition switch to the ON position, and depress the pilot reset switch. Pump the brakes 5 times, the pressure should remain above 70bar (1015 psi). It should take an additional 5 or more brake applications (total of 10 or more) to drain the accumulator from a full charge of 109-124bar (1450-1800psi).

HYDRAULIC VALVE COMPARTMENT

CHECKING ACCUMULATOR CHARGE CYCLE 1. Park the machine on level ground, place the crane in the park position, lower the snow blade (if equipped) to the ground and shut off the engine.

8. Remove the gauge.

2. Place the ignition switch in the ON position, and press the PILOT RESET switch. Press the BRAKE PEDAL 50 or more times to release the pressure stored in the accumulator.

SV

PR1

• P1

RV

PR2

• •• •• SW2

•• • •

•• SW1

1014-057

••

RP2 ACC1

HIGH PRESSURE MANIFOLD 3. Connect a 0-5000 psi gauge to the ACC1 test port on the high pressure valve manifold.

4. Ensure that the hydraulic oil temperature is at operating temperature. Refer to HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 5. Start the engine and run for 20 seconds, then shut off engine. The pressure should rise rapidly to 100-124bar (1450-1800 psi) and should not fall below this range until the engine is shut off. The accumulator is now holding pressure for the braking system.

Note: In cold weather, this time may need to be increased to account for thicker oil.

9.3

Tigercat 1065/1075 Forwarder

Brakes

BRAKE VALVE AND HIGH PRESSURE MANIFOLDS BRAKE / AUXILLARY CIRCUIT SET-UP: 1014-056.PLT

SV

The brake/auxiliary circuit is comprised of two manifolds. The high pressure manifold contains two reduced pressure circuits. The first reduction activates and charges the accumulator, the second supplies the low pressure manifold. The low pressure manifold controls the service brake with its inlet pressure and reduces pressure for park brake, ladder and differential lock functions. The low pressure manifold incorporates a pressure shut off circuit which will relieve pressure from the park brake, ladder and differential lock functions if it becomes too high.

1) Ensure that the hydraulic oil is at operating temperature (refer to hydraulic oil heat up procedure).

PR1

••

PR2

RV

• •• ••

P1

SW2

•• •• ••

•• •

SW1

RP2 ACC1

1014-057

HIGH PRESSURE MANIFOLD - FIGURE 1

2) Connect a 5000psi (345bar) gauge to ‘ACC1’ test port (figure 1).

3) Disconnect the 2 pin Deutsch connector from ‘SV’ (force main pump to stand by) and the spade connectors from ‘SW1’ & ‘SW2’ (figure 1). Disconnect the 2 pin Deutsch connectors from ‘SV1’, ‘SV2’, ‘SV3’, ‘SV4’ and ‘SV5’ (figure 2) 4) Adjust ‘PR1’ to minimum (turn adjustment screw counter clockwise until it stops).

The reading at ‘ACC1’ is the pressure directly affected by ‘PR1’ and can be adjusted as follows: i)

ii)

Use an 11/16” wrench to loosen the locknut on the pressure reducing valve adjustment screw (figure 1).

Turn the adjusting screw using a 3/16” allen key. Turning the adjusting screw IN (clockwise) will increase the pressure, turning the screw OUT (counter-clockwise) will decrease the pressure.

9.4

C6

C4

C5

••

•• ••

C1 C3

• ••

•• RP3

SV5 SV4

•• •• •• •• •• •• •

PU

PR3

SV2 SV3

SV1

1014-059

BRAKE VALVE MANIFOLD - FIGURE 2

Tigercat 1065/1075 Forwarder

Brakes

5) Start the engine, and depress the pilot reset switch twice, once to activate the IQAN computer system and once more to enable the controls.

6) Discharge the accumulator by setting the park brake switch to off and operating the park brake lever in the cab until ‘ACC1’ reads 400psi (28bar) or less.

19) Reset ‘PR2’ to 1450psi (100bar) ±30psi (2bar) and re-install end cover.

7) Disconnect the 2 pin Deutsch connector from ‘SV2’ (figure 2).

20) Connect a 1000psi (69bar) gauge to ‘RP3’ test port (figure 2).

8) Reconnect the 2 pin Deutsch connector to ‘SV1’ (allow main pump to stroke).

21) Use a ¼” allen key to remove the end cover of ‘PU’. Turn the adjusting screw of ‘PU’ 2 turns clockwise using a 1/4” allen key.

9) Connect a Multi-meter to ‘SW1’, set to measure continuity.

10) Slowly increase the pressure by adjusting ‘PR1’ as in step 4.

11) Once the pressure at ‘ACC1’ has reached 1450psi (100bar) ±30psi (2bar) the reading across ‘SW1’ should switch from open to closed.

•

18) Adjust ‘RV’ if required (Use a ¼” allen key to remove the end cover. Turn the adjusting screw using a 1/4” allen key. Turning the adjusting screw IN (clockwise) will increase the pressure, turning the screw OUT (counterclockwise) will decrease the pressure.) as required to achieve 1520psi (105bar) ±30psi (2bar) at ‘RP2’.

Adjustment to the pressure switch can be made by turning the small flat-head screw between the blade terminals clockwise to increase and counter-clockwise to decrease.

22) Adjust ‘PR3’ until the reading at ‘RP3’ is 798psi (55bar) +15psi (1bar) (Use a ¼” allen key to remove the end cover. Turn the adjusting screw using a 1/4” allen key. Turning the adjusting screw IN (clockwise) will increase the pressure, turning the screw OUT (counterclockwise) will decrease the pressure.) (figure 2).

23) Slowly adjust ‘PU’ counter-clockwise using a ¼” allen key until the pressure at ‘RP3’ drops to zero, re-install the end cover.

12) Connect a Multi-meter to ‘SW2’, set to measure continuity.

24) Reduce ‘PR3’ until a reading at ‘RP3’ is obtained and increase to 638psi (44bar) -15psi (1bar) and re-install end cover.

13) Continue adjusting the pressure at ‘ACC1’ to 1800psi (124bar) ±30psi (2bar). The reading across ‘SW2’ should switch from open to closed.

25) Reconnect the 2 pin Deutsch connectors from ‘SV1’, ‘SV2’, ‘SV3’, ‘SV4’ and ‘SV5’ (figure 2) and the spade terminals for ‘SW1’ & ‘SW2’ (figure 1).

If required, ‘SW2’ can be adjusted as in step 11.

14) Adjust the pressure at ‘ACC1’ to 2000psi (138bar) ±30psi (2bar), by adjusting ‘PR1’, then tighten the locknut.

15) Move the 5000psi (345bar) gauge from ‘ACC1’ to ‘RP2’ test port (figure 1).

16) Using a ¼” allen key, remove the end cover of ‘PR2’.

17) Slowly increase the setting of ‘PR2’ (Use a ¼” allen key to remove the end cover. Turn the adjusting screw using a 1/4” allen key. Turning the adjusting screw IN (clockwise) will increase the pressure, turning the screw OUT (counterclockwise) will decrease the pressure.). The reading at ‘RP2’ should increase to 1520psi (105bar) ±30psi (2bar), at which point RV will open to relieve the excess pressure.

9.5

Tigercat 1065/1075 Forwarder

Brakes

ACCUMULATOR

CHECKING THE GAS PRE-CHARGE PRESSURE Bleed off the system pressure as stated earlier.

The accumulator is piston type and is installed with a nitrogen pre-charge pressure of approximately 55 bar (800 psi).

•

•

After the accumulator has been put in service, the pre-charge pressure should be checked with an accumulator charging and testing device.

VALVE GUARD

Install the charging and testing device onto the gas valve. While depressing the button on the charging device, observe gas pressure reading on gauge.

GAS VALVE

If the gas pre-charge is low, investigate cause and correct. Possible causes of lost pre-charge pressure include leaking or damaged gas valve, or damaged piston.

WARNING •

The accumulator must not be altered. DO NOT weld or machine the pressure vessel.

PISTON

WARNING •

USE ONLY NITROGEN for charging accumulators, NEVER USE OXYGEN OR AIR, due to the risk of explosion.

HYDRAULIC CONNECTION AX205

ACCUMULATOR (PISTON TYPE)

CHARGING THE ACCUMULATOR

The gas pressure should be checked if the pilot system exhibits repeated and frequent charging cycles.

NOTE: A detailed instruction sheet is provided with the charging and testing device. The following is only a suggested guide.

NITROGEN BOTTLE

WARNING

HOSE*

Hydraulic circuits with accumulators store hydraulic oil under pressure, therefore the system may remain pressurized after the engine is turned off.

PRESSURE GAUGE*

ADAPTER* ADAPTER* ACCUMULATOR

Prior to performing any maintenance or system modifications, exercise CAUTION to bleed off any stored system pressure by depressing the brake pedal 50 or more times with the ignition switch ON, and the PILOT RESET depressed. Caution: Serious injury can result if this is not done.

ASSEMBLY PART NO. 90254 INCLUDES PARTS SHOWN * ACCU-2

A low pressure switch is installed in the hydraulic circuit, which will signal the Iqan display module when the accumulator has less than 40bar (580psi) of pressure. This will trigger an “Low Brake Pressure” alarm on the display terminal in the cab. This alarm warns the operator that the machine’s brake capabilities will NOT be sufficient.

9.6

CHARGING AND TESTING DEVICE

•

Place the crane in the park position, lower the snow blade to the ground (if equipped) and shut off the engine.

•

Turn the ignition switch to the ON position, and depress the pilot reset switch. Press the brake pedal 50 or more times to release the pressure stored in the accumulator.

•

Remove the hydraulic hose installed on the back of the accumulator.

Tigercat 1065/1075 Forwarder •

Close the drain valve on the charging and testing device and connect the hose to the nitrogen bottle.

•

Remove the valve guard and cap.

•

Screw the charging and testing device onto the gas valve.

•

Open the gas shut-off valve on the nitrogen bottle and allow gas to flow slowly into the accumulator.

•

Close the shut-off valve frequently and check the value of the pre-charge by depressing the button on the charging device and observe the gauge.

•

If the pre-charge pressure is too high, it may be reduced by opening the drain valve and carefully depressing the button on the charging device.

Brakes

Note: The pre-charge pressure will vary dependant upon the temperature. Once the desired pre-charge is reached, wait two minutes for the gas temperature to equalize.

Re-check pre-charge and adjust if necessary.

•

Disconnect hose from nitrogen bottle.

•

Remove charging and testing device from accumulator and install valve cap and guard.

•

Check to ensure there are no leaks, if gas valve is leaking, it should be replaced. Use only valves approved for accumulator service.

NEVER USE AN AUTOMOTIVE TYPE VALVE.

•

Re-install the hydraulic hose on the back of the accumulator.

•

Bleed Brake system. Refer to BRAKE BLEEDING in THIS SECTION.

9.7

Tigercat 1065/1075 Forwarder

Brakes

SERVICE/PARKING BRAKES

cylinder to move the piston and push on the operating disk lugs applying pressure to the steel and friction disks engaging the brakes. For information on the hydraulic brake circuit refer to SECTION 9 of THIS MANUAL.

The disk type brake assembly consists of a operating disk, a series of steel and friction disks and a brake cylinder. One brake assembly is located on each side of the differential case inside the slew bearings.

The brake cylinder assemblies are equipped with brake bleed screws. Brakes must be bled whenever there has been potential for air to enter the system, such as removal of hydraulic line. All passages must be bled one at a time. Refer to BRAKE BLEEDING in THIS SECTION for brake bleeding procedure.

The disk brake assembly (5) is mounted on the differential housing with locking dowels (6) that prevent rotation of the steel disks. The friction disks are splined to the gear shaft which connects the differential to the centre gear in the bogie housing.

Brake operation is accomplished by the use of a brake cylinder (1) applying force against the operating disk lugs (2) forcing the operating disk to spread apart and apply pressure against the friction disks (3) and steel disks (4).

2

•

6

3

• •

6

•

•

The brake cylinder (1) is activated in three ways: 1. Spring applied for Parking Brakes.

5

2. Hydraulic applied Service Brakes.

3. Hydraulic applied Secondary Parking Brakes

•

• 6

1014-002.TIF

DISK BRAKE ASSEMBLY

5

•

•

2

•

1

1014-001.PDF

•

6

When the brake pedal control in the cab is depressed, an electronic signal is sent to the computer. The computer then sends the proportional signal to the brake valve solenoids.

The brake valve then allows brake pressure oil to flow through the service brake port on the brake

1

4

•

•

BRAKE INSTALLATION CROSS SECTION 9.8

1014-002.PDF

Tigercat 1065/1075 Forwarder

1014-077.DWG

Brakes

BRAKE VALVE MANIFOLD

PARKING BRAKE VALVE

Pull the lever back to release the brakes. This shifts the valve spool and permits oil from the parking brake release solenoid valve (C3 on the brake valve manifold) to apply and release pressure.

The parking brake valve is located on the instrument panel in the cab. This control is a proportional manually actuated hydraulic valve which activates the parking brake, regardless of the condition of the parking brake release solenoid (C3 on the brake valve manifold). In case of emergency, this control can be engaged to stop the machine at any time.

STEERING

The parking brake control may be applied at anytime whether the machine is stationary or in motion.

A pressure switch is installed in this hydraulic circuit, which signals the MDM Control when the parking brakes are applied (ie: brake release circuit has less than 40bar (580psi) of pressure).

If the operator attempts to drive the machine when the parking brakes are applied, a “Park Brake” alarm will be triggered on the display in the cab. This alarm warns the operator that the parking brake is ENGAGED while attempting to drive.

•• ••

BRAKE 1014-D006B

Push the lever forward to engage the brake. This shifts the valve spool and permits oil on the front side of the brake piston to drain to tank. The removal of oil pressure allows the cup springs installed in the brake cylinder to push on the operating disk lugs applying pressure to the steel and friction disks applying the brakes.

9.9

Tigercat 1065/1075 Forwarder

Brakes

BRAKE BLEEDING The axle assemblies are equipped with brake bleed screws, two for each side (one for service brakes, and one for parking brake release).

Brakes must be bled whenever there has been potential for air to enter the system, such as removal of hydraulic line. All passages must be bled one at a time.

PROCEDURE 1. Start engine and run at IDLE, press the PILOT RESET switch.

1

••

•

2

BRAKE CYLINDERS 1014-D090

REAR CHASSIS BRAKE CYLINDERS

2. Loosen service brake bleed screw (1).

3. Push and hold service BRAKE PEDAL down.

4. Close bleed screw when oil is free of air.

5. Release the BRAKE PEDAL. 6. Repeat above procedure for each service brake bleed screw (2 per axle).

1014-001.PDF

7. Set Travel Direction switch to neutral.

BLEED SCREW ORIENTATION

8. Loosen parking brake release bleed screw (2).

9. Use the Park Brake lever to release the parking brake.

10. Close bleed screw when oil is free of air.

11. Release the park brake lever.

12. Repeat above procedure for each parking brake bleed screw (2 per axle).

9.10

Tigercat 1065/1075 Forwarder

Brakes

BRAKE ADJUSTMENT

3. With brake OFF, use a feeler gauge to measure gap between operating disks, then apply brakes and measure gap again.

The following procedure applies to both the front and rear bogie axles. Adjustment should be done as required. Both front and rear axles should be adjusted at the same time. Each axle has two brakes which require adjustment.

OPERATING DISK AIR GAP

PROCEDURE: 1. Park the machine on level ground, place the crane in the park position, and lower the blade to the ground (if equipped) and turn the engine off.

OPERATING DISK PLATES

BRAKE DISK PLATES

WARNING Hydraulic circuits with accumulators store hydraulic oil under pressure, therefore the system may remain pressurized after the engine is turned off.

••

••

••• ••••••• ••

BRAKE CYLINDERS

••

1014-D090

••

REAR CHASSIS BRAKE CYLINDERS

2. Remove the cover plates to gain access to the brake cylinders and top of the bogie axle brake inspection plug.

REMOVE COVERS

1014-207.PDF

4. Gap between the operating disk plates should be 2.2 to 3mm Max. If gap measures greater then 3mm disk plates require replacement.

• ••

5. If brake operating disk air gap is within the 2.2 to 3mm dimension, proceed to checking brake cylinder stroke adjustment.

1014-204

REMOVE PLUG

• 1014-205

CHECKING DISK AIR GAP

REMOVE DISK INSPECTION PLUG

2. Remove inspection plug on top of axle to gain access to brake disk assembly.

9.11

Tigercat 1065/1075 Forwarder

Brakes

CHECKING BRAKE CYLINDER STROKE BRAKE CYLINDER THREADED HOLE BRAKE CYLINDER COVERS

••

1014-D090

•

•

REAR CHASSIS BRAKE CYLINDERS

••

6. Remove brake cylinder covers and brake locking bolt inside cover.

1

7. Insert a depth gauge through threaded hole in the piston. Measure dimension "A" as shown with brakes OFF and then with brakes ON dimension "B".

8. The difference between "A" and "B" dimension should be 5.25mm. RECORD THIS DIMENSION it is required for BRAKE STROKE ADJUSTING BOLT PROCEDURE. If the dimension is greater or less then 5.25mm the bolt (1) can be adjusted to obtain this dimension, See BRAKE STROKE ADJUSTING BOLT ADJUSTMENT in this section.

1014-208.PDF

CHECKING BRAKE CYLINDER STROKE

9. If the brake disk air gap and the cylinder stroke dimension are correct install the covers and plugs.

10. Test brakes for proper operation.

SERVICE BRAKE OPERATION 1. Set the Travel Direction switch to either the FWD. or REV. position. Drive the machine and allow it to accelerate fully.

2. Press the service BRAKE PEDAL approximately half way down. This should result in slow, gentle stop of the machine.

3. Set the Travel Direction switch to either the FWD. or REV. position. Drive the machine and allow it to accelerate fully.

4. Press the service BRAKE PEDAL down fully to the floor. This should result in quick, severe stop of the machine.

9.12

Tigercat 1065/1075 Forwarder

Brakes

BRAKE CYLINDER STROKE ADJUSTING BOLT ADJUSTMENT The following procedure outlines adjustment of the brake stroke adjustment bolt. Both front and rear axles should be adjusted at the same time.

Each axle has two brakes which require adjustment.

PROCEDURE: 1. Park the machine on level ground, place the crane in the park position, and lower the snow blade to the ground (if equipped).

WARNING Hydraulic circuits with accumulators store hydraulic oil under pressure, therefore the system may remain pressurized after the engine is turned off.

2. Stop the engine and release pilot system pressure by performing the following steps: a. Close both doors. Turn key switch to the ON position. Do not start the engine.

Press pilot reset switch. b. Fully engage and then disengage the front or rear diff locks 50 times or more. c. Pressure may remain in the system after completing the above steps. Use caution when loosening hydraulic connections.

3. Remove the brake hoses from the brake cylinder.

4. Loosen and remove 4 allen bolts (28) and remove spring loaded cylinder (cylinder upper part). Do not loosen the remaining two allen bolts (8).

9.13

Item

Part Description

Qty.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Screw Plug Protective cap Hex bolt O-ring Housing Plate spring Piston Allen screw Locking ring Allen screw Hex nut Guide ring Cylinder (upper part) Gasket Piston seal Breather valve with dust hood Guide ring O-ring Cylinder (lower part) Piston seal Stud O-ring Pressure piston

1 1 1 1 1 26 1 2 2 1 1 1 1 1 1 2 1 1 1 2 1 1 1

Ring Piston seal Piston seal Allen screw Locking clip Wedge

1 2 1 4 4 1

Tigercat 1065/1075 Forwarder

Brakes

5. Loosen locking nut (11) and and remove adjusting allen bolt (10). Clean threads of the adjusting allen bolt (10) and locking nut (11) of oil and adhesive residue.

10 ADJUSTING BOLT

•• ••

11 LOCK NUT

7. Screw the locking nut (11) up to the head of the adjusting allen bolt (10).

CYLINDER LOWER PART

8. Coat entire diameter and length of thread of adjusting allen bolt (10) with Loctite 242.

••

9. Screw the adjusting allen bolt (10) into the pressure piston (23), until the bolt requires a turning torque of 8 to 15 Nm. The brake disks should be fully activated.

10. Screw the bolt out 3 1/2 turns. The brake disk air gap should now be 2.4 mm, and the adjusting bolt length should be 5.25 mm.

Tighten lock nut against pressure piston(23).

1014-209.PDF

MEASURE BOLT LENGTH

10. Insert a new o-ring (18) into the groove of the cylinder-bottom part (19) and install the spring loaded cylinder onto the brake cylinder (19) and tighten the four allen bolts (28).

NOTE: Recheck the brake cylinder stroke as outlined earlier in this section.

9.14

5.25 mm

Tigercat 1065/1075 Forwarder SECTION 10 - OIL COOLER/RADIATOR, FAN AND HYDRAULIC TANK MAY, 2005

CONTENTS - SECTION 10 BELT - ENGINE SERPENTINE ....................................................................... 10.3 CHARGE & COOLING PUMP CIRCUITS ....................................................... 10.2 CHARGE PRESSURE FILTER-DRIVE PUMP ................................................ 10.7 ENGINE SERPENTINE BELT ......................................................................... 10.3 FAN DRIVE ..................................................................................................... 10.3 FILTERS CHARGE PRESSURE ................................................................................. 10.7 HYDRAULIC OIL ......................................................................................... 10.6 SERVICING GUIDELINES FOR OIL FILTERS ............................................ 10.7 HYDRAULIC FILTERS ...................................................................................................... 10.4 OIL FILL PUMP ............................................................................................ 10.5 OIL RESERVOIR ......................................................................................... 10.4 OIL VACUUM PUMP ................................................................................... 10.5 OIL COOLER .................................................................................................. 10.2

Tigercat 1065/1075 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

OIL COOLER A/C CONDENSER

••

COOLER SCREEN

OIL COOLER

•

•

• ••

CLEAN AROUND FAN AREA

• ••

•• RADIATOR

CLEAN THE INSIDE OF HOOD SCREENS

•

1018-D069

ENGINE COMPARTMENT HYDRAULIC RESERVOIR

CHARGE AIR COOLER

STRAINER

FILTERS

The hydraulic oil cooler is part of the side by side by side oil cooler / radiator / charge air cooler package. The cooler package is mounted between the fan and the air conditioner condenser coil. The fan draws air from the front of the machine through the hood screen, A/C condenser, and cooler package and then blows it out either side of the engine compartment.

CLEAN BETWEEN A/C CONDENSER AND COOLER PACKAGE

•• ••

OIL COOLER CHARGE PUMP

COOLER PACKAGE

COOLING PUMP A/C CONDENSER CHARGE PUMP FILTER

•• 1014-053

CHARGE & COOLING PUMP CIRCUITS A/C CONDENSER AND 1014-D068 COOLER PACKAGE The cooling assembly should be checked daily and cleaned as required. The areas between the condenser and cooler package should be checked frequently, depending on operating conditions.

The A/C condenser can be swung open to clean the front of the radiator/oil cooler/charge air cooler package.

Refer to CLEANING A/C CONDENSER, OIL COOLER, RADIATOR AND CHARGE AIR COOLER in SECTION 2 of the OPERATOR’S MANUAL. 19887BILL.PLT

RADIATOR AND SURGE TANK MOUNTING 10.2

Tigercat 1065/1075 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

FAN DRIVE

REPLACING THE ENGINE SERPENTINE BELT

The engine cooling fan has nine blades and is driven by a serpentine belt. The belt also drives the alternator and the A/C compressor and is tensioned by a spring loaded idler assembly

Replace the engine serpentine belt as follows:.

1. Park the machine on level ground. Place the crane in the park position, lower the blade (if equipped) and turn engine off.

•• •

FAN GUARD FASTENERS

••

• 1014-D086

ENGINE FAN GUARD

2. Remove the six fasteners that attach the R.H. fan guard to the rad shroud and remove the fan guard.

3. Install a 1/2" Johnson bar with a 15mm socket on the hex head bolt of the belt tensioner.

4. Rotate the tensioner away from the belt to release belt tension. This will provide enough clearance to replace the serpentine belt.

1014-071

SERPENTINE BELT INSTALLATION

5. Reverse removal procedure to replace the belt.

6. Ensure that all of the ribs on the serpentine belt align with the grooves on the engine pulleys.

10.3

Tigercat 1065/1075 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank HYDRAULIC FILTERS

HYDRAULIC OIL TANK Located above the articulation joint on the front chassis, the hydraulic tank has a capacity of 185 liters (50 US gallons).

BLUE ELEMENT CHARGE PUMP FILTER

•

SIGHT GAUGE

FULL FLOW FILTER ELEMENTS

•

• •• • ••

FULL FLOW FILTER ELEMENT

• HYDRAULIC TANK

•

HYDRAULIC TANK

1014-D057

1014-D015

The hydraulic return line contains a double filter head with a built in restriction indicator and a 1.7 bar (25 psi) bypass valve. The oil cooling circuit contains another double filter head with the same restriction indicator and bypass valve. It is recommended that all machines use the following different filter elements:

HYDRAULIC OIL SIGHT GAUGE

A sight gauge visible through the right side panel indicates the HIGH and LOW level of the hydraulic oil.

3 white, Tigercat high performance, full flow hydraulic oil filter elements

LEVEL SENDER

1 blue, Tigercat water absorbing, full flow hydraulic oil filter element (installed in first location on return filter head).

HYDRAULIC TANK

TEMPERATURE SENDER 1014-D015

HYDRAULIC TANK AND FILTER LOCATION

•• ••• HYDRAULIC TANK ACCESS L.H. SIDE

A level sending unit and temperature sending unit signal the MDM to display a “Low Hydraulic Oil” or “High Oil Temperature” alarm in the cab when the oil level is low or the temperature is high.

Always keep the hydraulic oil level between the HIGH and LOW calibrations. A low hydraulic oil level can result in severe damage to pumps.

WARNING Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals. Refer to SCHEDULED MAINTENANCE in SECTION 3 of THIS MANUAL. Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

10.4

The drive pump charge circuit contains a single element, full flow, Tigercat hydraulic filter with a restriction indicator sending unit and a third port bypass valve.

For additional information on these filters, refer to HYD. FILTER BYPASS LIGHT in THIS SECTION. Also refer to FILTERS and SERVICE AND LUBRICATION POINTS in SECTION 3.

Tigercat 1065/1075 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

HYDRAULIC OIL FILL PUMP

HYDRAULIC OIL VACUUM PUMP

HYDRAULIC OIL FILL PUMP

•

FILL PUMP ON/OFF SWITCH

VACUUM PUMP

••••

QUICK COUPLER

VACUUM GAUGE

••

VACUUM PUMP ON/OFF SWITCH

•

1014-D057 1014-D059

•• R.H. SIDE OF HYDRAULIC TANK

With the IGNITION KEY SWITCH in the OFF position, place the vacuum switch in the ON position to energize the vacuum pump and open the air space in the top of the hydraulic tank to the vacuum created by the vacuum pump. This will greatly reduce oil leakage from the machine while hydraulic system repairs are underway. The pump should remain ON during the time the repairs are in progress. A gauge incorporated in the system will indicate the level of vacuum being held. Turn the switch to the OFF position when the work is complete

TOP OF HYDRAULIC TANK

The hydraulic oil fill pump, located on the top of the hydraulic tank is used to add oil to the hydraulic oil reservoir.

To add oil to the reservoir: Park the machine on level ground, with the crane in the “parked” position. Remove suction hose from storage compartment. Clean the suction hose, and remove cap. Open the right hand side access door on the hydraulic tank. Install hose into quick coupler on fill pump. Insert the end of suction tube into the supply drum and operate the pump by turning the fill pump switch ON. The oil is pumped into the reservoir through the return filters. When the oil level in the tank is satisfactory, switch the fill pump OFF.

Turning the vacuum switch OFF will stop the vacuum pump and open the tank to the atmosphere via a vent fitting.

Note: If the ignition key is turned ON while there is a vacuum in the tank, a valve will release the vacuum from the tank automatically.

IMPORTANT Replace the cap on the suction tube, disconnect from the fill pump, wipe dry and store in rear chassis compartment. Close the hydraulic tank doors.

10.5

Tigercat 1065/1075 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

HYDRAULIC OIL FILTERS

Changing the filters: 1. Park machine on level ground, install articulation lock bar, lower the blade (if equipped) and place the crane in the park position, stop engine, remove key, then switch battery disconnect off, and block wheels.

BLUE ELEMENT CHARGE PUMP FILTER

•• FULL FLOW FILTER ELEMENTS

•• • •• •

2. Wipe clean the area around the filter and head.

FULL FLOW FILTER ELEMENT

3. Place rags below to catch the spillage of oil.

••

4. Wearing face protection (in case of an oil spray), unscrew the old filter. Dispose of old filter and any oil properly.

HYDRAULIC RESERVOIR

1014-D015

HYDRAULIC RESERVOIR AND FILTER LOCATION

5. Check the seating area for the gasket on the filter head and wipe it clean.

The hydraulic return line contains a double filter head with a built in restriction indicator and a 1.7 bar (25 psi) bypass valve. The oil cooling circuit contains another double filter head with the same restriction indicator and bypass valve. In the event of a clogged filter element or thicker oil on cold starts, this bypass valve will open and redirect oil around the filter element. When the filter elements become restricted, the Red pop-up indicator will show RED, indicating that the elements must be changed. It is recommended that all machines use the following different filter elements: 3 white, Tigercat high performance, full flow hydraulic oil filter elements

6. The Tigercat spin-on filter element is supplied with two gaskets. A round ('O' ring style) section gasket is used for all four return filters.

Discard the square section gasket.

FILTER HEAD

• • GASKET

•

FILTER ELEMENT

FILTR_SEALS

ROUND SECTION GASKET INSTALLATION

1 blue, Tigercat water absorbing, full flow hydraulic oil filter element (installed in first location on return filter head).

7. Remove used gasket and clean gasket seat in head.

Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION POINTS in SECTION 3.

9. Install new gasket on inside lip of filter.

8. Apply clean oil to new gasket surfaces.

10. Screw on new filter until gasket makes contact.

11. Tighten filter until top edge makes metal to metal contact with filter head. (approximately 1 1/2 additional turns after gasket contact) 12. Start the engine and check for leaks.

IMPORTANT Contaminated hydraulic fluid can lead to premature failure of hydraulic components and costly repairs. Filters must be replaced at the recommended time intervals. Refer to SCHEDULED MAINTENANCE in THIS SECTION OF THIS MANUAL. Use of hydraulic oil filters other than the Tigercat brand could lead to severe wear and rapid failure of hydraulic system components.

10.6

Tigercat 1065/1075 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

CHARGE PRESSURE FILTER-DRIVE PUMP

HYDRAULIC FILTER SERVICING GUIDELINES

CHARGE PUMP FILTER

IMPORTANT

••

NEVER PRE-FILL ANY HYDRAULIC FILTERS

•• HYDRAULIC RESERVOIR

HYDRAULIC RESERVOIR AND FILTER LOCATION The drive pump charge circuit contains a single element, full flow Tigercat hydraulic filter with a restriction indicator sending unit and a 3.4 bar (50 psi) third port bypass valve. The restriction indicator sending unit turns on the filter bypass warning light in the cab when an oil flow restriction in excess of 3.4 bar (50 psi) is encountered at the filter head. When a restriction is encountered, the bypass valve diverts oil back to tank via the third port to prevent unfiltered oil from entering the drive circuit.

1014-D015

Changing a pressure filter:

Tigercat generally does not recommend the prefilling of spin-on filters due to the risk of damage to the hydraulic system caused by unfiltered oil.

Unfiltered oil used to pre-fill filters enters directly into the hydraulic circuit. Contaminants in unfiltered oil can cause significant and costly damage to hydraulic valves, pumps and motors.

The cleanliness of hydraulic oil cannot be guaranteed unless it is always prefiltered before use.

IMPORTANT

1. Park machine on level ground, install articulation lock bar, lower the snow blade (if equipped) and place the crane in the park position, stop engine, remove key, then switch battery disconnect off, and block wheels.

2. Wipe clean the area around the filter and head.

3. Place rags below to catch the spillage of oil.

4. Wearing face protection (in case of an oil spray), unscrew the old filter. Dispose of old filter and any oil properly.

5. Check the seating area for the gasket on the filter head and wipe it clean.

6. The new filter has an attached gasket. Apply hydraulic oil to the gasket surface.

7. Screw on the new filter until the gasket makes contact with the seat in the filter head.

8. Hand tighten filter an additional 1/2 turn only.

9. Start the engine and check for leaks.

10.7

Direct contact with oil implies a risk of skin complaints. Oil on skin should be washed off immediately with soap and water. Refer also to WORKING WITH OIL in SECTION 1 of THIS MANUAL.

Tigercat 1065/1075 Forwarder

Oil Cooler/Radiator, Fan and Hydraulic Tank

10.8

Tigercat 1065/1075 Forwarder SECTION 11- CENTER JOINT, STEERING, GATE AND SNOW BLADE FEBRUARY, 2009

CONTENTS - SECTION 11 CENTER JOINT ........................................................................................... 11.2 ARTICULATION JOINT DIAGRAM ................................................ 11.5, 11.7 ARTICULATION JOINT PRELOAD ADJUSTMENT ................................. 11.4 CHECKING ARTICULATION JOINT PRELOAD ...................................... 11.3 CHECKING/ADJUSTING THE OSCILLATION JOINT PRELOAD ............ 11.6 GREASE SEALS ...................................................................................... 11.4 LUBRICATION .......................................................................................... 11.2 MAINTENANCE OF ARTICULATION JOINT ........................................... 11.2 MAINTENANCE OF OSCILLATION JOINT .............................................. 11.2 ELECTRONIC SYSTEM .............................................................................. 11.8 LOAD GATE ............................................................................................... 11.13 STEER VALVE ............................................................................................. 11.9 ADJUSTING STEER VALVE FEED REDUCTION VALVE SETTING ..... 11.12 REPLACING MAIN PRESSURE RELIEF VALVE ................................... 11.12 REPLACING PORT RELIEFS ................................................................ 11.12 STEERING AND BLADE FUNCTIONS ELECTRONIC SYSTEM ........................................................................... 11.8 STEERING AND BLADE FUNCTIONS ........................................................ 11.8

Tigercat 1065/1075 Forwarder

Center Joint, Steering, Gate and Snow Blade REAR CHASSIS

FRONT CHASSIS

OSCILLATION JOINT CHECK FOR MOVEMENT IN THIS JOINT AREA

FRONT CHASSIS

•• ‘B’

••

‘A’

CENTER JOINT

• 1014-D071

CENTER JOINT

REAR CHASSIS

CENTER JOINT

1014-D071

250 HOUR CHECK

MAINTENANCE OF ARTICULATION JOINT

MAINTENANCE OF OSCILLATION JOINT

Maintenance in this area is usually limited to:

Maintenance in this area is usually limited to:

a) Regular lubrication of the two center joint articulation grease fittings to purge the articulation pivot bearings of debris and water.

Refer to SERVICE AND LUBRICATION POINTS in SECTION 3 for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide.

a) Regular lubrication of the two center joint oscillation grease fittings to purge the oscillation pivot bearings of debris and water.

Refer to SERVICE AND LUBRICATION POINTS in SECTION 3 for lubrication intervals. Use only high quality, lithium based EP2 grease containing molybdenum disulphide.

b) Visually checking the center joint articulation for looseness every 250 hours. With an observer on the ground, keeping well clear of the center joint area, perform the following test to check for looseness of center joint articulation.

b) Visually checking the center joint oscillation for looseness every 250 hours. With an observer on the ground, keeping well clear of the center joint area, perform the following test to check for looseness of center joint.

1. Have operator lift the crane out of the park position, and maneuver it 90 degrees to one side of the machine. Fold the stick boom down, and rapidly raise and lower the main boom several times to “bounce” machine.

2. As the machine bounces, check for motion between the front chassis and center joint lugs. Also check for a “clunking” sound at the center joint area.

3. Have operator place the crane back into the park position and switch the CRANE/ BLADE switch to OFF. 4. Movement between front chassis and center joint lugs or clunking of the pivot indicates a loose articulation joint and articulation joint preload must be checked.

Refer to CHECKING ARTICULATION PRELOAD in THIS SECTION.

11.2

1. Have operator place the crane into the park position. Drive the machine in forward and reverse rapidly several times.

2. Check for motion between the center joint and rear chassis. Also check for a “clunking” sound at the center joint area.

3. Movement between center joint and rear chassis or clunking indicates a loose oscillation joint and oscillation joint preload must be checked. Refer to CHECKING/ ADJUSTING OSCILLATION PRELOAD in THIS SECTION.

Tigercat 1065/1075 Forwarder

Center Joint, Steering, Gate and Snow Blade

CHECKING ARTICULATION JOINT PRELOAD 1. Park the machine on level ground. Set the Travel Direction switch in the OFF position, place the crane in the park position, and lower the blade to the ground (if equipped). Shut off engine.

••

•• 1014-D213

B

A

CENTER JOINT RIGHT SIDE

5. Fully loosen only the top pin retainer bolts. DO NOT REMOVE BOLTS. PLACE BLOCKS OR SAFETY STANDS UNDER FRONT AND REAR CHASSIS AS SHOWN 1014-095A

2. Place blocks or safety stands under front and rear chassis as shown to prevent any movement of the chassis during this procedure.

This is the proper bearing preload setting.

If the reading is within this range re-torque the top retainer bolts to 400Nm (300 lb. ft.).

A change of less than 0.008" indicates that the bearing preload is too low. No change on the dial indicator is the result of a loose center joint. In these cases, proceed to ARTICULATION JOINT PRELOAD ADJUSTMENT.

FRONT CHASSIS

•• ‘B’

••

‘A’

CENTER JOINT

• REAR CHASSIS 1014-D071

6. The dial indicator should now show a change of 0.009" to 0.010" between pin lugs ‘A’ and ‘B’.

CENTER JOINT LEFT SIDE

3. Place the magnetic base of a dial indicator on the top surface of the center joint bottom lug ‘A’ as close to the center pin as possible. It may be necessary to remove the mid driveshaft, depending upon the style of dial indicator.

4. Partially depress the plunger end of the dial indicator against the bottom surface of the top center joint lug ‘B’ as close to center pin as possible.

11.3

Tigercat 1065/1075 Forwarder

Center Joint, Steering, Gate and Snow Blade

ARTICULATION JOINT PRELOAD ADJUSTMENT

ORIENTATION OF GREASE SEALS

Before making any adjustments to the articulation joint, please follow CHECKING THE ARTICULATION JOINT PRELOAD procedure in THIS SECTION.

The articulation pivot bearings (10) installed in the center joint (item 5) are sealed on both sides by grease seals (items 6 and 7). These seals have proven to have a long life.

With dial indicator still in place;

If replacement becomes necessary, new seals must be installed in the proper orientation. Refer to the center joint diagram and follow these guidelines for correct installation;

1. Remove the bottom pin retainer bolts (item 1), the bottom pin retainer plate (item 3) and all of the shims in the shim pack (items 4).

NOTE: Keep upward pressure on the bottom pin (2) and do not allow pin to fall out from the bearing. These pivot pins are very heavy, block the pin in place if necessary.

2. Remove the thinnest shim from the pack.

3. Reinstall the remaining shims, the retainer plate and the bolts. Leave the bolts loose.

4. Zero the dial indicator and torque the bottom bolts in sequence to 400Nm (300 lbf-ft).

5. A change of 0.009" to 0.010" should register on the dial indicator.

This is the proper articulation bearing preload setting. If the reading is within this range no further action is required. a) If change in dial indicator reading is greater than 0.010", the shim removed (in step 2) may not have been the thinnest shim in the pack. Repeat steps 1 through 4, replacing this shim and removing only the thinnest shim from the shim pack (item 4). b) If the change in the dial indicator reading is less than 0.008", another shim will have to be removed. Repeat steps 1 through 4, removing additional shims but only the thinnest shim each time, until the change in the reading on dial indicator is within the proper range. c) It is possible that the total thickness of two shims is too great and a single shim, of lesser thickness than these two, must be removed.

11.4

• The seals installed on either side of the top and bottom bearings must be installed with the seal lips facing away from the bearings.

Apply blue 243 Loctite (removable) and torque the bolts (item 8) for the bearing retainer plate (item 9) to 270Nm (200 lbf-ft).

Tigercat 1065/1075 Forwarder

Center Joint, Steering, Gate and Snow Blade

•

8

9

•

10

•• •

6

7

• • • 5

1

•

3

•

•

2 4

• 3

•

1

•

1

3

6

5 4

18969B.PLT

ARTICULATION JOINT 11.5

2

BOLT TIGHTENING SEQUENCE

Tigercat 1065/1075 Forwarder

Center Joint, Steering, Gate and Snow Blade

CHECKING/ADJUSTING THE OSCILLATION JOINT PRELOAD

OSCILLATION END CAP

1. Park the machine on level ground. Set the Travel Direction switch in the OFF position, place the crane in the park position, and lower the snow blade fully (if equipped). Shut off engine.

2. Disconnect the rear driveshaft from the center joint driveshaft. Remove the rear driveshaft yoke (item 1) from the rear of the center joint assembly. Be careful not to damage seal (item 3).

3. Loosen the 6 oscillation end cap fasteners (item 4) evenly, and remove the oscillation end cap (item 2). CAUTION: Uneven loading of bolts can result in damage. Be careful not to damage Seal (Item 6) while removing the oscillation end cap.

VERNIER CALIPER

• •

1018-D114

OSCILLATION JOINT PRELOAD

8. Measure the thickness of the oscillation end cap (item 2).

9. Calculate the thickness of shims required.

Subtract the oscillation end cap thickness measured in step 8 from the average distance measured in step 6.

For example:

4. Remove the shim pack (item 5a & 5b).

Measured distance (step 6): 1.127” Measured thickness (step 8): 0.998” Total thickness of shims required: 0.129”

5. With the shim pack removed, install the oscillation end cap (item 2) using six washers and M16 bolts (item 4). Evenly torque to 275Nm (200 lbf-ft). Be careful not to damage Polypak Seal (item 6) while installing the oscillation end cap (item 2).

10. Select an arrangement of shims (item 5) that add up to the thickness of shims required calculated in step 9.

6. Measure distance from rear face of oscillation end cap (item 2) to rear face of centre joint through each of the small holes in oscillation end cap (2 places).

7. NOTE: The bearings are now PRE-LOADED! Loosen the six oscillation end cap fasteners (item 4) evenly, and remove the oscillation end cap (item 2). CAUTION: Uneven loading of bolts can result in damage. Be careful not to damage Polypak Seal (item 6) while removing the oscillation end cap (item 2).

11.6

11. Install selected shims (item 5), and oscillation end cap (item 2) using washers and bolts (item 4). Torque these fasteners to 275Nm (200 lbf-ft). Be careful not to damage Seal (item 6) while installing the oscillation end cap (item 2).

12. Re-assemble the rear driveshaft yoke (item 1) on the rear of the centre joint assembly. Be careful not to damage the seal. Reconnect the rear driveshaft to the center joint driveshaft.

Tigercat 1065/1075 Forwarder

Center Joint, Steering, Gate and Snow Blade

1

3

6

5 4

••

BOLT TIGHTENING SEQUENCE

2

1

•• 4

2

3

• ••

••

•

•• 5a 5b 6

1014-079.PLT

OSCILLATION JOINT 11.7

Tigercat 1065/1075 Forwarder

Center Joint, Steering, Gate and Snow Blade

STEERING AND BLADE FUNCTIONS The steering and blade functions are proportional valve functions. Each of them is controlled electro-hydraulically from a valve assembly located in the rear chassis. The term proportional means that the electronic signal sent to the proportional valve from the computer will vary comparably with the input joystick movement.

Steering “speed” is controlled by the amount the steering joystick is moved to the right or left. A small movement of the joystick will turn the machine slowly and a large movement of the joystick will turn the machine very rapidly. For example, when the steering joystick is moved 60% of its full travel towards the right, the signal sent to the steering valve will be enough to shift the spool for 60% of its full flow, which will result in the machine steering at 60% of its maximum steering “speed”.

1014-D018

ELECTRONIC SYSTEM The steer and blade functions are all controlled by the MDM Controller. The CON TROLLER monitors and analyzes inputs, then produces outputs (as defined in its program) to control the machine functions. The operator may adjust settings for all functions controlled by the MDM Controller. Refer to SECTION 2 of the OPERATOR’S MANUAL for details:

The blade function operates proportionally with respect to function “speed” in the same manner as the steering function.

11.8

Tigercat 1065/1075 Forwarder

Center Joint, Steering, Gate and Snow Blade

STEER VALVE DESCRIPTION

‘B’ SIDE

‘A’ SIDE

A B A B A B A B A B

1014-083

The steer valve, located in the rear chassis, is a load sensing and pressure compensated proportional valve and consists of spool sections, an inlet section and an end section.

A

B

GATE

A

B

STEER

A

B

BLADE

A

B

BLADE

A

B

VALVE SECTIONS (FIVE VALVE SECTION SHOWN)

Pressure Relief Valve

INLET SECTION The inlet section is equipped with connection ports to the main pump via the boom valve, tank, load sense signal (‘LS’) to the main pump, and test ports (‘PL’ and ‘PX’). Integrated into the inlet section are the steer valve main pressure relief, a load sense signal copy valve, a pressure reducer for the internal pilot-supply, and a counter pressure valve.

The inlet section of the steer valve houses a 250 bar (3625 psi) port relief. This pressure relief valve is intended to protect the steer valve from pressure peaks in the system. The cartridge also has a make-up function that allows oil to flow from the tank gallery to the pump gallery in the event of underpressure in the pump circuit. The relief cartridge is not adjustable. Refer to REPLACING MAIN PRESSURE RELIEF VALVE CARTRIDGE in THIS SECTION. PRESSURE RELIEF VALVE

INLET (FROM MAIN PUMP)

• •

1014-091

WINCH

•

INLET SECTION 11.9

OUTLET (RETURN TO MANIFOLD)

Tigercat 1065/1075 Forwarder “B” SIDE FEED REDUCTION VALVE “A” SIDE FEED REDUCTION VALVE

•

Center Joint, Steering, Gate and Snow Blade 24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

PORT RELIEF ‘A’ SIDE

PORT RELIEF ‘B’ SIDE

• •

•

•

•

• • PRESSURE COMPENSATOR 1014-007.PDF

SPOOL

SPOOL SECTION

Internal Pilot Pressure Supply The internal pilot pressure supply is a steer valve function that works as both a pressure reducer and a pressure relief valve in the pilot circuit. This cartridge has also been equipped with a separate safety valve that prevents the maximum reduced pressure from being exceeded. A check valve prevents pilot oil from leaking back to the main pump. This allows pilot pressure to be maintained in the event of a decrease in main pump pressure.

Pilot pressure is regulated at 35 bar (510 psi), and is not adjustable.

The steer valve internal pilot pressure supply provides pilot oil for the functions operated by both the steer valve and the boom valve. Oil from the main pump passes through the internal pilot pressure supply cartridge which reduces its pressure to the required pilot pressure.

Counterpressure Valve The counterpressure valve, housed in the outlet section, raises the pressure in the steer valve’s tank gallery. Raising the counterpressure reduces the risk of cavitation damage (which decreases the risk of damaging cylinder seals).

TANK CONNECTION

•

COUNTERBALANCE VALVE

••

PILOT PRESSURE CONNECTION

• ••

PILOT FILTER

•• LS CONNECTION 1014-006.PDF

END SECTION

END SECTION The end section is equipped with a separate tank connection for the pilot circuit. The main tank gallery in the steer valve and the pilot circuit tank gallery are not connected.

11.10

Tigercat 1065/1075 Forwarder “B” SIDE FEED REDUCTION VALVE “A” SIDE FEED REDUCTION VALVE

•

Center Joint, Steering, Gate and Snow Blade PORT RELIEF ‘A’ SIDE

PORT RELIEF ‘B’ SIDE

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

• •

•

•

•

• • PRESSURE COMPENSATOR 1014-007.PDF

SPOOL

SPOOL SECTION

SPOOL SECTIONS

Pressure Compensation

All of the steer valve spool sections are equipped with proportional, electro-hydraulic spool actuators.

The actuators are spring centered to the neutral position, and are shifted by sending a 24 volt proportional current signal (from the Iqan XP2 module) to the appropriate solenoid. Each section has a pilot restrictor installed in the ‘A’ and ‘B’ side to create a ‘ramping’ effect and result in smooth, gentle function operation. Each spool section is equipped with a pressure compensator. Both the cab rotate and snow blade sections are equipped with a feed reduction valve.

The primary purpose of pressure compensation is to maintain a constant flow rate to functions (ie: maintain the same speed of movement), regardless of pressure variations in the system.

The pressure compensator also contains a loadhold check valve. An orfice is installed immediately down stream of the pressure compensator to smoothly regulate the response of the compensator.

Spools Each of the spools installed in the steer valve is selected specifically for the function it is controlling. The steer section , cab rotate section and snow blade section (optional) spools each have different characteristics specific to their function. These spools cannot be interchanged.

11.11

Tigercat 1065/1075 Forwarder

Center Joint, Steering, Gate and Snow Blade

Port Reliefs The steer valve is equipped with port reliefs on each side of all spool sections. The function of the port relief is to protect the steer valve and the function cylinder or motor from pressure peaks in the system. The port reliefs also act as anticavitation valves, which means they allow oil to flow from the tank gallery in the valve to the service ports in the event of underpressure. Port reliefs cannot be adjusted. Port reliefs installed in each section are specifically designed for use in that section and should not be interchanged with port reliefs from other valve sections . Refer to REPLACING PORT RELIEF in THIS SECTION.

3. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 4. Start the engine (and run at idle). Depress the pilot reset switch.

5. Operate the function in one direction, to its full extent. Continue to hold the function at this position.

6. The reading on the 0-5000 psi gauge installed on the ‘LS’ test port should be 230 bar (3335 psi) for both A and B side. Release the function.

If adjustment is required, locate the feed reduction adjusting screws and remove the cover nut and loosen the locknut using a ½” socket. Then turn the adjusting screw using a 3/16” Allen key. Turn the adjusting screw IN (clockwise) to increase the pressure, or turn it OUT (counterclockwise) to decrease the pressure. Once the adjustment has been made, tighten the locknut, and install the cover nut.

REPLACING MAIN PRESSURE RELIEF VALVE: NOTE: Be sure to replace the relief cartridge with the appropriate replacement, as indicated in the PARTS CATALOG. 1. Park the machine on level ground, place the crane in the park position, and lower all attachments to the ground. Shut off the engine.

2. Switch the vacuum pump ON (refer to HYDRAULIC OIL VACUUM PUMP in SECTION 2 of the OPERATOR’S MANUAL).

7. Operate the same function again, and verify that the pressure being read on ‘PL’ is correct.

3. Remove the plastic cap from the relief to be changed.

8. Repeat steps 5 – 7 for the same function in the opposite direction.

4. Remove the relief cartridge using a ½” Allen key.

REPLACING PORT RELIEFS:

5. Install the replacement relief cartridge, and tighten to 60 Nm (45ftlb).

6. Install the plastic cap.

7. Switch the vacuum pump OFF. ADJUSTING STEER VALVE FEED REDUCTION VALVE SETTINGS: 1. Park the machine on level ground, place the crane in a secure position, and lower all attachments to the ground. Shut off the engine.

MAIN PUMP

DRIVE PUMP

COOLING PUMP

••

••

“LS” TEST PORT

•

•• •

1014-080.PLT

NOTE: Be sure to replace port relief cartridges with the appropriate replacement, as indicated in the PARTS CATALOG. 1. Park the machine on level ground, place the crane in the park position, and lower all attachments to the ground. Shut off the engine.

2. Switch the vacuum pump ON (refer to HYDRAULIC OIL VACUUM PUMP in SECTION 2 of the OPERATOR’S MANUAL).

3. Remove the plastic cap from the relief to be changed.

4. Remove the retaining cap from the valve body using a 1 1/16” wrench or socket.

5. Remove the existing relief, and install the replacement relief cartridge.

•• CHARGE PUMP

“LS’ TEST PORT LOCATION 2. Connect a 0-5000 psi gauge to the ‘LS’ test port on the main pump.

6. Install the retaining cap removed in step 4, and tighten to 60 Nm (45ftlb).

7. Install the plastic cap.

8. Switch the vacuum pump OFF.

11.12

Tigercat 1065/1075 Forwarder

Center Joint, Steering, Gate and Snow Blade

LOAD GATE

‘B’ SIDE

‘A’ SIDE

The load gate can be moved UP or DOWN to accommodate various load sizes, and crane movements.

A B

GATE UP/DOWN SWITCH

A B A

••

••

PILOT RESET SWITCH

B A B A B

WINCH

A

B

GATE

A

B

STEER

A

B

BLADE

A

B

BLADE

A

B

1014-001

R.H. JOYSTICK & CONTROL SWITCHES

1014-083

The GATE switch is momentary and must be held in either the UP or DOWN position for the gate to move. A hydraulic cylinder mounted to the stationary base of the load gate acts on the extension when an electrical signal is sent to a solenoid on the gate valve section.

Two gate valve port relief cartridges control the pressure made available to the cylinder for extension. The other controls the pressure available for the cylinder to retract.

6. Operate the GATE UP function, to its full extent. Continue to hold the function at this position.

7. The reading on the 0-5000 psi gauge installed on the ‘LS’ test port should be 191-195 bar (2770-2828 psi). Release the function.

NOTE: Relief valves are not adjustable, if pressure dose not meet specifications the relief valves must be replaced. See previous page, REPLACING PORT RELIEFS for replacement procedure.

TESTING PORT RELIEF PRESSURE IN GATE VALVE 1. Park the machine on level ground, place the crane in a secure position, and lower all attachments to the ground. Shut off the engine.

2. Remove the cover on the valve compartment of the rear frame to expose the gate valve.

MAIN PUMP

DRIVE PUMP

“LS” TEST PORT

•

•• •

1014-080.PLT

9. Operate the GATE UP function again, and verify that the pressure being read is correct.

10. Operate the GATE DOWN function, to its full extent. Continue to hold the function at this position.

11. The reading on the 0-5000 psi gauge installed on the ‘LS’ test port should be 230 bar (3335 psi). Release the function.

COOLING PUMP

••

••

VALVE SECTIONS (FIVE VALVE SECTION SHOWN)

NOTE: Relief valves are not adjustable, if pressure dose not meet specifications the relief valves must be replaced. See previous page, REPLACING PORT RELIEFS for replacement procedure.

• CHARGE PUMP

“LS’ TEST PORT LOCATION

12. Operate the GATE DOWN function again, and verify that the pressure being read is correct.

3. Connect a 0-5000 psi gauge to the “LS” test port on the maon pump.

13. Stop engine. Disconnect the 0-5000 psi gauge.

4. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL.

14. Install the valve compartment cover removed in step 2.

5. Start the engine (and run at idle). Depress the pilot reset switch. Place the crane in a position such that it will not hit the extended load gate.

11.13

Tigercat 1065/1075 Forwarder

Center Joint, Steering, Gate and Snow Blade

INLET SECTION

WINCH

GATE

STEER

BLADE

BLADE OUTLET SECTION

1014-083

1014-086

STEER, GATE, WINCH, AND BLADE CONTROL VALVE

HYDRAULIC VALVE COMPARTMENT - REAR CHASSIS 11.14

Tigercat 1065/1075 Forwarder SECTION 12 - CRANE, GRAPPLE AND MAIN PUMP MAY, 2005

CONTENTS - SECTION 12 BOOM VALVE .............................................................................................. 12.6 ADJUSTING BOOM VALVE FEED REDUCTION VALVE SETTING ....... 12.9 REPLACING MAIN PRESSURE RELIEF VALVE CARTRIDGE ............... 12.8 REPLACING PORT RELIEFS .................................................................. 12.9 CIRCUIT DIAGRAM ......................................................................... 12.3, 12.10 CRANE AND GRAPPLE .............................................................................. 12.2 CRANE AND GRAPPLE FUNCTIONS ELECTRONIC SYSTEM ........................................................................... 12.2 HYDRAULIC SYSTEM .............................................................................. 12.2 ELECTRONIC SYSTEM ............................................................................... 12.2 GRAPPLE ROTATOR .................................................................................. 12.2 HYDRAULIC SYSTEM DESCRIPTION ........................................................ 12.4 LOAD SENSING HYDRAULIC SYSTEM .............................................................................. 12.4 LOAD SENSING BASIC DESCRIPTION .................................................. 12.4 LOAD SENSING BASIC PRINCIPALS ..................................................... 12.4 LOAD SENSING OPERATING TIPS ........................................................ 12.5 MAIN PUMP ............................................................................................... 12.11 MARGIN PRESSURE ................................................................................ 12.13

Tigercat 1065/1075 Forwarder

Crane, Grapple and Main Pump

CRANE AND GRAPPLE All the crane functions listed below are proportionally controlled electro-hydraulically from a common boom valve assembly located in the rear chassis: CRANE ROTATE (Clockwise/Counterclockwise) MAIN BOOM (Up/Down) STICK BOOM (In/Out) TELESCOPE BOOM (Out/In) GRAPPLE ROTATE (Clockwise/Counterclockwise) GRAPPLE (Close/Open) The term proportional means that the electronic signal sent to the proportional valve from the computer will vary comparably with the input joystick movement. A small movement will operate the function slowly and a large movement will operate the function faster.

For example, if the boom up joystick is moved 60% of the full stroke, the signal sent to the boom valve will be enough to shift the spool for 60% of its full flow, which will result in the boom raising at 60% of its maximum boom up “speed”. All other boom valve functions operate in a similar manner.

1014-D018

ELECTRONIC SYSTEM All of the boom valve functions are controlled by the MDM Controller. The Controller monitors and analyzes inputs and produces outputs (as defined in its program) to control the machine. The operator may interface with the controller program using the MDM Display Terminal. Refer to SECTION 2 of the OPERATOR’S MANUAL for ionformation regarding the following: • GAUGE MENUS • MODE MENU • INFORMATION MENU • SETTINGS MENU

CRANE & GRAPPLE

• MEASURE MENU

The manufacturer’s instruction manuals for the crane and grapple installed on your machine has detailed information about operating, inspecting, and servicing your crane. Refer to the appropriate manuals before commencing any work on these components.

• PROPERTIES MENU

Grapple Rotator The grapple rotator consists of a motor, combined with a rotary manifold. The rotary manifold built into the rotator allows 360 degree, continuous rotation of the grapple.

Inputs: The computer monitors signals from the STEERING JOYSTICK and the LEFT and RIGHT MINI JOYSTICKS. The Controller also reacts to digital signals from the CRANE/BLADE switch, the TRANSMISSION GEAR SELECT switch, TRAVEL DIRECTION switch, TRAVEL SPEED switch, SEAT ROTATE POSITION switch, LADDER UP/ DOWN switch, BRAKE and THROTTLE FOOT PEDALS. Outputs: The computer directs an output (24 Volt proportional electrical current) to the boom valve solenoids to operate the various functions.

HYDRAULIC SYSTEM The proportional valve functions depend on a load sense hydraulic system composed of the following major components; 1.

2.

3.

4.

Main pump Steer Valve Boom Valve Working Components

LOAD SENSING Refer to SECTION 11 in THIS MANUAL for a complete description of the load sense system.

12.2

Tigercat 1065/1075 Forwarder

1014-087

Crane, Grapple and Main Pump

CIRCUIT DIAGRAM

12.3

Tigercat 1065/1075 Forwarder

Crane, Grapple and Main Pump

HYDRAULIC SYSTEM DESCRIPTION

LOAD SENSING BASIC DESCRIPTION

The proportional valve functions depend on a load sense hydraulic system composed of the following major components;

Load sensing systems use variable flow pumps and only flow the volume of oil that is required.

When in neutral, no oil flows through the control valve to tank and the pump output flow is zero. The pump’s output flow is controlled by a “control cylinder” which is connected to the pump output, and to the valve’s workport or “load”. This sense line to the actual working load defines the system as load sensing.

LOAD SENSING BASIC PRINCIPALS Early hydraulic systems used a fixed displacement pump, with valves to control or adjust flow rates or speeds. This throttling or restricting pump flow to achieve control over the functions causes excess oil to flow over the relief valve. This results in wasting power and at the same time creating heat.

In an attempt to recover some of the wasted energy, variable volume pumps evolved. These pumps are pressure regulated to limit the maximum output and since they reduce the pumps output to maintain a constant system pressure, oil flow over the relief valve is eliminated, therefore reducing the wasted power losses and heat generation.

However, the power wasted in the pressure control system is still considerable and still requires constant “throttling” by the operator if he wants the speeds to remain as selected, when the function pressure changes.

The load control system was developed to address the problems outlined above.

This system combines the energy saving benefits of flow on demand with pressure compensation at each work port. The compensator eliminates the need for operator flow adjustments (throttling), with changes in function pressure.

WASTED FLOW

Main pump.

Steer/Blade/Gate/Winch Valve Boom Valve Working Components

853SM18

W USED

FIG. 1

FIXED DISPLACEMENT PUMP

W FIG. 3

853SM19

PRESSURE REGULATED

HP =C ON ST AN

FLOW

T

∆p LS W

PRESSURE

1018-26

LOAD SENSING (FLOW ON DEMAND) 12.4

WASTED

USED

USED

FIG.5

PRESSURE FIG. 2 853SM16

FLOW

1.

2.

3.

4.

FIG.6

853SM16

PRESSURE FIG. 4 853SM16

Tigercat 1065/1075 Forwarder

Crane, Grapple and Main Pump regardless of load. It is important to remember the pump is really responding to the pressure differential resulting from flow through the valve, not the actual load pressure level.

The key component in the simplified system described is the spring in the control cylinder. The pump’s output pressure must be 24.5 to 25.5bar (355-370 psi) higher than the load pressure to compress the spring and reduce the flow of the pump. This 24.5 to 25.5bar (355-370 psi) is the differential or margin pressure.

1014-081.dwg

1014-081.dwg 355-370 PSI

In the figure above the control valve is closed blocking the pump from the load. With the load at zero the pump will maintain 24.5 to 25.5bar (355370 psi) of standby pressure and pump flow is zero.

0 PSI

1014-081.dwg

The following are key features of this load sensing system; 1. The load sensing valve’s maximum flow is not equal to the pumps maximum flow. The valves maximum flow is determined by the maximum size of opening or “orifice” it provides.

1014-081.dwg

When the control joystick is moved to actuate a cylinder or motor, the control valve opens the pump to the load. In this case the load is zero and the pump output pressure falls as the oil escapes through the valve. The 24.5 to 25.5bar (355-370 psi) that was holding the spring in the compressed state is reduced and the spring moves the pump to increase flow. Flow will increase to a level that requires 24.5 to 25.5bar (355-370 psi) to force the oil through the valve opening. At this point the load pressure combined with the spring force will be high enough to oppose the pump output pressure, and the control cylinder will stop moving.

Changing the control joystick position changes the size of the opening in the valve and upsets the balance of the control cylinder. The control cylinder then adjusts the flow of the pump to find a new balance point. The stroking piston will change the pump’s flow until pump pressure is 24.5 to 25.5bar (355-370 psi) higher than load pressure.

In the figures below note that even though the load pressure may change, (as illustrated by the extra restriction) the flow remains constant. This is because the difference in pressure, or differential pressure, between the pump and load pressures can be maintained by the control cylinder

2. The speed of the load does not change as the load changes. If the load increases on a boom cylinder the pump pressure will increase automatically to maintain the load’s original speed.

3. A load sensing system provides the speed the operator selects with the lever, and automatically adjusts the pressure to match the load.

LOAD SENSING OPERATING TIPS When using the controls on a load sensing system think of what the system is trying to do. If the joystick is moved 20% of its total angle, the system will provide whatever flow it takes (up to its maximum capacity if needed) to operate the function at 20% of full function “speed”.

Load sensing systems respond to rough operation by amplifying these movements. If you find the function is jerky or always giving “feedback”, you’re probably too active on the controls. Adjust the driver parameters on the MDM Controller to suit the operator and conditions. The margin pressure setting may be too high and should be checked and reset if needed.

Refer to SET MARGIN PRESSURE in this section.

12.5

Tigercat 1065/1075 Forwarder

Crane, Grapple and Main Pump

AT203.AI

1014-008.AI

BOOM VALVE DESCRIPTION The boom valve is located in the rear chassis. It can easily be accessed by opening the valve compartment enclosure door on the right side of the frame below the crane swing cylinders.

INLET SECTION

The boom valve, like the steer valve is a load sensing and pressure compensated proportional valve and consists of six* spool sections (*Note: the number of sections installed in the valve will vary with crane options selected). The valve also includes an inlet section and an end section.

12.6

The inlet section is equipped with connection ports to the main pump, tank, internal pilot filter, a load sense signal (‘LSP’) to the steer and gate valve.

Integrated into the inlet section are the boom valve main pressure relief, a load sense signal copy valve, and a counter pressure valve.

Tigercat 1065/1075 Forwarder

Crane, Grapple and Main Pump OUTLET (TO RETURN MANIFOLD)

INLET (FROM MAIN PUMP)

•

•

PRESSURE RELIEF VALVE

•

COUNTERPRESSURE VALVE

• LOAD SIGNAL COPY VALVE

• •

•

•

•

‘PS’ PORT (FROM PILOT SYSTEM FILTER)

‘PL’ TEST PORT (NOT COPIED) ‘LS’ TEST PORT (COPIED)

‘PX’ TEXT PORT (PUMP PRESSURE) 1018-I03X

INLET SECTION

Pilot pressure supply Pilot pressure supply is regulated by the steer valve, and filtered by an internal pilot system filter.

The pilot oil leaves the steer valve via the YS port, is filtered through the pilot system filter, and introduced into the boom valve through the PS port. The pilot filter protects the valve’s pilot system by providing cleaner oil compared to the rest of the hydraulic system.

Main Pressure Relief Valve The inlet section of the steer valve houses a 250 bar (3625 psi) direct acting port relief. This pressure relief valve is intended to protect the main pump , steer valve and boom valve from pressure peaks in the system. The cartridge also has a make-up function that allows oil to flow from the tank gallery to the pump gallery in the event of underpressure in the pump circuit. The relief cartridge is not adjustable. Refer to REPLACING MAIN PRESSURE RELIEF VALVE CARTRIDGE in THIS SECTION. Load sensing system

Refer to STEER VALVE - LOAD SENSING SYSTEM in SECTION 11 of THIS MANUAL for a complete description of the load sensing system.

Counterpressure Valve The counterpressure valve, housed in the inlet section, raises the pressure in the steer valve’s tank gallery. Raising the counterpressure reduces the risk of cavitation damage (which decreases the risk of damaging cylinder seals).

END SECTION The end section is equipped with a separate tank connection for the pilot circuit. The main tank gallery in the boom valve and the pilot circuit tank gallery are not connected. The TP port is connected to the rear chassis drain manifold.

SEPARATE TANK CONNECTION FOR PILOT SYSTEM

Shuttle valves installed in each spool section of the boom valve provide the load sense signal from the boom valve function sending the highest pressure signal. The load sense signal is then copied by the load signal copy valve located in the inlet section of the boom valve. The load sense signal is sent from the LS port in the boom valve to LSPB port on the steer valve, where it is compared to the needs 1018-I04 of the steer valve functions.

12.7

••

END SECTION

Tigercat 1065/1075 Forwarder

Crane, Grapple and Main Pump

SPOOL SECTIONS

Feed Reduction Valves

All of the boom valve spool sections are equipped with proportional, electro-hydraulic spool actuators.

The actuators are spring centered to the neutral position, and are shifted by sending a 24 volt proportional current signal (from the MDM Controller) to the appropriate solenoid. Each section has a pilot restrictor installed in the ‘A’ and ‘B’ side to create a ‘ramping’ effect and result in smooth, gentle function operation. Each spool section is equipped with a pressure compensator.

Both the stick boom and telescope boom sections are equipped with a feed reduction valve.

Feed reduction valves (also known as P.O.R. – Pressure Override) are installed in the “Stick Boom” and “Telescope Boom” sections of the boom valve. The purpose of the feed reduction is to limit the load sense pressure (from the ‘LS’ port) that the boom valve sends to the steer valve, and ultimately to the main pump, thereby limiting the pressure available to operate these functions.

Spools Each of the spools installed in the boom valve is selected specifically for the function it is controlling. For example, the telescope boom section spool has different characteristics than the stick boom spool. These spools cannot be interchanged Pressure Compensation The primary purpose of pressure compensation is to maintain a constant flow rate to function (ie: maintain the same speed of movement), regardless of pressure variations in the system.

The pressure compensator also contains a loadhold check valve. An orifice is installed immediately down stream of the pressure compensator to smoothly regulate the response of the compensator.

PORT RELIEF ‘B’ SIDE FEED REDUCTION SIDE ‘B’

•

•

Port Reliefs The boom valve is equipped with port reliefs on each side of all spool sections. The function of the port relief is to protect the boom valve and the function cylinder or motor from pressure peaks in the system. The port reliefs also act as anticavitation valves, which means they allow oil to flow from the tank gallery in the valve to the service ports in the event of underpressure. Port reliefs cannot be adjusted. Port reliefs installed in each section are specifically designed for use in that section should not be interchanged with port reliefs from other valve sections .

REPLACING MAIN PRESSURE RELIEF VALVE CARTRIDGE NOTE: Be sure to replace the relief cartridge with the appropriate replacement, as indicated in the PARTS CATALOG. 1. Park the machine on level ground, place the crane in the park position, and lower all attachments to the ground. Shut off the engine.

FEED REDUCTION SIDE ‘A’

PORT RELIEF ‘A’ SIDE

24V PROPORTIONAL ELECTRO-HYDRAULIC SPOOL ACTUATORS

•

•

•

•

•

• SPOOL 1014-089.PLT

SPOOL SECTION 12.8

PRESSURE COMPENSATOR

Tigercat 1065/1075 Forwarder

Crane, Grapple and Main Pump

2. Switch the vacuum pump ON (refer to HYDRAULIC OIL VACUUM PUMP in SECTION 2 of the OPERATOR’S MANUAL).

‘B’ SIDE PORT RELIEF

3. Remove the plastic cap from the relief to be changed.

4. Remove the relief cartridge using a ½” Allen key.

5. Install the replacement relief cartridge, and tighten to 60 Nm (45ftlb).

6. Install the plastic cap.

•

7. Switch the vacuum pump OFF.

• •

ADJUSTING BOOM VALVE FEED REDUCTION VALVE SETTINGS: 1. Park the machine on level ground, place the crane in the park position, and lower all attachments to the ground. Shut off the engine.

COOLING PUMP

MAIN PUMP

DRIVE PUMP

‘B’ SIDE FEED REDUCTION 1014-008 CV

••

••

“LS” TEST PORT

•

•• •

1014-080.PLT

‘A’ SIDE FEED REDUCTION

FEED REDUCTION ADJUSTMENTS

•

7. Operate the same function again, and verify that the pressure being read on ‘LS’ is correct.

CHARGE PUMP

8. Repeat steps 5 – 7 for the same function in the opposite direction.

“LS’ TEST PORT LOCATION 2. Connect a 0-5000 psi gauge to the ‘LS’ test port on the main pump.

REPLACING PORT RELIEFS: NOTE: Be sure to replace port relief cartridges with the appropriate replacement, as indicated in the PARTS CATALOG.

3. Ensure that the hydraulic oil is at operating temperature. See HYDRAULIC OIL HEATING PROCEDURE in SECTION 8 of THIS MANUAL. 4. Start the engine (and run at idle). Depress the pilot reset switch.

1. Park the machine on level ground, place the crane in the park position, and lower all attachments to the ground. Shut off the engine.

5. Operate the function in one direction, to its full extent. Continue to hold the function at this position.

2. Switch the vacuum pump ON (refer to HYDRAULIC OIL VACUUM PUMP in SECTION 2 of the OPERATOR’S MANUAL).

6. The reading on the 0-5000 psi gauge installed on the ‘LS’ test port should be 230 bar (3335 psi). Release the function.

3. Remove the plastic cap from the relief to be changed.

If adjustment is required, locate the feed reduction adjusting screws and remove the cover nut and loosen the locknut using a ½” socket. Then turn the adjusting screw using a 3/16” Allen key. Turn the adjusting screw IN (clockwise) to increase the pressure, or turn it OUT (counterclockwise) to decrease the pressure. Once the adjustment has been made, tighten the locknut, and install the cover nut.

4. Remove the retaining cap from the valve body using a 1 1/16” wrench or socket.

5. Remove the existing relief, and install the replacement relief cartridge.

6. Install the retaining cap removed in step 4, and tighten to 60 Nm (45ftlb).

7. Install the plastic cap.

8. Switch the vacuum pump OFF.

12.9

Tigercat 1065/1075 Forwarder

1014-088

Crane, Grapple and Main Pump

BOOM VALVE CIRCUIT DIAGRAM 12.10

Tigercat 1065/1075 Forwarder

Crane, Grapple and Main Pump

MAIN PUMP All proportional valve hydraulic functions are powered by the main pump. The main pump is mounted in tandem with the drive pump.

DRIVE PUMP

MAIN PUMP

•

• 1014-082.DWG

MAIN PUMP SCHEMATIC

Å FRONT

CONTROL

• 1014-146

PUMPS

The main pump is an axial-piston, variabledisplacement pump with load sensing, and pressure compensating controls. The main pump operates in an open-loop hydraulic circuit, meaning that hydraulic oil is always returned to tank.

When all of the control valves are in the neutral position the pump is destroked and the output is just sufficient to maintain a pressure of approximately 500 psi in the pump output line. The swashplate control piston is in a condition where control cylinder spring force, swashplate forces and control pressure forces are balanced.

When a proportional valve function is operated, the valve sends a load sense signal to the main pump load sense regulator. This signal shifts the load sense regulator spool, located in the controller installed on the pump. With the load sense regulator spool shifted, the oil behind the control cylinder is released to tank. The opposite side of the control cylinder has full pump pressure acting on it. The control cylinder shifts, changing the angle of the swashplate (increasing the displacement of the pump or “stroke”). Main pump pressure also acts on the load sense spool, opposing the load sense signal. The swashplate angle increases and the pump builds more pressure, until main pump pressure overcomes load sense pressure (and the spring force applied by the margin pressure adjustment). At this point, the load sense spool shifts the opposite direction, and main pump pressure is sent to both sides of the control cylinder. The control cylinder has the same amount of pressure on each side. However, the area of the “de-stroke” side of the control cylinder is larger than the area of the “stroke” side .

• • •

•

THROUGH DRIVE

DRIVE SHAFT SWASHPLATE 1018-28

PISTON ASEMBLY

MAIN PUMP

Therefore, the pump will begin to destroke (decrease swashplate angle), until the load sense spool shifts once again. A spring is installed on one side of the swashplate control cylinder to smooth out the operation of the control cylinder, and provide a relatively stable operating condition.

The pump is constantly reacting to the changes in the load sense signal, and never produces more pressure or flow than required for the functions being operated.

The pressure compensator limits the maximum pressure that the pump can build. The pressure compensation spool is held in its normal position by a spring force applied by the pressure compensator adjustment. Main pump pressure acts against the opposite end of the spool. When the main pump pressure exceeds the compensator pressure setting of 215 bar (3118 psi) the pressure compensator spool shifts. This allows main pump pressure to act on both sides of the control cylinder, forcing the pump to destroke as described above.

12.11

Tigercat 1065/1075 Forwarder

Crane, Grapple and Main Pump

MAIN PUMP / LOAD SENSE SET-UP

SV

PR1

PR2

RV

SET COMPENSATOR PRESSURE:

••

COMPENSATOR PRESSURE is the pressure at which the main pump will begin to automatically destroke to limit the maximum pressure from the pump to the valves and other components in the circuit. The compensator pressure setting should be 215-220 bar (3118-3190 psi).

P1

3) Start the engine, and depress the pilot reset switch.

4) Using the MDM controller, adjust the engine working speed to 1400 rpm.

5) Set CRANE/BLADE switch to WORKING RPM and rotate seat to face REAR. Maneuver the crane to a position where it is safe to operate the stick boom. The compensator pressure is to be determined by reading the gauge while operating the stick boom in function. Apply and hold the stick boom in function, and read the gauge installed at ‘P’.

DRIVE PUMP

•

MAIN PUMP

2

•

•• •

PUMP CONTROLLER VALVE

•• ••

•• •

SW1

RP2 ACC1

HIGH PRESSURE MANIFOLD HIGH PRESSURE MANIFOLD COMPONENTS ACC1 ............................ Accumulator Pressure Test P1 .................................. Pump Outlet Pressure Test PR1 ....................... Pressure Reducer 1 (*190 BAR) PR2 ................. Pressure Reducer Brakes 100 BAR RP2 .......................... Pressure Test Service Brakes RV .......................................... Relief Valve 105 BAR SW1 .. Low Pressure Switch 69 BAR (Start Charge) SW2 High Pressure Switch 124 BAR (Stop Charge) SV ............................... To LS Signal on Main Pump 1014-057

“LS” TEST PORT

COOLING PUMP

1

SW2

••

1) Ensure that the hydraulic oil is at operating temperature (refer to hydraulic oil heat up procedure).

2) Connect a 0-5000 psi gauge to the ‘P1’ test port of the High Pressure Manifold, located in rear chassis valve compartment.

• • •

•

••

2

1

••

••

•• CHARGE PUMP

1014-080.PLT PUMP ARRANGEMENT If the compensator pressure requires adjustment:

Use a 13mm wrench to loosen the locknut on the compensator pressure adjusting screw (1) (located on the main pump controller).

Turn the adjusting screw (1) using a 6mm wrench until the reading on the gauge is be 215-220 bar (3118-3190 psi). Turning the adjusting screw IN (clockwise) will increase the compensator pressure, turning the screw OUT (counterclockwise) will decrease the compensator pressure.

When the compensator pressure is correct, tighten the locknut on the adjusting screw. Repeat above procedure to verify the compensator pressure setting is still correct.

12.12

1014-D210

MAIN PUMP CONTROLLER VALVE

Tigercat 1065/1075 Forwarder

Crane, Grapple and Main Pump

SET MARGIN PRESSURE: MARGIN PRESSURE is the difference between the LOAD SENSE (LS) pressure and the PUMP OUTPUT (P) pressure while a function (crane, blade, steer or cab rotate) is being operated. For the load sensing system to operate correctly the differential pressure between ‘P’ and ‘LS’ should be 24.5-25.5bar (355-370 psi). ‘P’ being higher than ‘LS’.

R.H. JOYSTICK & CONTROL SWITCHES 4) Start the engine, and depress the pilot reset switch.

The margin pressure adjustment is made at the main pump controller attached to the main pump.

The pressure gauge connections are the ‘P1’ test port on the High Pressure Manifold and the ‘LS’ test port on the Main Pump.

5) Set CRANE/BLADE switch to WORKING RPM and CAB POSITION switch to REAR (1018B only) and maneuver the crane to a position where it is safe to rotate the grapple. Rotate the grapple in either direction, adjust the rotate speed with the joystick until a pump output reading of 90-110bar (1305-1595 psi) is achieved and maintained, the margin pressure will be the reading on the differential gauge.

1) Use a differential pressure gauge with ten psi increments.

MAIN PUMP

2

••

••

“LS” TEST PORT

COOLING PUMP

1

•• •• •• •

PUMP CONTROLLER VALVE

•

If the margin pressure requires adjustment:

••

DRIVE PUMP

•

••

CHARGE PUMP

PUMP ARRANGEMENT 2) With the hydraulic oil at operating temperature (refer to hydraulic oil heat up procedure), connect the “low” side of the differential pressure gauge to the ‘LS’ test port.

MAIN PUMP

2

••

“LS” TEST PORT

•• •• •• • •

P1

•

HIGH PRESSURE MANIFOLD

PUMP CONTROLLER VALVE 1014-080.PLT

COOLING PUMP

1

1014-080.PLT

1014-057

PILOT RESET SWITCH

1014-001

NOTE: If the margin pressure is not set correctly, the machine controls may not respond as they should, i.e. jerky or sluggish.

DRIVE PUMP

PILOT OFF INDICATOR LIGHT

••

• • CHARGE PUMP

PUMP ARRANGEMENT

With test gauge on LS test connection, reset margin adjustment screw (2)as follows: Use a 13mm wrench to loosen the locknut on margin pressure adjusting screw (2) (located on the main pump controller).

6) Turn the adjusting screw using a 6mm wrench until the differential reading on the gauge 24.525.5bar (355-370 psi). Turning the adjusting screw IN (clockwise) will increase margin pressure, turning the screw OUT (counterclockwise) will decrease the margin pressure.

NOTE: This is a sensitive adjustment, a small movement of the adjusting screw will produce a significant change in pressure.

3) Connect the “high” side of the gauge and a 05000 psi gauge to the ‘P1’ test port .

7) Allow a short time for pressure reading to stabilize then tighten the locknut on the adjusting screw. Repeat the above procedure to verify the differential pressure setting is still correct.

12.13

Tigercat 1065/1075 Forwarder

Crane, Grapple and Main Pump

12.14