Tigercat 480 MULCHER OPERATOR'S MANUAL - PDF DOWNLOAD

OPERATOR'S MANUAL Tigercat 480 MULCHER ISSUE 2.1, JANUARY, 2010

TABLE OF CONTENTS SECTION INTRODUCTION.................................................................................................................iii SAFETY............................................................................................................................... 1 USING HIGH SPEED DISC SAWS SAFELY............................. APPENDIX TO SECTION 1 CONTROLS AND OPERATION.......................................................................................... 2 LUBRICATION AND MAINTENANCE................................................................................. 3

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

480-SM00

480 Available Literature Operator's Manual (This Manual)...................................................Part No. 33590A Service Manual...............................................................................Part No. 33591A Parts Catalog..................................................................................Part No. 33592A

Tigercat Tigercat Industries Inc. P.O. Box 544 Paris, Ontario Canada N3L 3T6

Tel: (519) 442-1000

Fax: (519) 442-1855

Tigercat 480 Mulcher

Introduction

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Tigercat 480 Mulcher

Introduction

Tigercat 480 MULCHER

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 480 Mulcher serial number 4800101 and up.

The 480 mulcher is designed for land clearing and vegetation management applications such as fire breaks, easements, thinning of unwanted vegetation, forestry and reforestation site preparation, brush/ slash pile reduction after logging operations, survey lines, tree removal from insect infestation, pasture reclamation, road side management and land clearing for property development as well as many other land management, maintenance and reclamation operations.

The operator's manual will assist the operator with the techniques of proper and safe operation of the 480 Mulcher. There is also important information regarding the safe operation of the mulching head. The service manual contains safety and servicing procedures and a preventive maintenance schedule to assist in repair and to ensure optimum machine performance. For manual part numbers, see the title page in each manual.

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.

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Tigercat 480 Mulcher

Introduction

S.A.E. STANDARDS ROLL-OVER PROTECTION STRUCTURES (ROPS) FALLING OBJECTS PROTECTION STRUCTURES (FOPS) OPERATOR PROTECTION STRUCTURES (OPS) * MODIFICATIONS AND REPAIRS: The integrity of the ROPS, FOPS, OPS structure and its continued ability to provide the level of protection it was designed for could be seriously affected by any modifications to the structure, its mounting or to the chassis to which it is attached.

Tigercat emphasizes that the certification of approval of the ROPS, FOPS, OPS structure will become void if any such modification(s) take place.

Tigercat may officially grant approval for modifications only by: i. Written approval of repairs or modifications signed by the Tigercat Engineering Manager; or ii. Approved modifications officially released by Tigercat.

Both of the above are provided that the work is carried out in the factory approved manner.

Unauthorized modifications and/or repairs made or contributed to by a customer or a Tigercat distributor may result in creating a dangerous situation and therefore the customer or Tigercat distributor will be considered to have assumed the risk involved or be negligent in creating this situation.

Tigercat will not be held responsible for situations arising from having created unauthorized modifications/ changes to the structure.

Operator's cabs are designed to ROPS, FOPS, OPS standards so that they will withstand force and absorb energy during a roll-over (ROPS), when resisting the impact of a falling object (FOPS) and minimize the posibility of operator injury from penetrating objects (OPS). When a permanent deflection of the structure occurs, the structure can no longer provide the original designed level of protection and should be replaced. Attempts to straighten the structure, particularly by the application of heat, can reduce still further the structures remaining capability to protect.

The mounting and the frame or chassis to which the cab is attached is considered an integral part of the ROPS, FOPS, OPS and is included in the design, test and certification of the product.

Contact the Tigercat Service department before attempting any modifications or repair to roll-over protective structures.

Tigercat Industries Inc.

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Tigercat 480 Mulcher

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 it's ability to perform safely 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 to be undertaken 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 having created 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 dispute 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.

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Tigercat 480 Mulcher

Introduction

vi

Tigercat 480 Mulcher SECTION 1 - SAFETY MARCH, 2010

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

Read and understand all manuals for any attachments or accessories.

CONTENTS - SECTION 1 B

Battery disconnect switch.................................................................1.8 BOOM LIFT LOCK.........................................................................................1.14 C

CAB EXITS.......................................................................................................1.9 E

EMERGENCY CAB EXITS...............................................................................1.9 F

FIRE PREVENTION......................................................... 1.21, 1.22, 1.23, 1.24 DRY CHEMICAL CLEANUP PROCEDURES.............................................1.25 FIRE PREVENTION GUIDELINES.............................................................1.21 WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED.....................1.24 WHAT TO DO TO PREPARE FOR A MACHINE FIRE...............................1.22 WHAT TO DO WHEN A MACHINE FIRE OCCURS...................................1.23 FLUID INJECTION INJURY...........................................................................1.16 G

GREASE INJECTION INJURY.......................................................................1.17 H

HAZARD ZONE................................................................................................1.3 L

LIGHTNING SAFETY AWARENESS LIGHTNING SAFETY............................................................. 1.18, 1.19, 1.20 WHAT IS A LIGHTNING STRIKE................................................................1.18 M

MULCHING OPERATION SAFETY...............................................................1.10 P

PARKING THE MACHINE................................................................................1.8 S

SAFETY INTERLOCK SWITCHES ON CAB DOORS.....................................1.9 SAFETY LABELS............................................................. 1.26, 1.27, 1.28, 1.29 SAFETY PRECAUTIONS, GENERAL.............................................................1.2 SAFETY PRECAUTIONS, OPERATING..........................................................1.6 SAFETY PRECAUTIONS, SERVICING.........................................................1.12 SIGNAL WORDS..............................................................................................1.2

Tigercat 480 Mulcher

Safety

GENERAL SAFETY PRECAUTIONS

SAFETY symbols

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.

This safety alert symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

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

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.

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.

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

Do not let an untrained person operate the machine.

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

Use recommended protective clothing and safety devices such as orange safety vest, 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.

1.2

Tigercat 480 Mulcher

Safety When approaching an operating machine on foot, stay at least 500 feet (150 meters) away until the operator recognizes your presence. Make sure that all equipment has been shut down before advancing to the machine.

GENERAL SAFETY PRECAUTIONS continued

KEEP BACK 500 FEET

DANGER ROTATING CUTTER

DANGER

The safety of persons outside the cab is the responsibility of the machine operator

Thrown debris keep back 500 feet.

The following diagram illustrates the hazard zone. All personnel should be kept clear of this zone while the attachment is operating.

150 meters 500 FEET

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

Prolonged exposure to loud noise can cause impairment or loss of hearing.

150 meters 500 FEET

150 meters 500 FEET

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

150 meters 500 FEET

480-003

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

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

HAZARD ZONE

Do not use the joystick(s) or steering wheel as a handle to assist entering or leaving the cab.

The hazard zone should be considered off limits to all individuals.

Do not use the machine foot controls as a step.

DANGER Danger caused by flying debris.

Improper operation of the attachment and failure to follow safety precautions can result in personal injury.

When mounting or dismounting the machine always use the 3 point technique - Use 1 hand with 2 feet or 2 hands with 1 foot.

1.3

Tigercat 480 Mulcher

Safety

GENERAL SAFETY PRECAUTIONS continued 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.

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

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

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:

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.

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

Machine should be washed completely before and after 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 fluoro-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).

•

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

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

Check for fluid leaks, or faulty operation. Repair or replace malfunctioning parts and systems immediately.

Check windows and door guards for damage.

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

Note:

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

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

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

Check all fluid levels.

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

1.4

Tigercat 480 Mulcher

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 is provided and approved with seating for the operator only.

WARNING Battery posts, terminals and related accessories contain lead and lead compounds.

Wash hands after handling.

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.

When moving the machine, watch that enough clearance is available on both sides and above the machine or any of its attachments. Extra clearance may be required particularly where the ground is uneven.

Approach with extreme caution any area where overhanging electrical power lines 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 feet. (3 meters) between the machine or boom and any power line carrying up to 50,000 volts or less plus 1/2 inch (10 mm) 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 the articulation lock bar when ever 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 attachment manufacturer.

1.5

Tigercat 480 Mulcher

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

OPERATING SAFETY PRECAUTIONS

Make sure that all safety screens and guards including the skylight 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.

The operator’s seat is equipped with either a lap belt or lap and shoulder harness belts. Use either of these restraint systems at all times when operating 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.

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

Start the engine according to the instructions in this manual. Refer to OPERATING MACHINE in SECTION 2 of the OPERATOR'S MANUAL. Before moving the machine to the work site, check to ensure that all doors, panels, and access covers are installed properly and secured.

Machine operations should only be performed from the operator's seat.

Secure loose items in the cab.

1.6

Tigercat 480 Mulcher

Safety

OPERATING SAFETY PRECAUTIONS continued

CAUTION Do not open cab doors or window screens when machine is on a slope. The doors and screens are heavy and could swing out with considerable force.

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

NEVER travel across a STEEP slope or side hill:

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

Boom supports encroach on cab door opening when machine is steered.

•

Do not run engine when persons are on steps or in doorway area.

•

Serious injury or death could result from crushing.

Maintain a safe operating distance between the machine and other personnel. Never operate the boom or attachment over the heads of bystanders.

Do not turn on cutter until machine is at cutting site.

Never travel near co-workers or other pieces of equipment with cutter turning.

Do not allow people or other pieces of equipment near the machine during operation.

Use only prearranged and approved signalling practices.

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

Watch for ground hazards such as metal debris, wire fencing or rocks.

When travelling position attachment and boom accordingly so as not to impair vision.

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

1.7

•

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

•

To avoid tip over, keep the attachment as low as possible to maintain a low center of gravity.

Tigercat 480 Mulcher

Safety

OPERATING SAFETY PRECAUTIONS continued 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.

Before leaving operator's cab, apply the parking brake and lower the attachment onto the ground.

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

When parking the machine: • Park on level ground.

• Do not park on a hillside or incline.

• Lower attachment onto level ground.

• Stop the engine and vent the hydraulic tank.

1

480-028

CAUTION PRESSURIZED HYDRAULIC TANK. Before servicing any hydraulic components, vent hydraulic tank. Refer to SECTION 2 of this manual for VENTING THE HYDRAULIC TANK procedure.

24863A

BATTERY DISCONNECT SWITCH •

Refer to SECTION 2 of this manual for VENTING THE HYDRAULIC TANK procedure.

Turn the battery disconnect switch (1) off if the machine is to be parked for an extended period of time (Example - overnight).

When travelling on public roads, use accessory lights (when installed) and other cautionary devices to provide operators of other vehicles warning of your approach. Ensure your machine meets all regulatory requirements.

When transporting the machine watch 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.

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

1.8

Tigercat 480 Mulcher

Safety

OPERATING SAFETY PRECAUTIONS continued

SWITCH

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

CAB EXITS

ACTUATOR

There are three ways to exit the cab in case of an emergency.

1. Left door, this is also the main point of entry and is the only door that should be used under normal operating conditions to enter or leave the cab. This door is also equipped with a SAFETY INTERLOCK SWITCH. See SAFETY INTERLOCK SWITCH ON DOORS in THIS SECTION.

INTERLOCK SWITCH (L.H. DOOR SHOWN)

197-5

SAFETY INTERLOCK SWITCHES ON DOORS: 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).

2. Right door, should be used for emergency exits only. Do not use this door to routinely enter or leave the cab. This door is also equipped with a SAFETY INTERLOCK SWITCH. ALWAYS shut OFF engine before using the right door exit.

CAUTION Safety interlock switches do not lock out the steering function on machines equipped with a steering wheel.

3. Escape hatch, this is a third cab exit for use if the cab door exits become blocked.

CAUTION Do not use the steering joystick to assist entering or leaving the cab.

This hatch is not equipped with a safety interlock switch and therefore when left open will not deactivate the pilot controls in the cab.

ALWAYS shut OFF engine before using the escape hatch exit.

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

To operate:

It is important that the operator of the machine be familiar with these emergency exits and how to use them.

Close both doors and press the INTERLOCK reset switch.

All three exits should be checked to make sure that they are operational and will function in an emergency. The safety interlock mechanism on the cab doors and escape hatch retaining mechanisms must not be tampered with or defeated.

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.

IMPORTANT! Unlock both doors before operating machine to allow opening from the outside in case of an emergency. Make sure that the doors are operational, open the doors twice, once using the exterior handle and once using the interior latch handle.

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

For additional information, refer to EMERGENCY EXITS in SECTION 2 of the OPERATOR'S MANUAL.

1.9

Tigercat 480 Mulcher

Safety DANGER ZONES

OPERATING SAFETY PRECAUTIONS continued MULCHING OPERATION safety

Danger exists most prominently to the rear and front of the mulching head.

Operate so that the main discharge areas of the mulching head are not directed at people, livestock, buildings or other machines.

Land clearing operations generally involve other machinery and people on the site. Operators must maintain an awareness of all working traffic within 500 feet of the mulching operation.

Throw distance for metal pieces and stones can be many times the distance for wood chips.

Pieces of wood, debris from the ground and even cutting tools separating from the rotor become potentially dangerous projectiles when thrown from these machines.

Danger is greater if the site contains stones or abandoned metal.

Poor maintenance increases the danger.

Thorough timely inspection and replacement of worn cutter tools, fasteners and wear plates.

Always heed warning signs of missing cutter tool parts or sounds of striking rocks and adjust operation to suit the site.

Inspect cutter tools, cutter tool fasteners, rotor and mulching head assembly.

Ensure that all cutter tool retaining bolts are at correct torque value.

Replace all worn cutter tools.

Do not operate in a way that throws chips in a direct line at the machine cab.

Always replace the fastener whenever replacing a cutter tool.

REAR danger zone

Inspect the rotor for weld cracks and other damage.

Chunks of wood and rock can be thrown from the rear of the mulching head. This occurs when the mulching head is raised high enough to allow debris to escape the guard chains. No one should be allowed within the HAZARD ZONE. This condition is dangerous, refer to HAZARD ZONE in THIS SECTION. The following precautions should be followed:

Check that the rotor does not wobble due to worn shaft bearings.

Never start or use a machine if the rotor has missing cutting tools, missing cutting tool fasteners or a bent rotor.

Shut down the machine immediately if you feel excessive vibration when the rotating cutter is running.

• •

Check that the cutter housing is clear and undamaged.

•

DANGER ROTATING CUTTER

FRONT danger zone

The safety of persons outside the cab is the responsibility of the machine operator.

Danger caused by flying debris. Improper operation of the attachment and failure to follow safety precautions can result in personal injury.

FRONT danger zone

To the front a lower volume of projectiles may be experienced. However, no one should be allowed within the HAZARD ZONE. Refer to HAZARD ZONE in THIS SECTION. The following precautions should be followed: •

REAR danger zone

•

• 480-004

Never allow anyone to the rear of the machine while it is in operation.

Inspect daily for damaged or missing guard chains. Replace them before operating.

Be especially careful when the tool is lowered onto new material and when the tool is raised up and out of material it has been working.

•

DANGER ZONES

Never allow anyone to the front of the machine while it is in operation.

Close the mulch door (if equipped) while pullworking to better contain debris. This also increases the fineness of the shredded product.

Be especially careful when the tool is lowered onto new material and when the tool is raised up and out of material it has been working.

DO NOT operate without guards.

1.10

Tigercat 480 Mulcher

Safety Animal remains

OPERATING SAFETY PRECAUTIONS continued

Animal remains such as calf and deer carcasses will plug the machine due to their leathery skin.

Avoid the unpleasant task of removing the remains from the rotor.

URBAN PRECAUTIONS

Increased safety precautions are required when working: • • • •

AVOID FENCES

Near streets Near highways In parks, on golf courses or other inhabited areas.

Near buildings

Do not drive the mulcher into fences, especially chain link fences. Chain link fencing can damage the rotor. Refer to AVOID METAL AND WIRE above.

When operating mulching head properly position head for push working and pull working for safety and improved operation.

Establish Safety parameters that fit the site: • • •

String coloured warning tape to cordon off the area.

Use a traffic director when the hazard zone impinges on pedestrian or vehicular traffic.

Erect barriers.

When tree toppling always know and control the direction a tree will fall to prevent injury to coworkers or damage other vehicles.

CAUTION

assessing the potential dangers of the job site

To prevent component damage, always have deflector door open when preparing to fell standing trees

Before working in a new area a visual survey of the area to be worked is helpful in identifying undesirable materials which may be present.

Remove as much of the undesirable materials as is practical before proceeding.

Work within your operating skills, do not attempt to cut down a tree that is too large to handle.

When pull working (moving in reverse), watch for obstacles in your path.

Avoid metal and wire.

Metal can break cutter tools and create a projectile hazard.

Always travel with mulching head as close to the ground as possible, never elevate the mulching head unless necessary.

Wire wraps itself around the rotor shaft especially near the bearings. Near bearings this can cause wire to enter past the grease seals and cause damage to bearings if it is not removed promptly.

Never use this machine to clear an area when other equipment and operator's are also moving in. Pre-plan to work the area in advance before other equipment arrives.

Use caution with Stringy Vegetation

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

Shredding materials like Palmetto, Bird of Paradise, and yard waste tied with plastic should be approached with caution. Stringy vegetation and plastic ties gravitate toward the bearings.

The operator should exercise caution while working with this type of material.

Stop the rotating cutter before leaving the mulching area. NOTE: The cutter will continue to free wheel for several minutes after the cutter switch has been turned OFF.

Avoid Plastics

To stop cutter from rotating, CAREFULLY lower the rotor onto a stump. This should be done gently to prevent unnecessary loading of the rotor, housing and bearings.

Hoses, bags, tarps and ropes must be removed as soon as they are seen.

Mattresses, rugs, clothes and cloth will plug the machine immediately.

Inspect the rotor for clinging strands often.

1.11

Tigercat 480 Mulcher

Safety

SERVICING SAFETY PRECAUTIONS

WARNING This machine is equipped with a reversible cooling fan. Exercise care when working in this area with the engine running.

This machine is equipped with a reversible cooling fan to facilitate cleaning of the charge air cooler, radiator and oil cooler assembly. Exercise care when working in this area with the engine running.

If the fan switch in the cab is in the auto position, the fan could turn ON and/or go into reverse mode without warning.

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 electrical current does not pass through bearings, especially the center joint bearing.

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

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

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

This machine is equipped with sensitive electronic control equipment, prior to welding:-

24863A

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

BATTERY DISCONNECT SWITCH

Turn Battery Disconnect Switch to the OFF position and disconnect the positive (+) battery cable from both batteries.

ENGINE "CPU" MODULE

COOLER PACKAGE COMPARTMENT

The charge air cooler, radiator and the engine cooling system should be cleaned and serviced at least daily to maintain moderate engine temperatures.

480-010

DISCONNECT CPU HARNESS

Disconnect the engine CPU (Central Processing Unit) and engine wiring harness by unplugging the multi-pin connectors.

1.12

Tigercat 480 Mulcher

Safety 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.

SERVICING SAFETY PRECAUTIONS continued WARNING

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

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.

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

Never use bare hand to check for fluid leaks.

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.

Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down. Lower the attachment to the ground, stop engine and relieve trapped pressure from pilot system and brake accumulators 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.

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

1.13

Tigercat 480 Mulcher

Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING

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

Always install boom lift lock before working on or around machine with boom raised.

• Always install 'T' handle retainer bolt • Use only to support boom and cutting head • Do not use to set hydraulics pressures

CAUTION Do not open cab doors or window screens when machine is on a slope. The doors and screens are heavy and could swing out with considerable force.

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.

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

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

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

WARNING Always allow the cutter blade to come to a complete stop before approaching attachment to make adjustments.

1.14

Tigercat 480 Mulcher

Safety

SERVICING SAFETY PRECAUTIONS continued

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

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.

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

Dispose of fluids properly.

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

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

1.15

Tigercat 480 Mulcher

Safety

SERVICING SAFETY PRECAUTIONS continued

WARNING Diesel fuel or hydraulic fluid under pressure can penetrate the skin and could result in death or serious injury. If any fluid is injected under the skin, a medical doctor familiar with the treatment of this type of injury must surgically remove it within a few hours.

FLUID INJECTION INJURY Hydraulic and diesel fuel systems on forestry machines operate at very high pressures, often 207 bar (3000 psi) and above. If a loose connection or a defect in a hose should occur, a fine, high velocity stream of fluid will result. Even for systems pressurized to as little as 7 bar (100 psi), this fluid stream can penetrate human skin as if it were a hypodermic needle.

In the event of any suspected fluid injection injury • Report the injury to your supervisor immediately.

• Seek professional medical attention immediately.

As always the best defence against suffering the effects of fluid injection is to prevent the accident from occurring in the first place.

When searching for possible fluid leaks • Never search for leaks with your bare hands.

Always wear thick protective gloves.

• Be sure to wear safety goggles for eye protection.

• Keep all body parts well away from the area being investigated for leaks.

• Use the end of a long piece of wood to move hoses or other obstacles.

Initially, an accidental fluid injection beneath the skin may only produce a slight stinging sensation.

There is a danger that you will tend to ignore this, thinking that it will get better with time. Most often, it does not! Within a very short time the wound may begin to throb painfully, indicating that tissue damage has already begun.

Similarly fluid injected directly into a blood vessel can spread rapidly through your circulatory system. The human body has little ability to purge injected fluid.

Diesel fuel or hydraulic fluid under pressure can penetrate the skin and could result in death or serious injury. If any fluid is injected under the skin, a medical doctor familiar with the treatment of this type of injury must surgically remove it within a few hours.

•

Time becomes critical as tissue damage progresses rapidly. The longer you delay getting professional medical attention, the more damage can occur.

Although fluid injection accidents are rare, the resulting injury has on occasion required the amputation of a finger, a hand or in some cases the entire limb. The longer the delay in getting professional medical aid, the further up the limb the tissue damage can spread. An injury of this type can become very serious or even fatal if not dealt with promptly and properly.

1.16

Place the end of a long piece of wood in the suspected path of any fluid stream. Never use any part of your body.

• Recognize that the source of the leak and the fluid streaming from it may be very small and not easily visible. You may only be able to see the fluid that accumulates as a result of the fluid stream.

When performing any service work • Stop the engine and relieve all diesel fuel or hydraulic pressure before disconnecting any lines or otherwise working on the system.

• Never grab any hydraulic or diesel fuel connectors or hoses when they are subjected to pressure.

• Always ensure that hoses are rated for the pressures to which they will be subjected.

• Never use any hoses that you suspect could be defective.

Tigercat 480 Mulcher

Safety

SERVICING SAFETY PRECAUTIONS continued GREASE INJECTION INJURY WHEN USING PNEUMATIC GREASE GUNS Pneumatic grease guns can deliver grease at pressures from 17 - 400 Bar (246 - 5801 psi).

It takes less than 7 Bar (100 psi) to inject a substance through human skin.

ALWAYS get professional medical treatment immediately after any type of injection injury.

Provide the physician with information on the type of grease, the pressure setting of the gun, and similar details.

The amount of fluid injected, type of fluid (or material), pressure at which it was injected, and the elapsed time between injection and surgery all influence the chances of successful treatment for this type of serious injury.

Prior to using a high pressure pneumatic grease gun perform the following: •

All operators of high pressure pneumatic grease guns MUST be trained in the hazards of its operations and the treatment for such injuries.

•

DO NOT OPERATE a high pressure pneumatic grease gun unless you have been trained in the proper operation and are aware of all safety precautions of such a tool.

•

Wear protective clothing such as gloves, safety hat and safety glasses.

•

Inspect all parts of the grease gun for wear and tear and replace all worn or damaged parts.

•

Ensure that protective shrouds are installed on all grease gun nozzles as safety devices.

•

Remove dirt and grease from grease fittings prior to greasing.

•

Replace any defective grease fittings on equipment with new fittings immediately.

•

When badly positioned fittings are identified, replace them with angled or swivel fittings for easier access.

1.17

Tigercat 480 Mulcher

Safety

LIGHTNING SAFETY AWARENESS

LIGHTNING SAFETY

WHAT IS A LIGHTNING STRIKE?

In spite of the popular myth that being struck by lightning is an unlikely event, the facts show that lightning strikes occur frequently. As a result loggers are at high risk because their work is outdoors and close to known strike points such as tall trees and heavy equipment.

Lightning is a discharge of the electricity produced by a thunderstorm. As the thunderstorm develops, many small particles of ice within the storm clouds bump together. These collisions create a positive charge at the top of a cloud and a negative charge at the bottom. As this continues a second positive charge builds up on the ground beneath the cloud, concentrated around high objects such as hills, trees, buildings, equipment and even people.

Loggers can increase their chances of avoiding a lightning strike by following a few simple safety practices.

1. Designate a member of your crew to

When the difference between the electrical charge in the cloud and on the ground becomes great enough to overcome the resistance of the insulating air between them, an electrical current flows instantly. This is a lightning strike.

The electrical potential in a lightning strike can be as much as 100 million volts. Lightning strikes can occur over very large distances, even as much as 60 km (37 miles). Lightning travels both in front of and behind a thunderstorm and so strikes happen even when rain has not started or has stopped.

Lightning can hit in the same place, many times and often spreads out over 18 m (60 feet) within the soil around the strike point.

•

Monitor daily weather forecasts

•

Observe local weather conditions

•

Alert all other members of the crew when a possible lightning threat develops.

2. Don’t start or continue any work that cannot be stopped immediately, when a storm moves nearby.

3. Anticipate a high-risk situation and take action early by moving to a low-risk location. Do not hesitate. If there is lightning, you are in danger.

4. Obey the rule - If you see lightning, Flee. If you hear thunder, Clear.

Thunder always accompanies lightning. When lightning occurs, the air through which it travels is instantaneously heated to a temperature more than 28,000°C (50,000°F). The air expands rapidly due to this heating, then quickly contracts as it cools. It is this contracting shock wave that we hear as thunder.

5. Do not follow the now obsolete guideline to take shelter when the time between seeing lightning and hearing thunder is 30 seconds or less. This does not provide sufficient time to ensure safety. Always follow step 4.

6. Remain in your safe location for 30 minutes after the last sight of lightning or the last sound of thunder.

In many areas of the world, lightning strikes are second only to flooding as the greatest cause of storm related deaths and injuries. Although only 10% of lightning strike victims are killed, virtually all from cardiac or respiratory arrest, over 70% of those that survive suffer severe, life-long injury and disability. The symptoms of a lightning strike include memory loss, fatigue, chronic pain, dizziness, sleeping difficulty and the inability to complete several tasks at one time.

The safest location during lightning activity is inside a fully enclosed, substantially constructed building, a house, office, school, shopping area, etc. These are the safest because of the electrical wiring and plumbing that they contain. Should lightning strike, the electrical current will travel through the wiring or plumbing into the ground.

When such a building is nearby, always seek shelter there first.

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Safety

LIGHTNING SAFETY CONT'D Unfortunately loggers do not often work close to buildings and therefore other alternatives need to be considered.

What to do if you are outside and see lightning or hear thunder.

If you can, get inside.

1. Run to the nearest building, motor vehicle or fully enclosed ROPS equipment cab immediately. Being anywhere outside is not safe.

Sheds, weather shelters, hunting blinds, tents and other partially open or small structures are not safe against lightning strikes as they lack the electrically grounded components of larger buildings. They are intended for sun or rain protection only. Do not seek shelter from lightning strikes inside these structures.

2. If inside a building:

The second safest location during lightning activity is inside a fully enclosed car, van, truck or bus with a metal roof and metal sides. The electrical energy of a lightning strike to these vehicles is carried to ground by the conducting outer metal surfaces. This is called the skin effect.

•

Don’t watch the lightning storm from open windows or doorways. Stay in inner rooms.

•

Stay well away from corded telephones, electrical appliances, lighting fixtures, radio microphones, electrical sockets and plumbing pipes and fixtures.

3. If inside a motor vehicle or fully enclosed ROPS equipment cab:

Do not seek safety from lightning strikes in vehicles with fiberglass or plastic body shells or in convertible top vehicles. None of these are safe, as they do not offer skin effect lightning protection.

Heavy forestry equipment such as a skidder, loader, feller buncher, forwarder, etc. with a fully enclosed rollover protective structure (ROPS) cab take advantage of the skin effect and are therefore safe in electrical storms.

However machines with a rollover canopy only are not safe against lightning strikes as they are open to electrically conductive rainwater and do not benefit from the skin effect. Operators of this equipment must abandon their machines and get to a safer location before lightning strikes.

Note that the rubber tires on motor vehicles and heavy equipment do not increase safety from lightning strikes. Lightning has already travelled a great distance through the air to strike the vehicle.

In comparison a few inches of rubber in a tire offers absolutely no additional insulation.

1.19

•

Under no circumstances whatsoever step outside of the vehicle or off the equipment to move to another shelter. Very dangerous electrical pathways to ground may go through you.

•

Shut down all operation, turn off the engine, close all doors and raise all windows.

•

Sit squarely in the seat with your hands in your lap and your feet flat on the floor mat.

•

Do not touch any metallic objects referenced to the outside of the vehicle.

Do not touch any door and window handles, control levers, foot pedals, steering wheels, cab interior walls and any other inside to outside metal objects.

•

Do not touch any radio or telephone connected to an outside antenna.

Tigercat 480 Mulcher

Safety

LIGHTNING SAFETY CONT'D If you are caught outside and have no where else to go.

What to do if you feel your skin tingling, your hair stands on end, light metal objects vibrate or you hear a crackling sound.

1. Avoid wide-open areas where you project above the surrounding landscape.

1. Lightning is probably about to strike. You only have a few seconds to act.

2. Seek shelter in a low place, such as a ditch, ravine, valley, canyon or cave.

2. Put your feet together. Crouch down like in a baseball catcher’s position. Hold your head down. Cover your ears to protect them against the noise of the thunder.

3. Get away from open water such as ponds or streams.

3. Do not lie flat on the ground. By touching as little of the ground as possible, the lightning may not move across the ground to you.

4. Do not take shelter under any isolated tall trees or small groups of trees.

5. Seek shelter amongst the dense, thick growth of the shortest trees.

What to do if a co-worker has been struck by lightning.

6. Avoid entering any small enclosures or shelters.

1. The victim does not carry any electrical charge. There is no danger to anyone helping this person. You can touch him or her immediately.

7. Do not seek shelter under any motor vehicle or heavy equipment.

8. Keep clear of any materials that can conduct electricity such as wire fences and gates, metal pipes, poles, rails and tools.

2. Call your local emergency response telephone number immediately.

3. If the victim has no pulse, their heart has stopped or they have stopped breathing, start cardiopulmonary resuscitation (CPR) or mouth –to-mouth resuscitation immediately.

Use a portable defibrillator if one is available.

9. Stay at least 15m (50 feet) away from metal objects such as a fuel tank, a vehicle or machinery without a cab, motorcycle, ATV, etc.

10. Stay at least 5m (16 feet) apart from any other members of a group so that lightning won’t travel between you.

4. Be careful about staying in the storm to take care of the victim. You can get hit by lightning too. If you can, move the victim to a building as soon as possible.

11. Do not use the telephone except for emergencies.

To further increase your awareness about lightning safety, see the following web sites.

National Weather Service Lightning Safety http://www.lightningsafety.noaa.gov National Lightning Safety Institute http://www.lightningsafety.com

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Tigercat 480 Mulcher

Safety 4. 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.

fire prevention

5. Inspect the machine regularly for any signs of diesel fuel or hydraulic system leakage.

Check for worn or eroded fuel or hydraulic lines before starting up any equipment.

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.

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

7. Steam clean the engine, transmission, brake, fuel and hydraulic tank compartments of all equipment at least once a month or more frequently when working in logging conditions where large amounts of combustible forest debris are present.

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 to a minimum.

8. Use only nonflammable solutions for cleaning the machine and components.

1. Maintain a CHARGED fire extinguisher on the machine at all times and KNOW HOW TO USE IT. 2. Remove debris and blow out dust regularly from the air intake doors, engine radiator and charge air cooler, hydraulic oil cooler, diesel fuel cooler and air conditioning condenser core to prevent overheating of the engine and hydraulics and to maintain efficient operation of the machine. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the OPERATOR’S MANUAL. 3. Blow off all forest debris and fine organic material 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 when working in logging conditions where large amounts of combustible forest debris are present. 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 this smoldering debris can fall into other areas of the machine and thereby spread a fire.

1.21

9. 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.

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

12. Never leave the machine parked with boom, arch or blade suspended off the ground. Should their supporting hydraulic hoses burn through during a fire, pressurized hydraulic oil may be injected into the fire and the boom, arch or blade will fall rapidly to the ground.

Tigercat 480 Mulcher

Safety 17. AFTER transporting (trucking) a machine from one job site 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.

fire prevention 13. Turn the battery disconnect switch to OFF at shut down to de-energize all electrical circuits.

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

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

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

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

EQUIPMENT FIRES ADVERSELY EFFECT YOUR ABILITY TO LOG, MAY INCREASE YOUR INSURANCE PREMIUMS DRAMATICALLY or PREVENT YOU FROM OBTAINING INSURANCE COVERAGE AT ALL. What to do to prepare for a MACHINE fire •

Prevent the fire from happening in the first place by ensuring that all machine systems are frequently inspected and always well maintained.

•

Ensure that any hand held fire extinguishers are charged and in working order. Fire extinguishers require routine care. Follow the manufacturer’s instructions for inspection and maintenance shown on the label of the fire extinguisher and in the extinguisher manufacturer's manual.

•

Ensure that any pressurized water systems on the machine (if applicable) are charged and in working order. Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in SECTION 3 of the OPERATOR’S MANUAL.

•

Ensure that you have the proper fire extinguishers on site. Most fires involving mobile forestry equipment will be Class A or B. Dry chemical extinguishers should be rated ABC and pressurized water extinguishers should be rated A. Class A fires involve ordinary combustibles such as wood, cloth, paper, rubber and many plastics, Class B fires occur with flammable liquids such as diesel fuel, oil and grease and Class C fires apply to energized electrical equipment.

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

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

1.22

Tigercat 480 Mulcher

Safety WHAT TO DO WHEN A MACHINE FIRE OCCURS

fire prevention •

•

•

• •

•

•

•

If operating the machine when a fire occurs: 1. Lower all working attachments to the ground.

Ensure that the nozzle of any hand held extinguisher and pressurized water system available on the machine and at the work site fits within the access holes in the doors of the machine.

Ensure that your fire detection system* is in working order. Refer to fire DETECTION system in SECTION 2 of the OPERATOR’S MANUAL. Ensure that your fire suppression system** is charged and in working order. Refer to fire suppression system in SECTION 2 of the OPERATOR’S MANUAL. Ensure that you are familiar with the recommended procedures for fire contained in the emergency action plan of your company.

Ensure that you follow all national, state / provincial and local regulations dealing with fire fighting in effect in your specific geographic region. Regulations will vary from region to region but most will usually require that: 1. Workers assigned to fire fighting duties must be physically capable of performing them safely and effectively.

2. Workers designated to use fire fighting equipment as part of an emergency action plan must receive full and proper training from a qualified instructor.

3. Whenever portable fire extinguishers are provided for use in the workplace, training must be provided to familiarize workers with the general principles of fire extinguisher use and the hazards involved with fire fighting.

4. Training must be provided upon initial employment and at least annually thereafter.

Ensure that after you have received the training as outlined above, that you know how to use the fire extinguisher, the pressurized water system (if applicable) and the fire

2. Shut the engine off.

3. Activate the fire suppression system**.

4. Radio or call for help. Be certain to report a fire immediately.

5. Exit the machine taking fire extinguisher and pressurized water system hose (if applicable) with you.

6. 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. All fires can be very dangerous and life threatening.

7. Only if you can safely do so, turn OFF the battery disconnect switch.

•

Before deciding to fight the fire, be certain that: 1. The fire is small and not rapidly spreading.

2. There is always a clear, safe escape route to your back.

3. You have received training in the use of the available fire extinguishing systems and are confident that you can operate them effectively.

suppression system** on your machine.

There is not enough time available to read instructions during a fire emergency.

Ensure that all information necessary for you to immediately contact all sources of help (local fire department, etc) in the event of a fire emergency is recorded and readily available at all times.

1.23

•

Be aware that engine coolant , diesel fuel or hydraulic hoses could fail during a fire. If this happens, hot coolant, fuel or oil could possibly be ignited by the fire.

•

If in any doubt about whether or not to fight the fire – DON’T. Instead stand well clear of the fire and wait for help to arrive.

•

If possible a dry chemical fire extinguisher or

fire suppression system** should be used first to fight a machine fire. Then immediately afterwards use the pressurized water hose supplied with the machine (if applicable) or a pressurized water extinguisher (if available). A fire suppressed by dry chemical may re-ignite from the heat retained by any debris in the area. The water will cool the area, reducing the chances of re-ignition.

Tigercat 480 Mulcher

Safety What to do after a MACHINE fire HAS OCCURRED

fire prevention •

•

Before returning the machine to work.

1. Ensure that the cause of the fire is determined and all appropriate repairs are completed.

Use the PASS method. This is the most effective use of a fire extinguisher.

•

Pull the pin at the top of the extinguisher that keeps the handle from being pressed.

Break the plastic seal as the pin is pulled.

•

Aim the nozzle at the base of the fire. Do not aim the nozzle at the flames. In order to put out the fire, you must extinguish the fuel, not the flames. Hose nozzles are often clipped to the extinguisher body.

Release the hose before taking aim.

•

Squeeze the handle to release the pressurized extinguishing agent. The handle can be released at any time to stop the discharge.

*NOTE: Fire detection systems are offered by

•

•

2. Ensure that the fire detection system*

or the fire suppression system** is properly serviced and in working order (if applicable).

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

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

Tigercat as an optional installation on some Tigercat product lines. Please disregard any references made to fire detection systems if not installed on your machine.

Sweep from side to side at the base of the fire until the fire is completely out or the fire extinguisher is empty

**NOTE: Dry chemical fire suppression systems

are offered by Tigercat as an optional installation on some 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.

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

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

Ensure that the machine and all components have cooled down sufficiently after a fire so that re-ignition does not occur.

Remain with the machine until help arrives.

1.24

Tigercat 480 Mulcher

Safety

DRY CHEMICAL CLEANUP PROCEDURES

3. In areas exposed to heat during the fire, the dry chemical powder will melt forming a coating that cakes or crusts on all surfaces.

Both ABC dry chemical fire extinguishers and fire suppression systems discharge a chemical powder to extinguish the fire. The chemical makeup and the small particle size of the powder as well as the force of the discharge all contribute to the fire fighting capability. These same characteristics also permit the powder to penetrate into and fully cover all components in the vicinity of the discharge.

To break down the caked dry chemical, spray or wash these areas with a 50/50 mixture of hot water and isopropyl alcohol. Allow this mixture to stand in place for several minutes.

The caked dry chemical when exposed to moisture is also mildly acidic. Therefore when the break down procedure has been completed, follow this immediately with the neutralizing procedure as described in step 2.

The following are recommendations for the cleanup and neutralizing of areas exposed to dry chemical powder.

Workers performing this work should wear protective clothing, safety goggles and a fine particle dust mask to minimize their personal exposure to the dry chemical powder.

Ensure that all electrical systems have been completely de-energized prior to any cleanup.

1. In areas of the machine that remained cool and dry during the fire, the dry chemical will stay in powder form.

Be certain to clean these areas immediately to prevent any settled residual powder from coming into contact with moisture whether through direct contact or humidity in the air.

Remove the powder residue by blowing off with air, sweeping, dusting or vacuuming using a HEPA filter capable of trapping the small dry chemical particles. Then wipe all surfaces with a damp cloth.

2. In areas exposed to moisture, the dry chemical powder will combine with water to form a paste that is mildly acidic. Note that all surfaces covered by this dry chemical paste including electrical contacts are vulnerable to corrosive attack.

To neutralize the acidic paste on large surfaces, spray or wash these areas with a mixture of 3 parts hot water to 1 part baking soda. Allow this mixture to stand for several minutes before rinsing with warm water. Wash the area with a mild soap and water solution.

Rinse thoroughly with water. Blow-dry to remove all residual water.

Cleaning of electrical contacts should be done using an electrical contact cleaner that has no flash or fire point and is non-corrosive and non-conductive such as CRC Contact Cleaner 2000.

1.25

Tigercat 480 Mulcher

Safety

SAFETY LABELS SAFETY LABELS CAB LABELS The following safety labels are installed in the cab.

These labels are located inside the cab in full view of the operator. All labels must be periodically cleaned and inspected to ensure legibility is maintained. Replace any label that becomes illegible, damaged or removed.

OPERATOR'S MANUAL LOCATION This label indicates the storage location of the operator's manual.This labelis located on the outside of the operator's manual case inside the cab.

NO RIDERS

READ OPERATOR'S MANUAL Always read the operator’s manual before operating the machine. Pay close attention to WARNINGS and HAZARD identifications.

NO RIDERS INSIDE OR OUTSIDE OF THE MACHINE . Do not carry passengers either in the cab or anywhere else on the machine. The vehicle seating accommodation is for one operator only.

Persons riding on the outside of the machine are subject to hazards such as falling off the machine, crush hazards, thrown object hazards and many other hazards which cOULD result in death OR serious injury.

Study all the safety messages in this manual and on the labels on the machine carefully.

If any person attempts to climb onto the machine during operation, STOP THE MACHINE IMMEDIATELY. Do Not Operate the machine until other personnel are a safe distance away from the machine.

1.26

Tigercat 480 Mulcher

Safety KEEP BACK

SAFETY LABELS CRUSH HAZARD

This label warns personnel to KEEP BACK 150M / 500FT due to flying projectile hazard. Danger exists most prominently to the front and rear of the mulching head.

37795BUNI R0

This label warns of the CRUSH HAZARD caused by the boom when it is not properly supported.

When approaching an operating machine on foot, stay at least 500 feet (150 meters) away until the operator recognizes your presence. Make sure that all equipment has been shut down before advancing to the machine.

Never work under or near an unsupported boom or attachment. Contact with a falling boom COULD RESULT IN DEATH OR SERIOUS INJURY! Always lower the boom to the ground so that the weight of the boom and attachment is resting on the ground. Properly support and brace boom and shut off engine before performing service work.

1.27

Tigercat 480 Mulcher

Safety

SAFETY LABELS ROTATING CUTTER KEEP BACK

44438BUNI R0

This label warns of the ROTATING CUTTER hazard. All personnel must keep a safe distance from the mulching head when the cutter is rotating.

The safety of persons outside the cab is the responsibility of the machine operator.

Danger caused by flying debris. Improper operation of the attachment and failure to follow safety precautions can result in personal injury.

1.28

Tigercat 480 Mulcher

Safety CHECK DAILY

SAFETY LABELS FIRE PREVENTION!

This label is installed in the cab. In addition to the previous label it is a reminder to check the machine daily for the possibility of debris build-up, leaks, damaged wires and hoses and take the necessary action required to clean up any debris accumulation, repair any leaks, damaged wires or hoses.

This label is installed on the front of the engine front panel. It advises operator's of the following:

The label also advises to check and ensure that all fire fighting devices are in good working order.

Read understand and follow the FIRE PREVENTION guidelines in this manual.

These guidelines provide all the necessary action required to preventing fires on this machine. DO NOT OPERATE THIS MACHINE until you have read these instructions and have performed any necessary maintenance required that will prevent the potential of a fire from starting on this machine.

fire extinguisher ACCESS HOLE

It is also important to note that fire prevention inspections and maintenance MUST BE PERFORMED FREQUENTLY (several times per day). A clean combustible free machine as well as frequent inspections of the exhaust components, hydraulic hoses and electrical cables and performing any necessary repairs immediately will help prevent fires.

This label indicates the location of each FIRE EXTINGUISHER ACCESS HOLE. The label is installed on each fire extinguisher hole on the engine hood.

Maintain a CHARGED fire extinguisher on the machine at all times, know where it is and KNOW HOW TO USE IT! 1.29

Tigercat 480 Mulcher

Safety

1.30

DANGER USING HIGH SPEED DISC SAWS SAFELY This information is intended to encourage logging organizations and operators to develop and practice additional rules that suit particular terrain conditions and job requirements. It is also intended to assist towards a quicker understanding of how and why things can happen when a high speed disc saw is in use; and hence to assist in development of safe operating practices.

The following information is in addition to any safety instructions or recommended safe operating practices that may already be in circulation.

CONTENTS COMMENTS AND INSTRUCTIONS DIRECTION OF THROW.......................................................... 7 HIGH ANGLE WRIST ROTATION ABILITY.............................. 8 RECOGNIZING THE DANGERS.............................................. 7 THROWING LONG WOOD PIECES...................................... 10 DANGERS.................................................................................... 3 FORWARD................................................................................... 2 BE AWARE OF THE HAZARDS............................................... 2 OTHER INSTRUCTIONS.......................................................... 3 SAFE PRACTICES................................................................... 3 SEVERAL TYPES OF HEADS INVOLVED............................... 2 STORED ENERGY................................................................... 2 HIGH ANGLE WRIST ROTATION CAPABILITY........................... 9 SAW HEAD DON'TS.................................................................. 15 TYPE OF HOUSING MAKES A DIFFERENCE........................... 4

Tigercat

5211A • R2-1101

PAGE 1 OF 16

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using high speed disc saws safely forward:

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Several types of heads involved Tigercat wheel type feller-bunchers and crawler feller-bunchers can be supplied with several optional makes and models of high speed disc saw tree felling heads. Because each has certain advantages and disadvantages they are chosen where they best do specific types of work.

Stored energy The saw blade stores energy from the hydraulic motor during the times between tree cuts so that it can supply up to 1000 hp during a 1 sec tree cut. However this rotational energy, if misapplied can result in wood materials or other objects being thrown strongly enough to cause damage and to hurt people.

Be aware of the hazards It is important that users of machines with disc saw felling heads are aware of certain safety precautions that need to be taken. In this section some previously unknown, unexpected safety hazards are illustrated and explained . These should be studied before use of the machinery and then reviewed again after use has begun.

FIGURE 1: BROADSIDE SAW CONTACT WITH A LOG COULD PRODUCE A THROW

FIGURE 2: A SUDDEN MACHINE MOVEMENT MAY 2 THROW AT THE CAB CAUSE AN UNEXPECTED

using high speed disc saws safely

Tigercat

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Safe practices It is understood and expected that logging organizations and operators will develop and practice additional rules that suit (for example) particular conditions of terrain, trees, soil and job requirements. The information given here is intended to assist towards a quicker understanding of how and why things can happen when a high speed disc saw is in use; and hence to assist in development of safe operating practices.

It should not be assumed that all possible dangers have been discovered and described here.

Other instructions It is also understood and expected that all instructions contained in service and operator's manuals for use and maintenance of Tigercat disc saw heads and other disc saw heads installed on Tigercat machines will be followed.

The Dangers

There are at least these means by which a rotating disc saw can cause harm by throwing: • The normal throwing of chips from the cut.

• Soil particles are thrown from the ground.

• Loose chunks of wood encountered or produced are tossed by the exposed blade.

• Sticks and debris falling onto the blade or sliding across the blade are struck by the teeth and thrown.

• Metal pieces from the blade or from objects encountered are thrown.

• Wood pieces enter the saw housing and are expelled by the blade.

• In very peculiar cases the saw can throw long lengths of wood as spears.

3

using high speed disc saws safely

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Type of Housing makes a Difference Since the configuration of the saw housing can affect the safety of its use we need to identify some particular types of housing shapes and guarding being used.

Figure 3 shows a typical commonly used saw housing plan where there is a continuous skirt around the saw except at a mouth opening where the trees are cut and taken. The skirt extends below the saw enough to intercept tangential throw. There are snouts on both sides of the mouth so that if pushed against the side of a felled tree or log the saw teeth will not contact the wood.

THROW ANGLE

If A SAW HEAD IS pushed against the side of a felled tree, SNOUTS PREVENT saw teeth FROM contacting wood.

Figure 3: Typical commonly used saw housing, continuous skirt with opening where trees are cut. Snouts on both sides of the mouth.

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using high speed disc saws safely

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Figure 4 shows another commonly used plan. It has no blade guarding snouts so that the saw blade teeth do protrude ahead of the housing. This may be preferred over figures 3 and 5 for dexterity in tree getting.

THROW ANGLE

If A SAW HEAD WITHOUT SNOUTS IS pushed against the side of a felled tree, saw teeth will contact wood.

Figure 4: another commonly used HOUSING plan with no snouts, blade teeth protrude ahead of the housing.

In figure 5 there is a much longer snout on the ingoing side of the mouth, i.e., where the teeth of the rotating blade are entering the housing. The broad side of a log, if nudged, will not contact the saw teeth and more thrown material will be intercepted by the extra length of snout.

THROW ANGLE

nudged LOG will not contact saw teeth. extra length of snout WILL INTERCEPT PORTION OF thrown material.

figure 5: HOUSING USES longer snout on IN-GOING side OF MOUTH WHERE ROTATING BLADE ENTERS HOUSING.

5

using high speed disc saws safely Housing types cont.

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In figure 6a and 6b there is an additional opening in the housing skirt. Openings in this location are sometimes provided for escape of wood chips produced by the saw teeth in the cut and being taken into the housing.

A CHIP ESCAPE PORT CAN ALLOW THROW BEHIND THE MACHINE

rear

front

figure 6a

figure 6b

figure 6c

figure 6: additional opening in the housing skirt.

In figure 6c a guard has been added to the chip escape port so that tangential travel of chips and other material is intercepted as soon as it leaves the housing.

Each figure shows a shaded area where normally tangentially thrown material can escape from the saw housing. Deflected and dropped chips escaping below the bottom edge of the housing skirt are not included. The areas and angles are not exact but do show that one head can be different from another.

It is important that the operator familiarize himself with the blade rotation direction, the effectiveness of any snout on the in-going side and which direction any chip escape ports allow material to fly.

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using high speed disc saws safely Comments and Instructions

Tigercat

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Recognizing the Dangers While it may appear that these illustrated danger areas can be visually recognized on the job by observing how far chips fly during a cut, that is only true for chips and other light weight materials. Metal parts and wooden spears can be thrown to surprisingly greater distances. Even distant personnel on the ground, in other vehicles, or in buildings are at risk if the throw is in their direction.

Direction of throw The direction of possible tangential throw for metal parts and stones is dependent on the housing configuration and might be expected to be the same as observed for the chips. However, these throws can occur at any time the saw is running, in whichever direction the angle of throw is pointed by boom geometry, not just when a cut is being made.

Throw distance The throw distance for metal pieces and stones, can be many times the distance shown by the pattern for chips. More testing and data collection is needed to pin down a “safe distance” but if someone or something is in a place that can be seen by the operator and in the throw direction of a high speed disc saw, then the operation is not safe regardless of the distance.

Safe operating areas These saw heads must not be used in areas where the logging operation does not have control over the presence and movement of people. In particular, clearing of vegetation in urban and populated areas should not be done with a Tigercat manufactured or supplied high speed disc saw. High speed disc saw heads are intended for high productivity wood harvesting in areas remote from normal habitation. The possible presence of people and property within throw range and the likelihood of encountering scrap metal, wire fencing, steel posts and concrete must be respected.

Assessing the potential dangers on the job site The extent of danger from high speed disc saws on the logging operation has to be assessed on the job site, depending on how much other work activity is in the area and whether the operator can do his job of cutting and bunching with good control of throw patterns.

Danger is greater if the saw is equipped with detachable, or fragile, or brittle teeth, or if the site contains stones or abandoned metal.

7

using high speed disc saws safely Comments and Instructions cont.

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Regular maintenance Poor saw maintenance increases these dangers. Some designs that might allow fasteners to wear thin or fatigue and suddenly break, need thorough timely replacement procedures. It is important that the warning signs of missing saw tooth parts or the sounds of striking rocks be heeded and the operation adjusted to avoid danger.

High angle wrist rotation ability When a felling machine is equipped with a high speed disc saw head with a high angle wrist rotation ability it should be determined that the limits of the boom, stick, tilt, wrist, upper leveling and any other freedoms, do not permit a direct throw at the operators cab during normal operation, see figure 7a. It is probably essential that the housing have a long snout on the throw side and that if a chip escape port is used it should be guarded.

With these high mechanical freedom arrangements there is a chance that an unforeseeable operator misadventure or equipment failure could result in an accidental direct or deflected throw at the operators cab, refer to figure 2 and 7b. The cab should be capable of resisting such accidental and ricochet throws. The velocity energy of metal or rock pieces leaving the blade is extremely high. The operators cab cannot be considered safe to routinely operate in the chip throw area, even if it has been especially constructed to prevent penetration by accidentally thrown objects.

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using high speed disc saws safely

Tigercat

FELLING HEAD • WITH A CHIP ESCAPE PORT AND SHORT SNOUT. • SHOWN IN A HIGH ANGLE WRIST ROTATION POSITION, PLACING OPERATOR'S CAB IN DIRECT LINE WITH unguarded CHIP ESCAPE PORT

figure 7a

plan view of machine showing clockwise and counterclockwise blade rotation

figure 7b FELLING HEAD • WITH LONGER SNOUT ON THROW SIDE OF OPENING AND WITH A guarded CHIP ESCAPE PORT.

FIGURE 7: DISC SAW FELLING HEAD WITH HIGH ANGLE WRIST ROTATION CAPABILITY

9

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using high speed disc saws safely Comments and Instructions cont.

Tigercat

Throwing long wood pieces Dangers from throws of long wood pieces are illustrated in figures 8 to 11. Tests and experience have shown that when a high speed rotating saw is applied to a loose piece of wood, the wood is either blown or pushed away, without a throw. If the wood is held firmly in all directions and the saw advanced into it at any feed speed, cutting will take place. If the wood is only held against escape from the saw radially, but not held tangentially, then the wood will be both partly cut and partly moved tangentially. In this last case tests have shown that if the piece of wood is backed-up by a solid slippery surface; and if the feed in is very fast; and if the piece of wood is long enough; then the tangential movement is a dangerous spear-like throw.

a slab, which could later be thrown, might happen when not enough room in head to completely cut the last tree

slab

slab

n

i ed

fe

figure 8a: how a slab can be thrown from the side of a log

th dir row ec tio n

saw HOUSING HAS skis, BUT without snouts and blade teeth protrude ahead of the housing.

FIGURE 8

throw engagement distance FELLING HEAD MOVING INTO slab/log

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SLAB

LOG a long throw engagement distance can cause a dangerous spear throw

FIGURE 8b SIDE VIEW

feed in

if the side of a log can contact the saw, the throw engagement distance can be long

10

FIGURE 8c top view

using high speed disc saws safely Comments and Instructions cont.

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Figures 8 and 9 show two ways that this might happen in the woods if using the saw head of figure 4 (where the throw contact can be long). A slab, still partly attached to a well backed-up tree bole and wet with sap, makes an ideally bad throw situation which could unintentionally occur in woods work. A small log in a pile of other logs might also be propelled out with enough length of continued contact to reach near saw tip speed.

A small log in a pile of other logs might also be propelled out with enough length of continued contact with the blade to reach near saw tip speed.

in feed FELLING HEAD MOVING INTO log pile

figure 9a: how a log can be thrown like a spear

saw HOUSING without snouts and blade teeth protrude ahead of the housing. throw engagement distance

small log LOG pile feed in

a saw housing without snouts allows a long throw engagement distance

FIGURE 9b SIDE VIEW

FIGURE 9c top view

if the side of a log can contact the saw, the throw engagement distance can be long

feed in

11

using high speed disc saws safely Comments and Instructions cont.

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Figure 10 shows how a head with snouts does not allow a long throw contact. Although tests show that a short contact length on a long log or tree butt does not result in a spear like throw, this action should nevertheless be avoided because abnormally large chips are sometimes produced and thrown. uncut tree or stump backup

throw engagement distance

when only the end of a log can make contact with the saw, there is not much throw engagement distance

figure 10: felling head housing with snouts does not allow a long throw contact

FELLING HEAD MOVING INTO log

Figure 11 warns that blocks of wood can be tossed in any direction when improvising with a disc saw to trim over-size stumps. A long snout and a slow feed speed lessen danger during stump trimming.

A similar danger of throw may exist when clearing small brush with multiple pass cuts.

FELLING HEAD MOVING INTO stump (feed speed)

figure 11: a block of wood can be tossed when trimming stumps

12

using high speed disc saws safely Comments and Instructions cont.

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Saw blade throw gap Saw blades have gaps between adjacent teeth and holders to permit installation and removal of the teeth and to provide spaces to accumulate chips in the cut, see figure 12. Fallen sticks and debris or sticks and debris sliding across the the saw blade can enter these gaps when the blade is rotating and be struck by the teeth and be tossed or thrown. Larger gaps and lower rotation speeds increase these dangers.

THROW GAP

FIGURE 12: SAW BLADE THROW GAP

13

using high speed disc saws safely Comments and Instructions cont.

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Saw housing entrance and exit space To avoid the ingestion of materials into the housing space above the disc (and later ejection) the ingoing entrance for the saw rim of teeth is kept as small as practical. It is important that this high wear area be maintained at its original size and shape. The outgoing opening is large enough to allow the housing to clean itself and will allow most things inside to be thrown out, see figure 13. Its throw direction and angle must be respected. A long snout on the other side reduces this danger.

the ingoing entrance OF THE HOUSING for the saw rim of teeth should be small

The outgoing opening is larger to allow the housing to clean itself and will allow most things inside to be thrown out

figurE 13: Saw blade entrance and exit space

14

using high speed disc saws safely Comments and Instructions cont.

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This information is offered by Tigercat as part of interim action to make saw heads safer. It is based on what has recently been reported from the field and on tests conducted on proving grounds. Tigercat is continuing to do design and testing of tree felling machinery towards achieving greater safety in the woods. Tigercat would be thankful for written reports describing any unsafe happenings, including near misses, in the use of felling heads and their carriers.

The following are some “Saw Head Don’ts” that apply particularly to throw prevention.

Do not point the throw of a disc saw head in a direction towards people, vehicles or buildings at any visible distance.

Do not operate in a way that throws chips in a direct-line at the machine cab.

Do not push hard with the saw against anything except a standing tree to be cut.

Do not mix new sharp teeth with old dull teeth on the same saw.

Do not change the blade rotation from its designed direction in the head.

Do not over speed the blade rpm.

Do not remove or shorten snouts provided by the head manufacturer or installer.

Do not neglect tooth fastening inspection, maintenance and replacement.

Do not neglect to repair worn or damaged saw housings.

Do not neglect to replace any covers removed for service or clean out.

Do not count on skis to give the throw protection that snouts do.

Do not nudge loose short pieces with the front of any type of head.

Do not nudge anything, even long logs, with the front of a head which has no snouts.

Do not cut short small stalks when blade speed is low.

Do not operate a high speed disc saw in a populated area.

Do not assume that visitors and other workers are aware of disc saw dangers.

Do not assume that the operator will spare you, a visitor, from danger.

Do not select and operate heads that throw rearward.

Do not select and operate heads with unnecessarily wide throw angles.

Do not neglect to read and follow all instructions provided by the saw and head manufacturers.

15

using high speed disc saws safely

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Tigercat 480 Mulcher SECTION 2 - CONTROLS AND OPERATION CONTENTS - SECTION 2

JANUARY, 2010

A

AIR CLEANER.................................................................................................................................. 2.76 AIR COMPRESSOR - AIR SUPPLY.................................................................................................. 2.74 AIR CONDITIONER/HEATER........................................................................................................... 2.19 AIR CONDITIONING (A/C) SWITCH................................................................................................ 2.17 AIR PRECLEANER........................................................................................................................... 2.77 air supply connector............................................................................................................. 2.74 AIR VENTS....................................................................................................................................... 2.19 Attachment tilt....................................................................................................................2.9, 2.11 B

BATTERY DISCONNECT SWITCH.................................................................................................. 2.21 BOOM CYLINDER LOCK................................................................................................................. 2.84 BOOM FLOAT OPERATION...................................................................................................... 2.9, 2.11 Boom Lift................................................................................................................................2.9, 2.11 BOOM LIFT LOCK............................................................................................................................ 2.84 C

CAB LOWERING THE CAB................................................................................................................... 2.73 RAISING THE CAB........................................................................................................................ 2.72 CAB CONTROLS, ACCESSORIES AND INSTRUMENT PANEL........................................................2.7 CAB INTERIOR LIGHTING............................................................................................................... 2.26 CAB TILT PUMP................................................................................................................................ 2.71 CAMERA-MONITOR......................................................................................................................... 2.22 CARE OF THE MACHINE................................................................................................................. 2.84 CARE OF POLYCARBONATE WINDOWS.................................................................................... 2.85 CAUTIONS................................................................................................................................. 2.86 CLEANING INSTRUCTIONS..................................................................................................... 2.86 CONCEALING HAIRLINE SCRATCHES................................................................................... 2.86 FIRE PRECAUTIONS................................................................................................................ 2.87 GRAFFITI REMOVAL................................................................................................................. 2.87 INSPECTION AND MAINTENANCE.......................................................................................... 2.85 RESISTANCE TO CHEMICALS................................................................................................. 2.85 RESISTANCE TO WATER......................................................................................................... 2.85 CLEANING A/C CONDENSER, OIL COOLER, RADIATOR AND CHARGE AIR COOLER........................................................................................................ 2.82 COMPUTER......................................................................................................... 2.13, 2.30, 2.31, 2.32 ADJUSTMENT MENU................................................................................................................... 2.34 ALERT MESSAGES...................................................................................................................... 2.66 CRITICAL MESSAGES................................................................................................................. 2.55 DATE/TIME ADJUSTMENT........................................................................................................... 2.51 DISPLAY ADJUSTMENT............................................................................................................... 2.50 MAIN MENU PAGE........................................................................................................................ 2.49 MESSAGES AND WARNINGS...................................................................................................... 2.54 ERROR MESSAGES (RED)...................................................................................................... 2.62 MESSAGES AND WARNINGS - ERROR...................................................................................... 2.63 CURRENT OUTPUT ERROR (COUT)...................................................................................... 2.65 DIGITAL INPUT ERROR (DIN).................................................................................................. 2.65 DIGITAL OUTPUT ERROR (DOUT).......................................................................................... 2.65 MODULE NO CONTACT ERROR............................................................................................. 2.63 MODULE VREF ERROR........................................................................................................... 2.64 VOLTAGE INPUT ERROR (VIN)................................................................................................ 2.65 PREFERENCES MENU................................................................................................................ 2.49 SCREEN SAVER ADJUSTMENT.................................................................................................. 2.50

Tigercat 480 Mulcher Tigercat 480 Mulcher

Controls and Operation

SECTION 2 - CONTROLS AND OPERATION

CONTROLS - CAB.....................................................................................................................2.8, 2.10 COOLING ASSEMBLY...................................................................................................................... 2.82 CRUISE CONTROL OPERATION..............................................................................................2.8, 2.10 D

DRIVE LIMITER................................................................................................................................ 2.37 E

EMERGENCY EXITS CHECKING PROCEDURE FOR ESCAPE HATCH....................................................................... 2.28 CHECKING PROCEDURE FOR SIDE DOOR:............................................................................. 2.28 ESCAPE HATCH REMOVAL/REPLACEMENT............................................................................. 2.28 MAINTENANCE GUIDE................................................................................................................ 2.28 EMERGENCY STOP SWITCH.......................................................................................................... 2.19 ENGINE AIR CLEANER............................................................................................................................... 2.76 AIR PRECLEANER........................................................................................................................ 2.77 RPM............................................................................................................................................... 2.14 STARTING..................................................................................................................................... 2.80 STARTING IN COLD WEATHER................................................................................................... 2.81 STOPPING.................................................................................................................................... 2.82 ENGINE, HOT WATER SHUT OFF VALVE....................................................................................... 2.20 F

FILTER - CAB FRESH AIR................................................................................................................ 2.20 FILTER, RECIRCULATING AIR - A/C UNIT...................................................................................... 2.20 FIRE EXTINGUISHER...................................................................................................................... 2.27 FUEL TANKS..................................................................................................................................... 2.73 FUSE AND RELAY PANEL CAB................................................................................................................................................ 2.88 MAIN.....................................................................................................................................2.90, 2.91 FUSE PANEL.................................................................................................................................... 2.21 H

HEATER CONTROL.......................................................................................................................... 2.18 HOT WATER SHUT OFF VALVE (ENGINE)..................................................................................... 2.20 I

ICONS, PICTOGRAM DESCRIPTIONS......................................................................................2.4, 2.5 INSTRUMENT PANEL.............................................................2.12, 2.13, 2.14, 2.15, 2.16, 2.17, 2.18 J

JOYSTICKS...............................................................................................................................2.9, 2.11 M

MACHINE PREPARATION................................................................................................................ 2.81 MD3 COMPUTER....................................................................................................................2.30, 2.31 MD3 COMPUTER MAIN MENU........................................................................................................ 2.32 O

OPERATING MACHINE.................................................................................................................... 2.78 P

PICTOGRAM DESCRIPTIONS....................................................................................................2.4, 2.5 Pre-Start Checks...................................................................................................................... 2.78 PUMP CAB TILT................................................................................................................................ 2.71 S

SCREEN SAVER ADJUSTMENT...................................................................................................... 2.50 SEAT................................................................................................................................................. 2.24 SERVICE COMPARTMENTS, DOORS AND ACCESS PANELS..................................................... 2.70 starting engine.......................................................................................................................... 2.80 STOPPING ENGINE......................................................................................................................... 2.82 System Test and Warm-Up....................................................................................................... 2.81

2.2

Tigercat 480 Mulcher Tigercat 480 Mulcher

Controls and Operation

SECTION 2 - CONTROLS AND OPERATION

T

TILTING THE CAB............................................................................................................................ 2.72 TILT PUMP, CAB............................................................................................................................... 2.71 TRACK COMPONENTS MEASURING TRACK SAG TRACK SAG ADJUSTMENT...................................................................................................... 2.79 W

WARNING DEVICES BUZZER......................................................................................................................................... 2.19 DISPLAY........................................................................................................................................ 2.19 LIGHTS.......................................................................................................................................... 2.19 WINCH OPERATION.................................................................................................................2.9, 2.11 WORK LIGHTS................................................................................................................................. 2.19

2.3

Tigercat 480 Mulcher

Controls and Operation

PICTOGRAM DESCRIPTIONS Diagrams in pictorial form are used to represent machine function operation. Some of the symbols are signs, characters, figures, or any components related to the operation of the machine. They are a simple universal language of symbols or pictograms that illustrate a function or component without the use of words. Pictograms are installed on or in close proximity to the switch or device used to activate or deactivate the machine function or they may be a sign used on a warning or indicator light of a function that is operating or advising of an alarm condition.

Examples of these pictograms are the turtle speed such as SLOW =

or FAST =

and the rabbit

that are often used to describe

.

The pictograms used on this machine are as follows:

= Adjustment Menu Icon

P

P

= Control Lever Multiple Direction = Control Lever One Direction

= Air Conditioner ON

= Control Lever Two Direction = Air Conditioner OFF = Critical Message Symbol = Air Source, Fresh Air = Cruise Control = Air Source, Recirculate = Drive limiter Enabled = Alert Message Symbol = Engine Start = Auxiliary Power Outlet 12 V = Engine Stop = Battery Disconnect = Engine SPEED = Boom DOWN = Engine Wait to Start = Boom UP = Engine Warning

= Boom Tilt Back = Boom Tilt Forward

2.4

Tigercat 480 Mulcher

Controls and Operation

PICTOGRAM DESCRIPTIONS CONTINUED = Engine Menu Icon

= Imperial/Metric Toggle Symbol

= Error Message Symbol

= Information Menu Icon

= Fan Auto Reversing/Cleaning = Information Message Symbol = Fan Full ON = Instrument Bulb Test = Fuel - Diesel = Interlock Reset ON

= Fuel Level Low = Horn

= Interlock Reset OFF = Hydraulic Oil Temperature

= Lights, Work

= Hydraulic Oil Temperature High

= Lights, Engine Service = Mulching Head FLOAT

= Hydraulic Oil Level Low

= Mulching Head ON = Hydraulic Oil Level

= Mulching Head Off = Mulching Head Debris Door Closed

= Hydraulic Oil Level High

= Mulching Head Debris Door Open

= Mulching Head Push Bar IN = Hydraulic Oil Level Low = Mulching Head Push Bar OUT

2.5

Tigercat 480 Mulcher

Controls and Operation

= Speed FAST or Hi = Travel FORWARD

= Speed SLOW or LOW

= Travel REVERSE = Steer Left = Ventilation Blower Fan = Steer Right = Windshield Washer

= Switch ON

= Winch ON

= Winch Free Spool

= Switch OFF

= Winch Spool IN = Temperature = Winch Spool Out = Travel Direction

2.6

Tigercat 480 Mulcher

CAMERA MONITOR

Controls and Operation

MD3 COMPUTER

AM/FM RADIO CD PLAYER CAMERA

WARNING ALARM LIGHT

EMERGENCY SHUT-OFF SWITCH

SPEAKER

SPEAKER

CONVEX REAR VIEW MIRROR

WARNING ALARM HORN

CONVEX REAR VIEW MIRROR

STEER / TRACK DRIVE JOYSTICK

MD3 COMPUTER

BOOM/TILT JOYSTICK

45° LEVEL

INSTRUMENT PANEL

AIR RIDE SEAT

CUP HOLDER

WINDSHIELD WASHER FLUID RESERVOIR

SPEAKER

SPEAKER

OPERATOR'S MANUAL STORAGE STORAGE COMPARTMENT CAB FRESH AIR FILTER COMPARTMENT

480-017

TOP VIEW OF CAB CONTROLS, ACCESSORIES AND INSTRUMENT PANEL 2.7

Tigercat 480 Mulcher

Controls and Operation

IMPORTANT: This manual is applicable to factory installed machine functions and controls.

It does not take into account any changes or modifications made after shipment. Verify all functions before operating this machine.

CONTROLS - CAB (4800101 to 4800111) B C A

480-043 480-016

SPEED CONTROL DIAL

INSTRUMENT PANEL

34544BUNI R0

1. JOYSTICK - LEFT

C. Thumb Switch - Cruise Control

The Left Joystick is used for Track Drive and Steer functions. The drive and steer functions require very little movement of the joystick for smooth drive and steering control. Moving the joystick forward slowly and very slightly will result in forward machine movement, if the joystick is pushed forward quickly and fully the machine will lurch forward. Pull the joystick back for reverse machine movement.

When the machine is travelling forward, press switch momentarily to engage cruise control, press switch again to disengage cruise control.

CRUISE CONTROL OPERATION The cruise control function works in conjunction with the left joystick, thumb switch (C) on the joystick and the speed control dial on the instrument panel.

To Steer the machine move the joystick slowly and slightly to the left to steer left or to the right to steer right. Moving the joystick quickly and fully in either direction will cause the machine to lurch into the turn and turn on the spot.

NOTE: Cruise control will only work when the machine is travelling in forward direction. Cruise control does not work when machine is travelling in reverse.

NOTE: Move the left joystick slowly and slightly for smooth drive and steer control.

Set the speed control dial on the instrument panel to mid position (50% Max travel speed). Push the left joystick forward to move the machine forward.

Press thumb switch (C) once to engage cruise

Joystick Switches A. Trigger Switch

control

Horn (Trigger Switch on front of joystick) Press to sound warning horn

then release left joystick.

Use the speed control dial on the instrument panel to increase travel speed by turning the dial CW or decrease travel speed by turning the dial CCW.

B. Rocker Switch Push Bar Operation

To disengage cruise control press thumb switch (C) or pull back on left joystick momentarily.

Press LEFT side of switch to move push bar OUT. Press RIGHT side of switch to move push bar IN.

480-016

2.8

Tigercat 480 Mulcher

Controls and Operation BOOM FLOAT ICON

B

WINCH ICON

C A

480-043 480-016

MD3 COMPUTER DISPLAY

WINCH OPERATION To engage winch press thumb switch (C) on right joystick once. The winch Icon on the MD3 computer display will turn ON (icon will turn green). Use the rocker switch (B) on the right joystick to reel in/out the winch cable.

34545BUNI R0

2. JOYSTICK - right Boom Lift Move the joystick back to raise the boom.

Move the joystick forward to lower the boom.

Attachment tilt Move the joystick to the right to tilt the attachment OUT. Move the joystick to the left to tilt the attachment IN.

To free spool the winch cable, press the trigger switch (A) once when the winch icon is ON. The winch icon will change to the Free Spool icon . The winch cable will now free spool off the winch reel. Pressing the rocker switch to reel in the cable will turn off the free spool operation and return the winch to the winch IN/OUT mode and the winch icon will turn on.

To turn off the winch function press the thumb switch (C). The rocker switch (B) will now operate the debris door function.

Joystick Switches A. Trigger Switch Boom Float/Winch Free Spool ON/OFF (Trigger Switch on front of joystick) - Press mometarily to enable float operation or winch free spool operation.

B. Rocker Switch Debris Door Open/Close - Winch Spool IN/OUT Debris Door Operation Press LEFT side of switch to open door.

Press RIGHT side of switch to close door.

IMPORTANT: To prevent component damage, always have deflector door open when preparing to fell standing trees.

Winch Operation Press LEFT side of switch to spool winch cable IN. Press RIGHT side of switch to spool winch cable OUT. C. Thumb Switch Toggle - Winch Functions ON/OFF

BOOM FLOAT OPERATION To engage BOOM FLOAT, winch operation must be OFF (winch icon will turn grey). Press the trigger switch (A) to turn ON boom float function.

The boom float icon on the MD3 computer display will turn ON (icon will turn green).

To turn off the boom float function press the trigger switch. The boom float icon will turn OFF (icon will turn grey)

2.9

Tigercat 480 Mulcher

Controls and Operation

IMPORTANT: This manual is applicable to factory installed machine functions and controls.

It does not take into account any changes or modifications made after shipment. Verify all functions before operating this machine.

CONTROLS - CAB (4800112 AND UP) B

SPEED CONTROL VARIABLE SLIDER

C

CRUISE CONTROL SWITCH

CRUISE CONTROL ICON

A

480-178 480-043

1. JOYSTICK - LEFT The Left Joystick is used for Track Drive and Steer functions. The drive and steer functions require very little movement of the joystick for smooth drive and steering control. Moving the joystick forward slowly and very slightly will result in forward machine movement, if the joystick is pushed forward quickly and fully the machine will lurch forward. Pull the joystick back for reverse machine movement.

To Steer the machine move the joystick slowly and slightly to the left to steer left or to the right to steer right. Moving the joystick quickly and fully in either direction will cause the machine to lurch into the turn and turn on the spot.

NOTE: Move the left joystick slowly and slightly for smooth drive and steer control.

Joystick Switches/Sliders A. Switch - Cruise Control When the machine is travelling forward, press switch once to engage cruise control, press switch again to disengage cruise control.

B. Thumb Slider Push Bar Operation Press slider FORWARD to move push bar OUT. Pull slider BACK to move push bar IN.

LEFT JOYSTICK

480-178A

C. Thumb Slider - Drive Speed Control This variable slider control allows the operator to set the maximum drive speed of the machine to maintain a given travel speed without having to feather the drive joystick.

Push control forward to increase the maximum drive speed of the machine.

Pull control back to decrease the maximum drive speed of the machine.

This control can be used while the machine is in motion.

Caution: Setting the maximum speed control to the minimum setting lowers maximum drive speed only, it will NOT prevent the machine from travelling when the forward or reverse drive controls are used.

CRUISE CONTROL OPERATION The cruise control function works in conjunction with the momentary switch (A) and the drive speed control slider (C) on the left joystick.

NOTE: Cruise control will only work when the machine is travelling in forward direction. Cruise control does not work when machine is travelling in reverse.

Set the drive speed control slider to mid position (50% Max travel speed). Push the left joystick forward to move machine forward. Press switch (A) once to engage cruise control

.

To increase drive speed, push the slider (C) forward or, pull the slider back to decrease drive speed.

To disengage cruise control press switch (A) or pull back on left joystick momentarily.

2.10

Tigercat 480 Mulcher

Controls and Operation B

C

BOOM FLOAT ICON

WINCH ICON

A

480-043

480-179

MD3 COMPUTER DISPLAY

WINCH OPERATION To engage winch press switch (C) on right joystick

2. JOYSTICK - right Boom Lift Move the joystick back to raise the boom.

Move the joystick forward to lower the boom.

Attachment tilt Move the joystick to the right to tilt the attachment OUT. Move the joystick to the left to tilt the attachment IN. Joystick Switches/Sliders A. Trigger Switch Boom Float/Winch Free Spool ON/OFF (Trigger Switch on front of joystick) - Press mometarily to enable float operation or winch free spool operation. Press second time to disable float operation or winch free spool operation B. Thumb Slider Debris Door Open/Close - Winch Spool IN/OUT Debris Door Operation Push slider FORWARD to close door.

Pull slider BACK to open door.

IMPORTANT: To prevent component damage, always have deflector door open when preparing to fell standing trees.

Winch Operation Pull slider BACK to spool winch cable IN. Push slider FORWARD to spool winch cable OUT. C. Switch - Winch/Boom Float Toggle Toggle - Winch Functions ON/OFF

once. The winch icon on the MD3 computer display will turn ON (icon will turn green). Use the thumb slider (B) on the right joystick to reel in/out the winch cable.

To free spool the winch cable, press the trigger switch (A) once when the winch icon is ON. The winch Icon will change to the Free Spool icon . The winch cable will now free spool off the winch reel. Using the thumb slider to reel in/ out the winch cable will turn off the free spool operation and return the winch to the winch IN/ OUT mode and the winch icon will turn on.

To turn off the winch function press switch (C).

The thumb slider (B) will now operate the debris door function.

BOOM FLOAT OPERATION To engage BOOM FLOAT, winch operation must be OFF (winch Icon will turn grey). Press the trigger switch (A) to turn ON boom float function.

The boom float icon on the MD3 computer display will turn ON (icon will turn green).

To turn off the boom float function press the trigger switch. The boom float icon will turn OFF (icon will turn grey)

2.11

Tigercat 480 Mulcher INSTRUMENT PANEL

Controls and Operation

INSTRUMENT PANEL

1

2

480-017

TOP VIEW OF CAB CONTROLS AND COMPONENTS

The instrument panel is located on the right side of the cab beside the operator's seat right armrest. The following controls and switches are mounted on the instrument panel: 1. MD3 COMPUTER MODULE

3

5

4

6

8

7

9 11

10

12 13 16

14

2. INTERLOCK RESET SWITCH 3. THROTTLE SWITCH

15

4. CUTTER SWITCH 5. FAN SWITCH (Engine Cooling)

19

6. HORN - 4800112 AND UP

17

7. FUEL HEATER SWITCH - OPTIONAL 8. WORK LIGHTS SWITCH 9. SERVICE LIGHTS SWITCH 10. BLANK

18

11. BLANK

20

12. A/C DEFROSTER SWITCH 13. FRESH AIR SWITCH 14. SPEED CONTROL DIAL (4800101 TO 4800111) 15. WINDSHIELD WIPER/WASHER SWITCH 16. IGNITION KEY SWITCH 17. FAN SPEED SWITCH (Heater A/C) 18. 12 VOLT AUXILLARY POWER SUPPLY 19. HEATER CONTROL VALVE 20. 24 VOLT LIGHTER

480-018

2.12

INSTRUMENT PANEL CONTROLS AND SWITCHES

Tigercat 480 Mulcher INSTRUMENT PANEL - CONT'D

Controls and Operation

1. MD3 COMPUTER MODULE The MD3 computer, electronic control and display is the operator interface with the electronic control system. The MD3 is the central unit in the control system which works as both a master controller and a display unit. See MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY later in this section for complete details and operation instructions.

1

2. INTERLOCK RESET SWITCH This is a two position switch and is used to reactivate the interlock system after it has been deactivated by opening either of the cab doors, or by turning the ignition switch to the OFF position. This system prevents accidental or improper use of the controls from anywhere but the operator's seat.

2

With the engine running and both doors closed, press and then release this switch to REACTIVATE the interlock system.

3

5

4

6

8

7

9 11

10

12 13

2A 16

14 15 ACTUATOR 480-110

19

INTERLOCK SYSTEM SHUT OFF

17

2A. INTERLOCK SYSTEM SHUT OFF Both doors are equipped with interlock switches to prevent the machine from being operated while the doors are open (interlock system shut off).

18 20

To operate: Close both doors then press and release the interlock reset switch.

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.

These door interlock switches and the interlock reset switch are safety features and their function must not be defeated in any way.

480-018

2.13

INSTRUMENT PANEL CONTROLS AND SWITCHES

Tigercat 480 Mulcher INSTRUMENT PANEL - CONT'D

Controls and Operation

3. THROTTLE SPEED SWITCH This is a momentary switch used to increase/ decrease engine speed. Press on bottom of switch to decrease engine speed. Press on top of switch to increase engine speed.

1

Maintaining Correct Engine RPM. It is most important that the RPM of the engine be correct at all times: Low Idle 850 +/- 25 RPM (No Load) High Idle 1910 +/- 25 RPM (No Load) NOTE: The above values are with the hydraulic and engine oil at normal operating temperatures and no functions activated.

2 3

5

4

6

8

7

9 11

10

12 13 16

14 15

19 17

18 20

480-018

2.14

INSTRUMENT PANEL CONTROLS AND SWITCHES

Tigercat 480 Mulcher INSTRUMENT PANEL - CONT'D

Controls and Operation

4. CUTTER - ON/OFF This is a two position switch labelled ON, OFF. ON - Place throttle at HIGH IDLE before turning the cutter ON for normal operations.

Cutter rotates at FULL speed in the ON position.

1

NOTE: To STOP the CUTTER, engine should be at LOW IDLE when turning cutter OFF from an ON positon.

OFF - Cutter is turned off.

2

NOTE: If the engine is turned off with the cutter switch in the ON position, the cutter will not start up again when the engine is restarted. The cutter switch and interlock switch must be turned off and then back on for the cutter to start.

3

5

4

6

8

7

9 11

10

IMPORTANT! Serious component damage may result.

• Never stop engine with cutter rotating.

• Always stop cutter with engine at idle.

12 13 16

14

WARNING 15

When leaving the cab to check the cutter or other parts of the cutter head, observe all safety rules listed in this manual and cutter manuafacturer's manual.

19 17

18 20

480-018

2.15

INSTRUMENT PANEL CONTROLS AND SWITCHES

Tigercat 480 Mulcher INSTRUMENT PANEL - CONT'D

Controls and Operation

5. FAN SWITCH (Engine Cooling) This is a three position momentary switch, labelled CLEAN/AUTO/FULL ON*. This switch along with the MD3 Computer, controls the operation of the varriable pitch fan.

1

AUTO POSITION - AUTO is the normal operating position for the fan control switch.

When the switch is in the AUTO position, the fan will operate completely in an automatic mode.

NOTE: The MD3 Computer is programed to reverse pitch the fan blades automatically when the fan switch is in the AUTO position.

The default setting is reverse every ten minutes for ten seconds, This setting is adjustable See COOLING FAN PURGE INTERVAL and COOLING FAN PURGE LENGTH in this section for adjustment information.

2 3

5

4

6

8

7

9 11

10

FULL ON POSITION - When the switch is in the FULL ON (OVERRIDE) position, the fan control system is overridden and the fan will operate at full blade pitch forward. The FULL ON (OVERRIDE) position is intended for use in the event of a temporary failure of the fan control system. AUTOMATIC reversing/ cleaning does not function in full on position.

12 13 16

14 15

19

CLEAN POSITION - When the switch is pressed momentarily to the CLEAN position, the pitch of the fan blade is reversed.

Reverse pitch is used to help clean the charge air cooler, radiator, oil cooler, A/C condenser and air intake door screen. By "reversing" the pitch of the fan blades, air flow is propelled in the opposite direction, thereby helping to force dust and debris off of the heat exchanger cores and screens.

17

18 20

It is also important to manually clean debris from the machine on a regular basis to maintain low machine operating temperatures. Refer to CLEANING A/C CONDENSER, CHARGE AIR COOLER, OIL COOLER AND RADIATOR in THIS SECTION. 6. HORN - 4800112 AND UP Press to sound warning horn 7. FUEL HEATER SWITCH - OPTIONAL This switch will turn on the fuel heater.

8. WORK LIGHTS SWITCH This is a two position switch. Use to turn ON the work lights.

480-018

2.16

INSTRUMENT PANEL CONTROLS AND SWITCHES

Tigercat 480 Mulcher INSTRUMENT PANEL - CONT'D

Controls and Operation

9. SERVICE LIGHTS SWITCH This is a two position switch. Use to turn ON the service lights.

10. OPTIONAL SWITCH LOCATION

1

11. OPTIONAL SWITCH LOCATION 12. A/C/DEFROSTER SWITCH This is a three position switch, A/C ON, OFF and DEFROSTER ON. NOTE: Defrosting in cold weather ocurrs when the heater is in use and this switch is set to defrost position. Moisture is removed from the air (dehumidifyed) by the evapourator core of the A/C unit during the defrosting cycle.

2

13. AIR SOURCE SWITCH

3

5

4

6

8

7

9

This is a two position switch to select either, outside fresh air or to recirculate inside cab air.

11

10

12

14. DRIVE SPEED CONTROL (4800101 TO 4800111)

13

This is a rotary control dial (potentiometer) used to adjust the travel speed from minimum to maximum speed. Turn the control clockwise to increase speed or counterclockwise to decrease speed. This dial is used in conjunction with the track drive joystick to adjust min/max drive speed.

16

14 15

19 17

15. WINDSHIELD WIPER/WASHER The wiper/washer rotary dial controls the windshield wiper. Turning the dial one setting clockwise, operates wiper on low speed.

18

Turning the dial a setting further clockwise sets the wiper to high speed. To slow or turn off the wiper, turn the dial counterclockwise until the desired setting is reached.

20

To operate the washer function, press the dial. This function sprays washer fluid on the windshield.

16. IGNITION KEY SWITCH This is a three-position switch labelled OFF/ RUN/START. OFF Position - All electrical power fed through the ignition switch is turned “OFF” RUN Position - Connects the battery to electrical functions used for machine operation.

START Position - Used to energize the starter motor to start the engine.

480-018

2.17

INSTRUMENT PANEL CONTROLS AND SWITCHES

Tigercat 480 Mulcher INSTRUMENT PANEL - CONT'D

Controls and Operation

17. CAB BLOWER FAN SPEED - OFF/LOW/ MED/HIGH This is a rotary, four position switch used to control the cab blower fan speed.

18. 12 VOLT AUXILLARY POWER SUPPLY

1

A 12 volt outlet with 20 amp capacity for portable devices such as cell phones.

19. HEATER CONTROL VALVE This is a variable, rotary dial to adjust the amount of heated air for the cab. The blue area of the scale indicates cooler temperatures the red area indicates warmer temperatures. Make sure this control is off, when using the air conditioning.

20. 24 VOLT LIGHTER

2

Cigar/cigarette lighter.

3

5

4

6

8

7

9 11

10

12 13 16

14 15

19 17

18 20

480-018

2.18

INSTRUMENT PANEL CONTROLS AND SWITCHES

Tigercat 480 Mulcher

Controls and Operation 21

25

22

23

480-046

21. EMERGENCY STOP SWITCH When the emergency stop switch (21) is pressed DOWN, it immediately turns OFF ALL electrical power and shuts down the engine and hydraulic systems. To return the power, turn the knob clockwise to allow it to pop back up.

480-110

AIR VENTS/OUTLETS

25. AIR VENTS The Air Conditioner/Heater system has nine adjustable air outlets in the cab.

22. WARNING ALARM LIGHT The warning light is used as a visual warning indicator. The light is located in the front panel (shown above). The warning alarm light and alarm horn are turned on by the computer system whenever an alarm is activated.

23. WARNING ALARM HORN An audio alarm is provided by a warning alarm horn located on the side of the instrument panel. The warning alarm horn and light are turned on by the computer system whenever an alarm is activated.

480-046 480-047

CAB A/C HEATER AIR VENT OUTLETS

480-096

24. WARNING DISPLAY When the warning light and horn are active, observe the MD3 Computer Display on the instrument panel for warning alarm information. See MD3 COMPUTER DISPLAY in this section.

2.19

Tigercat 480 Mulcher

Controls and Operation 27 13

19

FRESH AIR FILTER

480-037

27. FILTER - CAB FRESH AIR

480-017

When the AIR SOURCE control switch (13) on the instrument panel is in the FRESH AIR position, outside air is drawn into the cab A/C Heater unit through this filter and mixed with interior air from the cab. The filter is located in the rear of the cab roof and accessible from outside the cab. It should be checked every 125 hours. This is done by removing 6 bolts and removing the air inlet cover. Next remove 2 bolts and remove the filter retainer. This will allow access to the filter.

26

480-045

26. FILTER, RECIRCULATING AIR - A/C UNIT When the AIR SOURCE switch (13) is in the RECIRC AIR position, air in the cab is drawn into the A/C- HEATER unit via this filter (26) and recirculated. The filter is located at the base of the A/C / Heater combo unit, behind the operator’s seat in the rear of the cab. It should be cleaned every 125 hours and replaced every 500 hours. Remove the two thumb screws in the filter cover to access the filter.

IMPORTANT! The RECIRCULATING AIR FILTER and the CAB FRESH AIR FILTER may require cleaning more frequently under extreme operating conditions.

28 SHUT-OFF VALVE HOSE TO A/C HEATER UNIT

480-123

ENGINE

HOT WATER SHUT OFF VALVE

28. HOT WATER SHUT OFF VALVE (ENGINE) To maximize the efficiency of the air conditioning system, the heatER control (19) on the instrument panel must be rotated to the "OFF" position. During times when cab heating is not required the hot water shut off valve, on the heater hose from the engine, should also be closed to prevent hot water from seeping through the A/C unit, thereby reducing the efficiency of the cooling system.

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

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

2.20

Tigercat 480 Mulcher

Controls and Operation

480-028

480-029 480-028

CAB FUSE PANEL

24863A

29. FUSE PANEL - CAB The fuses, diodes, resistors and relays are located behind a panel below the instrument panel. Press the latch button to open the door to access the fuses, diodes, resistors and relays. See FUSE AND RELAY PANEL - CAB in THIS SECTION for more detail.

BATTERY DISCONNECT SWITCH 31. Battery Disconnect - Switch This manually operated switch located in the cab mounted to the side of the seat pedestal, completely disconnects all electrical circuits on the machine from the battery.

30. FIRE 'FOE' AUTOMATIC FIRE EXTINGUISHER UNIT - OPTIONAL

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

When equipped with the optional "Automatic Fire Extinguishers", four (4) tube shaped fire extinguishers are installed on the

NOTE: Wait for 30 seconds after turning key switch off before turning the battery disconnect switch off. The engine ECM requires time after the engine is turned off to record the engine data and log the information for the current operating session. If the battery disconnect is turned off too soon, the data will not be recorded and an error message will be displayed when the battery power is turned back on and the key switch is turned on.

480-153

important!

Only use the battery disconnect switch to shut off a running machine in an emergency. A fault code will be logged by the ECM on the engine for improper shut down and power down.

machine. Two units are installed in the engine compartment (one on each side of the engine), one unit is installed in the hydraulic compartment behind the cab and one unit is installed in the pump area below the cab.

The fire extinguishers are activated by high temperatures in excess of 80°C (170°F).

The fire extinguishers are equipped with a pressure gauge and an electrical switch that is connected to the MD3 computer module.

The switches are normally closed and in the event the extinguisher is activated the switch will open and the audio and visual alarm will be activated by the computer. When the alarm is activated shut the engine OFF and investigate the cause of the alarm.

Refer to manufacturer's owners manual for complete details on operation of the automatic fire extinguishers.

2.21

Tigercat 480 Mulcher

Controls and Operation

CAMERA-MONITOR

front CAMERA 4800101 to 4800111

CAMERA MONITOR

480-005

The camera monitor is located in the front panel of the cab. The monitor is a high performance 7" wide format, flat panel, colour, LCD, video display.

480-007

TOP VIEW OF CAB CONTROLS AND COMPONENTS

front camera

front camera location 4800101 to 4800111

480-042

front CAMERA 4800112 and up

480-006

CAMERA MONITOR SYSTEM COMPONENTS (See details on oposite page)

REAR CAMERA

The system consists of the monitor, wire harness, junction box, and two cameras. The (front camera on machines 4800101 to 4800111is mounted in the cab in front of the monitor pointing up at the tree tops) (on machines 4800112 the front camera is mounted on the cab roof). The rear camera is mounted on the rear door of the machine facing rearward. When the machine is travelling forward the tree top camera view will be displayed on the monitor. When the machine is travelling in reverse the rear camera view will be displayed on the monitor.

480-037A

Using the control buttons on the bottom front of the monitor the operator can toggle the monitor to display front view or rear view all the time.

See the manufacturer's owners manual (located in the operator's manual storage compartment on the back of the seat) for complete operation instructions of the camera system.

480-180

2.22

front camera location 4800112 and up

Tigercat 480 Mulcher

Controls and Operation

COLOUR LCD MONITOR

• CAMERA 480-007

CAMERA MONITOR SYSTEM WIRING AND COMPONENT DESCRIPTION 2.23

Tigercat 480 Mulcher

Controls and Operation RIDE Adjustment Procedures After adjusting height, the ride adjustment should be made by pulling or pushing the air ride control valve knob.

seat adjustments

To Raise Push ride adjustment control to inflate air spring to obtain desired height. lumbar horizontal adjustment (NOT SHOWN)

back angle adjustment

To Lower Pull ride adjustment control to deflate air spring to obtain desired height.

2-Way Adjustable Lumbar For fore-and-aft displacement, rotate horizontal adjustment knob.

BACK ANGLE ADJUSTMENT Back angle adjustment knob or lever is used to place seat at the desired angle.

FORE/AFT SLIDE Move and hold fore/aft slide lever. Roll seat forward or backward to the desired position relative to the footpedal controls.

ride adjustment knob 720E-001

fore/aft slide lever

height adjustment lever

lumbar horizontal adjustment

OPERATOR’S SEAT - AIR RIDE WARNING The seat belt supplied with this seat must be used at all times when operating this machine.

ADJUSTMENTS Height Adjustment Procedures The SPRING-ASSISTED height adjustment is controlled by the height adjustment lever located on the front left side of the seat chassis.

The four height settings: top, bottom and two inbetween, provide a total height adjustment of 3”.

To Raise Firmly lift up on the height adjustment lever.

When the lever releases, hold it up while partially lifting the operator’s body weight from the seat.

When the seat is at the desired height, FIRMLY PUSH DOWN on the lever until the seat locks (a click should be heard).

332-6

view from right rear of seat

armrest adjustment

ARMREST ADJUSTMENT Each armrest has 2 adjustments to place it in the required position. Loosen adjustment locking wingbolts to reposition armrest height and fore/aft position.

To Lower Firmly lift up on the height adjustment lever.

When the lever releases, partially apply operator body weight to the seat until the seat is at the desired height. FIRMLY PUSH DOWN on the lever. Hold lever down until the seat locks into position (a click should be heard).

2.24

Tigercat 480 Mulcher

Controls and Operation SEAT TOO HIGH/SEAT TOO LOW There are several things which can cause improper seat height. Refer to the HEIGHT ADJUSTMENT and adjust seat to the desired position. If the proper height cannot be reached using one of the four height adjustment settings, it may be necessary to install the seat on a higher base.

seat adjustments

lumbar horizontal adjustment (NOT SHOWN)

back angle adjustment

ride adjustment knob 720E-001

fore/aft slide lever

OPERATOR’S LEGS FALLING ASLEEP The seat is adjusted too high, and the air ride control valve has under pressurized the seat air suspension ride adjustment, resulting in the operator sitting in a “bucket”. Refer to height adjustment and RIDE ADJUSTMENT.

height adjustment lever

PROBLEMS AND CORRECTIVE ACTION RIDES TOO STIFF/SEAT TENDS TO PUSH OR THROW OPERATOR FORWARD The air ride control valve has over pressurized the seat air suspension. This typically happens because the operator is trying to use the air suspension to adjust the ride height rather than using height adjustment lever to raise the seat.

Refer to height adjustment.

RIDES TOO SOFT OR BOTTOMS OUT AND PINCHES OPERATOR The air ride control valve has under pressurized the seat air suspension ride adjustment Insufficient pressure exaggerates the knee-action movement of the seat. This usually happens because the operator is trying to lower the seat by decreasing the amount of air pressure instead of using the Height Adjustment lever. Refer to height adjustment.

2.25

Tigercat 480 Mulcher

Controls and Operation

interior lights

am/fm stereo radio cd player

level indicator

rear view mirrors

cab roof interior

480-014c

CAB INTERIOR LIGHTING

AM/FM STEREO RADIO CD PLAYER

Two light assemblies mounted in the roof inside the cab are used for cab interior lighting and reading lights.

PIVOTING READING LIGHT

interior LIGHT SWITCH

480-010

INTERIOR LIGHT

The AM/FM stereo radio CD player is located in the front of the cab roof above the front windshield. The system has four 2 way 5.25" speakers (2 front mounted and 2 rear mounted).

See the manufacturer's owners manual (located in the operator's manual storage compartment) for complete operation instructions.

READING LIGHT SWITCH 1075-078

REAR VIEW MIRRORS CAB INTERIOR LIGHTING

Press on the corresponding light switch to turn on the desired light. To aim the reading light press on the reading light lens and pivot the light in the socket to the desired location.

Two (4" x 8") convex rear view mirrors are located in the front of the roof to assist in the view out the rear windows. Use the mirrors along with the camera monitor when driving the machine in reverse.

LEVEL INDICATORS Two level indicators are provided, one on the side of the cab interior roof frame (shown above) for indicating fore/aft level and one on the front console (not shown) for indicating side to side level.

2.26

Tigercat 480 Mulcher FIRE EXTINGUISHER

Controls and Operation DIESEL HEATER CONTROLS - OPTIONAL

CHECK CHARGE GAUGE DAILY

480-089

1075-089

This digital timer is used only if the machine is equipped with the optional diesel heater.

726E-019b

A portable fire extinguisher is located in operator's cab. The extinguisher should be checked daily to ensure that it is charged. The indicator on the charge gauge should be in the green region.

If the indicator falls out of this green area, the extinguisher should be serviced immediately.

Maintain a CHARGED fire extinguisher on the machine at all times and KNOW HOW TO USE IT. Refer to the manufacture's Use and Information manual for proper usage, additional information and recommended inspection and maintenance intervals.

1075-087b

Consult the manufacture’s instruction manual for additional information. Refer also to HOT WATER SHUT OFF VALVE in THIS SECTION for more related information.

2.27

Tigercat 480 Mulcher SIDE DOOR AND ESCAPE HATCH EMERGENCY EXIT MAINTENANCE GUIDE

Controls and Operation

Two alternate exit routes are provided on the RH. side and roof of the cab. These are only to be used if the left door cannot be opened.

It is therefore essential that these emergency exits be checked at least once per month or after major impacts to the cab to ensure they are fully operational.

Unlock cab doors, engine enclosure doors and hydraulic compartment doors before operating machine.

It is also important that snow, debris and particularly ice not be allowed to build up in these areas. Check frequently and remove any accumulation immediately.

CHECKING PROCEDURE FOR SIDE DOOR: 1. Open side door twice, once using the interior latch handle and once using the exterior handle.

2. Check for proper operation of both handles, latches and hinges. Adjust and/or lubricate any part of the mechanism that requires attention.

CHECKING PROCEDURE FOR ESCAPE HATCH: CLAMP BRACKET

822-D30

The escape hatch should move without using excessive force by pushing up on one side.

If the escape hatch does not move without excessive force refer to ESCAPE HATCH REMOVAL FOR MAINTENANCE OR REPAIR and ESCAPE HATCH REPLACEMENT in THIS SECTION. 3. Engage clamp bracket in slot of cab roof bracket and re-tighten the hand knobs hand tight.

NOTE: If the hand knobs become loose when operating the machine, the nylon inserts in the studs should be replaced.

ESCAPE HATCH REMOVAL for maintenance or repair: REMOVE BOTH CLAMP BRACKETS

UNSCREW RETAINING KNOB FOUR COMPLETE TURNS

CHECK ESCAPE HATCH

822-D31

ESCAPE HATCH REMOVAL

1. Unscrew both of the retaining knobs and remove the two clamp brackets.

2. Push open from the inside the escape hatch. In the event that the hatch has become bonded to cab roof due to improper maintenance, use a pry bar taking care not to damage the sealing surface of the roof.

3. Refer to ESCAPE HATCH REPLACEMENT in THIS SECTION for instructions on the proper method to use when replacing the escape hatch.

1. Partially unscrew both the interior retaining knobs four complete revolutions.

2. Disengage clamp brackets from slot on cab roof attachment bracket.

2.28

Tigercat 480 Mulcher

Controls and Operation FOAM SEAL

ESCAPE HATCH 'C' CHANNEL RUBBER

APPLY LUBRICAnT TO TOP SURFACE OF FOAM SEAL BETWEEN SEAL AND ESCAPE HATCH

CAB ROOF

APPLY LUBRICAnT TO 'C' CHANNEL RUBBER BETWEEN CHANNEL AND CAB ROOF

escape hatch ESCAPE HATCH REPLACEMENT:

480-014B

LH830-06

NOTE: Do not apply silicone sealant between Escape Hatch and Cab Roof

5. To prevent foam seal or rubber ‘C’ channel from sticking to escape hatch or roof over time, apply a thin film of Tigercat part number AM926 dielectric non-curing silicone lubricant to the contact surfaces of foam seal and rubber ‘C’ channel. Remove excess spray with a dry rag so no build up remains.

Silicone sealant in these areas can bond the escape hatch to the cab, preventing removal of the escape hatch.

1. Clean all mating surfaces on both the escape hatch and cab roof, remove any silicone residue that may have been used to seal the joint.

WARNING: Too much lubricant will cause the roof escape hatch to stick to the cab roof.

6. Install escape hatch on roof and engage clamp bracket in slot of cab roof bracket and re-tighten the hand knobs hand tight only.

2. Ensure that the escape hatch gasket is in good condition and replace if damaged. nylon insert

CROSS SECTION OF ESCAPE HATCH SEAL

SKY LIGHT

WARNING Heat from sun exposure can cause the exit seals to bond to the cab's painted surfaces.

Careless use of glues or sealants to repair leaks also bond the exit panel.

Failure to follow these proper maintenance procedures can result in the exit being unusable in an emergency

CAB

REMOVE HATCH FROM INSIDE CAB 822-01

NYLON STUD REPLACEMENT

3. Replace the nylon inserts in each stud, leaving approx. 1/8" protruding at each end. These are to prevent the hand knobs from coming loose under vibration.

4. Apply an anti-seize compound to stud threads on the escape hatch and engage hand knob threads 3 revolutions with washer and clamp bracket in place as illustrated.

480-015A

2.29

escape hatch

Tigercat 480 Mulcher

Controls and Operation MD3 COMPUTER

COLOUR DISPLAY

480-043

MD3 COMPUTER, ELECTRONIC CONTROL AND DISPLAY

MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY The MD3 computer, electronic control and display is the operator interface with the electronic control system. The MD3 is the central unit in the control system which works as both a master controller and a display unit. It has a 3.5" backlit colour graphic transflective display for reading system information.

MD3 COMPUTER

The front of the MD3 consists of a control panel with a display and nine buttons. The buttons are arranged on the bottom and right hand side of the display.

• F1 through F4 function buttons,

,

,

, .

Programmed buttons that are configured by program software to bring up a display page, bring up an adjustment group or act as an input.

• Up and down arrow buttons

.

Navigation buttons that are used to scroll thru selections on a menu page. The buttons are configured by program software to bring up a display page, bring up an adjustment group or act as a virtual input.

• OK button .

Pushing this button equals ’enter’. Saves the value or confirms the selection you have made.

• Menu button .

Always brings up the Menu page. It is not programmable.

• ’Esc’ or BACK button

.

Returns you to the previous display page. May be configured by program software to bring up a display page, bring up an adjustment group or act as a virtual input.

2.30

Tigercat 480 Mulcher

Controls and Operation 5

1 9

2

6

3

4

7

8

480-013a

8

MD3 COMPUTER, SYSTEM MAIN COMPONENTS AND CONNECTIONS

MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY The MD3 computer control system is part of a network of components (shown above). The system is made up of the following components: 1. MD3 Computer and Display Module 2. Electronic Joysticks 3. XA2 A1 Front Chasis Expansion Module 4. XA2 A2 Pump Area Expansion Module 5. Engine Electronic Control Module 6. Boom Control Valve Electronic Solenoids 7. Cutter Control Valve Electronic Solenoids 8. Drive Motors Electronic Solenoids 9. Drive Pumps Electronic Solenoids 10. Various controls, switches, and sensors not shown.

The MD3 computer is the main controller in the system. The MD3 computer program is the operating system for the computer display as well as the control system for the machine operating parameters.

As an example, the joystick movement/ position is transmitted to the MD3 controller electronically. This signal is then transmitted to the corresponding XA2 expansion module from the MD3 control and on to the corresponding control valve solenoid controls. The applicable hydraulic control valves will be activated allowing hydraulic oil to flow to the functions activated by the joystick movement.

The engine electronic control module provides electronic information to the MD3 computer via the J1939 CAN BUS link. This information is displayed on the computer display.

NOTE: The computer control system is softwarebased. This software may be updated after the machine is in service as a part of on-going product improvement programs and service newsletters. The information contained in this manual is accurate at the time of printing.

Improvements to the machine and/or software are on-going and may not be covered. In these cases contact your Tigercat dealer for appropriate information.

2.31

Tigercat 480 Mulcher

Controls and Operation

1

2

3

4

5

6

7

18

8

17 16

9

15

10 14

11

480-059A

12

13

main menu

MD3 COMPUTER MAIN MENU 1. INTERLOCK RESET - ON/OFF

10. ENGINE MENU - Press F1 to select

2. CRUISE CONTROL ENABLED - ON/OFF

11. ADJUSTMENT MENU - Press F2 to select

3. DRIVE LIMITER ENABLED - ON/OFF

12, INFORMATION MENU - Press F3 to select

4. CUTTER INDICATOR - ON/OFF

13. ENGINE COOLANT TEMPERATURE

5. MULCHING HEAD FLOAT ENABLED - ON/OFF

14. ALARM INDICATORS - Press F4 to select

6. WINCH FREE SPOOL ENABLED - ON/OFF

15. OIL GRADE

7. TIME AND DATE

16. COLD OIL PROTECTION INDICATOR

8. CUTTER PRESSURE GAUGE

17. HYDRAULIC OIL TEMPERATURE GAUGE

9. ENGINE TACHOMETER RPM

18. FUEL LEVEL GAUGE

2.32

Tigercat 480 Mulcher

Controls and Operation Press the F2 button to toggle between metric and imperial units of measure.

ENGINE MENU

Press the F3 button to select the fuel information display.

Press the back button again to return to the main menu.

480-043

From the main menu press the F1 button to select the engine display.

480-046A

The fuel information on display is as follows: • • • •

Fuel Rate - US gph or L/h (instantaneous) Total Fuel Used - US gal or L Trip Average Fuel Rate - US gal or L Trip Fuel Used - US gal or L Press the F3 button to reset the trip fuel used and trip average fuel rate functions.

Press the F2 button to toggle between imperial and metric units of measure.

Press the back button to return to the engine display.

480-045

When selected the engine menu icon is on display and the engine functions will also be displayed.

Press the back button again to return to the main menu.

The engine functions on display are as follows: • • • • • • • • •

Engine Speed - rpm Percent Load Coolant Temperature - °F or °C Engine Oil Pressure - psi or bar Voltage - V Turbocharger Boost Pressure - psi or bar Charge Air Temperature - °F or °C Engine Hours Engine Oil Temperature - °F or °C

2.33

Tigercat 480 Mulcher

Controls and Operation ENGINE SETTINGS

ADJUSTMENT MENU

480-048B 480-043

From the main menu press F2 button to select the ADJUSTMENT MENU.

Press F1 button to select the Engine Settings Menu from the ADJUSTMENT MENU.

480-049 480-48B

The adjustment menu screen will be displayed.

The adjustment menu icon is on display and all the adjustment selections will also be displayed.

The adjustment selections are as follows: •

Engine Settings - select F1

•

Drive Settings - select F2

•

Main Valve Sttings - select F3

•

General Settings - select F4

The Engine Settings menu appears on the display and the following settings can be selected:

•

Cooling Fan Purge Length

•

Cooling Fan Interval

Use the arrow up/down buttons to scroll to the desired selection then press the OK button to make the selection.

2.34

Tigercat 480 Mulcher

Controls and Operation

COOLING FAN - PURGE LENGTH

COOLING FAN - PURGE INTERVAL

When the Purge Length setting is highlighted in the engine settings menu. Press the OK button to make adjustments.

When the Purge Interval setting is highlighted in the engine settings menu. Press the OK button to make adjustments.

480-054

480-052

The Purge Length menu will appear. The setting value can be adjusted between 10 seconds and 30 seconds. This is the time the cooling fan will remain in the purge (reverse/clean) mode. The factory default is 10 seconds. Press the arrow up or arrow down to scroll to the desired selection and press the OK button when desired value is selected.

The Purge Interval menu will appear. The setting value can be adjusted between 5 minutes and 20 minutes. This is the setting for auto reverse of the cooling fan to go into the purge mode (reverse/ clean) . The factory default setting is every 10 minutes. Press the arrow up or arrow down to scroll to the desired selection and press the OK button when desired value is selected.

Press the back button to return to the engine settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

Press the back button to return to the engine settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

2.35

Tigercat 480 Mulcher

Controls and Operation

DRIVE SETTINGS

480-055A

Press the F2 button to select the Drive Settings Menu from the ADJUSTMENT MENU.

480-105A

The Drive Settings menu appears on the display and the following settings can be selected:

•

Drive Limiter ON/OFF

•

Counter Rotate ON/OFF

•

Counter Rotate Speed

•

Steering Configuration

•

Drive Response

•

Steering Response

Use the arrow up/down buttons to scroll to the desired selection then press the OK button to make the selection.

2.36

Tigercat 480 Mulcher DRIVE LIMITER ON/OFF

480-105a

Shown above the Drive Limiter ON/OFF setting is highlighted in the drive settings menu. Press the OK button to make adjustments.

Controls and Operation DRIVE LIMITER OPERATION The drive limiter control has two selections. These selections (ON/OFF) have no effect when the cutter switch is in the OFF position.

Selecting the ON position (when the cutter switch is also in the ON position) activates the drive limiting system. This system detects decrease in engine speed and automatically limits power to machine drive functions in order to prevent engine stalling and divert maximum engine horsepower to the mulching head.

This function is intended to aid the operator in maintaining optimum mulching operations for maximum productivity.

It is important not to stop or stall the engine with the mulching head cutter rotating. Serious component damage may result. Always stop the cutter with the engine at idle.

NOTE: When drive limiter is actively limiting drive power the drive limiter icon on the main screen will turn yellow.

480-057

The Drive Limiter ON/OFF menu will appear. Two choices are given, ON or OFF. Drive Limiter ON = Activates Drive Limiter Drive Limiter OFF = Deactivates Drive Limiter NOTE: See DRIVE LIMITER OPERATION for more details.

Press the arrow up or arrow down to scroll to the desired selection and press the OK button when desired mode is selected.

Press the back button to return to the engine settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

2.37

Tigercat 480 Mulcher DRIVE SETTINGS - CONTINUED

Controls and Operation COUNTER ROTATE SPEED

COUNTER ROTATE ON/OFF

480-105B 480-105B

Scroll to Counter Rotate ON/OFF then press the OK button to make adjustments.

Scroll to Counter Rotate Speed setting then press the OK button to make adjustments.

480-060A

480-107

Use the arrow up/down buttons to select ON or OFF. Press the OK button when value is selected.

Press the back button to return to the engine settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

The Counter Rotate Speed menu will appear.

The adjustment value is 0% to 100%. This value is a percentage of maximum track speed when the joystick is placed in full left or right turn. It prevents track overspeed when turning on the spot that could result in severe ground damage/ disturbance.

Use the arrow up/down buttons to select value desired. Press the OK button when value is selected.

Press the back button to return to the engine settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

2.38

Tigercat 480 Mulcher DRIVE SETTINGS - CONTINUED STEERING CONFIGURATION

Controls and Operation STEERING CHOICE 1 Description (c Path)

‘C’ Path

480-105b

Scroll to the Steering Configuration selection in the drive settings menu. Press the OK button to make adjustments.

If 'C' Path is chosen, the direction the machine will steer when driving forward is shown above. Push joystick forward to drive forward then push joystick left to steer left or push joystick right to steer right.

The direction the machine will steer when driving in reverse is also shown above. Pull joystick back to drive in reverse then pull joystick left to steer left or pull joystick right to steer right.

STEERING CHOICE 2 Description (s Path)

480-193

The Steering Configuration menu will appear. Two choices are given, C Path or S Path.

Use the arrow up/down buttons to select C Path or S Path. Press the OK button when selection has been chosen.

Press the back button to return to the drive settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

‘S’ Path

If 'S' Path is chosen, the direction the machine will steer when driving forward is shown above. Push joystick forward to drive forward then push joystick left to steer left or push joystick right to steer right.

The direction the machine will steer when driving in reverse is also shown above. Pull joystick back to drive in reverse then pull joystick left to steer right or pull joystick right to steer left.

2.39

Tigercat 480 Mulcher DRIVE SETTINGS - CONTINUED DRIVE RESPONSE

Controls and Operation STEERING RESPONSE

480-105B 480-105B

Scroll to the Drive Response selection in the drive settings menu. Press the OK button to make adjustments.

Scroll to the Steering Response selection in the drive settings menu. Press the OK button to make adjustments.

480-195 480-194

The Drive Response menu will appear. Eight choices are given, 1 Least Aggressive through to 8 Most Aggressive.

Use the arrow up/down buttons to select level of drive response desired. Press the OK button when selection has been chosen.

Press the back button to return to the drive settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

The Steering Response menu will appear. Four choices are given, 0 Least Aggressive through to 4 Most Aggressive.

Use the arrow up/down buttons to select level of Sterring Response desired. Press the OK button when selection has been chosen.

Press the back button to return to the drive settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

2.40

Tigercat 480 Mulcher MAIN VALVE SETTINGS

Controls and Operation DEBRIS DOOR SPEED

480-196

Press the F3 button to select the Main Valve Settings Menu from the ADJUSTMENT MENU. The Main Valve Settings menu appears on the display and the following settings can be selected:

•

Debris Door Speed %

•

Push Bar Speed %

•

Boom Float Down Pressure

480-197

Scroll to the Debris Door Speed selection in the Main Valve Settings menu. Press the OK button to make adjustments.

Use the arrow up/down buttons to scroll to the desired selection then press the OK button to make the selection.

480-065

The Debris Door Speed menu will appear. The adjustment value is 25% to 100%. This value is a percentage of maximum door speed when the debris door function is activated. It provides variations in door open close speed.

Use the arrow up/down buttons to select value desired. Press the OK button when value is selected.

Press the back button to return to the engine settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

2.41

Tigercat 480 Mulcher PUSH BAR SPEED

Controls and Operation BOOM FLOAT DOWN PRESSURE

480-197

Scroll to the Push Bar Speed selection in the Main Valve Settings menu. Press the OK button to make adjustments.

480-197

Scroll to the Boom Float Down Pressure selection in the Main Valve Settings menu. Press the OK button to make adjustments.

480-198

480-071

The Push Bar Speed menu will appear. The adjustment value is 25% to 100%. This value is a percentage of maximum push bar speed when the function is activated. It provides variations for more precise positioning of the push bar.

Use the arrow up/down buttons to select value desired. Press the OK button when value is selected.

Press the back button to return to the engine settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

The Boom Float Down Pressure menu will appear.

The adjustment value is 0% to 100%. This value is a percentage of increase/decreasing the down pressure of the boom.

NOTE: If the boom float results in the head raising off the ground, increase the down pressure setting to obtain the desired boom float.

Use the arrow up/down buttons to select value desired. Press the OK button when value is selected.

Press the back button to return to the engine settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

2.42

Tigercat 480 Mulcher GENERAL SETTINGS

Controls and Operation OIL GRADE In the Oil Grade menu seven choices are available: • ISO 22 • Petro Can MV 22 • ISO 32 • Petro Can MV 26 • ISO 46 •

Petro Can MV 60

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ISO 68

480-082

Press the F4 button to select the General Settings Menu from the ADJUSTMENT MENU.

480-104

Use the arrow up/down buttons to scroll to the desired selection then press the OK button to set selection.

480-135

Press the back button to return to the general settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

The General Settings menu appears on the display and the following setting can be selected:

• • • •

Hydraulic Oil Grade Auto Camera Select Winch

Program Mode Press the OK button to make the selection.

2.43

Tigercat 480 Mulcher

Controls and Operation

GENERAL SETTINGS CONT'D COLD OIL PROTECTION

1

480-059

This feature limits hydraulic pump output during the warm-up period when starting the machine in cold temperatures until the oil temperature warms up to a predetermined temperature based on the oil grade selected, set by the computer program.

A blue cold oil temperature Icon (1) will appear on the display when the hydraulic oil is at or below minimum temperature setting. At this time the hydraulic pump stroke is limited, it is recommended to keep engine rpm low and to avoid working machine until all systems have warmed up. When the oil warms and the cold oil icon turns off, pump output can be increased to full stroke.

2.44

Tigercat 480 Mulcher

Controls and Operation

GENERAL SETTINGS CONT'D

480-140 480-135

AUTO CAMERA SELECT In the General Settings Menu use the arrow down button to scroll to the AUTO CAMERA SELECT function then press the OK button.

The Auto Camera Select menu appears on the display and the following settings can be selected:

• •

On Backup Camera Only

Selecting the Backup Camera Only mode displays the backup camera view at all times regardless of machine travel direction. This is a good mode to select when the machine is travelling between work sites. That way the operator has a constant rear view on the monitor display during the trip.

Press the back button to return to the general settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

480-139

Selecting the On mode will allow the monitor to display the sky camera when travelling forward and display the backup camera when the machine is in reverse backing up.

2.45

Tigercat 480 Mulcher GENERAL SETTINGS CONT'D

Controls and Operation Selecting the Setup RH Drive Pump mode is the mode the program must be set to that allows setting up the RH drive pump. The RH drive pump pressures "Forward, Reverse and pump POR" can be set in this mode and the RH track will not be activated.

Selecting the Setup LH Drive Pump mode is the mode the program must be set to that allows setting up the LH drive pump. The LH drive pump pressures "Forward, Reverse and pump POR" can be set in this mode and the LH track will not be activated.

480-135

PROGRAM MODE In the General Settings Menu use the arrow down button to scroll to the PROGRAM MODE then press the OK button.

Select the Lockout Drives mode when the machine is being serviced. In this mode the machine can not be moved when either joystick is activated with the engine runing. Setting the program to Lockout Drives will prevent accidental machine movement.

Selecting the Setup Drive Motors Mode is the mode the program must be set to to allow the drive motor setup to be performed. When the program is set to this mode the drive motor begin of regulation can be adjusted. The tracks can not move when in this mode.

IMPORTANT: When setup procedures and/or machine service is completed be sure to set the program mode back to Normal in order for machine drive functions to operate.

Press the back button to return to the general settings menu or back button twice to return to the adjustment menu. Press the Back button again to return to the main menu.

480-143

The Program Mode menu appears on the display and the following settings can be selected:

• • • • •

Normal Setup RH Drive Pump Setup LH Drive Pump Lockout Drives Setup Drive Motors

Selecting the Normal mode will allow machine drive functions to operate. This is the mode the program is set to for normal machine operation.

2.46

Tigercat 480 Mulcher INFORMATION MENU

Controls and Operation CUTTER FUNCTIONS

480-086 480-043

Press the F3 button to access the information menu.

Press the F1 button to select the Cutter Functions display from the Information Menu. The following information will be on display: • • • •

Cutter Pressure Gauge and Digital Display Pressure - psi or bar Engine Speed - rpm Hydraulic Oil Temp -°F or °C Engine Temp -°F or °C Press the back button to return to the information menu.

480-085

When selected the information functions displayed are as follows: • Hydraulic Oil Level - Full/Low • Hydraulic Oil Temp -°F or °C • Cutter Pressure - psi or bar • LH Track Drive Pressure - psi or bar • RH Track Drive Pressure - psi or bar • Machine Hours - hrs • Machine Voltage - V • Cutter Functions - Press F1 • Drive Functions - Press F2 Press the F3 button to toggle between imperial and metric units of measure.

Press the back button to return to the main menu.

2.47

Tigercat 480 Mulcher

Controls and Operation

DRIVE FUNCTIONS Press F2 button in the Information Menu to select Drive Functions Information. The following information is displayed:

480-087

• • • • •

LH Track System Pressure - psi or bar LH Track Motor Speed - rpm RH Track System Pressure - psi or bar RH Track Motor Speed - rpm Machine Speed - mph or km/h Press the back button to return to the information menu.

2.48

Tigercat 480 Mulcher

Controls and Operation

MAIN MENU PAGE

PREFERENCES MENU

480-090

480-043

Press the menu button menu page.

to go to the main

From the main menu page press the F3 button (Preferences) and the preferences menu page appears.

480-090

The main menu page displays the following selections:

234-056

The following menu items can be selected.

•

Display

•

Adjust - Select F1

•

Date/Time

•

Measure - Select F2

•

Language

•

Preferences - Select F3

•

Info - Select F4

To return to the Main menu press the back button.

2.49

Tigercat 480 Mulcher DISPLAY ADJUSTMENT

Controls and Operation SCREEN SAVER ADJUSTMENT

234-065

After selecting F1 the display adjustment screen opens and the following adjustments can be selected: RETURN TO MAIN MENU - Select F1 BACKLIGHT ADJUSTMENT - Select F2 SCREEN SAVER - Select F3 BACKLIGHT ADJUSTMENT

1075b-24

Select F3 to open the screen saver adjustment screen. Use the Arrow Up and Arrow Down buttons to scroll through the choices. Three choices are available:

•

SCREEN SAVER OFF

•

DIMMED - Timeout 5 seconds

•

BLACK - Timeout 5 seconds

1075B-23 234-070

After selecting F2 the backlight adjustment screen opens. Use the Arrow Up or Arrow Down buttons to adjust the display backlight. The range is 10 to 100. The default setting is 100.

After making a selection press the OK button to confirm selection and press the back button to return to the main menu screen.

When the desired setting is selected press the OK button. A good rule to follow is the lower the number the longer the life of the display unit.

2.50

Tigercat 480 Mulcher DATE/TIME ADJUSTMENT

Controls and Operation DATE ADJUSTMENT

1075b-27

1075B-21

Press F2 to select the DATE/TIME adjustments in the PREFERENCES menu.

Press F1 to select DATE. Use the Arrow Up or Arrow Down to scroll through the YEAR list to select the year. Press OK to confirm year selected.

1075b-26

1075b-28

The DATE/TIME menu screen turns on. Two choices are available for adjustment: DATE - select F1 TIME - select F2

When the year has been confirmed the display will highlight the MONTH. Use the Arrow Up or Arrow Down to select the month. Press OK to confirm month selected.

2.51

Tigercat 480 Mulcher DATE ADJUSTMENT CONT’D

Controls and Operation TIME ADJUSTMENT Select F2 Time adjustment from the DATE/TIME display screen.

1075b-29

When the month has been confirmed the display will highlight the DAY. Use the Arrow Up or Arrow Down to select the day. Press OK to confirm day selected.

1075b-34

The Time display screen will turn on. Use the Arrow Up or Arrow Down to select the HOUR. Press the OK button to confirm selection. The display will show the MINUTES highlighted.

1075b-26

The display will return to the DATE TIME menu.

1075b-35

Use the Arrow Up or Arrow Down to select the minute. Press OK button to confirm the selection.

The display will return to the DATE/TIME menu screen. Press the back button main menu screen.

2.52

to return to the

Tigercat 480 Mulcher INFO MENU PAGE

Controls and Operation MODULES

480-094

480-090

From the main menu page press the F4 button

Press F1 to select the modules menu. This menu provides information on the following machine modules: • MD3 Computer Module • XA2 A1 Front Chassis Expansion Module • XA2 A2 Pump Area Expansion Module • LH Joystick • RH Joystick • Cummins Engine ECM Press the back button (or F1) to return to the main menu page.

LOGS

480-093

(Info) and the Info menu page appears.

The following menu items can be selected.

•

Modules - Select F1

•

Logs - Select F3

The machine ID information will be displayed on the screen.

480-095

Press F3 from the info menu page to select logs.

This menu lists System Logs and Hydraulic Logs and the number of records within each log. The records are a list of all the fault occurrences in each log.

Use the Arrow Up or Arrow Down to select the menu item. Press OK to confirm the selection.

Press the back button (or F1) to return to the main menu page.

2.53

Tigercat 480 Mulcher

Controls and Operation

MESSAGES AND WARNINGS The MD3 computer displays messages and warnings, activates the master alarm and alarm light whenever a system fault occurs. Note that the computer control system will automatically perform a bulb test at engine start up to ensure that master alarm and alarm light are functioning.

Refer to STARTING ENGINE in THIS SECTION. There are different types of Messages and Alarms, they appear on the screen as a block message.

The types of messages are: • • • •

CRITICAL MESSAGE - Colour RED ERROR MESSAGE - Colour RED ALERT MESSAGE - Colour YELLOW INFORMATION MESSAGE - Colour BLUE

Messages can be hidden or acknowledged by pressing the F2 button (Hide or OK).

All messages that have been hidden or acknowledged are stored in the computer.

In some instances it will be necessary to immediately stop the machine, shut the engine OFF and repair the problem causing the message.

480-059

Active fault messages that have been hidden can be reviewed by pressing the F4 button. Recalled messages and warnings will be displayed in order starting with the highest priority first.

2.54

Tigercat 480 Mulcher CRITICAL MESSAGES and warnings (red)

Controls and Operation

Critical messages advise the operator that a critical machine fault is about to occur or a system fault has occurred.

Critical messages have the highest level of priority and are used to alert operator that immediate action must be taken to prevent damage to machine or to ensure operator safety.

When a critical message is displayed, the master alarm and alarm light will sound and flash continuously. The message remains on the screen until the operator hides it.

480-059

Critical messages and warnings flash the critical symbol above the F4 button when active messages are hidden. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

Active messages that have been hidden can be reviewed by pressing the F4 button.

CRITICAL MESSAGE LIST: Hardware Fault - Engine Hydraulic Oil - Level Low. 480-096

The message will give brief details of the fault and advise what action is necessary.

Hydraulic Oil - Temperature High Return Oil Filters - Bypassed Fire Suppression System - Discharged

In some instances the machine requires immediate action to correct the problem which requires the operator to STOP machine operation, SHUT THE ENGINE OFF and service the machine to correct the problem.

Engine Stop - Critical Engine Fault

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message. In this instance the machine should only be operated long enough to move the machine to a safe location, then STOP machine operation and SHUT THE ENGINE OFF before serious machine damage can occur!

Hardware Fault - Engine

Messages can be hidden by pressing the F2 button (Hide).

Hardware Fault - MD3 Hardware Fault - XA2-A1 Hardware Fault - XA2-A2 Hardware Fault - LH Joystick Hardware Fault - RH Joystick Engine Coolant Temperature High Engine Coolant Level low Engine CAC Temperature High Engine Oil Pressure Low Engine Fault Code Messages - Critical LH Joystick - No Contact or invalid data RH Joystick - No Contact or invalid data Note: Not all messages are shown.

2.55

Tigercat 480 Mulcher CRITICAL messages and warnings

Controls and Operation

Hydraulic Oil Level Low

Hydraulic Oil Level Low.

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

480-097

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.

480-085

Repair leaks and refill the main hydraulic tank to FULL mark on the monitor display gauge. Restart engine and inspect for leaks.

2.56

Tigercat 480 Mulcher

Controls and Operation

Hydraulic Oil Temperature High

Hydraulic Oil Temperature High.

This warning will be displayed, alarm warning light will flash and alarm will sound when the oil temperature exceeds the recommended operating range for the type of hydraulic oil in use.

480-096

If the temperature rises above the recommended operating range for the type of hydraulic oil in use check the following: • • • • • •

Plugged oil cooler Malfunction in a hydraulic system High loads on the hydraulic system Malfunction of the cooling fan Low hydraulic oil level Correct Hydraulic Oil Grade Selection

If hydraulic oil temperature rises above the recommended operating range DO NOT continue to operate the machine.

This alarm must not be used to monitor the hydraulic oil. The operator must use the hydraulic oil temperature gauge on the main menu, together with the operating range chart in SECTION 3 to prevent damage to the hydraulic system.

Hydraulic oil grade information is shown on the main menu below the hydraulic oil temperature gauge.

Operating outside the recommended operating range will shorten hydraulic component life.

Refer to COMPUTER ~ ADJUSTMENT MENU SERVICE SETTINGS ~ HYDRAULIC OIL GRADE in THIS SECTION for hydraulic oil grade selection settings information.

Refer also to APPROVED HYDRAULIC OILS in SECTION 3 of THIS MANUAL for hydraulic oil operating range information.

Refer to COMPUTER ~ INFORMATION MODE MENU ~ HYDRAULIC OIL TEMPERATURE in THIS SECTION for hydraulic oil temperature information display.

2.57

Tigercat 480 Mulcher Engine stop

Controls and Operation Hardware Fault - MD3

Hardware Fault - MD3

Engine Stop

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Critical engine fault active - contact service.

Engine Stop

Hardware Fault - MD3

Critical engine fault active - contact service.

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

480-102

This warning will be displayed, alarm warning light will flash and alarm will sound when critical engine alarms are triggered. STOP ENGINE. Refer to engine manufacturer's manual for specific information regarding the engine.

480-102

This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the MD3 Display module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

A VREF (modules reference voltage) error is an example of the type of hardware fault which will be the original active fault which triggers this message.

2.58

Tigercat 480 Mulcher Hardware Fault - XA2

Controls and Operation Hardware Fault - Engine

Hardware Fault - XA2

Hardware Fault - Engine

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - XA2

Hardware Fault - Engine

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

480-102

480-102

This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the XA2 module has been hidden.

This warning will be displayed, alarm warning light will flash and alarm will sound when a critical active hardware fault related to the Engine has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

To recall the original active fault(s) the operator must turn the key off and on.

A VREF (modules reference voltage) and no contact errors are examples of the type of hardware fault which may be the original active fault which triggers this message.

No contact error is an example of the type of hardware fault which may be the original active fault which triggers this message.

2.59

Tigercat 480 Mulcher

Controls and Operation

COMMUNICATION Fault - L.H. JOYSTICK

COMMUNICATION Fault - R.H. JOYSTICK

LH Joystick Communication

RH Joystick Communication

No contact or invalid data.

No contact or invalid data.

LH Joystick Communication

RH Joystick Communication

No contact or invalid data.

No contact or invalid data.

480-102

480-102

This warning will be displayed, alarm warning light will flash and alarm will sound when a critical communication fault related to the L.H. joystick is activated.

This warning will be displayed, alarm warning light will flash and alarm will sound when a critical communication fault related to the R.H. joystick is activated.

No contact error (the joystick has lost the electrical connection with the MD3 computer) is an example of the type of fault that triggers this message.

No contact error (the joystick has lost the electrical connection with the MD3 computer) is an example of the type of fault that triggers this message.

2.60

Tigercat 480 Mulcher

Controls and Operation

ENGINE FAULT CODE MESSAGES - CRITICAL

SPN: 0 FMI: 0 1 of 1 Engine fault parameter - Fault Identifier

SPN: 0 FMI: 0 1 of 1 Engine fault parameter - Fault Identifier

480-102

Critical engine fault message(s) will be displayed, alarm warning light will flash and alarm will sound when a critical engine fault message is received from the engine electronic control module.

They provide the SPN code (suspect parameter number) and the FMI code (fault mode identifier) as well as a message describing the fault (when available).

Critical engine fault codes are higher priority messages than alert level engine fault code messages. Critical messages can be hidden but immediate action must be taken, STOP machine operation and service engine immediately to resolve the cause of the fault.

An example of a critical engine fault message is shown above.

Note that some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN and FMI codes and contact service for more information.

Refer to engine manufacturer's manual for specific information regarding the engine.

2.61

Tigercat 480 Mulcher ERROR MESSAGES (red)

Controls and Operation

Error messages advise the operator that a critical machine fault is about to occur or a system fault has occurred.

Error messages are computer system generated and are generally triggered by computer system error and fault related conditions.

Error messages have the second highest level of priority and are used to alert operator that immediate action must be taken to prevent damage to machine or to ensure operator safety.

Error messages are activated whenever a fault such as an electrical connection is broken/ disconnected. Most error messages are due to computer system hardware or connection faults.

When an error message is displayed, the master alarm and alarm light will sound and flash continuously. The message remains on the screen until the operator hides it.

The message will give brief details of the fault and advise what action is necessary.

A list some types of ERROR MESSAGES is as follows: Module No Contact Error Module VREF Error Voltage Input Error (VIN) Digital Input Error (DIN) Digital Output Error (DOUT) Current Output Error (COUT) * Note that not all error messages are shown.

In some instances the machine requires immediate action to correct the problem which requires the operator to STOP machine operation, SHUT THE ENGINE OFF and service the machine to correct the problem.

However, if the machine cannot be stopped immediately for safety reasons, the operator can hide the message. In this instance the machine should only be operated long enough to move the machine to a safe location then STOP machine operation and SHUT THE ENGINE OFF before serious machine damage can occur!

Messages are acknowledged by pressing the F2 button (OK). To recall active messages turn key off and on. On screen messages will indicate to the operator that an active hardware fault has been hidden.

Error messages flash the critical symbol

or the

above the F4 button when active messages are hidden depending on the type of error message. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

480-149

Active messages that have been hidden can be reviewed by pressing the F4 button.

2.62

Tigercat 480 Mulcher ERROR messages

Controls and Operation XA2-A1

Front Chasis Module No contact

XA2-A1

Front Chasis Module No contact

XA2-A2 480-149

Pump Area Module No contact

XA2-A2

J1939-B0

Pump Area Module No contact

Cummins QSX 15L Engine No contact 480-149

MODULE NO CONTACT ERROR The module no contact error message will be displayed to indicate a loss of communication with or power to a module. The module is identified on the display screen.

J1939-B0

Cummins Engine

When a module goes loses contact all machine functions controlled by that module cease and all messages 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.

No contact

Note that if the MD3 display module has a loss of power or other malfunction the screen may go blank and all machine functions controlled by the computer system will be affected..

480-149

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ HARDWARE FAULT in THIS SECTION. 2.63

Tigercat 480 Mulcher

Controls and Operation MD3

Display VREF error MD3

Display VREF error

XA2-A1

Front Chassis Module

480-149

VREF error

XA2-A2

Pump Area Module VREF error

MODULE VREF ERROR The module VREF message will be displayed to indicate a problem related to the 5 V reference signal coming from the module.

The module is identified on the display screen.

This message indicates a problem with a sensor, connecting wires or the 5V reference signal itself.

Once acknowledged this message will be replaced with a hardware fault message for the corresponding module when active faults are recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - CRITICAL ~ HARDWARE FAULT in THIS SECTION.

2.64

Tigercat 480 Mulcher

Controls and Operation XA2-A1 Front Chasis Pin C1:12

Hydraulic Oil Level Sensor VIN Low error

VOLTAGE INPUT ERROR (VIN) Voltage input error messages will be displayed to indicate a problem with a voltage input signal to a computer system module.

480-150

The module and pin number are identified on the display screen.

CURRENT OUTPUT ERROR (COUT)

The heading identifies the signal source and the text indicates the type of error.

Current output error messages will be displayed to indicate a problem with a current output signal from a computer system module.

An example of a voltage input error message is shown above.

DIGITAL INPUT ERROR (DIN) Digital input error messages will be displayed to indicate a problem with a digital input signal to a computer system module.

The module and pin number are identified on the display screen.

The heading identifies the signal source and the text indicates the type of error.

The display is similar to the voltage input error message shown above.

The module and pin number are identified on the display screen.

The heading identifies the signal destination and the text indicates the type of error.

The display is similar to the voltage input error message shown above.

Once acknowledged these message will be replaced with a hardware failure message for the corresponding module when active faults recalled to the screen. Refer to COMPUTER ~ MESSAGES AND WARNINGS - ALERT ~ HARDWARE FAILURE in THIS SECTION.

DIGITAL OUTPUT ERROR (DOUT) Digital output error messages will be displayed to indicate a problem with a digital output signal from a computer system module.

The module and pin number are identified on the display screen.

The heading identifies the signal destination and the text indicates the type of error.

The display is similar to the voltage input error message shown above.

2.65

Tigercat 480 Mulcher ALERT MESSAGES (YELLOW)

Controls and Operation There are two types of alert messages:

Alert messages advise the operator that machine operation will be compromised.

Alert messages have the second level of priority and are used to indicate to the operator that action is required to prevent future damage to the machine.

All alert message will give brief details of the fault and advise what action is necessary.

Action should be taken to service the machine to correct the problem at the earliest opportunity to prevent future damage to the machine.

Alert programmed messages generally triggered by machine function related conditions.

When an alert message is displayed, the external alarm and light will sound and flash three times to alert the operator of the message. The message remains on the screen until the operator hides it.

Messages can be hidden by pressing the F2 button (Hide).

480-101

Alert messages flash the alert symbol above the F4 button when active messages are hidden.

Active messages that have been hidden can be reviewed by pressing the F4 button. The symbol will continue to flash until the problem is resolved and the fault becomes inactive.

Note that if both a critical level fault and an alert level fault are present the critical symbol will take priority until the critical fault becomes inactive.

Alert computer system generated messages are generally triggered by computer system error and fault related conditions.

When a system generated alert message is displayed the external alarm and light will sound and flash three times to alert the operator of the message.

The message remains on the screen until the operator hides it.

Note that active hardware fault alert messages are acknowledged by pressing the F2 button (OK). To recall these messages turn key off and on. On screen messages will indicate to the operator that an active hardware fault has been hidden.

2.66

Tigercat 480 Mulcher

Controls and Operation

InterACTIVE ALERT MESSAGES

ENGINE FAULT CODE MESSAGES - alert

•

Engine Air Intake Filter Restricted

•

Drive Charge Filter Bypassed

•

Cutter Control Valve Pilot Pressure Low

•

Fire Detection System Malfunction

•

Machine Voltage High

•

LH Track Charge System Pressure Low

•

LH Track Overspeed

•

Fuel Level Low

•

Machine Voltage Low

•

Hardware Fault – MD3

•

RH Track Charge System Pressure Low

•

RH Track Overspeed

•

Hardware Fault COUT

•

Hardware Fault DIN

SPN: 110 FMI: 16 1 of 1

•

Hardware Fault DOUT

•

LH Track Speed Sensor No Speed Reading

Engine coolant temperature high Above normal, severe

•

RH Track Speed Sensor No Speed Reading

•

Track Brake Release Pilot Pressure Low

•

Hardware Fault VIN

•

Hardware Fault XA2-A1

•

Hardware Fault XA2-A2

•

J1939 Eng Alert

•

Engine Fault Code Messages Alert

•

LH Joystick DM1 Alert

•

Module MD3 Alert

•

RH Joystick DM1 Alert

•

Speed Control Slider - Voltage above normal

•

Speed Control Slider - Voltage below normal

•

Push Bar Slider - Voltage above normal

•

Push Bar Slider - Voltage below normal

•

Debris Door Slider - Voltage above normal

•

Debris Door Slider - Voltage below normal

Engine

Engine fault active - contact service

480-103

Alert engine fault message(s) will be displayed, alarm warning light will flash and alarm will sound when an alert engine fault message is received from the engine electronic control module.

They provide the SPN code (suspect parameter number) and the FMI code (fault mode identifier) as well as a message describing the fault (when available).

Alert engine fault codes are lower priority messages than critical level engine fault code messages. Alert messages can be hidden but action (service engine) is required to resolve the cause of the fault.

An example of an alert engine fault message is shown above.

Note that some less common engine fault codes will appear without a message describing the fault. Make a note of the SPN and FMI codes and contact service for more information.

Refer to engine manufacturer's manual for specific information regarding the engine.

2.67

Tigercat 480 Mulcher DRIVE CHARGE FILTER BYPASS - ALERT

Controls and Operation Hardware Fault - JOYSTICK

LH Joystick - SPN: 19 Short circuit output on Axis 2. Restart power on joystick. If problem persists, contact the service department

480-100

480-043

This warning will be displayed when an alert level active fault related to the DRIVE CHARGE FILTER BYPASS has been triggered.

Restricted. Service machine alert message is an example of the type of fault that triggers this message. The charge pressure filter is restricted and requires service or the oil temperature is cold allowing the filter to be bypassed.

RH Joystick - SPN: 19 Short circuit output on Axis 2. Restart power on joystick. If problem persists, contact the service department

480-043

This warning will be displayed when an alert level active fault related to the Joystick module has been triggered.

Short circuit alert message is an example of the type of fault that triggers this message. Restart power on joystick (turn key off then back on). If problem persists contact the service department.

2.68

Tigercat 480 Mulcher Hardware Fault - MD3

Controls and Operation Hardware Fault - XA2

Hardware Fault - MD3

Hardware Fault - XA2-A0

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Active fault has been hidden. Turn key off and on to recall active hidden hardware faults.

Hardware Fault - XA2-A0

Hardware Fault - MD3 Active fault has been hidden. Turn key off and on

Active fault has been hidden. Turn key off and on

to recall active hidden hardware faults.

to recall active hidden hardware faults.

480-043

480-043

This warning will be displayed when an alert level active hardware fault related to the MD3 Display module has been hidden.

This warning will be displayed when an alert level active hardware fault related to the XA2-A0 module has been hidden.

To recall the original active fault(s) the operator must turn the key off and on.

To recall the original active fault(s) the operator must turn the key off and on.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

High temperature, low supply voltage and high supply voltage module alert messages are examples of the type of hardware fault which will be the original active faults which trigger this message.

2.69

Tigercat 480 Mulcher SERVICE COMPARTMENTS, DOORS AND ACCESS PANELS

Controls and Operation RIGHT SIDE COMPARTMENTS, DOORS AND ACCESS PANELS

REAR DOOR

4

3

2

The rear door provides access to the Debris Screen and Cooler Package/Heat Exchanger compartment. The door is perforated and acts as the first stage of screening for the cooler package, the debris screen is the second stage.

1

The following compartments, doors and access panels are located on the right side of the machine: 1. Cab R.H. Door 2. Hydraulic compartment R.H. side.

3. Engine compartment R.H. side.

4. Battery Compartment.

OPENING THE DOORS

To open the door, swing the latch pin stop to the side, lift up the pin and swing open the door. Lift the door safety stop out of it's storage position and place the safety stop bolt in hole provided in the door ledge to brace the door open. Reverse this procedure to close doors.

DEBRIS SCREEN The debris screen is located inside the rear door, open the rear door as previously describe to access the debris screen.

To open the engine compartment door (3), swing the latch pin stop to the side, lift up the pin and swing open the door.

To open the hydraulic compartment door (2) pull on the latch handles and swing the door open.

2.70

Tigercat 480 Mulcher LEFT SIDE COMPARTMENTS, DOORS AND ACCESS PANELS 4

Controls and Operation CAB TILT PUMP

5

SUPPORT LINK

CAB TILT PUMP AND HANDLE

3 480-028

2 1

The following compartments, doors and access panels are located on the left side of the machine: 1. Cab L.H. Door 2. Windshield Washer reservoir Compartment.

CAB TILT PUMP

Located in the hydraulic compartment on the right side of the machine, the cab tilt pump consists of a hydraulic pump with an independent reservoir, and valve.

Insert the handle (stored in the hydraulic compartment) in the pump lever to operate the pump to tilt the cab. See TILTING THE CAB procedure later in this section.

3. Hydraulic compartment L.H. side.

4. Engine compartment L.H. side.

5. Storage Compartment.

OPENING THE DOORS

To open the engine compartment door (4), swing the latch pin stop to the side, lift up the pin and swing open the door.

To open the hydraulic compartment door (3) pull on the latch handles and swing the door open.

2.71

Tigercat 480 Mulcher TILTING THE CAB WARNING Before tilting the cab, ensure that the machine is parked on level ground. Lower the attachment to the ground. Turn the ignition switch off. Secure all loose articles in the cab and close all compartments in cab. Close all cab doors.

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

2. Lower the attachment to the ground.

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

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

Controls and Operation 8. Place tilt pump control lever in RAISE position. Pump the lever until the cab weight is just off the locking pins.

CAUTION Keep hands away from the locking pin area.

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.

10. Locate the support link and remove it and the retainer pins from the storage location.

11. Operate pump until the cab is tilted just enough to install the support link. Use the RAISE/LOWER CONTROL LEVER to meter the hydraulic flow at the cab tilt cylinder, position the support link in the mounting lugs and install the link retainer pins.

CAB LOCKING PINS PIN LOCK PLATES

480-026A

RIGHT SIDE BELOW CAB

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

cab SUPPORT LINK

CAB IN TILT POSITION WITH SUPPORT LINK INSTALLED

12. Use the RAISE/LOWER CONTROL LEVER to meter the hydraulic flow to lower the cab until the cab is resting on the support link.

WARNING

CAB TILT PUMP AND HANDLE

Before working under cab;

Machine must be parked on level ground.

Cab must be tilted and supported by the tilt support link or in the Full Tilt position.

PUMP LEVER 480-028

480-113

CAB TILT PUMP

6. Locate the cab tilt pump inside the right side hydraulic compartment access door.

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

FULL TILT POSITION The cab can be tilted to the full tilt position to service the hydraulic pumps, hydraulic tank and components located under the cab. In the full tilt position the cab tilt cylinder is fully extended and the cab is supported by a restraint cable.

To place the cab in the full tilt position follow steps 1 through 9 then operated hand pump until cab tilt cylinder is fully extended and restraint cable is supporting cab.

2.72

Tigercat 480 Mulcher

Controls and Operation FUEL TANKS FUEL FILL CAP

CYLINDER FULLY EXTENDED

480-144

RESTRAINT CABLE

FUEL TANKS FUEL FILL CAP

CAB FULLY TILTED

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

2. Use the RAISE/LOWER CONTROL LEVER to meter the hydraulic flow at the cab tilt cylinder to lift the cab weight off the support link and remove the link retainer pins and support link.

3. Place the pump control lever in the LOWER position. Operate pump until the cab is all the way down in the ride position onto the locking pins.

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

Located on the right and left rear sides of the machine, the fuel tanks have a combined total capacity of 833 liters (220 US gal). The left fuel tank incorporates a filler screen under the filler cap (located on the left top side of the fuel tank).

The filler screen should be removed and cleaned every 125 hours (reach in and lift it out). Replace the screen if it is damaged.

NOTE: When the cab locking pins are seated in the locking plates, rotate the pins so the flat surfaces of the locking pins are horizontal.

CAB LOCKING PINS PIN LOCK PLATES

480-026A

RIGHT 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, support link and retainer pins back in the storage location.

7. Close the hydraulic compartment door.

2.73

Tigercat 480 Mulcher

Controls and Operation

AIR COMPRESSOR - AIR SUPPLY

CAUTION Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces.

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

Always use personal protective equipment to guard against flying debris

CAUTION 480-112

Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine.

air COMPRESSOR

An air compressor, air tank and air supply connector are provided.

The air compressor is mounted on the engine and is located in the R.H. side engine compartment.

•

QUICK CONNECTOR

DRAIN VALVE

480-125 480-028

air supply tank

The air supply tank is located in the compartment behind the cab.

The compressor governor turns the compressor on at 5.5 bar (80 psi) and off at 8.3 bar (120 psi).

A pressure relief valve (150 psi/10.3 bar max) is located on the left side of the compressed air supply tank.

QUICK CONNECTOR AND DRAIN VALVE A drain valve and air supply connector are located in the hydraulic compartment on the R.H. side of the machine.

NOTE: The air supply tank must be drained every day to flush the tank of any moisture that may have accumulated due to condensation build up.

RELIEF VALVE

480-126

air supply tank

2.74

Tigercat 480 Mulcher

Controls and Operation

HYDRAULIC OIL RESERVOIR

HYDRAULIC HAND FILL PUMP

IMPORTANT

PRESSURIZED HYDRAULIC TANK.

34.5 kPa (5 psi) MAXIMUM. Before servicing hydraulic system, wearing eye protection, release air pressure from tank using air vent valve.

FILTER BREATHER

AIR VENT VALVE HANDLE

MANIFOLD

480-060 480-132

PRESSURE GAUGE

AIR VENT EXHAUST

SCHRADER VALVE

After service is completed, close air vent valve and add air pressure from a clean air source to the hydraulic tank via the schrader valve. Do not exceed 34.5 kPa (5 psi). Refer to HYDRAULIC TANK PRESSURIZATION INSTRUCTIONS in this section for details.

OIL LEVEL SENDING UNIT

sight gauge

LOW LEVEL WARNING SENDER

TEMPERATURE SENSOR 480-018 480-020

The hydraulic hand fill pump, located in the hydraulic compartment behind the cab is accessed through the service panel on the right side of the machine. It is used for adding oil to the hydraulic oil reservoir.

To add oil to the reservoir, locate suction hose in storage compartment and attach hose quick coupler to connector on hand fill pump. insert end of suction tube into supply drum and operate the pump. The oil is pumped directly into the hydraulic reservoir via a return filter. The pump should always be operated at a medium speed with steady motion. Pumping too fast may cause oil to bypass oil filter. After filling disconnect hose from pump and reinstall it in storage compartment. air supply shut off valve

air supply tank air vent valve

HYDRAULIC TANK

Located in the front of the machine chasis under the cab, the hydraulic reservoir has a capacity of 78 gallons (295 liters). The tank is pressurized by SCHRADER compressed air to 34.5 kPa (5 psi). Incorporated VALVE into the tank is a hydraulic oil level sending unit that 480-132 provides the hydraulic oil level signal for the MD3 HYDRAULIC TANK PRESSURIZATION computer display, a low level sending unit which signals a “low hydraulic oil” warning message on After service is completed, close air vent valve the MD3 display to come ON when the oil level and add air pressure from the air supply tank. is low and a temperature sensor that provides a Open the air supply shut off valve and add air to temperature signal to the MD3 unit. Always keep the hydraulic tank. Do not exceed 34.5 kPa (5 the hydraulic oil level in the safe zone indicated on psi). the MD3 display and the sight gauge on the tank NOTE: If air supply tank is empty, add air (check on flat level ground). pressure from a clean air source to the hydraulic IMPORTANT: tank via the schrader valve.

A low hydraulic oil level can result in severe damage to pumps.

2.75

Tigercat 480 Mulcher

Controls and Operation

AIR CLEANER

ELECTRICAL RESTRICTION INDICATOR SWITCH

MECHANICAL AIR FILTER RESTRICTION INDICATOR

480-0184

AIR FILTER RESTRICTION INDICATOR A mechanical filter restriction indicator is connected to the outlet side of the air filter.

Replace the primary air filter when the indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down. After replacing the filter, reset the indicator by pressing the reset button.

NOTE: Replace the safety element every third primary filter change.

480-012 480-016a

The air cleaner on this machine uses two filter elements; a primary element and a safety element. Accessible through a hinged service panel on the right side of the engine compartment.

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

A filter restriction switch is installed on the air cleaner, the switch is used to signal the MD3 computer when the filter is restricted.

Engine Air Intake Filter Restricted. Service Machine to correct.

An alert warning message will appear on the MD3 display to indicate the engine air intake filter is restricted. Replace the primary air filter element if the alert message is displayed. Replace the secondary (safety) filter every third primary filter change to guarantee maximum performance and reliability.

2.76

Tigercat 480 Mulcher

Controls and Operation

ENGINE AIR PRECLEANER 3

3 4

2 1 5

480-017

The engine air precleaner cleans engine air before it reaches the air cleaner filter elements.

It removes contaminants such as dust, powder, insects, rain and snow. This precleaner is self powered and self cleaning requiring virtually no maintenance. However, it should be checked periodically to make sure that foreign materials have not plugged the intake area or the exhaust port area.

HOW IT WORKS 1. Dirty air (1) enters the Precleaner, which is clamped onto the engine air intake.

2. Specially-designed vanes (2) , curved and angled to precisely direct air flow, move the dirty air toward the stainless steel impeller (3).

3. The dynamically balanced, one piece impeller (3) (only moving part) creates a tornado inside the housing.

4. The centrifugal force of the tornado expels the heavier than air dirt particles (4), chaff, dust, snow, rain, etc., out the discharge louver 5. Cleaned air (5) enters the engine air cleaner intake pipe, and the filter element has only the very light particles to remove.

RESULTS • Cleaner Air for The Engine!

• Longer Filter Element Life!

• Increased Engine Life!

• Increased Engine Performance!

• Reduced Operating Costs!

2.77

Tigercat 480 Mulcher OPERATING MACHINE

Controls and Operation WARNING

Before operating the machine, follow the Periodic Maintenance instructions in SECTION 3 of THIS MANUAL. Also, refer to the Engine Operator's Manual supplied with this machine.

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.

Pre-Start Checks: 1. Unlock cab doors, engine enclosure doors and hydraulic compartment doors.

2. Ensure ignition switch and saw switch are in the OFF position.

el

Fu

3. Turn Ignition switch on to check fuel level on MD3 display and if required fill the fuel tank with clean prefiltered fuel.

check engine coolant level

195-17

7. Check the engine coolant level.

8. Drain water from fuel line water separator.

9. Check air intake pre-cleaner for foreign material build-up in air intake area or exhaust port area.

10. Clean radiator, A/C condenser and oil cooler.

Refer to CLEANING A/C CONDENSER, OIL COOLER, RADIATOR AND CHARGE AIR COOLER in THIS SECTION.

480-146

11. Be sure that all covers, guards and doors are securely fastened.

CRACKING

4. With Ignition switch on check hydraulic oil level on MD3 display, the level should be between the HIGH and LOW marks on the level gauge.

BENT

worn holes EDGE WEAR

5. Check the engine oil level. The level of the oil must be between the ADD and FULL marks on the dipstick.

6. Check pump drive gearbox oil level (Dipstick provided - located in hydraulic compartment on R.H. side of machine).

EDGE WEAR BROKEN EDGE 830-02

CHECK CONDITION OF TRACK SHOES

12. Check condition of track pads.

2.78

Tigercat 480 Mulcher

Controls and Operation

13. Check track chain tension by measuring track sag as follows:

idler adjusting 4 cylinder

MEASURING TRACK SAG

• 3

A. Park machine on flat level ground.

B. Place attachment on the ground.

C. Place a 1.2 meter (4 foot) straight edge across the tracks over two rollers as shown .

SAG DIMENSION

straight edge

• CW001-2A 480-058

TIP OF GROUSER straight edge over two rollers

MEASURING SAG DIMENSION

D. Measure distance between tip of the grouser and the bottom surface of the straight edge between the track rollers as shown.

E. This dimension should be between 30mm and 40mm (1¼" - 15/8") for normal operations.

TRACK TOO TIGHT NO SAG

• 2

TRACK ADJUSTMENT

CAUTION: The grease is under very high pressure, DO NOT remove the adjustment fitting valve body (1) from the idler adjusting cylinder (4).

To loosen track, slowly loosen valve body (1) until grease begins to escape via a relief passage in the valve body housing, grease will be seen escaping from around valve body threads. When track sag is correct, tighten valve body.

TRACK CORRECT 32mm - 41mm (11/4" - 15/8") SAG

TRACK TENSION

NOTE: If track sag is less than specified, track chain wear will be accelerated. If track sag is excessive, it is possible for the track to jump off the sprocket. Refer to track sag adjustment for track chain tension adjustment procedure.

F.

1

To tighten track, attach adjustment fitting adapter (3) onto valve body (1). Connect a grease gun to the grease fitting (2) on the adjustment fitting adapter (3). Add grease until track sag dimension is within recommended limits. Remove adjustment fitting adapter.

TRACK TOO LOOSE TOO MUCH SAG

480-056

CW001-3

TRACK SAG ADJUSTMENT

rollers

480-056

•

DO NOT REMOVE

Repeat this procedure for the oposite track.

2.79

Tigercat 480 Mulcher starting engine:

CAUTION Do not start engine by shorting across starter terminals. Start engine only from operator's seat.

1. Ensure that PRE START CHECKS have been performed and that the area is clear of personnel prior to starting the engine.

2. Sound horn to warn personnel of machine start-up.

3. Turn the key switch to the RUN position. DO NOT START engine until the ENGINE WAIT TO START WARNING message has cleared.

4. Turn key switch to START position to crank engine. When engine starts, release key to RUN position.

Controls and Operation IMPORTANT! To prevent damage to starter, do not engage starter motor for more than 15 to 20 seconds.

Wait 2 minutes between each attempt to start the engine. If engine fails to start, refer to engine manufacturer operator's manual.

RESTARTING AN ENGINE THAT HAS RUN OUT OF FUEL If the engine runs out of fuel, the fuel line must be primed: 1. Refill fuel tank completely with clean prefiltered fuel.

2. Refer to engine manufacturer's operator's manual for instructions on priming the fuel system on the engine.

3. Bleed the system according to engine manual procedures.

4. Crank engine until it starts. If it fails to start after 20 seconds, stop and wait for 2 minutes before trying again.

NOTE: Do not use ether to restart an engine.

480-045

5. Observe the MD3 display module to ensure the engine oil pressure rises above 10 psi.

NOTE: If the engine does not start after three attempts, check the fuel supply system. Absence of blue or white exhaust smoke during cranking indicates no fuel is being delivered.

If engine stalls while operating the machine, turn the key to the OFF position and repeat steps (1) through (5).

IMPORTANT! • After engine has started, keep engine speed low until engine oil pressure registers on MD3 display. If it does not register within 10 seconds, stop engine and investigate cause.

•

Allow a cold engine to warm up at LOW IDLE for at least five minutes before applying any load. Check all engine parameters on the MD3 display often during the warm up period.

2.80

Tigercat 480 Mulcher

Controls and Operation

COLD WEATHER STARTING

Assuming machine was parked on level ground at last shutdown:

IMPORTANT! Cold start-ups can result in pump failure, refer to "HYDRAULIC OIL CHART" for recommended oil viscosity and temperature ranges.

(a) Start engine. (b) Ensure MD3 display is indicating normal operating conditions.

NOTE: Cold temperatures require the use of an engine block heater, hydraulic oil heater and fuel heater.

(c) Check that all personnel are clear of the machine. (d) Increase engine speed to 1100 rpm.

Preheating of hydraulic oil is recommended as standard procedure in cold weather.

1.

(e) Slowly raise and lower boom, check for proper operation.

Follow the STARTING ENGINE - SEE ENGINE MANUAL instructions for COLD WEATHER STARTING procedure.

With the attachment raised slightly off the ground: (f) Tilt the attachment forward and back and check that it is operating correctly.

IMPORTANT! To prevent damage to starter, do not engage starter motor for more than 15 to 20 seconds.

Wait 2 minutes between each attempt to start the engine. If engine fails to start, refer to engine manufacturer operator's manual.

(g) Lower and raise the attachment several times. (h) When cold weather conditions exist, continue the process of warming up the hydraulic system by repeating steps (e) through (g) several times. As the hydraulic system warms up, engine speed can be increased gradually to the HIGH IDLE position.

2. During the engine warm-up period constantly monitor engine coolant temperature and engine oil pressure. Stop engine if any pressure or temperature does not meet the specification.

3.

(i) Turn cutter on. (j) After completion of the warm-up and system testing, turn the cutter OFF, stop the drum and rest the cutting head on the ground.

Continue with MACHINE PREPARATION procedure when the engine coolant temperature registers NORMAL.

(k) Reduce engine speed to LOW IDLE.

WARNING

MACHINE PREPARATION System Test and Warm-Up Before commencing cutting operations, follow steps (a) through (l) to accomplish the following:

Ensure that the cutter drum has stopped rotating before leaving the cab. (l) Leave the cab and visually check hose connections and cylinders for leaks. Check under the machine for oil leaks.

• Warm up the hydraulic system.

• Test all systems for proper operation.

• Inspect for hydraulic oil leaks.

WARNING

CAUTION If any system fails to respond to the controls, stop the warm-up procedure and call a mechanic, otherwise serious damage to pumps and other components could result.

Never use your bare hand to check for fluid leaks.

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.

2.81

Tigercat 480 Mulcher STOPPING ENGINE IMPORTANT! Stopping the engine immediately after it has been working under load can result in overheating and premature wear of the engine components.

Follow the stopping procedure outlined below to allow the engine to cool.

Controls and Operation CLEANING A/C CONDENSER, OIL COOLER, RADIATOR AND CHARGE AIR COOLER (COOLING ASSEMBLY)

1. Park machine on level ground and rest cutting head on the ground.

The hydraulic oil cooler/A/C condenser core/ radiator/charge air cooler (CAC) is mounted at the rear of the machine. The engine driven fan draws air through the A/C condenser/oil cooler/radiator/ CAC cooling assembly.

2. Reduce engine speed to LOW IDLE and let run for approximately three to five minutes to allow gradual dissipation of heat and also to reduce turbocharger speed. This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

3. Do not race engine before shut-off.

4. Stop engine by turning ignition switch to the OFF position.

WARNING

The A/C condenser core/oil cooler/radiator/CAC cooling assembly should be checked every 8 hours (every shift) for accumulation of twigs, leaves, pine needles and dust. All of the engine enclosure doors should also be kept clean.

CLEANING PROCEDURE: 1. Shut down as per instructions in ENGINE STOPPING in this SECTION. Always follow proper engine shutdown procedures. The important benefits are: •

Extended life of engine, cooling and exhaust systems.

•

Reduced risk of post shutdown fires.

•

Interior of machine cools significantly reducing risks from touching hot surfaces.

• Before leaving the machine, park it in a safe position on level ground.

• Lower the head to the ground.

• Never work behind, in front of, or below a machine that has been parked on a grade.

• Take additional precautions by blocking the tracks using a secure object.

2. Swing the latch pin stop to the side, lift up the pin and swing open the door on the rear of the machine. Lift the door safety stop out of it's storage position and place the safety stop bolt in hole provided in the door ledge to brace the door open.

3.

2.82

When the units have been cleaned return all cooling components to their operating position.

Tigercat 480 Mulcher

Controls and Operation CAUTION Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris being blown into contact with hot surfaces.

If using compressed air for cleaning, use at 2 bar (30 psi) or less.

Always use personal protective equipment (eyewear) to guard against flying debris.

CHARGE AIR COOLER

RADIATOR

CAUTION Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine.

A/C CONDENSER CORE

OIL COOLER

480-115

HEAT EXCHANGER/COOLER PACKAGE

NOTE: The cooling assembly must be checked daily and may have to be thoroughly cleaned on a daily, weekly or monthly basis, depending on operating conditions. Use personal protective equipment (eyewear) to guard against flying debris. Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces. Care must be taken not to set the pressure too high otherwise damage to the components could result.

Thoroughly clean the debris screen and pay particular attention to cleaning in the corners of the cooler as these areas usually plug deeply.

Reversing the fan at least once per hour will help reduce the dust accumulation in the cooler cores.

Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine. For more information on fire prevention refer to FIRE PREVENTION in SECTION 1 of THIS MANUAL.

480-114

FAN FINGER GUARD

WARNING Do not remove the fan finger guard. The guard is provided to prevent personal injury. Removing the finger guard can result in serious injury.

If an oil leak occurs in this area it should be thoroughly power-washed with a mild soap to ensure that all of the oil is removed. The presence of oil causes dust and dirt to cling to surfaces which will impair the fan's ability to remove dust and dirt particles when the air flow is reversed.

2.83

Tigercat 480 Mulcher LIFT BOOM CYLINDER LOCK

Controls and Operation NOTE: Do not use the boom lock to set or test hydraulic pressure. Remove the boom lock as previously described prior to testing hydraulic pressure.

WARNING

Always install lift boom lock before working on or around machine with boom raised.

• Always install 'T' handle retainer bolt • Use only to support boom and attachment.

Before performing work under the attachment or lift boom, ensure that the attachment is firmly supported on level ground, on solid stands or, install lift boom cylinder lock.

DANGER CRUSH ZONE! DO NOT change boom hydraulic relief valve with boom raised.

Lower the attachment to the ground and be sure the full weight of the attachment and boom are resting on the ground before removing the relief valve.

LIFT BOOM

CYLINDER

'T' HANDLE

195-22

LIFT BOOM CYLINDER LOCK IN LOCK POSITION

Completely raise lift boom and place lock over one of the two cylinder rods with the open side facing down and wide end against the keeper plate bolt heads. Install 'T' handle retaining bolt through center hole.

Do not place yourself under the boom or attachment, while doing this. Do not damage the piston rod when installing the boom lift lock. Turn off the engine, turn key back to RUN position, press the INTERLOCK SWITCH to activate the system and SLOWLY lower the boom until the boom lift lock is securely in place. To remove the boom lift lock, start the engine, press INTERLOCK switch and raise the boom completely. Without placing yourself under the boom or attachment, remove the 'T' handle retainer bolt, remove the boom lift lock and secure it in place inside the storage compartment door using the 'T' handle retainer bolt.

Failure to follow these instructions could result in serious injury or death from crushing.

CARE OF THE MACHINE 1. Ensure that all fluid levels are always at the proper level. Use the preventative maintenance schedule in SECTION 3 of this manual .

2. Apply grease to all lubrication points at required intervals.

3. Do not apply load to a cold engine.

4. Close and secure all doors and access covers.

5. Do not allow branches, twigs, leaves or other obstructions to build up around radiator intake doors or anywhere else on the machine.

Clean frequently.

6. Be sure that the attachment is resting on the ground before servicing or parking the machine.

7. Follow proper procedure for cleaning windows described in this section.

2.84

Tigercat 480 Mulcher CARE OF POLYCARBONATE WINDOWS IN cab

Some windows used in the cab are made from a polycarbonate resin thermoplastic. This material is a replacement for glass when improved strength, durability and safety is required.

Polycarbonate material is expected to resist heavy impact and to absorb high levels of energy when contacted by high velocity thrown objects such as wood chips, cutter tools or stones.

The extreme operating environment seen in logging applications heightens the need to regularly inspect and properly maintain polycarbonate cab windows.

Polycarbonate windows are an essential piece of operator protective equipment and should be maintained as such. It is important to note that cracks, chips, notches or scarring anywhere on the viewing surface or edges of the window will decrease ability to resist heavy impacts and therefore compromise effectiveness as operator safety protective equipment. Windows with these defects must be replaced immediately.

Refer to the next section for detailed information regarding inspection and maintenance of polycarbonate windows.

INSPECTION AND MAINTENANCE Daily inspection and maintenance is essential to confirm that the window’s ability to protect the operator has not been compromised.

• Inspect all windows daily and immediately after any impacts.

• Check for any damage to the window material or steel structure in the area of the window mounting.

• The edges of the polycarbonate window must be evenly and fully supported on a flat surface around the entire window opening at all times.

Bent or dented skylight structures must be replaced immediately. Bent or dented cab structures must be evaluated immediately for possible repair or replacement.

• The edges of the polycarbonate window must be free from cracks, chips, notches or scarring and must not be pinched or stressed.

These defects will decrease ability to resist heavy impacts. Windows with these defects must be replaced immediately.

• Cracks, chips, notches or scarring anywhere on the viewing surface of the window will decrease ability to resist heavy impacts.

Windows with these defects must be replaced immediately.

Controls and Operation •

Bent, dented or missing window retaining parts must be replaced immediately.

• Rubber materials used in mounting the window must be maintained in good condition.

• Identification of the polycarbonate originally used by Tigercat is hot stamped in a corner of the window to identify its composition. Do not use any replacement window without proof of its material composition. Do not substitute with any other materials.

• Skylights, cab structures, windows and window retaining parts must not be modified or replaced with components that are not approved by Tigercat.

RESISTANCE TO CHEMICALS The resistance of polycarbonate material to chemical exposure varies widely. Fortunately, polycarbonate materials have good resistance to diesel fuel, grease, hydraulic oil, kerosene and engine oil.

Other chemicals however can seriously weaken the polycarbonate.

DO NOT permit any of the following chemicals to come into contact with polycarbonate windows: • acetone • air conditioning refrigerant • ammonia • anti-freeze • benzene • brake fluid • carbon tetrachloride • cutting oils • gasoline • lacquer thinner • toluene • turpentine • xylene RESISTANCE TO WATER Polycarbonate material has good resistance to water up to approximately 65°C (150°F). Above this temperature the effect of water is timetemperature related. This means that the higher the water temperature, the shorter the time before the polycarbonate is adversely affected.

Exposing polycarbonate to repeated steam cleanings or high temperature pressure washing may result in crazing, a phenomenon that causes clouding of the surface. Crazing can ultimately result in a loss of physical strength and may precede a fracture.

2.85

Tigercat 480 Mulcher

Controls and Operation

CLEANING INSTRUCTIONS

CAUTIONS

The viewing surfaces of polycarbonate cab windows are specially treated with a hard coating to provide enhanced resistance to abrasion and ultra-violet (UV) radiation.

•

DO NOT use abusive cleaning procedures either by hand or pressure washing on polycarbonate windows.

•

DO NOT use brushes, razor blades, scrapers, squeegees or other sharp tools on polycarbonate windows.

•

DO NOT clean polycarbonate windows when the daytime temperature is high or in direct sunlight.

•

DO NOT use abrasive or highly alkaline cleaners on polycarbonate windows.

•

DO NOT use glass cleaners in either aerosol or non-aerosol containers to clean polycarbonate windows.

•

Failure to follow these cleaning instructions will shorten the service life of polycarbonate and may cause visual hazing, loss of light transmission and delamination of the polycarbonate hard surface coating.

The following instructions are provided to prolong the life of this protective hard coating.

1. Rinse the window thoroughly with lukewarm water 2. Using a soft cloth, cellulose sponge or chamois, gently wash the window with a mild solution of soap or detergent in lukewarm water. Do not scrub or use brushes or squeegees.

Brand name soaps and detergents recommended for cleaning polycarbonate are: • Fantastik • Formula 409 • Hexcel F.O. 554 • Joy • Lysol • Mr. Clean • Neleco-Placer • Pine-Sol • Top Job 3. Rinse the window thoroughly with lukewarm water.

4. Dry the window with a moist soft cloth, cellulose sponge or chamois to prevent water spotting.

5. To remove grease or oil, first rub lightly with a good grade of VM&P Naphtha or isopropyl alcohol followed by the same rinse, wash, rinse and dry procedure described in steps 1 to 4.

CONCEALING HAIRLINE SCRATCHES The appearance of scratches and minor abrasions on the surfaces of polycarbonate windows can be minimized by using a mild automotive polish such as: • • •

Johnson’s Paste Wax Novus Plastic Polish #1 and #2 Mirror Glaze Plastic Polish

Be certain to clean the polycarbonate window as outlined prior to application of an automotive polish. Refer to CLEANING INSTRUCTIONS.

Refer also to RESISTANCE TO CHEMICALS for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

2.86

Tigercat 480 Mulcher

Controls and Operation

GRAFFITI REMOVAL •

•

For removal of paints, marking pen inks, etc., the use of Butyl Cellosolve is generally effective. The use of masking tape, adhesive tape or lint removal tools works well for lifting off old weathered paints.

window screen handknob

To remove labels, stickers, etc., the use of kerosene, VM&P Naphtha, or petroleum spirits is generally effective. When the solvent will not penetrate sticker material, apply heat (hair dryer) to soften the adhesive and promote removal.

173-25

side window screen

SIDE WINDOW SCREENS The side window screens (if equipped) can be removed to clean the windows. Screens are provided for the personal protection of the operator and must be reinstalled immediately after cleaning the windows.

Refer also to RESISTANCE TO CHEMICALS for a list of chemicals which should not be permitted to come into contact with polycarbonate windows.

A handknob is provided on both the inside and the outside. By unscrewing either (not both) of these knobs, the screen will be free to swing out on the hinges. Be aware that the screen will swing outwards with considerable force, if the door is open.

FIRE PRECAUTIONS Polycarbonate window material will ignite when exposed to an ignition source in excess of 427°C (800°F). When working around polycarbonate windows, observe similar fire precautions to those in place for wood.

All handles should be hand tight only at all times.

20231A R1

2.87

Tigercat 480 Mulcher FUSES AND RELAYS

Controls and Operation

FUSE AND RELAY PANEL - CAB Each major circuit on the vehicle is protected against current overload by fuses. The fuses and relays are located in two places on the machine. The Cab fuse and relay panel is located in the compartment just below the instrument panel as shown above. The main fuse and relay panel is located in the electrical box in the engine compartment.

2.88

Tigercat 480 Mulcher

480-029 480-028

Controls and Operation

CAB FUSE PANEL

LABEL - MAIN FUSE AND RELAY PANEL ~ CAB 2.89

44528Beng r0

Tigercat 480 Mulcher FUSES AND RELAYS

Controls and Operation

MAIN FUSE AND RELAY PANEL - ENGINE COMPARTMENT This main fuse and relay panel is located in the electrical box in the R.H. side of the engine compartment on the front wall.

2.90

Tigercat 480 Mulcher

Controls and Operation

44526Beng r0

LABEL - MAIN FUSE AND RELAY PANEL ~ ENGINE COMPARTMENT 2.91

Tigercat 480 Mulcher

Controls and Operation

2.92

Tigercat 480 Mulcher SECTION 3 - LUBRICATION & MAINTENANCE MARCH, 2010

CONTENTS - SECTION 3 A

AIR CLEANER...............................................................................................3.18 AIR CONDITIONING SYSTEM, CHECKING.................................................3.20 AIR FILTER ELEMENTS................................................................................3.19 AIR PRECLEANER........................................................................................3.19 C

CASE DRAIN STRAINER..............................................................................3.17 E

EMERGENCY EXITS, CHECK DAILY.............................................................3.6 ENGINE AIR CLEANER............................................................................................3.18 AIR PRECLEANER....................................................................................3.19 F

FILTERS FUEL FILTER/WATER SEPARATOR..........................................................3.14 FUEL TANK STRAINER.............................................................................3.15 HYDRAULIC OIL RETURN........................................................................3.16 HYDROSTATIC CHARGE PUMP PRESSURE FILTERS..........................3.17 SERVICING GUIDELINES FOR OIL FILTERS...........................................3.17 FIRE PREVENTION.........................................................................................3.6 H

HYDRAULIC OIL RETURN FILTERS.............................................................3.16 HYDRAULIC OILS......................................................................................... 3.11 L

LUBRICATION AND SERVICE POINTS........................................................3.13 N

NEW MACHINE MAINTENANCE FIRST 125 HOUR INSPECTION AND SERVICE REPORT.........................3.2 INITIAL PRE-DELIVERY INSPECTION........................................................3.2 TIGHTENING POINTS.................................................................................3.2 O

OIL LOST FROM LEAKAGE............................................................................3.5 OIL SAMPLE COLLECTION PROCEDURES..................................................3.4 OIL SAMPLING PROGRAM..................................................................... 3.3, 3.4 P

PRESSURE SETTINGS.................................................................................3.25 S

SCHEDULED MAINTENANCE 8 HOURS......................................................................................................3.7 125 HOURS..................................................................................................3.8 250 HOURS..................................................................................................3.8 500 HOURS..................................................................................................3.9 1000 HOURS................................................................................................3.9 2000 HOURS................................................................................................3.9 GENERAL............................................................................................. 3.5, 3.6 SEASONAL.................................................................................................3.10 SERVICE AND LUBRICATION POINTS........................................................3.13 T

TORQUE, FLUID CONNECTIONS............................................ 3.22, 3.23, 3.24 W

WEIGHTS OF COMMERCIAL WOOD...........................................................3.27 WINCH...........................................................................................................3.21

Tigercat 480 Mulcher

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE NEW MACHINE MAINTENANCE *INITIAL PRE-DELIVERY INSPECTION:PERFORM THE INITIAL PRE-DELIVERY INSPECTION USING Tigercat FORM NUMBER 5338; "PDI AND 125 HOUR INSPECTION REPORT"

*FIRST 125 HOUR INSPECTION AND SERVICE REPORT:WITH THE OWNER'S MECHANIC PRESENT, PERFORM AN INSPECTION AND SERVICE ACCORDING TO THE Tigercat FORM NUMBER 5338; "PDI AND 125 HOUR INSPECTION REPORT" THIS MUST BE COMPLETED WITHIN THE FIRST 125 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 First 125 hour inspection report:~

Hour meter ~ maintenance: Check the machine hour meter on a regular basis to determine your scheduled maintenance times.

All hydraulic connections

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

Hose clamps All cylinder and boom pin retainers

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

Engine mounting bolts Pump mounting bolts Pump drive gearbox securing bolts Track shoe bolts Track roller retaining bolts

IMPORTANT

Track sprocket retaining bolts

BEFORE DRIVING MACHINE ENSURE THAT THE TRACK TENSION (SAG) IS SET CORRECTLY.

Track drive gearbox mounting bolts Track drive motor mounting bolts

TRACK SAG MAY BE SET LESS THAN SPECIFIED FOR SHIPPING PURPOSES.

Cab securing bolts Any other loose nut, bolt or fitting

SAG DIMENSION

straight edge

NOTE: Use of filters other than genuine Tigercat replacement filters is not recommended.

TIP OF GROUSER straight edge over two rollers

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

rollers

480-056

MEASURING SAG DIMENSION REFER TO SECTION 2 OF THIS MANUAL FOR PROCEDURE.

3.2

Tigercat 480 Mulcher

Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM Using the Tigercat Advanced Oil Analysis Program on a regular basis is an excellent preventative maintenance tool. Oil sampling cost is at the owner’s expense, however, studies have shown that it is possible to receive a 10 to 1 payback when looking at the amount saved on repair costs to the amount invested in a scheduled oil analysis program. Some of the benefits of a sampling program include: •

Detect problems early before they become major catastrophic failures.

•

Better ability to schedule downtime and forecast cost of repairs.

•

Monitor maintenance schedules and practices and confirm that the required maintenance is being done on time.

•

Increase used equipment value by providing proof of proper maintenance.

This Program uses the most modern technology available to analyze all oil samples. Most test results are available within 24 hours after receipt of the sample and are supplied in an easy to understand report, which calls for specific action and makes detailed recommendations. This report is available as a mailed or faxed hardcopy, sent via e-mail or can be viewed on the internet.

This program will provide Tigercat machine owners access to an Advanced Oil Analysis Program for all major machine components including powertrain components, specifically hydrostatic pump and motors, boom/steer pump, axles, transfer case, pump drive gearbox, etc.

Recommended Testing Schedule Location

First Sample

Follow-up Samples

Hydraulic Oil

125 hrs

Every 1000 hrs or 6 Months

Track Drive Gearboxes

125 hrs

Every 1000 hrs or 6 Months

Pump Drive Gearbox

125 hrs

Every Oil Change (500 hours or 3 Months)

Tigercat Oil Analysis Kits are available from your Tigercat dealer parts department. If required, arrangements can also be made with your Tigercat dealer to supply and perform all of the required followup oil samples.

Refer also to OIL SAMPLE COLLECTION PROCEDURES in THIS SECTION for sample valve and drain plug locations.

TIGERCAT OIL ANALYSIS KITS Each kit includes a Pre-paid Sample Bottle and Sample Information Form. Pre-printed mailing labels are also included to ensure all samples are quickly returned directly to the lab for immediate analysis and results within 24 hours of receipt.

The same type of sample bottle can be used for all types of oil testing including: Hydrostatic pump and motors, boom/steer pump, axles, transfer case, pump drive gearbox, etc.

To ensure accurate and meaningful results are obtained, each kit also includes detailed instructions on how to properly collect, prepare and ship the oil samples.

Contact your Tigercat Dealer Parts Department to order Kits.

3.3

Tigercat 480 Mulcher

Lubrication and Maintenance

TIGERCAT OIL SAMPLING PROGRAM Hydraulic Oil Samples: • Hydraulic oil samples should be taken from the circulating oil flow at operating temperature, with no functions actuated, using sample valves that are permanently located on the machine whenever possible.

OIL SAMPLE COLLECTION PROCEDURES Fill out the Sample Information Form (SIF) completely and accurately. When taking multiple oil samples, fill out all of the required SIF forms in their entirety, prior to taking any oil samples. Then, immediately package each completed SIF form together with the matching oil sample in the black outer shipping container as each individual sample is taken. This will reduce the possibility of mixing up or incorrectly identifying the SIF forms and oil samples. Incorrectly identified samples could result in a false warning alarm.

The accuracy of the lab analysis results is very dependent on the quality of the oil sample taken. Collection of clean oil samples that are representative of the main body of oil are essential if meaningful lab results are to be obtained.

Erroneous readings may result if proper collection, handling, packaging and shipping practices are not followed prior to the sample being tested by the lab. To be able to accurately compare and trend the lab results over time, all follow-up samples should be consistently taken from the same location using the same techniques as all previous samples.

•

Ensure that all sample valves and drain plugs are clean and free of debris.

•

Remove the sample bottle cap only when ready to take the sample. Keep the cap clean – do not put it in your pocket or let it get contaminated in any way.

•

Do not allow any airborne dirt, etc. to enter the sample bottle.

•

Avoid contamination of the sample – replace the sample bottle cap immediately after filling the bottle to approximately ¾ full. All samples taken should be immediately forwarded to the lab for processing.

•

To obtain a representative oil sample, sample valves must be purged before the actual oil sample is taken. Drain a minimum of 3 or 4 ounces of oil into a separate container and discard this oil using approved recycling methods.

•

Replace the dust cover on the sample valve immediately after taking the oil sample and sealing the sample bottle.

Gearbox Samples: • These samples can be taken during the oil change process.

Contact your Tigercat dealer to purchase additional or replacement hydraulic sample valves or drain plugs.

In cases where oil samples must be pumped or otherwise drawn out of a reservoir or housing, a hand operated oil suction pump is also available from your Tigercat dealer.

3.4

•

To obtain a representative oil sample, ensure the oil is warm and has not settled very long (within 30 minutes of shutdown).

•

Place the required drain container under the machine to capture the used oil to be discarded using approved recycling methods.

•

Remove the drain plug and allow approximately 50% of the oil to drain, then place the sample bottle in the stream of draining oil to obtain a representative sample.

Tigercat 480 Mulcher

Lubrication and Maintenance

GENERAL CAUTION All handles, steps and platforms must be kept free of grease, oil, fuel, mud, snow, ice and forest debris to prevent risk of personal injury.

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.

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.

Clean away all branches, bark and chips.

Clean up all traces of oil to avoid fires.

Always have a fire extinguisher at hand.

For safety, always lower boom assembly to the ground when leaving cab, leaving machine unattended or during service.

For safety, before working under boom, always lower to ground, support properly or install lift boom cylinder locking device . (Refer to section 2 of this manual)

Clean around filler caps before checking or adding fluids.

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

Plug or cap immediately.

Clean up spills as soon as possible.

Always use clean hydraulic oil and filters.

Drain dirty oil while still warm.

Do not exceed recommended fluid levels.

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

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

Clean up oil spills on walking surfaces and top of engine enclosure immediately.

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.

*Oil lost from leakage Lost 0il (LITERS) Lost 0il (GALLONS) per per per per per per day month year day month year Leakage rate One drop In 10 Seconds 0.424 12.72 152.0 0.112 3.36 40.0 One drop In 5 Seconds 0.852 25.6 306.6 0.225 6.75 81.0 One drop per second 4.26 127.76 1533.1 1.125 33.75 405.0 Three Drop per Second 14.2 425.86 5110.31 3.75 112.5 1350.0 Drops Break Into Stream 90.83 2725.5 32706.0 24.00 720.0 8640.0

3.5

Tigercat 480 Mulcher

Lubrication and Maintenance

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

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

CHECK EMERGENCY EXITS, DAILY:~ An alternate exit route is provided: • Right hand cab door.

• Roof Hatch.

CHECK FIRE EXTINGUISHER, DAILY:~

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

CHECK CHARGE GAUGE DAILY

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.

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.

480-110

A portable fire extinguisher is located in operator's cab. The extinguisher should be checked daily to ensure that it is charged. The pointer on the charge gauge should point to the green region.

If the indicator falls out of this green area, the extinguisher should be serviced immediately.

Maintain a CHARGED fire extinguisher on the machine at all times and KNOW HOW TO USE IT. Refer to the manufacture's Use and Information manual for proper usage, additional information and recommended inspection and maintenance intervals.

3.6

Tigercat 480 Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE WARNING

Check:~ • All engine air intake system components (including charge air cooler) rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair or replace immediately.

• Charge Air Cooler for damage, wear, cracks, or leaks and repair immediately.

• For leakage around hydraulic components and flexible hoses.

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.

•

• For loose nuts, bolts and fittings.

• Visually check condition of tracks.

• Exhaust system for leaks.

• Condition and tension of accessory drive belt.

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

• Conduct an overall visual inspection.

• Inspect winch to insure that there are no oil leaks present and that the wire cable is in good condition.

Every 8 hours (every shift):~

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

• Check engine oil level • Check engine coolant level • Drain fuel/water separator • Check air intake precleaner, clean as required • Check air cleaner unloader valve • Check air intake filter restriction indicator.

Replace primary filter if indicator is in red zone.

Replace secondary (safety) filter every third primary filter change to guarantee maximum performance and reliability.

• Check hydraulic oil level • Check pump drive gearbox oil level with dipstick • Lubricate tilt and lift cylinder ends, 8-fittings, purge • Lubricate lift boom and tilt linkage, 9 or 10 fittings, depending on attachment), purge Clean:~ • Potentially damaging limbs or sticks from machine.

• Between air conditioner condensor, charge air cooler, oil cooler and radiator.

3.7

Tigercat 480 Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE Every 250 hours:~

Every 125 hours:~

• Perform 8 hour maintenance

• Perform 8 hour maintenance

• Perform 125 hour maintenance

And in addition:~ • Carry out A/C system inspection; Refer to CHECKING THE AIR CONDITIONING SYSTEM in THIS SECTION

And in addition replace:~ • Oil in pump drive gearbox • Replace oil in track drive gearboxes with drain plug at 6 O'clock position and fill plug at 9 O'clock.

• Lubricate winch rollers, if equipped.

Check:• Check track gearboxes oil level with level plug at 9 O'clock and other plug at 6 O'clock.

• • • • •

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

Fluid level in batteries unless maintenance free Engine rpm.

Hydraulic pump and motor securing bolts Check fuel tank filler screen Torque tightening points as per new machine maintenance

Visually check for damage to:• Lift boom and tilt linkage • Upper frame • Tracks, track frames and carbody • Attachment 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.

† Use of filters other than genuine Tigercat replacement filters is not recommended.

3.8

Tigercat 480 Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE EVERY 500 HOURS:~

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

• Perform 8 hour maintenance • Perform 125 hour maintenance • Perform 250 hour maintenance And in addition replace:~ • Engine oil and change oil filter • Engine fuel filter • Hyd. Oil press. Filter, drive charge press. † • Hyd. Oil return filters, boom/fan/steer/saw (high pressure)† • Hyd. Oil return filter, pilot (low pressure) † • Lubricate door and door screen hinges.

Check:~ • All hydraulic pressures.

• Torque on track drive gearboxes and motor mounting bolts.

• Check track rollers for leakage. Rollers are filled with oil and are considered to be maintenance free. If a lubricant leakage is detected the rollers must be removed, repaired and replaced.

• Check track idler assembly for leakage, the bearing is filled with oil and is considered to be maintenance free. If a lubricant leakage is detected the idler must be removed, repaired and replaced.

• Check winch gearboxes and brake assembly fluid levels • Inspect winch to insure that there are no oil leaks present, that all mounting bolts and other fasteners are tight, and that the wire cable is in good condition.

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

Every 1000 hours:~ • Perform 8 hour maintenance • Perform 125 hour maintenance • Perform 250 hour maintenance • Perform 500 hour maintenance And in addition replace :~ • Engine air cleaner unloader valve • Fuel intake strainer • Gear oil in winch gearboxes and automatic transmission fluid in winch brake assembly

Every 2000 hours:~ • Perform 8 hour maintenance • Perform 125 hour maintenance • Perform 250 hour maintenance • Perform 500 hour maintenance • Perform 1000 hour maintenance And in addition replace:~ • Oil in hydraulic reservoir • Replace all air intake rubber components such as elbows and connectors - High temperatures in this area can cause the rubber to harden.

See AIR INTAKE MAINTENANCE in THIS SECTION • Check ALL air intake tubing, rubber couplings and band clamps for signs of wear and leakage and repair immediately.

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

Note: When refilling the hydraulic system, vent pumps, motors and valves of air by opening a plug or hose fitting located near or on top of the pumps, motors and valves until oil free of air is seen flowing out of the plug or hose fitting. Failure to vent air from the hydraulic system could cause serious damage to hydraulic components. Tighten plugs or fittings and clean up any spilled oil when completed.

Note: Changing strainers, filters and replacing the hydraulic oil tends to aerate the oil. For maximum pump life, the machine should sit for 1 hour after servicing to allow entrained air to escape from the oil prior to applying working pressures to the pumps.

Note: Check all hydraulic system components especially cooling fan for proper operation after hydraulic oil has been replaced.

3.9

Tigercat 480 Mulcher

Lubrication and Maintenance

SCHEDULED MAINTENANCE SEASONAL:~ Drain and refill hydraulic oil tank with recommended hydraulic oil. See "approved hydraulic oils".

3.10

Tigercat 480 Mulcher

Lubrication and Maintenance

APPROVED HYDRAULIC OILS Use one of the following oils to fill or replenish the hydraulic system.

Recommended Lubricants - Grease Esso Beacon EP - 2

Shell Alvania EP - 2

Mobil Mobilux EP - 2

3.11

BP EPEnegrease EP - 2

Petro Canada Supreme EP - 2

Tigercat 480 Mulcher

Lubrication and Maintenance L.H. TRACK PIVOT BUSHING

R.H. TRACK PIVOT BUSHING

1 FTG/8

1 FTG/8

FRONT BEAM PIVOT BUSHING

1 FTG/8

22

16

20

4

6

1

ATTACHMENT

WINCH ROLLERS

8 FTG/125

21

5

19

14

DOOR HINGES

12

8 FTG/500

DOOR/SCREEN HINGES

8 FTG/500 15

13

7

8 9

11

10

3

2

BOOM LINK AND CYLINDER PINS

18 FTG/8 REAR DOOR HINGES

3 FTG/500 22

17 HINGES

WALKING BEAM BUSHING

2 FTG/8

2 FTG/500

18

PIVOT SHAFT BUSHING

2 FTG/8

44464b

LEGEND

CHK REP DRN D/R LUB

3.12

..... ..... ..... ..... ..... .....

HOURS CHECK REPLACE DRAIN DRAIN AND REFILL LUBRICATE

Tigercat 480 Mulcher

Lubrication and Maintenance Tigercat model 480 ®

SERVICE AND LUbRICATION POINTS

REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION CAPACITY

SERVICE EVERY ITEm

DESCRIPTION

1

COOLING SySTEM

2

COOLANT FILTER

3

ENGINE OIL ANd FILTER CUMMINS QSX 15L

CHK dRN

4

FUEL FILTER/WATER SEPARATOR

5

FUEL CAP SCREEN

6

IN-TANK FUEL STRAINER

7

AIR INTAKE PRECLEANER

8

CHANGE COOLANT EVERy 2 yEARS

CHK

53

1•

REP

•

REP

•

60% ANTIFREEZE/40% dISTILLEd WATER (SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL FOR SPECIFICATIONS)

14

•

1•

• SEE ENGINE MANUFACTURER'S MAINTENANCE MANUAL FOR PROCEdURES, CAPACITIES ANd REPLACEMENT INTERVALS

1•

REP

1

CLEAN OR REPLACE AS NECESSARy

1

dRAIN TANK, CLEAN OR REPLACE AS NECESSARy

CHK

1

CLEAN AS REQUIREd / INSPECT IMPELLER FOR WEAR OR dAMAGE REPLACE AS NECESSARy

AIR INTAKE PRIMARy FILTER ELEMENT

CHK

1

9

AIR INTAKE SAFETy FILTER ELEMENT

CHK

1

10

AIR CLEANER UNLOAdER VALVE

CHK

11

AIR INTAKE CONNECTIONS

12

HydRAULIC OIL FILTER * dRIVE/BOOM/ATTACHMENT

13

HydRAULIC TANK BREATHER

14

HydRAULIC dRIVE CHARGE PRESSURE FILTER

15

RECIRCULATING CAB FILTER FRESH AIR CAB FILTER

16

PUMP dRIVE GEARBOX

CHK CHK

REP

CHK

REP

REP † REP †

CHK

CHK

17

TRACK dRIVE GEARBOX;

18

TRACK ROLLERS ANd IdLERS CHECK FOR LUBRICANT LEAKAGE

19

HydRAULIC RESERVOIR

CHK †††

20

COMPRESSEd AIR TANK

dRN

21

WINCH

22

ATTACHMENT

1

REFER TO SECTION 3 IN MANUAL

2

CHECK FOR LOOSE CLAMPS ANd dAMAGEd RUBBER COMPONENTS. REPLACE RUBBER COMPONENTS.

6

5 HydRAULIC OIL FILTERS 1 WATER ABSORBING HydRAULIC OIL FILTER (BLUE)

1

REP †

2

REP †

2

CLEAN OR REPLACE AS NECESSARy

1

CHECK LEVEL WITH dIPSTICK. FILL WITH MIL-L-2105C OR API-GL-5 BELOW -10ºF(-23ºC) USE 75W-90 ABOVE 100ºF(38ºC) USE 85W-140 RECOMMENdEd SyNTHETIC GEAR OIL FOR SEVERE dUTy APPLICATIONS MIL-PRF 2105E OR API GL-5 BELOW TO -100ºF(-38ºC) USE 75W-90 UP TO 100ºF(38ºC) USE 85W-140

d/R

CHK ††

CHECK FILTER RESTRICTION INdICATOR. REFER TO 8 HOUR SCHEdULEd MAINTENANCE FOR dETAILS (SECTION 3 IN MANUAL).

5.7

d/R

CHK

d/R

CHK

d/R

1.5

6

1.6

2

FILL WITH S 75W-90 (SPEC) RECOMMENdEd SyNTHETIC GEAR OIL FOR SEVERE dUTy APPLICATIONS †† CHECK OIL WITH LEVEL PLUGS AT 6 ANd 9 O'CLOCK POSITIONS.

7.6

2

1

IF LEAKING REMOVE ANd REPAIR FILL WITH SAE 80W-90 HT OIL, REFER TO 500 HOURS SCHEdULEd MAINT. FOR dETAILS

285

75

dRAIN ANd REFILL AT SEASONAL OIL CHANGE REFER TO MANUAL FOR APPROVEd OILS ††† CHECK USING VEHICLE dISPLAy MOdULE 1

dRAIN TANK dAILy

3

CHECK OIL LEVELS EVERy 500 HOURS/ dRAIN ANd REFILL GEAR BOXES ANd BRAKE HOUSING EVERy 1000 HOURS - SEE WINCH MANUFACTURER'S MANUAL. SEE ATTACHMENT MANUFACTURER'S MANUAL

44464BENG R1

SERVICE AND LUBRICATION POINTS

3.13

Tigercat 480 Mulcher

Lubrication and Maintenance

FILTERS - REMOVE AND REPLACE 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 FILTER/WATER SEPARATOR One fuel filter is supplied with the engine. Refer to the engine manufacturer's operation and maintenance manual for service information and replacement interval.

IMPORTANT! 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.

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.

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.

Unfiltered fuel used to pre-fill filters enters directly into the fuel system. Contaminants in unfiltered fuel can cause significant and costly damage to the engine. The cleanliness of fuel cannot be guaranteed unless it is always prefiltered before use.

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.

3.14

480-111

FUEL FILTER/WATER SEPARATOR

Tigercat 480 Mulcher

Lubrication and Maintenance

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 R.H. fuel tank.

Changing or cleaning the strainer: 1. Park machine on level ground, lower attachment to ground, stop engine.

2. Drain the fuel tanks. (plug in bottom) 3. Remove the round fuel tank cleanout cover plate and “O” ring from the access hole on R.H. fuel tank.

4. Before removing the strainer, 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.

7. Reinstall the strainer using the hex on end.

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

FUEL TANK STRAINER

9. Refuel with pre-filtered fuel and check for leaks. Start the engine and check for leaks again.

3.15

Tigercat 480 Mulcher

Lubrication and Maintenance Apply clean oil to new gasket surfaces.

Install new gasket on inside lip of filter.

DO NOT pre-fill filter. Screw on new filter until gasket makes contact with filter head.

Tighten filter until top edge makes metal to metal contact with filter head. (Approximately 1 1/2 additional turns after gasket contact) DO NOT use bottom nut for filter installation or damage/leakage may result. Bottom nut is to assist in filter removal only.

IMPORTANT: PRESSURIZED HYDRAULIC TANK. 34.5 kPa (5 psi) MAXIMUM.

Before servicing hydraulic system, wearing eye protection, release air pressure from tank using air vent valve.

FILTER BREATHER MANIFOLD

AIR VENT VALVE HANDLE PRESSURE GAUGE

RETURN MANIFOLD

480-060 480-152

AIR VENT EXHAUST

SCHRADER VALVE

HYDRAULIC OIL RETURN FILTERS

Filter change procedure: 1. Park the machine on level ground with the attachment resting on the ground.Stop engine.

2. Open hydraulic compartment doors.

3. Turn the BATTERY DISCONNECT SWITCH to the ‘OFF’ position.

4. Wearing eye protection, release air from the hydraulic reservoir by opening the AIR VENT VALVE. Note: Air pressure expelling from the vent valve will blow accumulated loose debris in the compartment.

5. Wipe clean the area around the filters and head.

6. Place drip pan and rags below filters to catch any oil spillage.

7. Wearing face protection (in case of an oil squirt), unscrew the old filter.

8. Dispose of old filter and any oil properly.

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

FILTER HEAD GASKET

FILTER ELEMENT FILTR_SEALS

'O' Ring Gasket INSTALLATION

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

Discard the square section gasket.

Remove used gasket and clean gasket seat in head.

COUPLER CONNECTION

BLEED HOSE

480-037A

WASTE OIL CONTAINER

BLEEDING AIR FROM HYDRAULIC RETURN CIRCUIT

11. Attach bleed hose to the oil sample coupler on the return manifold. Route hose to a waste oil container.

12. Check oil level on computer display.

13. Use fill pump to replace oil lost during filter change.

14. Close AIR VENT VALVE. 15. Pressurize hydraulic tank by adding air at the schrader valve or by using the air tank on the machine.

16. Purge air out the bleed hose from the return manifold until a steady stream of oil is coming from the bleed hose.

17. Recheck oil level and if oil level is low, vent tank at air vent valve and repeat steps 13 to 17. If oil level is OK procede to step 18.

18. Disconnect bleed hose from the coupling at the manifold.

19. Clean up any spilled oil.

20. Start the engine and check for leaks.

21. Run engine at IDLE speed for at least 5 minutes to purge any remaining air from the filter system. Then STOP the engine for 15 minutes to allow air bubbles in the hydraulic tank to rise.

22. Recheck hydraulic oil level – top up as needed.

3.16

Tigercat 480 Mulcher

Lubrication and Maintenance

HYDROSTATIC CHARGE PUMP PRESSURE FILTERS

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

6. Place drip pan and rags below filters to catch any oil spillage.

HYDRAULIC FILTER SERVICING GUIDELINES

7. Wearing face protection (in case of an oil squirt), unscrew the old filter.

IMPORTANT

8. Dispose of old filter and any oil properly.

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

NEVER PRE-FILL ANY HYDRAULIC FILTERS

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

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.

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

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

13. Add air pressure to the hydraulic tank via the schrader valve from the on board air supply or a clean air source (ie: compressed air from service truck or shop). Monitor the hydraulic reservoir pressure gauge when adding air pressure. Do not exceed 34.5 kPa (5 psi).

There are two other full flow filters mounted on filter heads with built-in bypasses. They are in the output side of the track drive charge pumps. For service and replacement intervals see SERVICE AND LUBRICATION CHART in THIS SECTION.

14. Start the engine and check for leaks.

Changing the filters: 1. Park the machine on level ground with the attachment resting on the ground. Stop engine.

2. Open hydraulic compartment doors.

3. Turn the BATTERY DISCONNECT SWITCH to the ‘OFF’ position.

IMPORTANT: PRESSURIZED HYDRAULIC TANK. 34.5 kPa (5 psi) MAXIMUM.

Before servicing hydraulic system, wearing eye protection, release air pressure from tank using air vent valve.

FILTER BREATHER MANIFOLD

15. Run engine at IDLE speed for at least 5 minutes to purge any remaining air from the filter system. Then STOP the engine for 15 minutes to allow air bubbles in the hydraulic tank to rise.

16. Recheck hydraulic oil level – top up as needed.

CASE DRAIN STRAINER IMPORTANT: Only in the event of a pump or motor major failure should this element be replaced. Always use the correct replacement part.

AIR VENT VALVE HANDLE PRESSURE GAUGE

STRAINER ELEMENT 480-116

480-060 480-152

AIR VENT EXHAUST

SCHRADER VALVE

4. Wearing eye protection, release air from the hydraulic reservoir by opening the AIR VENT VALVE. Turn valve 90° to open valve.

Note: Air pressure expelling from the vent valve will blow accumulated loose debris in the compartment.

CASE DRAIN STRAINER

The case drain strainer element is located in the pump compartment under the cab and services pump and motor case drains.

ONLY IN THE EVENT OF A PUMP OR MOTOR CATASTROPHIC FAILURE SHOULD THIS ELEMENT BE REPLACED.

3.17

Tigercat 480 Mulcher

Lubrication and Maintenance

AIR CLEANER ELECTRICAL RESTRICTION INDICATOR SWITCH

MECHANICAL AIR FILTER RESTRICTION INDICATOR

480-0184

FILTER RESTRICTION INDICATOR A mechanical filter restriction indicator is connected to the outlet side of the air filter. Replace the primary air filter when the indicator shows RED. This indicator provides a continuous reading whether the engine is running or is shut down.

After replacing the filter, reset the indicator by pressing the reset button.

NOTE: Replace the safety element every third primary filter change.

OVER CENTER LATCH 480-016A

ENGINE AIR CLEANER

The air cleaner on this machine uses two filter elements; a primary element and a safety element.

Accessible through a hinged service panel on the right side of the engine compartment.

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

A filter restriction switch is installed on the air cleaner, the switch is used to signal the MD3

The most common and damaging servicing problems are: OVER SERVICING Filter elements increase in dust cleaning efficiency as dust builds up on the media. Looks can be deceiving. A filter that looks dirty may actually be 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 hydraulic oil or diesel engine oil filters.

SERVICING

Engine Air Intake Filter Restricted. Service Machine to correct.

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 are removed for replacement. The safety element does reduce this risk but it should also be replaced at every third primary element change.

computer when the filter is restricted.

IMPORTANT STEPS TO FOLLOW when changing filter elements

An alert warning message will appear on the MD3 display to indicate the engine air intake filter is 1. restricted. Replace the primary air filter element if the alert message is displayed. Replace the 2. secondary (safety) filter every third primary filter change to guarantee maximum performance and reliability.

3.18

Release the six overcenter latches and lift cover/dust bowl off of air cleaner assembly .

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

Tigercat 480 Mulcher

Lubrication and Maintenance ENGINE AIR PRECLEANER 3

3

safety element

4

2 1 5

primary element 480-023

480-017

AIR FILTER ELEMENTS

The engine air precleaner cleans engine air before it reaches the air cleaner filter elements.

It removes contaminants such as dust, powder, insects, rain and snow. This precleaner is self powered and self cleaning requiring virtually no maintenance. However, it should be checked periodically to make sure that foreign materials have not plugged the intake area or the exhaust port area.

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

4. Always clean the inside of the outlet tube.

5. Check your old filter sealing surfaces. This will 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.

HOW IT WORKS 1. Dirty air (1) enters the Precleaner, which is clamped onto the engine air intake.

2. Specially-designed vanes (2) , curved and angled to precisely direct air flow, move the dirty air toward the stainless steel impeller (3).

3. The dynamically balanced, one piece impeller (3) (only moving part) creates a tornado inside the housing.

4. The centrifugal force of the tornado expels the heavier than air dirt particles (4), chaff, dust, snow, rain, etc., out the discharge louver 5. Cleaned air (5) enters the engine air cleaner intake pipe, and the filter element has only the very light particles to remove.

RESULTS • Cleaner Air for The Engine!

• Longer Filter Element Life!

• Increased Engine Life!

• Increased Engine Performance!

• Reduced Operating Costs!

6. Inspect the new filter for damage.

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

8. Check connections and ducts for an air tight fit. Ensure that all clamps, bolts and connections are tight. Check rubber elbows intake tubing and joints for hardening cracks, splits or wear points and replace as needed.

Leaks in these locations send dust directly to the engine.

INTAKE TUBING AND JOINTS Check all air intake system components, rubber elbows, connector hoses, tubes and clamps for damage, hardening, wear, cracks, leaks, loose clamps or loose hanger bracket hardware and repair or replace immediately.

Replace all air intake rubber components such as elbows and connectors every 2000 hours - High temperatures in this area can cause the rubber to harden.

3.19

Tigercat 480 Mulcher

Lubrication and Maintenance

checking the AIR CONDITIONING SYSTEM

A/C belt

serpentine belt

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.

A/C SYSTEM TOTAL CAPACITIES R134a REFRIGERANT 1.7 kg (3.75 lbs)

PAG OIL (polyalkylene glycol) 0.06 kg (2 oz)

The compressor and charge valves and receiver drier are accessed from the left side engine compartment. The evaporator core is accessed within the cab behind the seat in the combo unit. belt tightener

Use this checklist to maintain system between service intervals. a/c compressor belt

480-012

check SERPENTINE BELT

important!

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.

CAUTION

a/c compressor belt tightener

Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces.

If using compressed air for cleaning, use at 2.07 Bar (30 psi) or less.

Always use personal protective equipment to guard against flying debris

480-012

a. Check compressor drive belt tension.

CAUTION

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

Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Always use care when cleaning to ensure that debris removed from one area of the machine does not accumulate on other areas of the machine.

Check the condenser core for dirt and debris.

Clean as required. Refer to CLEANING A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR'S MANUAL.

d. Check the evaporator core and the inside of the A/C housing for dirt and debris. Clean as required. e. Run air conditioning system for 3 - 5 minutes. f.

Check to see that compressor clutch will engage.

3.20

Tigercat 480 Mulcher

Lubrication and Maintenance

WINCH - OPTIONAL WINCH

L.H. SIDE OF MACHINE The winch is located in the rear of the main frame, under the engine.

480-128

1. A daily inspection to insure that there are no oil leaks present and that the wire cable is in good condition.

If winch use calls for operation in temperatures outside this range, contact the Winch Manufacturer for special oil recommendations.

Gearbox oil in gear section is drained by removing the fill and drain plugs located on the gearbox cover. Gearbox oil in the drum section is drained by removing the plug located on the barrel of the drum. Examine the used oil for signs of significant metal deposits and then dispose of it in a proper manner. Reinstall the plugs and fill the gearboxes with the proper amount of new SAE 90 EP gear lube through the fill hole. Make sure the breather/ vent is operational and replace if necessary. vent and fill plug 0.5 pint

2. The winch should be operated once every 30 days to ensure that the cable will free spool and that the winch will pull the machine in the event that it is needed to recover the machine from an unexpected accident or equipment failure.

3. Periodic servicing of the winch includes changing the oil in both the gearboxes and the brake section. Severity of use will determine the need for oil changes but it should be checked at a minimum of every 500 hours and changed every 1000 hours. Factors such as extremely dirty conditions or widely varying temperature changes may dictate even more frequent servicing.

Drain the brake section by removing the drain plug and breather in the brake cover. Inspect the oil for signs of metallic particles and/or burning and re-install the drain plug. Fill brake section with automatic transmission fluid, or hydraulic oil.

NOTE: When performing 1000 hour oil change, also check that all mounting bolts and other fasteners are tight.

DRAIN and fill plug - TURN DRUM WITH PLUG FACING DOWN TO DRAIN AND UP 90° TO FILL

480-127

WINCH ROLLERS

WINCH ROLLERS Two vertical and two horizontal rollers guide the winch cable in and out of the winch at the rear of the machine. It is recommended to grease the The winch is factory filled with SAE 90 EP gear rollers (2 fittings per roller) every 125 hours or lube in the gearboxes and automatic transmission more frequently depending on severity of winch fluid in the brake section. This oil should be use. Use lithium based EP-2 grease containing 5% satisfactory for operation in ambient temperatures molybdenum disulfied from -10°F to +110°F. 3.21

Tigercat 480 Mulcher

Lubrication and Maintenance

Parker

Assembly Torque The four-bolt port is simply a circular opening (flow passage) surrounded by four tapped holes in a certain pattern for acceptance of the flange clamping bolts. The flat surface of the port compresses the O-ring contained in the groove in the flange head when the clamp bolts are torqued. In some instances, the groove is in the port and not in the flange head. The bolts, through the clamp halves, clamp down the flange head on to the flat surface of the port compressing and trapping the O-ring in the groove and leaving no gap for it to extrude under pressure. The hydraulic pressure is thus sealed by the compressed O-ring as long as the bolts are tightened enough to maintain solid metal to metal contact between the flange head at the outside diameter of the O-ring and the top of the port.

The 4-Bolt Split Flange consists of four main components: • A body (flange head) • An O-ring • One “captive” or two “split” flange clamps

• Four bolts and washer

WASHERS BOLTS FLANGE CLAMP

Flange Port Assembly

FLANGE HEAD

The steps to properly assemble the flange port clamping bolts are: 1. Make sure sealing surfaces are free of burrs, nicks, scratches or any foreign particles.

2. Lubricate the O-ring.

3. Position flange and clamp halves.

4. Place lock washers on bolts and insert through clamp halves.

5. Hand tighten bolts.

6. Torque bolts in diagonal sequence (see Fig. T9) in small increments to the appropriate torque level listed in Table T6 or Table T7 on this page.

o-RING TAPPED HOLES

FLANGE.JPG

Fig. T8 - 4 Bolt Split Flange Components

FLANGE2.jpg

Fig. T9 - Flange Bolt Tightening Sequence

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

8 12 16 20 24 32 40 48 56 64 80

1/2 3/4 1 1-1/4 1-1/2 2 2-1/2 3 3-1/2 4 5

5/16-18 3/8-16 3/8-16 7/16-14 1/2-13 1/2-13 1/2-13 5/8-11 5/8-11 5/8-11 5/8-11

17 +/- 2 25 +/- 3.5 31 +/- 4.5 41 +/- 5 52 +/- 6 60 +/- 6 85 +/- 9 144 +/- 15 125 +/- 8 125 +/- 8 125 +/- 8

M8 M10 M10 M12 M12 M12 M12 M16 M16 M16 M16

25 49 49 85 85 135 95 220 220 220 220

8 12 16 20 24 32

1/2 3/4 1 1 1/4 1 1/2 2

5/16-18 3/8-16 7/16-14 1/2-13 5/8-11 3/4-10

17 +/- 2 30 +/- 4.5 46 +/- 4.5 69 +/- 6 125 +/- 8 208 +/- 20

M8 M10 M12 M14 M16 M20

25 49 85 135 210 425

* Does not meet ISO 6162 specification.

Table T7 - Code 62 Flange Recommended Bolt Torque

* Does not meet ISO 6162 specification.

Table T6 - Code 61 Flange Recommended Bolt Torque

3.22

Tigercat 480 Mulcher

Lubrication and Maintenance

Parker

Assembly Torque

JIC 37 Degree Flare SAE Dash Size

Thread Size

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

NPTF

Tube Connection Swivel or Hose Connection FFWR FFWR

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

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

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

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

Tube Connection Swivel or Hose Connection TFFT TFFT

Thread Size 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

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

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR

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

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 SAE Dash Size

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

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

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

Tube Connection Swivel or Hose Connection TFFT TFFT

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

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

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

SAE J1926 Straight Thread Port Assembly Torques ASSEMBLY TORQUE = 10 % -0 SAE DASH SIZE

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

NON-ADJUSTABLE THREAD SIZE

SEAL-LOK

FT.LBS.( IN.LBS) 5/16-24 (310) 3/8-24 (310) 7/16-20 (310) 1/2-20 (360) 9/16-18 (420) 3/4-16 60 7/8-14 100 1 1/16-12 135 1 3/16-12 175 1 5/16-12 200 1 5/8-12 250 1 7/8-12 305 2 1/2-12 375

N-M 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS FT.LBS.( N-M IN.LBS) (85) 10 (155) 18 (260) 29 (280) 32 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

ADJUSTABLE SEAL-LOK FT.LBS.( IN.LBS) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

3.23

N-M 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS FT.LBS.( N-M IN.LBS) (60) 7 (100) 11 (180) 20 (250) 28 (350) 40 (620) 70 85 115 135 183 175 237 200 271 250 339 305 414 375 509

PLUGS HOLLOW HEX HP5ON-S FT.LBS.( IN.LBS) (30) (55) (120) (170) (410) 60 100 135 175 200 250 305 375

N-M 3.5 6 13.5 19 46 80 135 185 235 270 340 415 510

HEX HEAD P5ON-S FT.LBS.( IN.LBS) (85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

N-M 10 18 29 32 40 70 115 183 237 271 339 414 509

Tigercat 480 Mulcher

Lubrication and Maintenance

EATON Aeroquip

Assembly Torque

Recommended Parallel Connection Assembly torque

Eaton recommends that a Torque wrench be used to assure proper fitting assembly of these connections.

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

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

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

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

The values listed are for steel connections. Contact Teaton for torque values for other materials.

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

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

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) 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

3.24

Tigercat 480 Mulcher

Lubrication and Maintenance

PRESSURE SETTINGS 480 mULCHER

With hydraulic oil at operating temperature (49°C - 60°C / 120°F - 140°F) Location

Pressure (bar)

Pressure (PSI)

Engine RPm

Engine RPm 1850 ± 25 High Idle 850 ± 25 Low Idle

main Pump Standby Pressure / Pilot Pressure Pump P.O.R.

33 - 35 180

480 - 500 2600

850 850

25 400 435 435

350 5800 6300 6300

850 850 850 850

49 - 62 3200 rpm

700 - 900 3200 rpm

850 1850

Cutter Control Valve Main Relief

386

5600

850

Cutter Pump Pump P.O.R.

350

5050

850

104 - 117 207

1500 - 1700 3000

850 850

1550 - 1565 rpm 1675 - 1725 rpm

1550 - 1565 rpm 1675 - 1725 rpm

1850 1850

207 241 241 241 241 241 241 241 96 158 158

3000 3500 3500 3500 3500 3500 3500 3500 1400 2300 2300

850 850 850 850 850 850 850 850 850 850 850

Drive Pumps R.H. and L.H. Charge Pressure Relief Valve Pump P.O.R. High Pressure Relief Forward High Pressure Relief Reverse Drive motors drive Motor Begin of Stroke (Set-up) drive Motor Maximum Speed

Cutter motors Motor Begin of Stroke (Set-up at M1 port) Motor Begin of Stroke (at G port) Rotor Speed (Motor at Min displacement) Fecon FGT9025 (dd029-02) FAE 500/U (dd026, dd026-01) main Valve Main Relief Tilt In Port Relief * Tilt Out Port Relief * Boom Lift Port Relief * Boom Lower Port Relief * debris door Open Port Relief * debris door Close Port Relief * Push Bar Out Port Relief * Push Bar In Port Relief * Winch In Port Relief * Winch In Port Relief *

ImPORTANT NOTES: ~ Boom support must be used part# 4128A ~ When performing tilt out function, without an attachment installed, do not allow crank arms to hit boom * non adjustable settings

PRESSURE SETTINGS

3.25

Tigercat 480 Mulcher

Lubrication and Maintenance

B

A AM

AL

AI

AH

AJ

AK

AG

AF

AD

AE

34583AUNI R0

480-014

MAIN CONTROL VALVE - SECTION DESIGNATIONS 3.26

Tigercat 480 Mulcher

Lubrication and Maintenance

Weights of Commercial Wood

Species

kg/m3

lb/ft3

Species

kg/m3

lb/ft3

Alder, Red Ash, White Aspen, Quaking Bald Cypress Basswood, American Beech, American Birch, Paper Birch, Yellow Cedar, Alaska Cedar, Incense Cedar, Northern White Cedar, Port-Orford Cedar, Western Red Cherry, Black Cottonwood, Eastern Douglas Fir, Coast Douglas Fir, Inland North Elm, American Fir, Alpine Fir, Balsam Fir, Nobel Fir, Red Fir, Silver Fir, White Gum, Black Gum, Blue Gum, Red Gum, Tupelo Hemlock, Eastern Hemlock, Western Hickory, Pecan Hickory, True Larch, Western Locust, Black Magnolia, Cucumber

737 769 689 817 673 865 801 929 577 721 449 897 433 721 785 881 577 865 449 721 481 769 577 753 721 1121 801 897 801 657 993 1009 769 929 785

46 48 43 51 42 54 50 58 36 45 28 36 57 45 49 55 36 54 28 45 30 48 36 47 45 70 50 56 50 41 62 63 48 58 49

Maple, Big Leaf Maple, Black Maple, Red Maple, Silver Maple, Sugar Oak, Black Oak, Chestnut Oak, Red Oak, Red, Swamp Oak, Swamp Chestnut Oak, White Oak, White, Swamp Pine, Jack Pine, Loblolly Pine, Lodgepole Pine, Long Leaf Pine, Norway, Red Pine, Short Leaf Pine, Slash Pine, Sugar Pine, Western Yellow Pine, White-Western Pine, White-Eastern Poplar, Yellow Redwood Spruce, Black Spruce, Engleman Spruce, Red Spruce, Sitka Spruce, White Sweetgum Sycamore, American Tamarack Walnut, Black Willow, Black

753 865 801 721 897 1009 977 1009 1073 1041 993 1105 801 993 625 993 673 993 993 817 721 561 577 609 801 513 625 545 529 545 801 833 753 929 801

47 54 50 45 56 63 61 63 67 65 62 69 50 62 39 62 42 62 62 51 45 35 36 38 50 32 39 34 33 34 50 52 47 58 50

Note: The values shown here are green weights.

3.27

Tigercat 480 Mulcher

Lubrication and Maintenance

3.28