Tigercat 480 MULCHER SERVICE MANUAL - PDF DOWNLOAD

SERVICE MANUAL

Tigercat 480 MULCHER ISSUE 1.0, MARCH, 2010 TABLE OF CONTENTS SECTION INTRODUCTION.................................................................................................................iii NON-APPROVED FIELD PRODUCT CHANGES............................................................... v SAFETY............................................................................................................................... 1 USING HIGH SPEED DISC SAWS SAFELY............................ APPENDIX TO SECTION 1 CONTROLS AND OPERATION...............................See separate operator's manual LUBRICATION AND MAINTENANCE................................................................................. 3 HYDRAULIC SYSTEM/ LOAD SENSE CONTROL............................................................ 4 PILOT SYSTEM.................................................................................................................. 5 ELECTRICAL AND COMPUTER SYSTEM......................................................................... 6 ENGINE............................................................................................................................... 7 OIL COOLER/RADIATOR AND COOLING FAN............................................................... 10 TRACK DRIVE.................................................................................................................. 11 LIFT BOOM ...................................................................................................................... 12 TILT................................................................................................................................... 13 ATTACHMENT DRIVE ..................................................................................................... 17 PUSH BAR & DEBRIS DOOR.......................................................................................... 19 WINCH (OPTIONAL)......................................................................................................... 20

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..........................................................................Part No. 33590A Service Manual (This 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

ii

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.

iii

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.

• Monitor daily weather forecasts

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.

•

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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Tigercat 480 Mulcher

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

1.20

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

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

•

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.

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.

4

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.

6

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.

8

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

®

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.

Tigercat

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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

16

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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 month year day month year Leakage rate day 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

Tigercat 480 MULCHER SECTION 4 - HYDRAULIC SYSTEM MARCH, 2010

CONTENTS - SECTION 4 F

FILTERS HYDRAULIC OIL RETURN..........................................................................4.4 HYDROSTATIC CHARGE PUMP PRESSURE FILTERS............................4.4 SERVICING GUIDELINES FOR OIL FILTERS.............................................4.4 H

HYDRAULIC OIL RETURN FILTERS...............................................................4.4 HYDRAULIC SYSTEM OPERATION MAIN HYDRAULIC SYSTEM.......................................................................4.2 PILOT CIRCUIT............................................................................................4.2 P

PRESSURE SETTINGS.................................................................................4.16 PRESSURE SETTINGS PUMP CONTROL VALVE.......................................4.16

Tigercat 480 MULCHER

Hydraulic System

HYDRAULIC SYSTEM COMPONENTS ENGINE

PUMP DRIVE GEARBOX

LEFT TRACK DRIVE PUMP

MAIN PUMP

ATTACHMENT DRIVE PUMP

RIGHT TRACK DRIVE PUMP

ENGINE, PUMP DRIVE GEAR BOX AND HYDRAULIC PUMPS to stroke the pumps and send high pressure The hydraulic system is composed of the following oil to the track drive motors. circuits: The track drive pumps have an internal • Main pump and main hydraulic valve which charge pump that provides make up oil to provide hydraulic oil for the boom lift and tilt, keep the pumps charged as well as provide winch (if equipped), mulcher debris door, cooling and lubricating oil for the pumps.Refer mulcher push bar and pilot supply. to section 11 of this manual for details on the • Track Drive system which incorporates a left TRACK DRIVE system. and right track drive pump and motor.

3. ATTACHMENT DRIVE 480-061a

•

Attachment pump, valve and motors.

The mulcher rotor is belt driven via a belt and pulley arrangement on each side of the rotor. Two (axial piston, bent axis) variable displacement hydraulic motors drive the pulleys on each side of the mulcher attachment. A variable displacement electronically controlled hydraulic pump mounted on the pump drive gearbox supplies oil flow to the motors. Refer to section 17 of this manual for details on the ATTACHMENT DRIVE system.

1. main hydraulic system The main hydraulic system is a constant pressure (with unloading), closed centre system utilizing a variable-displacement axialpiston pump.

The main control valves are pressure and flow compensated to provide load independent operation for all functions.

2. track drive This closed loop circuit uses two variabledisplacement piston pumps which deliver oil to the track drive motors and back to the pumps. Electronic joystick operated controls send electrical signals to the proportional electro-hydraulic solenoid controls on the track drive pumps to direct charge pressure oil 4.2

Tigercat 480 MULCHER

Hydraulic System

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

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 tank.

To add oil to the hydraulic tank, open air vent valve and release air pressure in tank. Locate suction hose in storage compartment, clean quick coupler and connector 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

TEMPERATURE SENSOR 480-018 480-020

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 compressed air to 34.5 kPa (5 psi). Incorporated into the tank is a hydraulic oil level sending unit that provides the hydraulic oil level signal for the MD3 computer display, a low level sending unit which signals a “low hydraulic oil” warning message on the MD3 display to come ON when the oil level is low and a temperature sensor that provides a temperature signal to the MD3 unit. Always keep the hydraulic oil level in the safe zone indicated on the MD3 display and the sight gauge on the tank (check on flat level ground).

IMPORTANT: A low hydraulic oil level can result in severe damage to pumps.

480-132

air supply tank air vent valve

SCHRADER VALVE

HYDRAULIC TANK PRESSURIZATION After service is completed, close air vent valve and add air pressure from the air supply tank.

Open the air supply shut off valve and add air to the hydraulic tank. Do not exceed 34.5 kPa (5 psi).

NOTE: If air supply tank is empty, add air pressure from a clean air source to the hydraulic tank via the schrader valve.

4.3

Tigercat 480 MULCHER

Hydraulic System

HYDRAULIC OIL RETURN FILTERS

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

WATER ABSORBING ELEMENT (COLOR BLUE) 480-060 480-152

AIR VENT EXHAUST

SCHRADER VALVE

HYDRAULIC FILTER SERVICING GUIDELINES IMPORTANT HYDRAULIC RETURN FILTERS (6) CHARGE PRESSURE FILTERS 480-157

HYDRAULIC OIL FILTERS

There are six full flow filters mounted on filter heads with built-in bypasses. These filters are for boom, attachment drive, deflector door, push bar and winch (if equipped). One of the filters is (blue) it contains a water absorbing element. For service and replacement intervals see SERVICE AND LUBRICATION CHART in SECTION 3.

HYDROSTATIC CHARGE PUMP PRESSURE FILTERS There are two other full flow filters mounted on filter heads with built-in bypasses. They are on the output side of the hydrostatic drive charge pump for the track drive pumps. For service and replacement intervals see SERVICE AND LUBRICATION CHART in SECTION 3.

Note: Changing strainer, 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.

NEVER PRE-FILL ANY HYDRAULIC FILTERS

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.

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.

STRAINER ELEMENT 480-116

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. 4.4

Tigercat 480 MULCHER

Hydraulic System

MAIN HYDRAULIC PUMP AND VALVE

MAIN PUMP

480-160

main pump

As previously mentioned, the main hydraulic system is a constant pressure (with unloading), closed centre system utilizing a variable-displacement axial-piston pump. The main pump is mounted on the back of the left track drive pump.

STANDBY ADJUSTMENT

STANDBY ADJUSTMENT

'POR' ADJUSTMENT PUMP CONTROLLER

'POR' ADJUSTMENT

720E-005 720E-006

MAIN pump 4.5

Tigercat 480 MULCHER

Hydraulic System

A

main pump The main pump supplies oil to the boom lift and tilt, mulcher deflector door, mulcher push bar, winch (if equipped) and pilot oil via the main valve located in the hydraulic valve compartment in the front of the machine.

480-161

B

AM

AL

AI

AH

AJ

AK

AG

AF

AD

AE

34583AUNI R0

CUTTER CONTROL VALVE

AT312 VALVE (FC130CP)

T2

MAIN CONTROL VALVE

• 480-163

HYDRAULIC VALVE COMPARTMENT

The main valve controls the flow of oil from the main pump to the boom lift and tilt, mulcher deflector door, mulcher push bar, winch (if equipped) and pilot oil. See MAIN CONTROL VALVE operation later in this section.

4.6

P1

Tigercat 480 MULCHER

480-063

Hydraulic System

MAIN PUMP AND CONTROL VALVE CIRCUIT SCHEMATIC 4.7

Tigercat 480 MULCHER

480-068

Hydraulic System

MAIN PUMP AND CONTROL VALVE CIRCUIT DIAGRAM 4.8

Tigercat 480 MULCHER

Hydraulic System

RETURN PORT TO TANK

PUMP SUPPLY INLET PORT MAIN RELIEF VALVE 3000 PSI (207 BAR)

WINCH SPOOL OUT PORT

WINCH SPOOL IN PORT

A

B DEBRIS DOOR OPEN PORT

DEBRIS DOOR CLOSE PORT

A

B PUSH BAR FORWARD PORT

PUSH BAR BACK PORT

A

B TILT IN PORT

TILT OUT PORT

A

B BOOM DOWN PORT

BOOM UP PORT

A

B

PILOT SUPPLY 'PS' PORT PILOT RELIEF VALVE - 508 PSI (35 BAR)

480-014a

MAIN CONTROL VALVE

MAIN VALVE DESCRIPTION

INLET SECTION

The main control valve is located in the front of the machine in the valve compartment. It can easily be accessed by removing the valve compartment cover.

The inlet section is equipped with connection ports to the main pump and tank. Integrated into the inlet section is the main pressure relief valve.

The main control valve consists of five* spool sections (*Note: the number of sections installed in the valve will vary with options selected). The valve also includes an inlet section and an end section.

Pilot pressure supply is provided as an internal function of the Main Valve. Pressure is regulated internally to 35 bar (508 psi).

Pilot pressure supply

4.9

Tigercat 480 MULCHER

Hydraulic System

MAIN PRESSURE RELIEF VALVE

spool section

480-170

SPOOL SECTIONS The main valve spool sections are equipped with proportional, electro-hydraulic spool actuators.

The actuators are spring centered to the neutral position, and are shifted by sending a 24 volt proportional current signal to the appropriate solenoid.

MAIN PRESSURE RELIEF VALVE

480-167A

Spools

MAIN VALVE

Main Pressure Relief Valve The inlet section of the main valve houses a 207 bar (3000 psi) direct acting, adjustable main relief valve. This pressure relief valve is intended to protect the main pump and main valve from pressure peaks in the system. Refer to ADJUSTING MAIN PRESSURE RELIEF VALVE in THIS SECTION.

Each of the spools installed in the main valve is selected specifically for the function it is controlling.

For example, the hoist boom section spool has different characteristics than the winch drive spool.

These spools cannot be interchanged.

Port Reliefs

PILOT RELIEF VALVE

PORT RELIEFS

END SECTION

PILOT RELIEF VALVE 480-168A 480-171

'PS' PORT 'PS' PORT

MAIN VALVE

END SECTION The end section is equipped with a separate connection for external pilot pressure supply labeled 'PS'. The pilot pressure reducing valve (not adjustable) is housed in the end section

PORT RELIEFS

480-166a

The main valve is equipped with port reliefs on each side of all spool sections. The function of the port relief is to protect the valve and the function cylinder or motor from pressure peaks in the system. The port reliefs also act as anti-cavitation valves, which means they allow oil to flow from the tank gallery in the valve to the service ports in the event of underpressure. The port reliefs cannot be adjusted. Port reliefs installed in each section are specifically designed for use in that section and should not be interchanged with port reliefs from other valve sections .

4.10

Tigercat 480 MULCHER

Hydraulic System

MAIN PUMP AND VALVE OPERATION

CUTTER solenoid CONTROL VALVE (S1)

The main hydraulic system is a constant pressure (with unloading), closed centre system utilizing a variable-displacement axial-piston pump.

The main pump will only pump oil when the interlock switches (both cab doors) are closed and the interlock reset switch on the instrument panel has been reset. When the engine is running the pump will be at stand-by pressure with minimum flow and pressure, just enough to provide pilot pressure. When a function, boom lift, boom tilt, winch, debris door or mulcher push bar is activated the MD3 computer will activate the main pump solenoid control valve (S2) located on the cutter valve assembly, which will then place the pump at full stroke.

The main pump solenoid control valve (S2) provides hydraulic oil pressure to the main pump controller which allows the pump to stroke and provide oil flow (60cc/36 GPM)and pressure (179 Bar/2600 psi) to the main control valve. Once a function is activated, hydraulic oil will flow from the pump through the main valve to the function selected.

CUTTER CONTROL VALVE

MAIN CONTROL VALVE

480-163

HYDRAULIC VALVE COMPARTMENT

When the MD3 computer determines that no functions are active, the digital output signal from the XA2 #1 (Front Module) to the main pump solenoid control valve (S2) is turned off and the main pump is destroked to provide only minimum oil flow at stand-by pressure.

480-076

MAIN PUMP SOLENOID CONTROL VALVE (S2)

ELECTRONIC AND HYDRAULIC CONTROLS AND COMPONENTS 4.11

Tigercat 480 MULCHER

Hydraulic System

480-079

480-085

MD3 MODULE, XA2 MODULE AND HARNESS PIN ASSIGNMENT CHARTS 4.12

Tigercat 480 MULCHER

Hydraulic System

CONNECTOR 'BJ' GREY PIN NO. WIRE NO.

FUNCTION

CONNECTOR 'Bl' GREen PIN NO. WIRE NO.

FUNCTION

1

12

Startfuse-IMS Relay Power

1

58

Webasto Mod Ctrl from Timer

2

25

AC ON DIN

2

59

Webasto Mod Ctrl from Timer

3

26

Defroster ON DIN

3

62

Rear Work Light RH

4

28

AC ON DOUT

4

62A

Rear Work Light RH

5

29

AC ON Relay to Press SW

5

140

Sky Camera Trigger

6

32

XA2 Module #1 Power

6

141

Backup Camera Trigger

7

33

XA2 Module #2 Power

7

69

Track Light RH

8

40

Horn Power

8

69A

Track Light LH

9

41

Charge Filter Bypass Signal

9

71

Air Valve Limit SW Signal

10

42

Return Filter Bypass Signal

10

82

Service Lights SW to Relay

11

46

Low Hyd Oil Level DIN

11

-

12

47

Key SW Signal to ECM

12

-

CONNECTOR 'Bk' BLACK PIN NO. WIRE NO. 1

HA4

2

LA4

FUNCTION

CONNECTOR 'Bm' brown PIN NO. WIRE NO.

FUNCTION

1

72

Eng ISC Increment

Iqan CAN A HIGH

2

73

Eng ISC Decrement

CAB to Iqan XA2#2

3

74

Eng ISC (Redundant)

Iqan CAN A LOW

4

74A

Engine Panel Ground

CAB to Iqan XA2#2

5

-

3

48

Unswitched Power - Amerex

6

-

4

51 Master Discon't Relay Power

7

54A

5

53

E-Stop to Air Shutoff Relay

8

-

6

54

Fuel Shutoff Valve Power

9

G31A

Cab Computer Grounds

7

55

Fuel Heater Relay Power

10

G31B

Cab Computer Grounds

8

56

Eng Stop Lamp Signal

11

-

to Resistor

12

217

9

70

Sensor Power

10

HB3

J1939 CAN B High

11

LB3

12

3B3

Cab to Y-Conn J1939 CAN B Low Cab to Y-Conn J1939 CAN B Shield

Starter Disconnect

Re-fueling System

CONNECTOR 'BS'

PIN NO. WIRE NO. 1 HA1 2 HA2 3 HA3 4 HA4

FUNCTION Iqan CAN A High - MD3 Iqan CAN A High - RH Joystick Iqan CAN A High - LH Joystick Iqan CAN A High - Cab Entry

CONNECTOR 'Bt'

Cab to Y-Conn

PIN NO. WIRE NO. 1 LA1 2 LA2 3 LA3 4 LA4 4.13

FUNCTION Iqan CAN A Low - MD3 Iqan CAN A Low - RH Joystick Iqan CAN A Low - LH Joystick Iqan CAN A Low - Cab Entry

Tigercat 480 MULCHER

Hydraulic System

CONNECTOR 'AM' PIN NO. WIRE NO. FUNCTION 1 115B WINCH OUT 'COUT' 2 120 WINCH OUT 'CRET' CONNECTOR 'AI' PIN NO. WIRE NO. FUNCTION 1 107B DEBRIS DR CLOSE 'COUT' 2 111 DEBRIS DR CLOSE 'CRET' CONNECTOR 'AJ' PIN NO. WIRE NO. FUNCTION 1 112A PUSH BAR OUT 'COUT' 2 113 PUSH BAR OUT 'CRET' CONNECTOR 'AG' PIN NO. WIRE NO. FUNCTION 1 103B BOOM TILT IN 'COUT' 2 105 BOOM TILT IN 'CRET'

A

B

AM

AL

AI

AH

AJ

AK

AG

AF

AD

AE

CONNECTOR 'AD' PIN NO. WIRE NO. FUNCTION 1 100A BOOM UP'COUT' 2 101 BOOM UP'CRET'

480-082

CONNECTOR 'AL' PIN NO. WIRE NO. FUNCTION 1 115A WINCH IN 'COUT' 2 117 WINCH IN 'CRET'

34583AUNI R0

CONNECTOR 'AH' PIN NO. WIRE NO. FUNCTION 1 107A DEBRIS DR OPEN 'COUT' 2 110 DEBRIS DR OPEN 'CRET' CONNECTOR 'AK' PIN NO. WIRE NO. FUNCTION 1 112B PUSH BAR IN 'COUT' 2 114 PUSH BAR IN 'CRET' CONNECTOR 'AF' PIN NO. WIRE NO. FUNCTION 1 103A BOOM TILT OUT 'COUT' 2 104 BOOM TILT OUT 'CRET' CONNECTOR 'AE' PIN NO. WIRE NO. FUNCTION 1 100B BOOM DOWN 'COUT' 2 102 BOOM DOWN 'CRET'

xa2 MODULE #1 AND MAIN VALVE CIRCUIT SCHEMATIC 4.14

Tigercat 480 MULCHER

480-083

Hydraulic System

xa2 MODULE #2 PUMPS, MOTORS,SENSORS, AND PUMP AREA COMPONENTS CIRCUIT SCHEMATIC 4.15

Tigercat 480 MULCHER

Hydraulic System

PRESSURE SETTINGS - mAIN PUMP 'POR' AND 'STANDBY' ADJUSTMENTS 1. Park machine on level ground, lower attachment to the ground and stop engine.

2. Ensure that the hydraulic oil temperature is between 49°C and 60°C (120°F and 140°F).

CUTTER solenoid CONTROL VALVE (S1)

MAIN PUMP SOLENOID CONTROL VALVE (S2)

6. Shut the engine off.

7. Remove the test gauge and install a 0-350 Bar (0-5000 psi) test gauge on the B1 test port of the cutter control valve.

8. Start engine, close the cab doors and press the interlock reset switch.

9. Operate the boom tilt back function and hold the function over relief.

10. Observe the gauge, the reading should meet specifications.

'B1' TEST PORT

STANDBY ADJUSTMENT

'POR' ADJUSTMENT

LOCKING SCREWS

CUTTER CONTROL VALVE

MAIN CONTROL VALVE 480-078

480-163

HYDRAULIC VALVE COMPARTMENT

3. Install a 0-70 Bar (0-1000 PSI) pressure gauge on the B1 test port of the Cutter Control Valve.

NOTE: * Refer to section 3, PRESSURE AND SPEED chart in this manual for pressure and speed specifications.

11. If pressure is less then or greater then specifications adjust pump POR pressure by loosening the locking screw and turn the POR adjustment screw IN to increase pressure or OUT to decrease pressure.

12. When pressure has been set tighten locking screw, shut engine off and remove test gauge.

Wipe up any spilled oil.

4. Start the engine and observe the pressure gauge on the B1 test port. Stand-by pressure should be meet specifications.

STANDBY ADJUSTMENT

'POR' ADJUSTMENT

LOCKING SCREWS

480-078

PUMP ADJUSTMENTS

PUMP ADJUSTMENTS

5. If pressure is less or greater then specifications adjust stand-by pressure by loosening the locking screw and turn the adjustment screw IN to increase pressure or OUT to decrease pressure then tighten locking screw.

4.16

Tigercat 480 MULCHER SECTION 5 - PILOT SYSTEM CONTENTS - SECTION 5 I

INSTRUMENT PANEL......................................................................................5.4 INTERLOCK SYSTEM.....................................................................................5.4 INTERLOCK SYSTEM ELECTRICAL..............................................................5.5 P

PILOT CIRCUIT SCHEMATIC..........................................................................5.3 PILOT FUNCTIONS.........................................................................................5.2 PILOT PRESSURE CHECK.............................................................................5.6 PILOT SYSTEM COMPONENTS.....................................................................5.2 PILOT SYSTEM ELECTRONIC AND HYDRAULIC CONTROLS AND............5.2 PILOT SYSTEM GENERAL DESCRIPTION....................................................5.2

MARCH, 2010

Tigercat 480 MULCHER

Pilot System

PILOT SYSTEM

PRESSURE SUPPLY FROM MAIN PUMP

GENERAL DESCRIPTION The pilot circuit is supplied with oil by the main pump via the main valve. A pilot supply valve located in the main valve reduces and maintains the pressure of the oil from the main pump to 35 Bar / 507 psi for the pilot system. The pilot oil is supplied to the various pilot actuated functions of the machine whenever the interlock is reset and a pilot control is activated.

PRESSURE REDUCING VALVE

PILOT RELIEF VALVE

PILOT STRAINER (coarse)

CHECK VALVE

'PS' PILOT SUPPLY TO REMOTE PILOT CONTROLS PILOT RELIEF VALVE

480-092

END SECTION

PILOT RELIEF VALVE 480-168A 480-171

480-091

MAIN VALVE end section pilot suppy circuit schematic

PILOT FUNCTIONS The following is a list of the various functions that require pilot oil:

'PS' PORT

'PS' PORT

1. Boom Lift

2. Boom Tilt

3. Debris Door

4. Push Bar

5. Winch

6. Cutter Controls

7. Cutter Pump

8. Track Brakes

9. Cooling Fan Control Valve

MAIN VALVE

PILOT SYSTEM ELECTRONIC AND HYDRAULIC CONTROLS AND COMPONENTS 5.2

Tigercat 480 MULCHER

480-088

Pilot System

PILOT CIRCUIT SCHEMATIC 5.3

Tigercat 480 MULCHER

Pilot System

INTERLOCK SYSTEM INTERLOCK SHUT-OFF SWITCH

1

INSTRUMENT PANEL

INTERLOCK RESET SWITCH

ACTUATOR 480-110

INTERLOCK SYSTEM SHUT OFF

INTERLOCK SYSTEM SHUT OFF Both cab doors are equipped with interlock switches (1) to prevent the machine from being operated while the doors are open (interlock system shut off).

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

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

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

INTERLOCK RESET SWITCH 480-017

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.

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

5.4

TOP VIEW OF CAB CONTROLS AND COMPONENTS

Tigercat 480 MULCHER

Pilot System

INTERLOCK SYSTEM ELECTRICAL CIRCUIT

480-093

INTERLOCK SYSTEM / MD3 ELECTRICAL

The interlock circuit can not be energized until the two cab doors are closed. When the engine is running, the cab doors are closed and the interlock reset switch on the instrument panel is reset, all machine functions including pilot controls can be operated.

5.5

Tigercat 480 MULCHER

Pilot System

CHECK PILOT PRESSURE PRESSURE TEST GAUGE

FAN CONTROL VALVE

480-175

CHECK PILOT PRESSURE

1. Install a 0-70 Bar (0-1000 psi.) gauge in the fan control valve pilot pressure hose tee fitting at the pilot pressure port on the fan control valve.

2. Start the engine close both doors and engage the interlock reset switch. Operate the machine functions, Boom raise/lower, Boom Tilt, Debris Door and Push Bar over relief momentarily several times until Hydraulic Oil Temperature reaches between 49°C to 60°C (120 °F to 140 °F). This procedure will take 20-30min depending on Ambient Air Temperature.

3. With hydraulic oil temperature between 49°C to 60°C (120 °F to 140 °F), observe the gauge, the reading should be approx. 33 to 35 Bar (480 to 507 psi).

5.6

Tigercat 480 MULCHER SECTION 6 - ELECTRICAL AND COMPUTERS CONTENTS - SECTION 6

ALTERNATOR..................................................................................................6.4 ALTERNATOR BELT........................................................................................6.4 BATTERY COMPARTMENT.............................................................................6.5 BATTERY DISCONNECT SWITCH.................................................................6.5 CHANNELS....................................................................................................6.58 INPUTS DIGITAL IN (DIN).....................................................................................6.58 FREQUENCY IN (FIN)............................................................................6.58 VOLTAGE IN (VIN)..................................................................................6.58 OUTPUTS CURRENT OUT (COUT).........................................................................6.58 DIGITAL OUT (DOUT).............................................................................6.58 PWM OUT (PULSE WIDTH MODULATION)..........................................6.58 COMPUTER................................................................................6.10, 6.11, 6.12 ADJUSTMENT MENU................................................................................6.20 ALERT MESSAGES...................................................................................6.52 CRITICAL MESSAGES..............................................................................6.41 DATE/TIME ADJUSTMENT........................................................................6.37 DISPLAY ADJUSTMENT............................................................................6.36 MAIN MENU PAGE.....................................................................................6.35 MAIN MENU PAGE - MEASURE MENU EXAMPLE ~ MEASURE MENU..............................................................6.59 MESSAGES AND WARNINGS...................................................................6.40 ERROR MESSAGES (RED)...................................................................6.48 MESSAGES AND WARNINGS - ERROR..................................................6.49 CURRENT OUTPUT ERROR (COUT)...................................................6.51 DIGITAL INPUT ERROR (DIN)...............................................................6.51 DIGITAL OUTPUT ERROR (DOUT).......................................................6.51 MODULE NO CONTACT ERROR..........................................................6.49 MODULE VREF ERROR........................................................................6.50 VOLTAGE INPUT ERROR (VIN).............................................................6.51 PREFERENCES MENU.............................................................................6.35 SCREEN SAVER ADJUSTMENT...............................................................6.36 COMPUTER SYSTEM COMPONENTS AND CONNECTIONS.................... 6.11 CONNECT TO THE MD3 WITH IQANrun 2................................................6.66 DOWNLOADING APPLICATIONS FROM DEALER WEBSITE.....................6.63 DRIVE LIMITER.............................................................................................6.23 ELECTRICAL KIT - SERVICE AND DIAGNOSTICS......................................6.60 ELECTRICAL SCHEMATIC 4800101 to 4800120...................... 6.76, 6.77, 6.78, 6.79, 6.80, 6.81, 6.82 4800121 AND UP............................. 6.83, 6.84, 6.85, 6.86, 6.87, 6.88, 6.89 ELECTRICAL SYSTEM....................................................................................6.4 FUSE AND RELAY PANEL CAB..............................................................................................................6.6 MAIN..................................................................................................... 6.8, 6.9

MARCH, 2010

Tigercat 480 MULCHER

Electrical and Computers

ID-TAG............................................................................................................6.18 IQAN MODULES MD3 DISPLAY AND MASTER MODULE....................................................6.13 XA2-A0 FRONT CHASSIS MODULE.........................................................6.16 IQANrun 2....................................................................................................6.64 ADJUST......................................................................................................6.72 CONNECT TO THE MD3 WITH IQANrun 2.............................................6.66 IQANrun 2 QUICK SUMMARY.................................................................6.64 ADJUST..................................................................................................6.65 CONNECT TO THE MD3 WITH IQANrun2..........................................6.64 GET CLONE............................................................................................6.64 GET SETTINGS......................................................................................6.64 LOGIN.....................................................................................................6.64 LOGS......................................................................................................6.65 MEASURE (GRAPH)..............................................................................6.65 SEND CLONE.........................................................................................6.64 SEND SETTINGS...................................................................................6.64 SYSTEM..................................................................................................6.65 UPDATE..................................................................................................6.64 LOGIN.........................................................................................................6.67 LOGS..........................................................................................................6.74 MEASURE/ GRAPH...................................................................................6.73 REQUIRED EQUIPMENT & INFORMATION.............................................6.64 SERVICING THE MD3 WITH IQANrun 2.................................................6.64 SYSTEM.....................................................................................................6.75 UPDATE APPLICATION.............................................................................6.68 GET CLONE FILE...................................................................................6.68 GET settings FILE.............................................................................6.69 update APPLICATION TO MD3...........................................................6.70 IQAN SOFTWARE.........................................................................................6.62 application PROGRAM UPDATES for product service bulletins................................................6.63 DOWNLOADING APPLICATIONS FROM DEALER WEBSITE.................6.63 SERVICING THE MD3 WITH IQANrun 2.................................................6.64 MD3 COMPUTER................................................................................ 6.10, 6.11 MD3 COMPUTER MAIN MENU.....................................................................6.12 SCREEN SAVER ADJUSTMENT...................................................................6.36 SERVICING THE MD3 WITH IQANrun 2....................................................6.64 TROUBLESHOOTING...................................................................................6.58 UPDATE APPLICATION.................................................................................6.68

6.2

Tigercat 480 MULCHER

Electrical and Computers

6.3

Tigercat 480 MULCHER

Electrical and Computers

ELECTRICAL SYSTEM

ALTERNATOR - a/c compressor belt

The electrical system is 24 volt DC. It is equipped ALTERNATOR

belt tightener

480-012

480-114

Two serpentine belts on the front of the engine are used to drive the water pump, A/C compressor and the alternator. The belts are tensioned by spring loaded belt tighteners. Refer to section 3 for service of the serpintine belts.

24 VOLT ALTERNATOR

with a 110 amp 24 volt alternator to charge the system.

ALTERNATOR

480-187

L.H. SIDE OF ENGINE COMPARTMENT The alternator is located on the front of the engine and accessed through L.H. side of the engine compartment. The power cables (positive and negative) from the alternator connect to the batteries via the starter motor on the left side of the machine.

6.4

Tigercat 480 MULCHER

Electrical and Computers

BATTERY COMPARTMENT NEGATIVE PARALLEL CABLE

R.H. STARTER DISCONNECT RELAY

+

40 amp inline fuse

-

TOP 24 VOLT POWER SUPPLY

480-028 POSITIVE PARALLEL CABLE

-

+ NEGATIVE PARALLEL CABLE

24863A

BATTERY DISCONNECT SWITCH BOTTOM 24 VOLT POWER SUPPLY

-

+

BATTERY DISCONNECT RELAY

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.

10 amp inline fuse

480-186

+

POSITIVE PARALLEL CABLE

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

BATTERY COMPARTMENT

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.

The battery compartment is located on the right rear side of the machine.

480-101

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.

BATTERY SCHEMATIC

The battery group consists of four 12 volt (950 CCA each) batteries which are paired and connected in series to form two 24 volt systems.

The two 24 volt systems are then connected in parallel to form a common 24 volt system for charging and power supply to the machine electrical system including the starting system.

The engine is equipped with two starter motors (one on the left side and one on the right side).

There are two battery disconnect relays (as shown above).

6.5

Tigercat 480 MULCHER

Electrical and Computers

FUSES AND RELAYS

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.

6.6

Tigercat 480 MULCHER

480-029 480-028

Electrical and Computers

CAB FUSE PANEL

LABEL - MAIN FUSE AND RELAY PANEL ~ CAB 6.7

44528Beng r2

Tigercat 480 MULCHER

Electrical and Computers

FUSES AND RELAYS

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.

6.8

Tigercat 480 MULCHER

Electrical and Computers

44526Beng r0

LABEL - MAIN FUSE AND RELAY PANEL ~ ENGINE COMPARTMENT 6.9

Tigercat 480 MULCHER

Electrical and Computers 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.

6.10

Tigercat 480 MULCHER

Electrical and Computers 5

1 9

2

6

3

4

7

10

8

480-013a

8

MD3 COMPUTER, SYSTEM COMPONENTS AND CONNECTIONS

MD3 COMPUTER ELECTRONIC CONTROL & DISPLAY

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 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

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.

4. XA2 A2 Pump Area Expansion Module 5. Engine Electronic Control Module 6. Boom Control Valve Electronic Solenoids

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.

7. Cutter Control Valve Electronic Solenoids 8. Drive Motors Electronic Solenoids 9. Drive Pumps Electronic Solenoids 10. Cutter Pump Electronic Solenoids 11. 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.

6.11

Tigercat 480 MULCHER 1

Electrical and Computers 2

3

4

5

6

7

18

8

17 16

9

15

10 14

11

480-059

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

6.12

Tigercat 480 MULCHER

Electrical and Computers

MD3 DISPLAY AND MASTER MODULE 1

2

3

4

480-059 480-094

REAR OF MD3 MODULE The back of the MD3 Module consists of the following.

1. Tag with serial number and part number.

2. CAN bus connector C2 (VIN inputs, USB communication and alarm output).

R8.0 max

3. CAN bus connector C1 (voltage supply, CAN communication J1939 and expansion modules).

4. Membrane valve for condensation prevention inside unit.

MD3 MODULE WIRING PIN ASSIGNMENT MD3-REPLACEMENT

MD3 MODULE REPLACEMENT 1. Turn battery disconnect switch OFF.

6

DIN-A / VIN-A DIN-B / VIN-B DIN-C / VIN-C DIN-D / VIN-D -VREF USB-D-

USB-D+ +VREF DIN-E / VIN-E DIN-F / VIN-F DIN-G / VIN-G DOUT-A

5 8

1

12

7 8 9 10 11 12

1 2 3 4 12 11 10 9

4 9 1 2 3 12 11 10

1

1 2 3 4 5 6

C1

5 8

C2

7 6 7

7 6 7

6

2. Remove the 6 screws holding the instrument panel assembly in place and carefully remove the assembly.

1 2 3 4 5 6

-BAT CAN-A-L CAN-B-L CAN-C-L/Diag RS232 DATA IN Reserved

3. Remove 4 screws holding MD3 in place as shown in the illustration.

12

7 8 9 10 11 12

+RTC RS232 DATA OUT CAN-C-H/Diag CAN-B-H CAN-A-H +BAT

3. Lift the module out of the instrument panel carefully.

4. Disconnect the wiring harness at the module C1 and C2 connectors.

MD3-WIREASSIGN

NOTE: Refer to the MD3 MODULE SCHEMATIC and ELECTRICAL SCHEMATIC in THIS SECTION for detailed pin and wiring assignment.

5. Install module in reverse order as removed.

NOTE: Refer to IQANRUN 2 ~ APPLICATION UPDATE in THIS SECTION for procedure to update the application in an MD3 module.

6.13

When replacing a MD3 module the machine serial number information and machine hours will need to be reset. Refer to IQANRUN 2 ~ SYSTEM for more information regarding access and maintenance of logs using IQANrun 2.

Tigercat 480 MULCHER

Electrical and Computers

480-079

480-085

MD3 MODULE, XA2 MODULE AND HARNESS PIN ASSIGNMENT CHARTS 6.14

Tigercat 480 MULCHER

Electrical and Computers

CONNECTOR 'BJ' GREY PIN NO. WIRE NO.

CONNECTOR 'Bl' GREen

FUNCTION

PIN NO. WIRE NO.

FUNCTION

1

12

Startfuse-IMS Relay Power

1

58

Webasto Mod Ctrl from Timer

2

25

AC ON DIN

2

59

Webasto Mod Ctrl from Timer

3

26

Defroster ON DIN

3

62

Rear Work Light RH

4

28

AC ON DOUT

4

62A

Rear Work Light RH

5

29

AC ON Relay to Press SW

5

140

Sky Camera Trigger

6

32

XA2 Module #1 Power

6

141

Backup Camera Trigger

7

33

XA2 Module #2 Power

7

69

Track Light RH

8

40

Horn Power

8

69A

Track Light LH

9

41

Charge Filter Bypass Signal

9

71

Air Valve Limit SW Signal

10

42

Return Filter Bypass Signal

10

82

Service Lights SW to Relay

11

46

Low Hyd Oil Level DIN

11

-

12

47

Key SW Signal to ECM

12

-

CONNECTOR 'Bm' brown

CONNECTOR 'Bk' BLACK PIN NO. WIRE NO. 1

HA4

2

LA4

PIN NO. WIRE NO.

FUNCTION

FUNCTION

1

72

Eng ISC Increment

Iqan CAN A HIGH

2

73

Eng ISC Decrement

CAB to Iqan XA2#2

3

74

Eng ISC (Redundant)

Iqan CAN A LOW

4

74A

Engine Panel Ground

CAB to Iqan XA2#2

5

-

3

48

Unswitched Power - Amerex

6

-

4

51 Master Discon't Relay Power

7

54A

5

53

E-Stop to Air Shutoff Relay

8

-

6

54

Fuel Shutoff Valve Power

9

G31A

Cab Computer Grounds

7

55

Fuel Heater Relay Power

10

G31B

Cab Computer Grounds

8

56

Eng Stop Lamp Signal

11

-

to Resistor

12

217

9

70

Sensor Power

10

HB3

J1939 CAN B High

11

LB3

12

3B3

Starter Disconnect

Re-fueling System

CONNECTOR 'BS'

PIN NO. WIRE NO. 1 HA1 2 HA2 3 HA3 4 HA4

Cab to Y-Conn J1939 CAN B Low Cab to Y-Conn J1939 CAN B Shield

FUNCTION Iqan CAN A High - MD3 Iqan CAN A High - RH Joystick Iqan CAN A High - LH Joystick Iqan CAN A High - Cab Entry

CONNECTOR 'Bt'

Cab to Y-Conn

PIN NO. WIRE NO. 1 LA1 2 LA2 3 LA3 4 LA4 6.15

FUNCTION Iqan CAN A Low - MD3 Iqan CAN A Low - RH Joystick Iqan CAN A Low - LH Joystick Iqan CAN A Low - Cab Entry

Tigercat 480 MULCHER

Electrical and Computers

Xa2 MODULES

•

Three red primary flashes in a row and two yellow secondary flashes in a row indicates that the fault is related to the address.

•

Four red primary flashes in a row and one yellow secondary flash indicates a memory error.

•

Continuous red primary flashing indicates a fatal error.

B A

Internal diagnostics in the master (MD3) can be used to get more information about the XA2 module. The following values are supervised:

XA2 MODULE LED INDICATORS

•

Internal temperature (°C)

Xa2 MODULE LED INDICATORS

•

Power supply (V)

If there is an error detected, the master (MD3) will present a message on the display. The XA2 module also indicates error status through the red blinking LED.This gives an immediate diagnosis as to the nature of the error that has occurred.

•

Reference voltage (V)

•

CAN address voltage (V)

A. Supply Voltage LED (green).

LED with green light ON indicates supply voltage is ON. LED OFF indicates supply voltage is OFF. B. Status indicator LED (yellow/red).

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows: •

One red primary flash and one secondary yellow flash indicates an error controlled by the master (MD3).

•

Two red primary flashes in a row and one yellow secondary flash indicates an error controlled by the master (MD3).

•

Three red primary flashes in a row and one yellow secondary flash indicates that the fault is related to the CAN-bus.

6.16

Tigercat 480 MULCHER

Electrical and Computers

XA2 MODULE WIRING PIN ASSIGNMENT

42 28 14

1 2 3 4 5 6 7 8 9 10

ADDR-H COUT-A/DOUT-G COUT-B/DOUT-H COUT-C/DOUT-I COUT-D/DOUT-J COUT-E/DOUT-K COUT-F/DOUT-L DOUT-A DOUT-B VIN-A/DIN-A

15 16 17 18 19 20 21 22 23 24

11 12 13 14

VIN-B/DIN-B VIN-C/DIN-C VIN-D/DIN-D ADDR-L

25 26 27 28

29 15 1

-BAT CRET-A+/DIN-I CRET-B+/DIN-K CRET-C+/DIN-M CRET-D+/DIN-O CRET-E+/DIN-Q CRET-F+/DIN-S DOUT-C DOUT-D VIN-E/DIN-E/FIN-A DFIN-A+ VIN-F/DIN-F/DFIN-ACAN2-H CAN-H +BAT(+12V, +24V)

29 30 31 32 33 34 35 36 37 38 39 40 41 42

-VREF CRET-A-/DIN-J CRET-B-/DIN-L CRET-C-DIN-N CRET-D-/DIN-P CRET-E-/DIN-R CRET-F-/DIN-T DOUT-E DOUT-F VIN-G/DIN-G/FIN-B DFIN-B+ VIN-H/DIN-H/DFIN-BCAN2-L CAN-L +VREF

XA2-WIREASSIGN

Note that the XA2 module is equipped with eight voltage inputs (VIN-A to VIN-H) which may be configured as digital inputs (DIN), frequency inputs (FIN) or directional frequency inputs (DFIN). The XA2 module is also equipped with six double proportional ouputs (COUT-A to COUT-F) which may be configured as digital outputs (DOUT) and digital inputs (DIN). See wiring pin assignment diagram above for details.

The function of these inputs determined by the machine program.

NOTE: Refer to the MODULE SCHEMATIC and ELECTRICAL SCHEMATIC in THIS SECTION for detailed pin and wiring assignment.

6.17

Tigercat 480 MULCHER

Electrical and Computers

id-tag Addressing Each module has a specific address, enabling the master module to communicate with it through the CAN-bus. Practically, the system distinguishes between different modules through firstly verifying the module type and then, secondly, through the modules having a unique addresses.

MODULE

ID-TAG

RESISTANCE

MD3

NO TAG

-

XA2 -#1

1

590 Ω

XA2 -#2

2

976 Ω

42

29

28

15

14

1

ADDR-L, pos. 14

ADDR-H, pos. 1

Id-Tag

connecting id-tag

assembling id-tag Assembling of the Id-Tag The Id-Tag is placed in the connector in order to address/ terminate the module. The Id-Tag is mounted under the connector casing. Bend the IdTag’s cables towards the opposite side, where the other cables enter the connector.

6.18

Tigercat 480 MULCHER

Electrical and Computers 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

6.19

Tigercat 480 MULCHER

Electrical and Computers 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.

6.20

Tigercat 480 MULCHER

Electrical and Computers

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.

6.21

Tigercat 480 MULCHER

Electrical and Computers

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.

6.22

Tigercat 480 MULCHER

Electrical and Computers

DRIVE LIMITER ON/OFF

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.

480-105a

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

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.

6.23

Tigercat 480 MULCHER DRIVE SETTINGS - CONTINUED

Electrical and Computers COUNTER ROTATE SPEED

COUNTER ROTATE ON/OFF

480-108 480-106

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.

480-062

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.

6.24

Tigercat 480 MULCHER

Electrical and Computers

DRIVE SETTINGS - CONTINUED STEERING CONFIGURATION

STEERING CHOICE 1 Description (c Path)

‘C’ Path

480-105A

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.

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

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.

‘S’ Path

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.

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.

6.25

Tigercat 480 MULCHER DRIVE SETTINGS - CONTINUED DRIVE RESPONSE

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

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.

Electrical and Computers STEERING RESPONSE

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

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.

6.26

Tigercat 480 MULCHER

Electrical and Computers

MAIN VALVE SETTINGS

DEBRIS DOOR SPEED

480-196

480-197

Press the F3 button to select the Main Valve Settings Menu from the ADJUSTMENT MENU.

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

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

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.

6.27

Tigercat 480 MULCHER PUSH BAR SPEED

Electrical and Computers 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.

6.28

Tigercat 480 MULCHER

Electrical and Computers

GENERAL SETTINGS

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

•

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.

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.

480-135

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.

6.29

Tigercat 480 MULCHER

Electrical and Computers

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.

6.30

Tigercat 480 MULCHER

Electrical and Computers

GENERAL SETTINGS CONT'D

480-140 480-136

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.

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:

• •

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.

On Backup Camera Only

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.

6.31

Tigercat 480 MULCHER GENERAL SETTINGS CONT'D

Electrical and Computers 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.

480-138

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.

6.32

Tigercat 480 MULCHER

Electrical and Computers CUTTER FUNCTIONS

INFORMATION MENU

480-086 480-043

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

Press the F3 button to access the information menu.

• • • •

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.

6.33

Tigercat 480 MULCHER

Electrical and Computers

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.

6.34

Tigercat 480 MULCHER

Electrical and Computers

MAIN MENU PAGE

PREFERENCES MENU

480-090

480-043

Press the menu button page.

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

to go to the main menu

480-090

234-056

The following menu items can be selected.

The main menu page displays the following selections:

•

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.

6.35

Tigercat 480 MULCHER DISPLAY ADJUSTMENT

Electrical and Computers 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 butto 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.

6.36

to

Tigercat 480 MULCHER

Electrical and Computers

DATE/TIME ADJUSTMENT

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:

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.

DATE - select F1 TIME - select F2

6.37

Tigercat 480 MULCHER DATE ADJUSTMENT CONT’D

Electrical and Computers 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.

6.38

to return to the

Tigercat 480 MULCHER

Electrical and Computers

INFO MENU PAGE

MODULES

480-094

480-090

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

From the main menu page press the F4 button

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.

6.39

Tigercat 480 MULCHER

Electrical and Computers

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.

6.40

Tigercat 480 MULCHER

Electrical and Computers

CRITICAL MESSAGES and warnings (red) 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

Hydraulic Oil - Temperature High Return Oil Filters - Bypassed

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

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

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

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

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.

6.41

Tigercat 480 MULCHER

Electrical and Computers

CRITICAL messages and warnings 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.

6.42

Tigercat 480 MULCHER

Electrical and Computers

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.

6.43

Tigercat 480 MULCHER Engine stop

Electrical and Computers 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.

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Electrical and Computers

Hardware Fault - XA2

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.

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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.

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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.

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ERROR MESSAGES (red) 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.

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ERROR messages 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. 6.49

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Electrical and Computers 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.

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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.

The module and pin number are identified on the display screen.

DIGITAL INPUT ERROR (DIN)

The heading identifies the signal destination and the text indicates the type of error.

Digital input error messages will be displayed to indicate a problem with a digital input signal to a computer system module.

The display is similar to the voltage input error message shown above.

The module and pin number are identified on the display screen.

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.

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.

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.

6.51

Tigercat 480 MULCHER ALERT MESSAGES (YELLOW)

Electrical and Computers 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.

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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.

6.53

Tigercat 480 MULCHER DRIVE CHARGE FILTER BYPASS - ALERT

Electrical and Computers 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.

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Hardware Fault - MD3

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.

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Electrical and Computers B A

XA2 MODULE LED INDICATORS 2. Check module status indicators The XA2 module also indicates error status through the yellow/red blinking LED.This gives an immediate diagnosis as to the nature of the error that has occurred.

Xa2-A0 MODULE no contact ERROR Expect all machine functions controlled by this module to cease and all alarms and warnings associated with this module to be triggered.

(A) Supply Voltage LED (green).

LED with green light ON indicates supply voltage is ON.

1. Check for other error/alarm messages on screen

LED OFF indicates supply voltage is OFF. (B) Status indicator LED (yellow/red).

Press OK to acknowledge each error message. Note that module offline errors will be followed by other alarm messages associated with the module(s) which is(are) out of contact.

LED yellow flashing light indicates status is correct.

LED flashing red light indicates error status as follows:

Note also that the XA2-A0 module is the terminal module in the series connection.

Therefore failure of this module alone will not affect any other modules in the series.

• •

If XA2-A0 MODULE NO CONTACT is the only module is NO CONTACT error message the likely causes are: • Power - Fuse (XA2 MODULE)

•

Three red primary flashes in a row and one yellow secondary flash indicates that the fault is related to the CAN-bus.

•

Three red primary flashes in a row and two yellow secondary flashes in a row indicates that the fault is related to the address.

• Ground • Address (ID-Tag) • CAN wire connection If the XA2-A0 MODULE IS OFFLINE error is not the only module is offline error message check other affected modules in order from the MD3 connection (XS2-A0).

One red primary flash and one secondary yellow flash indicates an error controlled by the master (MD3).

Two red primary flashes in a row and one yellow secondary flash indicates an error controlled by the master (MD3).

LED indicator showing different XS2 and XA2 modes Status

Flash

Normal operation (yel.)

Refer to MODULE NO CONTACT ERROR for each module for more detailed information.

Error code

Error

1:n

See note a

2:n

See note a

3:1

CAN error

3:2

Address error

4:1

Memory errorb

FE

Fatal error

Primary Flash (red) Error category

Secondary Flash (yellow) Error description

a. Error groups 1:n and 2:n are controlled by the master. b. FRAM memory error.

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Electrical and Computers

Four red primary flashes in a row and one yellow secondary flash indicates a memory error.

•

Continuous red primary flashing indicates a fatal error.

Internal diagnostics in the master (MD3) can be used to get more information about the XS2 module. The following values are supervised: • • • •

Internal temperature (°C) Power supply (V) Reference voltage (V) CAN address voltage (V)

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Electrical and Computers

Channels

Digital out (dout)

The definition ‘channels’ is a collective name for the inputs and outputs found on the different IQAN modules. There are also channels internally in the system, to handle for example, MD3 messages and mathematical calculations. The channels are used to collect and/or send data. Input and output channels are described below.

A PWMOUT with 100% duty cycle is a Digital Out (DOUT). The outputs have a value of low or high.

These are mostly used to activate lamps, on/off valves or to pull relays.

INPUTS Voltage in (vin) The input signal at these inputs comes primarily from analog sensors, levers, and switches. These devices use a power/signal/ground system to provide an input value (VIN) between the high (+5V) and low (-5V) signals generated in the modules.

TROUBLESHOOTING diagnostic breakout harnesses Diagnostic breakout harnesses are available for use to verify computer readings independently.

Refer to ELECTRICAL KIT - SERVICE AND DIAGNOSTICS in this section for more information about diagnostic breakout harnesses.

Digital in (din) An input that is typically on or off, such as a switch. This input is often used to determine if an event has occurred, such as pushing a button or engaging a relay.

Frequency in (fin) Typical functions are speed measure or revolution measure. This input can count the number of signals per second to determine the speed of a rotating or reciprocating body.

OUTPUTS PWM out (pwmout) PWM (Pulse Width Modulation) Out is a way of producing an analog signal level with a digital output that turns on and off many times a second.

By varying the ratio between on and off time (duty cycle) an output proportional to the system voltage can be obtained. PWMOUT maintains a constant output voltage, and the output current is governed by output voltage and the resistance in the circuit.

Current out (cout) In this application outputs labeled COUT are actually PWM signals programmed to operate in closed loop mode. The close loop mode features a PWM signal with current regulation. The programmed COUT channel maintains a constant output current to control proportional solenoids.

The voltage is regulated to maintain the constant current based on the programmed input command independant of the resistance of the circuit.

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EXAMPLE ~ MEASURE MENU:

measure group. Module and pin information for the highlighted channel is shown on screen.

The grey arrow(s) to the right at the top and/ or bottom of the screen indicate that more channels can be viewed above or below those currently on screen.

From the main menu page press the F2 button (Measure) to access the measure menu.

Press F2 to toggle between scaled value and raw value readings. Scaled values show the measured value in a scaled unit of measure (°C, %, psi etc). Raw value (where applicable) shows same readings as the raw value (mV, Hz etc) in which they are measured.

Note that for some channel types the raw value selection is not applicable and the reading will be displayed as “-” when viewing raw values.

Press F2 to return to the scaled values to view readings for these channels.

Press F1 (Main) to return to the main menu page.

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

Press the back button return to the main menu.

OR Press the back button to return to the measure menu.

Press again to return to the main menu page.

Press again to return to the main menu.

Use the Arrow Up or Arrow Down move through the list of measured values in a

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Electrical and Computers 7. ID-TAG ‘1’ (an069)

ELECTRICAL KIT - SERVICE AND DIAGNOSTICS

This is a replacement address tag. Refer to ID-TAG in THIS SECTION for more detailed information.

This kit includes a variety of electrical connectors, tools, cable, IQAN components, diagnostic breakout harnesses and service harnesses (Tigercat part number 20045B).

8. ID-TAG ‘2’ (an070) This is a replacement address tag. Refer to ID-TAG in THIS SECTION for more detailed information.

Selected Items 1. DIAGNOSTIC BREAKOUT HARNESS DEUTSCH connector - CURRENT (20036B)

9. DEUTSCH 2 POLE SERVICE HARNESS (24860b)

This harness is used to check current (amps) flow to a component with a Deutsch connector and verify outputs.

This harness is used to bypass a wiring harness while troubleshooting electrical problems. This will identify or eliminate the wiring harness as a cause.

2. DIAGNOSTIC BREAKOUT HARNESS DEUTSCH connector - voltage (20037b)

10. AMP 2 POLE SERVICE HARNESS (24859b) This harness is used to bypass a wiring harness while troubleshooting electrical problems. This will identify or eliminate the wiring harness as a cause.

This harness is used to check voltage (volts) to a component with a Deutsch connector and verify inputs.

3. DIAGNOSTIC BREAKOUT HARNESS amp connector - CURRENT (20038b) This harness is used to check current (amps) flow to a component with a Amp connector and verify outputs.

4. DIAGNOSTIC BREAKOUT HARNESS amp connector - voltage (20039b) This harness is used to check voltage (volts) to a component with an Amp connector and verify inputs.

5. USB CABLE (TYPE A-B) (AN155) This cable is used to connect the IQAN MD3 (via the machine USB port) to an isolated USB hub plugged into a PC/Laptop.

IMPORTANT !

Connecting the USB cable directly to the USB port on a PC/Laptop is NOT recommended.

Using an isolated USB hub will protect your PC/Laptop USB port and the MD3 module from ground loops which can cause communication signal problems or damage to the PC/Laptop and MD3 module.

6. USB HUB (4 PORT, TYPE A, isolated (AN154)

)

This isolated USB hub is used to protect your PC/Laptop and the MD3 module from ground loops. can cause communication signal problems or damage to the PC/Laptop or module.

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Electrical and Computers

1

2

9

3

4

10

5

TWISTED PAIR WIRE REPAIR HARNESS

6

7

855c-002

8

ELECTRICAL KIT - SERVICE AND DIAGNOSTICS - SELECTED ITEMS 6.61

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Electrical and Computers

iqan software IQAN Active Studio software can be downloaded from the Tigercat Dealer Website.

All software required for PC/Laptop use is included in this download. A user’s manual in PDF format is also included. Some of the software requires a software key (available from Tigercat).

Contact Tigercat Customer Service for more information about specific hardware requirements for PC/Laptop.

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application PROGRAM UPDATES for product service bulletins Machine program updates are also available on the Tigercat dealer website. These program updates are generally associated with specific Product Service Bulletins. Updating of programs should only be undertaken as part of a PSB or under instruction from Tigercat Customer Service.

The latest version of the application can be run on any machine provided that all applicable Product Service Bulletin updates have been completed.

DOWNLOADING APPLICATIONS FROM THE TIGERCAT DEALER WEBSITE NOTE: The following downloading instructions apply to the Tigercat dealer website format at the time of printing. If you experience difficulty due to changes on the website contact Tigercat Customer Service for assistance.

3. Select the folder you wish to save the program in.

4. Click on Save.

5. The IQAN program file has now been downloaded.

1. Click on the IDA to the right of the file you wish to download.

2. Click on Save.

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SERVICING THE MD3 WITH IQANrun 2

IQANrun 2 QUICK SUMMARY

REQUIRED EQUIPMENT & INFORMATION

CONNECT TO THE MD3 WITH IQANrun2

1. PC/Laptop

Servicing the computer system requires a PC/ Laptop, the use of IQANrun2 software, a USB hub and a USB cable. Refer to CONNECT TO THE MD3 WITH IQANrun 2 in THIS SECTION for details.

2. IQAN MD3 SERVICE KIT (40705B) a. IQAN Active Studio software,Tigercat part number DG047. Refer to IQAN SOFTWARE in THIS SECTION for dealer website download information. b. USB hub (4 port, Type A, isolated Tigercat part number AN155

),

c. USB cable (Type A-B), Tigercat part number AN154 3. Service Password. Contact Tigercat Service department to obtain passwords and additional information.

LOGIN Some service operations require username and password access. Refer to LOGIN in THIS SECTION for details.

UPDATE Most commonly used operation. Use to update the MD3 to a newer program or program revision.

Does not overwrite settings. Refer to UPDATE APPLICATION in THIS SECTION for details.

GET SETTINGS Gets and saves the existing settings from the MD3. Recommended as a backup prior to tuning or updating the applicaton. Refer to IQANRUN 2 ~ UPDATE APPLICATION ~ GET SETTINGS in THIS SECTION for details.

SEND SETTINGS Sends a previously saved settings file to the MD3.

Overwrites factory default, adjustable and stored values. Only to be used under the direction of Tigercat Customer Service or Engineering. Refer also to important notes on the use of settings files at the end of IQANRUN 2 ~ UPDATE APPLICATION ~ GET SETTINGS in THIS SECTION. GET CLONE Gets and saves the existing application, settings and machine ID from the MD3. Recommended as a backup prior to tuning or updating the application.

Refer to IQANRUN 2 ~ UPDATE APPLICATION ~ GET CLONE in THIS SECTION for details.

SEND CLONE Sends a previously saved clone file to the MD3.

Overwites the application, factory defaults, adjustable values, stored values and machine ID. Only to be used under the direction of Tigercat Customer Service or Engineering. Refer also to important notes on the use of settings files at the end of IQAN RUN 2 ~UPDATE APPLICATION ~ GET CLONE in THIS SECTION.

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ADJUST Allows access to adjustment groups. In addition to adjust groups normally accessible on screen additional adjust groups that require sufficient rights restricted by username and password login. Refer to IQANRUN 2 ~ ADJUST in THIS SECTION for details.

MEASURE (GRAPH) Allows the user record, graph and measure group channel readings during machine operation, testing or setup procedures. These recordings can be saved or printed. Refer to IQANRUN 2 ~ MEASURE (GRAPH) in THIS SECTION for details.

LOGS Allows the user to access to logs for service troublshooting, maintenance documentation or clearing. Some log operations require sufficient rights to perform. Refer to IQANRUN 2 ~ LOGS in THIS SECTION for details.

SYSTEM Allows the user to access system information including machine serial number information.

Refer to IQANRUN 2 ~ SYSTEM in THIS SECTION for details.

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CONNECT TO THE MD3 WITH IQANrun 2

grey indicates, not connected to md3

PC/Laptop USB port and the MD3 module from ground loops which can cause communication signal problems or damage to the PC/Laptop and MD3 module.

4. Connect the other end of the USB A/B Cable to the MD3 USB connector. Exact location of the connector will vary between machine models.

1. Turn on PC/Laptop and launch IQANrun by double clicking the shortcut on your desktop.

IQANrun is part of the IQAN Active Studio.

2. Turn the machine key switch to the ‘ON’ position, so the MD3 has power. Do not start machine.

green indicates, connected to md3

5. IQANrun will now indicate that it is online.

Proceed with service operations and login if required. Refer to LOGIN in THIS SECTION. NOTE: If the MD3 does not contain an application (replacement module), the application will have to be Updated, before a user can login. Refer to UPDATE APPLICATION and LOGIN in THIS SECTION.

3. Connect the USB Hub into the PC/Laptop USB jack. Then connect the USB cable into the hub.

IMPORTANT !

Connecting the USB cable directly to the USB port on a PC/Laptop is NOT recommended.

Using an isolated USB hub will protect your 6.66

Tigercat 480 MULCHER

Electrical and Computers

LOGIN 1. Press the Login button on the left.

login

LOGGED IN username

4. The Login status at the bottom of the screen now indicates the login username.

NOT LOGGED IN

1. A dialog box will appear, asking for a Username and Password. Contact the Tigercat Service Department for the Username and Password.

5. Note that each username and password combination comes with access rights appropriate for that user’s function.

If a user has insufficient rights to perform an operation (or is not logged in when login is required) a dialog box will pop up to inform the user that this operation is not possible without the correct login and password.

2. A dialog box will appear to confirm a successful login. Click OK to continue.

NOTE - SERVICE PASSWORDS: Contact Tigercat Service department to obtain passwords and additional information.

Note: After a successfully login, Windows provides the option to save the password. If Yes is selected, only the Username will be required at the next login.

6.67

Tigercat 480 MULCHER UPDATE APPLICATION

Electrical and Computers A. GET CLONE FILE

Updating of machine programs should only be undertaken as part of a PSB or under instruction from Tigercat Customer Service.

Before updating an application, it is recommended that a Clone file and Settings file are taken from the MD3 and saved.

A. Get Clone file and save (*.irc).

A Clone file contains the application, machine ID, the settings and logs from the MD3. It is a good record of exactly what was in the machine before the update.

get clone

B. Get Settings file and save (*.isa).

A Settings file contains only the settings (factory defaults and adjustable values) from the MD3.

C. Update application.

1. Click on the Get Clone button on the left.

A dialog box will appear prompting the user to select whether or not to get the logs with the clone.

Application programs (*.ida) are available on the Tigercat dealer website. Refer to DOWNLOADING APPLICATIONS FROM THE TIGERCAT DEALER WEBSITE in THIS SECTION.

Click on Yes to continue.

2. IQANrun will now get a clone. This might take several minutes.

6.68

Tigercat 480 MULCHER

Electrical and Computers b. GET settings FILE

get settings

3. A dialog box will appear prompting selection of a suitable folder and file name to save the Clone file (.irc).

4. Click on the Get Settings button on the left.

5. A dialog box will appear prompting selection of a suitable folder and file name to save the Settings file (.irs).

The file name by default is the machine ID (serial number). It is recommended to use the serial number followed by the date for the file name.

The file name by default is the machine ID. It is recommended to use the serial number followed by the date for the file name.

Press Save to continue.

IMPORTANT !

A Clone file should rarely be used. It should only be used if updating the application and/ or settings file is not successful in returning a machine’s performance to a previously acceptable state. A Clone file may be date sensitive and should only be used on the day that they were taken.

Press Save to continue.

IMPORTANT !

A Settings file should rarely be used. It should only be used if manually adjusting machine settings is not successful in returning a machine’s performance to a previously acceptable state. Settings files may be date sensitive and should only be used on the day that they were taken.

A Clone should NOT be used on a machine different than that which it was taken from, as machine specific configurations may differ and cause the machine to function improperly.

If a Settings file is used on a machine different than that which it was taken from, all adjustments must be reviewed in IQANrun to ensure machine specific parameters (such as options, pump/motor currents, hour counters) are correct. If this is not done the machine may function improperly.

6.69

Tigercat 480 MULCHER

Electrical and Computers

c. update APPLICATION TO MD3 Ensure that a Clone file and Settings file are saved as a backup prior to Update. Refer to GET CLONE FILE and GET SETTINGS FILE in THIS SECTION.

update

10. IQANrun 2 will provide warning to ensure the machine is not moving and that the engine is shut down (keyswitch in the run position to power the MD3, engine not running).

Press OK to continue, if the machine is inactive.

6. Click on the Update button on the left.

7. A dialog box will appear, prompting the selection of an MD3 application file (.ida).

Select the appropriate application file for the machine.

8. Click on Open to continue.

11. IQANrun will now send the application to the MD3.

9. IQANrun 2 will request confirmation that the application being loaded is correct.

Click on Yes to continue, if the application is correct.

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Electrical and Computers

12. Once the application is loaded successfully, the dialog box will indicate the application was successfully sent.

The MD3 will restart and show the main screen of the application.

The Update is now complete.

6.71

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Electrical and Computers

ADJUST 1. Click on the Adjust button on the left.

ADJUST

LOCK SYMBOL INDICATES PIN REQUIRED

EXAMPLE ADJUST SCREEN WITHOUT LOGIN ACCESS

2. The adjust groups available will be shown on the right.

3. Double click an adjust group to adjust channels in that group.

Note that a lock symbol to the left of an adjust group indicates that a PIN/password is required to access that group. Contact Tigercat Service department to obtain password information.

EXAMPLE ADJUST SCREEN WITHOUT LOGIN ACCESS

Note also that some adjust groups are accessible through the MD3 menus unrestricted during normal operation.

Other service related or owner/supervisor use related adjust groups are restricted by passwords on screen or available only through IQANrun 2 with username and password restrictions.

Some adjust groups are only visible on screen for users with the appropriate username and password login rights.

6.72

Tigercat 480 MULCHER

Electrical and Computers

MEASURE/ GRAPH 1. Click on the Measure button on the left.

STOP

start

MEASURE

pause

STOP

EXPAND MEASURE GROUP

USER DEFINED MEASURE GROUPS comment comment

+add

comment

9. User defined measure groups can be customized with the available channels in the existing groups.

-delete

2. All of the predefined measure groups available will be shown on the right.

It is not possible to add and delete measure groups or items while you are measuring.

Click on the red square to stop measuring and enable the +Add and -Delete buttons.

Each group can be expanded to view the channels in the groups.

3. To graph the channels in a measure group, double click the measure group and the graph will appear. (A single channel can also be chosen for graphing by double clicking on that channel.)

Click the +Add button on screen to add a New measure group. Click on the New measure group, then right click to rename the new measure group appropriately.

Available channels can then be dragged and dropped into the New measure group.

4. Click on the red square to stop measuring.

Click on the green arrow to start measuring.

Click on pause to pause the graph illustration while continuing to measure.

5. Click on Comment to add comments to the measure file at any time. The measure file data must be saved (*.irm) retain comments for later viewing.

6. Click on the red square to stop measuring and access the zoom function. Select an area of the graph to zoom in an view in more detail.

Click on Zoom Out to return to the full graph view.

7. Click on the red square to stop measuring and access save function. Click on Save to save the measure data as a *.irm file.

8. Click on the red square to stop measuring and access print function. Click on print to print the graph and data recorded.

6.73

To delete User defined measure groups or items in a group click on the group or item you wish to remove then click the -Delete button.

Note that User defined measure groups are automatically saved on your PC. These groups are application program specific and will be available the next time the same application is in use on any machine using the same application program.

Tigercat 480 MULCHER

Electrical and Computers

LOGS 1. Click on the Logs button on the left.

logs

2. Logs available to view and/or clear will be shown on the right.

NOTE: User name and password access level rights determine whether the logs can be viewed and/or cleared. Some log items are restricted to higher level users only.

3. Double click on the log you wish to view or click on a log and click on Select to view the records in the log. Click on Done to return to the logs screen.

3. Click on Add Record to add a comment to the system log. For example to record a filter change or other service event in the log.

Entries are restricted to 250 characters.

4. Click on Clear log to clear log entries for the selected log. Note that this function is rights restricted.

5. Click on Get Log to get the log information and save as a *.irf file.

6. Click on Print to print the log being viewed.

7. Click on Save to save the log file as *.irl file.

6.74

Tigercat 480 MULCHER

Electrical and Computers

SYSTEM 1. Click on the System button on the left.

SYSTEM

2. System info is on the right including the application program name and the Machine ID (Serial Number).

3. The Machine ID (Serial Number) is factory set. However, in the event that the MD3 is replaced, this information would need to be configured for the new module.

Updating Machine ID information requires a Login with sufficient rights.

Click on the Machine Id button. Enter the correct Serial Number. Click Set. If the update is successful a dialog box will pop up. Click OK to acknowlege the update.

A restart of the module will be requested.

Follow the on screen instructions to restart the module before continuing. If further service work is being performed you will need to login to IQANrun2 again.

6.75

Tigercat 480 MULCHER

Electrical and Computers

ELECTRICAL SCHEMATIC - 4800101 to 4800120

480-124

6.76

Tigercat 480 MULCHER

Electrical and Computers

ELECTRICAL SCHEMATIC - 4800101 to 4800120

480-125

6.77

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Electrical and Computers

ELECTRICAL SCHEMATIC - 4800101 to 4800120

480-126

6.78

Tigercat 480 MULCHER

Electrical and Computers

ELECTRICAL SCHEMATIC - 4800101 to 4800120

480-127

6.79

Tigercat 480 MULCHER

Electrical and Computers

ELECTRICAL SCHEMATIC - 4800101 to 4800120

480-128

6.80

Tigercat 480 MULCHER

Electrical and Computers

ELECTRICAL SCHEMATIC - 4800101 to 4800120

480-129

6.81

Tigercat 480 MULCHER

Electrical and Computers

ELECTRICAL SCHEMATIC - 4800101 to 4800120

480-130

6.82

Tigercat 480 MULCHER

Electrical and Computers

ELECTRICAL SCHEMATIC - 4800121 AND UP

480-107

6.83

Tigercat 480 MULCHER

Electrical and Computers

ELECTRICAL SCHEMATIC - 4800121 AND UP

480-108

6.84

Tigercat 480 MULCHER

Electrical and Computers

ELECTRICAL SCHEMATIC - 4800121 AND UP

480-109

6.85

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Electrical and Computers

ELECTRICAL SCHEMATIC - 4800121 AND UP

480-110

6.86

Tigercat 480 MULCHER

Electrical and Computers

ELECTRICAL SCHEMATIC - 4800121 AND UP

480-111

6.87

Tigercat 480 MULCHER

Electrical and Computers

ELECTRICAL SCHEMATIC - 4800121 AND UP

480-112

6.88

Tigercat 480 MULCHER

Electrical and Computers

ELECTRICAL SCHEMATIC - 4800121 AND UP

480-113

6.89

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Electrical and Computers

6.90

Tigercat 480 MULCHER SECTION 7 - ENGINE CONTENTS - SECTION 7 C

CHARGE AIR COOLER................................................................................................. 7.11 COOLING SYSTEM CHARGE AIR COOLER............................................................................................. 7.11 COOLANT FLOW DURING OPERATION.................................................................. 7.10 FILLING THE SYSTEM WITH COOLANT.................................................................. 7.10 E

ENGINE STARTING.................................................................................................................... 7.2 S

START CIRCUIT DIAGRAM AT REST....................................................................................................................... 7.4 AT REST - BATTERY DISCONNECT SWITCH ON..................................................... 7.5 RUN, INTERLOCK ACTIVATED (INTERLOCK RESET SWITCH RELEASED)........... 7.9 RUN, INTERLOCK DEACTIVATED.............................................................................. 7.7 RUN, INTERLOCK RESET SWITCH REACTIVATED.................................................. 7.8 START.......................................................................................................................... 7.6 starting engine......................................................................................................... 7.2 Starting system DESCRIPTION.............................................................................. 7.2

MARCH, 2010

Tigercat 480 Mulcher CAUTION Do not start engine by shorting across starter terminals. Start engine only from operator's seat.

STARTING CIRCUIT

Engine 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.

•

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.

For detailed engine information, refer to the engine manufacturer's manual.

Refer also to starting engine and stopping ENGINE in section 2 of the OPERATOR’S MANUAL. starting engine: 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.

480-045A

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).

7.2

Tigercat 480 Mulcher

Engine

CIRCUIT DESCRIPTION When the key is turned to the START position, voltage is supplied to the start circuit to wire 11 through a 10 amp fuse to wires 12 and 12A to the start relays which close when the start relays are closed, voltage is supplied by the battery disconnect relay to the L.H. starter relay and from the R.H. starter disconnect relay to the R.H. starter relay to turn the engine. For schematic diagrams, showing various stages of the start circuit, refer to START CIRCUIT DIAGRAMS in THIS SECTION.

480-114

7.3

Tigercat 480 Mulcher

Engine start circuit diagram

START CIRCUIT - AT REST

480-095

7.4

Tigercat 480 Mulcher

Engine start circuit diagram

START CIRCUIT - AT REST - BATTERY DISCONNECT & eMERGENCY sTOP SWITCH ON

480-096

7.5

Tigercat 480 Mulcher

Engine start circuit diagram

START CIRCUIT - START

480-097

7.6

Tigercat 480 Mulcher

Engine start circuit diagram

START CIRCUIT - RUN, INTERLOCK DEACTIVATED

480-098

7.7

Tigercat 480 Mulcher

Engine start circuit diagram

START CIRCUIT - RUN, INTERLOCK RESET SWITCH REACTIVATED

480-099

7.8

Tigercat 480 Mulcher

Engine start circuit diagram

START CIRCUIT - RUN, INTERLOCK ACTIVATED (INTERLOCK RESET SWITCH RELEASED)

480-100

7.9

Tigercat 480 Mulcher ENGINE COOLING SYSTEM

Engine Additional coolant stored in the surge tank flows slowly down the shunt hose to the water pump inlet replacing the air removed from the cooling system.

COOLANT FLOW DURING OPERATION The water pump circulates coolant through the radiator, engine oil cooler, engine block and cylinder head. If the thermostat is closed, coolant is returned to the water pump through a bypass inside the engine.

FILLING THE SYSTEM WITH COOLANT The coolant is added through the filler neck in the surge tank. This coolant fills the bottom radiator hose at the water pump through the shunt hose and then fills the radiator from the bottom upwards. Air is displaced through the vent tube to the surge tank. As the radiator is filled, coolant flows through the water pump and engine oil cooler to fill the engine. Coolant will flow out the top radiator hose through the thermostat bypass and into the engine once the radiator has filled.

The engine vent discharges air directly from the engine to the surge tank.

The thermostat begins to open when the coolant reaches operating temperature allowing all or a portion of the coolant to flow through the radiator core and back to the water pump.

A surge tank is located above the engine. Vent tubes are connected between the surge tank, the top of the radiator and the thermostat housing.

The anti-freeze/water solution used in the cooling system always contains small amounts of gas produced by combustion leakage. This gas must be vented to the outside to prevent cavitation of the engine water pump and to promote efficient heat transfer between the engine block and the coolant. These gases separate from the coolant and are carried up through the vent tubes where they collect in the surge tank and eventually discharge through the pressure cap.

When the engine has been run up to operating temperature and the thermostat has opened, any remaining air is purged through the vent tube and the engine vent. The system will then require more coolant to fully top off both the engine and the radiator.

overflow TUBE

FLOW OF COOLANT WITH ENGINE RUNNING AT OPERATING TEMPERATURE AND THERMOSTAT OPEN

RAD CAP

SURGE TANK

CHARGE AIR COOLER

SHUNT HOSE

VENT TUBE shut-off valve

VENT TUBE

THERMOSTAT HOUSING

heater HOSES

RADIATOR HOSES

COOLANT CORROSION RESISTOR water pump

480-104

7.10

RADIATOR

OIL COOLER

Tigercat 480 Mulcher CHARGE AIR COOLER (CAC) The charge air cooler is an air to air heat exchanger which cools turbocharged engine intake air. This cooling makes the intake air more dense for improved combustion, reduced emissions and increased efficiency of the engine.

Other advantages of a charge air cooler include increased fuel economy and reduced wear of engine components due to lower intake manifold temperatures. The charge air cooler is located above the radiator section of the heat exchanger.

Refer also to ENGINE MANUFACTURER'S MANUAL. AIR FLOW DURING OPERATION Intake air from the engine air cleaner enters the turbocharger where the air is pressurized. The pressurized air flows from the turbocharger to the charge air cooler where it is cooled by ambient air flow. The cooler pressurized air flows from the charge air cooler to the intake manifold of the engine.

Engine MAINTAINING THE CHARGE AIR COOLER Inspect charge air cooler for dirt and debris blocking fins. Inspect the charge air piping and hoses for leaks holes, cracks or loose connections. Tighten hose clamps as required.

Refer to SCHEDULED MAINTENANCE in SECTION 3 of THIS MANUAL and CLEANING THE A/C CONDENSER AND COOLING ASSEMBLY in SECTION 2 of the OPERATOR'S MANUAL. NOTE: If the engine experiences a turbocharger failure or other event where oil or debris enters the charge air cooler the charge air cooler must be cleaned. If debris cannot be removed the charge air cooler must be replaced. Refer to ENGINE MANUFACTURER'S MAINTENANCE MANUAL. Refer also to COOLING SYSTEM AND ENGINE FAN in SECTION 10 of THIS MANUAL.

AIR FLOW WITH ENGINE RUNNING AT OPERATING TEMPERATURE

CHARGE AIR COOLER

DENSE COOL AIR FROM CHARGE AIR COOLER FLOWING TO INTAKE MANIFOLD

LESS DENSE HOT AIR FROM TURBOCHARGER ENTERING CHARGE AIR COOLER RADIATOR

A/C CONDENSOR

TO INTAKE MANIFOLD

OIL COOLER AIR FROM TURBOCHARGER

480-105A

7.11

Tigercat 480 Mulcher

Engine

7.12

Tigercat 480 Mulcher SECTION 10 - OIL COOLER/RADIATOR AND FAN

MARCH, 2010

CONTENTS - SECTION 10 C

CHARGE AIR COOLER................................................................................................. 10.2 CLEANING.............................................................................See OPERATOR’S MANUAL F

FAN CIRCUIT DIAGRAM.................................................................................................... 10.5 CONTROL OPERATION............................................................................................. 10.4 SAFETY...................................................................................................................... 10.6 FAN MAINTENANCE..................................................................................................... 10.6 O

OIL COOLER CIRCUIT DESCRIPTION............................................................................................ 10.3 CIRCUIT DIAGRAM.................................................................................................... 10.3 OPERATION............................................................................................................... 10.2

Tigercat 480 Mulcher

Oil Cooler, Radiator and Fan

CHARGE AIR COOLER/RADIATOR/A/C CONDENSER/OIL COOLER

CHARGE AIR COOLER

480-39a

RADIATOR

COOLER compartment access door AND LATCH

A/C condenser

The rear door provides access to the Debris Screen (located inside the rear door) 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.

OIL COOLER 480-118

HEAT EXCHANGER/COOLER PACKAGE The charge air cooler, engine radiator, A/C condenser core and hydraulic oil cooler are mounted on top of each other in front of the engine.

The engine fan draws air from the rear of the machine, through the cooler compartment access door and the debris screen.

latch pin lock pin

480-199

debris screen

This air passes through the charge air cooler/oil cooler/radiator/A/C condenser core assembly and is blown across the engine exiting out through the side doors. This cooling assembly must be checked and cleaned daily for accumulation of debris.

For detailed cleaning procedures, refer to CLEANING COOLER PACKAGE in SECTION 2 of the OPERATOR’S MANUAL.

Open the rear door, lift up on the latch pin ring and pull the latch pin up. Turn the lock pin away from the debris screen and lift it out. Swing open the debris screen to inspect both sides of the screen and the rear door.

10.2

Tigercat 480 Mulcher

Oil Cooler, Radiator and Fan

OIL COOLER CIRCUIT DESCRIPTION The oil cooler is situated down stream from the boom float valve, cutter control valve and the attachment. Hydraulic oil returning from the boom float valve, attachment and the cutter control valve passes through the oil cooler and returns to tank via the hydraulic oil filters.

An oil cooler bypass valve is located between the inlet hose and the outlet hose of the cooler. The bypass circuit aids in warming cold hydraulic fluid up to operating temperature. It also protects the cooler from pressure spikes and provides a bypass if the internal core of the cooler is clogged.

Cooling of the oil occurs as air is drawn over the oil The bypass valve is a check valve set at 2.75 Bar/40 cooler cooling fins. Cooled oil then passes through psi and allows a portion of oil to return directly to tank (bypassing the oil cooler) when open. the return filters and into the hydraulic tank. pressure supply

l.H. ATTACHMENT MOTOR

R.H. ATTACHMENT MOTOR RETURN oil

RETURN oil

RETURN FILTERS

CUTTER VALVE

OIL COOLER RETURN OIL

BOOM FLOAT VALVE

OIL COOLER

OIL COOLER OUTLET

OIL COOLER INLET

480-132A

OIL COOLER BYPASS VALVE

CUTTER VALVE, BOOM FLOAT AND R.H. ATTACHMENT MOTOR RETURN OIL TO COOLER INLET

OIL COOLER CIRCUIT

OIL COOLER FLOW The volume of return oil flow to the oil cooler varies • depending on what functions are activated and operating. Examples are as follows: •

Attachment OFF - Minimum oil flow from the cutter control valve and attachment pump.

•

Attachment ON - Oil flows from the R.H. attachment motor, cutter control valve and attachment pump.

Attachment ON & Boom Float ON - Oil flows from the boom float valve, R.H. attachment motor, cutter control valve and attachment pump.

NOTE: Minimum return oil flow to the oil cooler ocurrs with the Attachment OFF. Maximum return oil flow occurs with the Attchment ON and Boom Float ON.

10.3

Tigercat 480 Mulcher

Oil Cooler, Radiator and Fan

FAN CONTROL OPERATION FAN DECREASE PITCH

BLOCKING VALVE fH

ff

BLOCKING VALVE

FAN INCREASE PITCH

fG PILOT SUPPLY

f1

PULL (SUCKER) 480-121

FAN DECREASE PITCH

RETURN TO TANK

FAN INCREASE PITCH

f2 480-122

PUSH (BLOWER)

FAN HYDRAULIC SCHEMATIC

During a reverse/clean cycle the computer turns on the blocking solenoid valve and energizes the fan decrease pitch solenoid valve to reverse the fan blade pitch (to full push) to aid in cleaning the cooler package/heat exchanger.

FAN CONTROL VALVE

The fan blade pitch is controlled by pilot oil supplied via ports F1 and F2 on the fan control valve. The MD3 computer controls the fan control valve via the XA2 #2 pump module.

When engine coolant temperature, hydraulic oil temperature, or charge air temperature is cold (and the air conditioning is not in use) the blocking valve is energized draining oil from both sides of the double acting hydraulic cylinder to tank allowing the fan pitch to go to minimum (pull). In this position a minimum amount of air flows past the cooler package/heat exchanger.

As the fluid temperatures begin to rise the computer will see increasing cooling demand and will increase the fan blade (pull) pitch proportionally. As the fluid temperatures cool the fan blades (pull) pitch will be decreased.

After the reverse/clean duration cycle the computer turns on the blocking solenoid valve to place the fan blades to minimum pitch. The computer then determines the cooling demand requirement and will increase or decrease the fan blade pitch as required.

NOTE: The auto reverse/clean mode frequency and reverse/clean duration is an adjustable function, see section two of the operator’s manual for complete details and adjustment procedure.

To increase pitch the computer energizes the blocking solenoid valve and pulses the fan increase solenoid valve on the fan control valve. One pulse places the fan blades at 10% (pull) pitch to a max of ten pulses (100% pull). To hold the fan blades at a determined pitch the computer de-energizes the blocking solenoid valve.

To decrease pitch the computer energizes the blocking solenoid valve and pulses the fan decrease pitch solenoid valve until the desired fan blade pitch is set, then both solenoid valves are de-energized.

10.4

Tigercat 480 Mulcher

480-120

Oil Cooler, Radiator and Fan

FAN CIRCUIT 10.5

Tigercat 480 Mulcher maintenance of FLEXXAIRE® fan The following information is an excerpt from the manufacturer’s manual. For further information about the Flexxaire® fan please refer to the manufacturer’s installation and maintenance manual. safety In addition to the safety information presented here, please refer to all the safety instructions outlined in SECTION 1 of THIS MANUAL prior to working on the Flexxaire® Fan Assembly.

WARNING Please refer to all safety information supplied, prior to doing any work on the Flexxaire® Fan Assembly.

Improper operation, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

The person(s) servicing the product may be unfamiliar with many of the systems or components on the product. This makes it important to use caution when performing any type of service work. A knowledge of the product and/or its components is important before the removal or disassembly of any component.

Oil Cooler, Radiator and Fan A. If possible, make all repairs to the fan assembly on an engine stand or any other suitable stand. Do not attempt to work on the fan assembly if not safely supported or mounted.

B. If repair is to be done to the internal fan components, drain oil from the hub prior to removing any components.

C.

Always use the required tools and be sure you understand how to use them before performing any service work. Keep tools in good condition and replace if necessary.

D. Replace all fasteners with the same part number. Do not use a lesser quality fastener if replacements are necessary.

E. Do not attempt to weld any components on the fan assembly without first contacting Flexxaire® Engineering or one of their approved dealers.

F.

Do not damage wiring harnesses during removal operations. Secure the wiring harnesses so they are not contacting sharp corners, hot surfaces, or rubbing against objects. Do not connect wires to lines containing fluid for the possibility of exploding.

G. If a guard or shield must be removed to perform repair work, use extra caution. Repair any loose or damaged fluid lines, tubes or hoses because leaks can cause fires.

WARNING

WARNING Because of the size of the product and/or its components, the service person(s) should use proper lifting procedures when removing the product and/or any of its components.

Use a hoist when lifting the assembly or any of its components that approximately weigh 23 kg (50 lb.) or more, to avoid back injury.

Make sure all chains, hooks, slings, etc., are in good condition and are in the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during any lifting operation.

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.

10.6

Tigercat 480 Mulcher

Oil Cooler, Radiator and Fan

H. Tighten fasteners to the correct torque. Make sure all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields that protect against oil spray onto hot exhaust in an event of a line, tube or seal failure must be installed correctly.

I.

Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing. Make sure all guards and shields are properly installed and functioning correctly, before starting the engine or operating the machine.

Standard suction mode. Prescreened air passes through the coolers.

fan Service Intervals The Fan requires visual inspections every 1000 hours.

A. Mechanical Review •

Ensure that the fan and blades rotate smoothly.

•

Check for damage to fan blades.

•

Monitor wear of internal fan components by oil analysis (optional).

B. Fan Blades Typical service life for fan blades is 10,000 hours or higher. Actual blade is dependent on operating conditions. High abrasive environments will subject the blades to considerably higher wear.

Clean mode. Quickly and effectively removes debris from the heat exchangers and air intake screens. fan operation

NOTE: If blades are wearing out before 10,000 hours due to abrasive wear, contact the Product Support Department for Abrasion Resistant Blades.

MAINTENANCE CHECKLIST Refer to manufacturer’s manual for maintenance checklist which provides some basic infomation to be used at time of machinery delivery and at regular maintenance intervals.

10.7

Tigercat 480 Mulcher

Oil Cooler, Radiator and Fan

10.8

Tigercat 480 Mulcher SECTION 11 - TRACK DRIVE CONTENTS - SECTION 11 B

BRAKE CIRCUIT DESCRIPTION.................................................................................. 11.7 C

CIRCUIT DIAGRAM, DRIVE SYSTEM........................................................................ 11.10 CIRCUIT HYDRAULIC SCHEMATIC............................................................................11.11 D

DRIVE MOTOR DESCRIPTION........................................................................................................... 11.6 DRIVE MOTOR AND GEARBOX ASSEMBLY............................................................... 11.5 DRIVE MOTOR BEGIN OF STROKE ADJUSTMENT................................................. 11.12 DRIVE PUMP CHARGE PRESSURE.......................................................................... 11.12 drive Pump High Pressure Relief and POR Valve ADJUSTMENT............. 11.14 G

GEARBOX AND DRIVE MOTOR ASSEMBLY............................................................... 11.5 P

PUMP DRIVE GEARBOX.............................................................................................. 11.8 S

SCHEMATIC DIAGRAMS DRIVE CIRCUIT........................................................................................................11.11 DRIVE MOTOR........................................................................................................... 11.5 T

TRACK COMPONENTS BOTTOM ROLLER RETAINING BOLTS............................................................... 11.19 TRACK SHOE RETAINING BOLTS...................................................................... 11.19 WEAR LIMITS BOTTOM ROLLER WEAR.................................................................................... 11.21 BUSHING WEAR, OUTSIDE DIAMETER............................................................. 11.21 IDLER WEAR........................................................................................................ 11.21 PIN AND BUSHING WEAR................................................................................... 11.20 TRACK LINK WEAR............................................................................................. 11.20 TRACK SHOE GROUSER HEIGHT WEAR......................................................... 11.20 TRACK SLIDE WEAR........................................................................................... 11.21 TRACK COMPONENTS MEASURING TRACK SAG TRACK SAG ADJUSTMENT................................................................................. 11.18 TORQUING UNDERCARRIAGE BOLTS................................................................. 11.19 TRACK DRIVE ASSEMBLY......................................................................................... 11.17 TRACK DRIVE CIRCUIT DIAGRAM............................................................................ 11.10 TRACK DRIVE HYDRAULIC SCHEMATIC...................................................................11.11

MARCH, 2010

Tigercat 480 Mulcher

Track Drive

TRACK DRIVE SYSTEM The track drive system is a closed loop hydraulic system utilizing two variable displacement piston pumps and two variable displacement piston motors that transmit power to the tracks through a triple reduction planetary gearbox on each track frame. The gearbox has an integral spring apply, hydraulic-release, multi-disc brake which is released via the brake release pilot manifold whenever the drive joystick is activated The primary components of each track drive system are a hydraulic pump and a hydraulic motor connected together by hydraulic hoses. The pump converts the mechanical power of the diesel engine into hydraulic power. This high pressure flow of hydraulic oil is then transmitted to the hydraulic motor through the connecting hoses.

480-143

The motor then reconverts the hydraulic power back into the mechanical power to drive the planetary gearbox to propel the machine. Low pressure hydraulic oil flow then returns from the motor to the pump through the other connecting hose thereby completing a continuous closed loop hydraulic circuit.

A hydraulic system is termed closed loop when the hydraulic oil returning from the motor is fed straight back to the pump without first returning to tank. When a track drive system is driving forward, one side of the closed loop is a high pressure supply while the other side is a low pressure return. The supply and return will alternate from side to side of the closed loop as the direction of travel of each track goes from forward to reverse.

closed loop hydraulic circuit

11.2

Tigercat 480 Mulcher

Track Drive

DRIVE PUMP

As the swashplate is de-stroked the flow smoothly decreases until there is no flow at an angle of zero (0°). Continuing to angle the swashplate past this neutral position steplessly reverses the direction of flow from the piston pump.

L.H. DRIVE PUMP

The secondary pump is a fixed displacement, internal gear type which provides charge oil via the charge filter for the drive pump controls. The charge pump continuously introduces oil from the hydraulic tank back into the hydrostatic drive system. The charge relief valve (in the drive pump) maintains a constant charge pressure for use by the swashplate control system. In addition, the charge pump oil is used as make up oil to the low pressure side of the closed loop to replenish losses due to internal leakage in the hydrostatic pump and motor. This same flow acts as a cooling fluid for the piston pump and motors to ensure peak hydrostatic drive performance and long service life.

MAIN PUMP

R.H. DRIVE PUMP CUTTER PUMP

480-141

ENGINE AND PUMP INSTALLATION The drive pumps are mounted to the engine drive gearbox. The input shaft of each drive pump is connected directly to the output of the gearbox.

The gearbox is driven by the engine through a torsional coupler.

CONTROL UNIT

CHARGE PUMP

SWASHPLATE CRADLE

CHARGE PRESSURE RELIEF

DRIVE SHAFT PISTON 480-215

480-144

ROTARY GROUP

DRIVE PUMP SCHEMATIC

Excess charge pump oil is relieved by the charge pump relief valve back into the case of the piston pump. The charge pump pressure filter ensures that only clean charge pump oil is introduced into the closed loop hydrostatic circuit and the swashplate control system. Should this pressure filter become clogged with debris, charge pump flow is diverted to tank thus preventing the entry of unfiltered charge pump oil.

PUMP CROSS SECTION

The drive pump is actually two separate hydraulic pumps mounted in a common case and driven by the same input driveshaft.

The primary pump is a variable displacement, axial piston type. This pump is made variable by slipping the pump pistons against a tiltable swashplate cradle. The volume and direction of oil flow from the piston pump is determined by the angle of this swashplate. When the swashplate is stroked to a maximum displacement angle, the piston pump will produce maximum flow in one direction of the closed loop.

11.3

Tigercat 480 Mulcher PROPORTIONAL SOLENOID VALVE

CONTROL UNIT

Track Drive CHARGE PUMP

CONTROL PISTON

P.O.R.

CHARGE PRESSURE RELIEF

HIGH PRESSURE RELIEF 'B'

PROPORTIONAL SOLENOID VALVE 480-216

CONTROLLER VIEW OF PUMP

The drive pump is equipped with an electrical control with proportional solenoid valves (A and B).

When no current is flowing to either of the proportional solenoid valves the pump will remain in the neutral position with the swashplate at an angle of zero° and no flow.

When the drive joystick is operated, a signal (VOLTAGE IN - Drive Joystick Fwd or Drive Joystick Rev) is sent to the computer control system. The computer control system generates a corresponding signal (CURRENT OUT Drive Pump) and sends it to one of the drive pump proportional solenoid valves (forward or reverse). A magnetic force is generated at the solenoid coil, in the proportional valve a pressure corresponding to the solenoid signal acts on the control spool. The control spool then directs control oil in and out of the stroking piston to stroke the pump as required. A feedback lever, connected to the stroking piston, maintains the pump flow for any given current within the control range. If the signal at the solenoid is lessened, the proportional valve reduces pressure to the actuation piston and the swash plate angle is reduced.

480-144

HIGH PRESSURE RELIEF 'A'

DRIVE PUMP SCHEMATIC

the swashplate, reducing piston pump flow and maintaining system pressure at the P.O.R. setting.

The P.O.R. prevents continuous dumping of high pressure oil across the piston pump high pressure relief valves. This eliminates unnecessary heating of the oil and protects the pump and motors during rapid acceleration and deceleration or when the drive system stalls.

The two high pressure relief valves at ‘A’ and ‘B’ ports are intended only to act as pressure limiting safety devices in the event that the P.O.R. valve malfunctions or does not respond quickly enough to high pressure surges. For this reason the high pressure relief valves are always adjusted higher than the P.O.R. valve setting. The high pressure relief valves always dump oil from the high pressure to the low pressure side of the closed loop thereby keeping the hydraulic oil within the closed loop.

In addition, a pressure sensor, connected to the drive pump provides a feedback signal to the computer control system for use in overall control of the drive circuit.

The hydrostatic piston pump is equipped with a pressure override (P.O.R.) valve to protect the closed loop hydrostatic drive components from excessive pressure. When the tractive effort requirements of the vehicle are demanding then pressure on the high side of the closed loop can reach maximum. At this pressure the P.O.R. valve signals the swashplate control valve to destroke 11.4

Tigercat 480 Mulcher

Track Drive

TRACK DRIVE MOTORS

The displacement control spool is operated by an electrical control with proportional solenoid. The control is proportional to the applied electrical signal from the computer control system. When sufficient pressure from the proportional electrical control is directed to the spool, it shifts against a spring and directs oil to one side of the displacement control cylinder thus decreasing the displacement of the motor. Removal of the pressure signal from proportional electrical control will cause the displacement control spool to return to the neutral position, shutting off the pressure to one side of the displacement control cylinder thus increasing motor displacement towards maximum.

The track drive system is a closed loop hydraulic system utilizing two variable displacement piston pumps and two variable displacement piston motors that transmit power to the tracks through a triple reduction planetary gearbox on each track frame. The gearbox has an integral spring apply, hydraulic-release, multi-disc brake which is released via the brake release pilot manifold whenever the drive joystick is activated.

The motor is an axial piston, variable displacement type. It forms a closed loop circuit with the pump.

High pressure oil from the pump enters the motor via port 'A' or port 'B', depending on the direction of travel. The oil is directed to the back of a set of pistons in the motor's rotary group. The pistons push against the back of the drive shaft at an angle causing it to rotate.

DISPLACEMENT CONTROL SPOOL

The angle of the pistons relative to the drive shaft determine the speed of the motor and the available torque. Reducing the angle provides increased speed with less torque. Increasing the angle will reduce the speed and provide more torque.

BEGIN OF DISPLACEMENT

The angle of the pistons is variable and is changed by an internal control cylinder that receives high pressure oil via the MOTORS' displacement control spool.

FLUSHING RELIEF VALVE FLUSHING VALVE 480-138

CONTROL CYLINDER

DRIVE MOTOR schematic

PLANETARY TRACK DRIVE GEARBOX

BRAKE ASSEMBLY

TRACK DRIVE MOTOR

480-233a

TRACK DRIVE MOTOR and gearbox crossections 11.5

480-210

Tigercat 480 Mulcher

Track Drive

DRIVE MOTOR DESCRIPTION The drive motor is a variable displacement swashplate design. The motor is interchangeable from side to side.

The motor rotating group consists of a cylinder block with seven pistons and an output shaft that is attached to the rotating group by a retainer plate.

Supply oil from the drive pump enters the motor through the port plate to the pistons. During operation, high pressure supply oil enters the piston bores in the cylinder block. The position of the rotating group forces the cylinder block against the concave surface of the port plate and the pistons against the output shaft. Piston sliding action causes the rotating group to turn.

The cylinder block is attached to the output shaft which causes the output shaft to turn. During the second half of the motor rotation, low pressure is discharged as the pistons ride up to a higher position on the concave surface of the port plate. To reverse rotation, oil flow is reversed.

During operation a small amount of supply oil flows through the centre of each piston. This oil lubricates the piston to output shaft joint.

The rotating group angle is changed by the control cylinder in the motor port plate from minimum displacement to maximum displacement. When the electric control solenoid demands minimum displacement, the motor runs at its highest speed.

When the electric control solenoid demands maximum displacement, the motor runs at its slowest speed.

A flushing valve is incorporated into the motor.

This valve provides a regulated flow of oil from the low pressure side of the loop in the motor case.

This action reduces the possibility of particle build up in the loop by providing a continuous change of oil, it also assists with cooling. Flushing occurs only when there is a pressure differential between the high pressure and low pressure sides of the loop. This valve is factory set (2.1 US gpm /8 L/ min) and requires no adjusting.

MINIMUM DISPLACEMENT ADJUSTMENT STOP 'DO NOT ADJUST' SPEED SENSOR

control housing and port plate

PISTON

OUTPUT SHAFT

ROTATING GROUP

ELECTRO-HYDRAULIC PROPORTIONAL SOLENOID CONTROLLER RETAINER

control lens

MAXIMUM DISPLACEMENT ADJUSTMENT STOP 'DO NOT ADJUST'

CROSS SECTION OF DRIVE MOTOR 11.6

Tigercat 480 Mulcher

Track Drive

BRAKE circuit DESCRIPTION The brakes are housed in the planetary drive gearbox. They are spring applied and hydraulically released.

BRAKE ASSEMBLY

BRAKE PRESSURE SWITCH

BRAKE VALVE

When the drive joystick is activated, pilot oil from the brake release solenoid control valve is directed to the track drive brake cylinders. Pilot oil is limited to 500 psi., the brake is fully released by 250 psi.

480-213

TRACK DRIVE PLANETARY GEARBOX

11.7

Tigercat 480 Mulcher

Track Drive

PUMP DRIVE GEARBOX

PUMP DRIVE GEARBOX

GEARBOX DIPSTICK

480-145

PUMP DRIVE GEARBOX INSTALLATION

The pump drive gearbox is a spur gear, 3 pad, 1.21:1 gear ratio (increaser / output shafts and gears turn faster then the input shaft) type gear box. The gear box is installed inverted and mounted to the engine flywheel housing. It is driven by the crankshaft flywheel through a drive coupling. The gear box input shaft is splined to the drive coupling hub.

drive coupling

Engine power is transmitted from the flywheel to the drive coupling through the drive coupling hub to the gear box input shaft. The input shaft drives the main drive gear which drives the three output drive gears that drive the pumps.

480-148

EXPLODED VIEW OF PUMP DRIVE COUPLING AND GEARBOX 11.8

Tigercat 480 Mulcher

Track Drive

PUMP DRIVE GEARBOX OIL AND LUBRICATION Oil flow and circulation in the gear box is one of the most important features to give all internal parts the maximum life. The pump drive gearbox incorporates strategically placed oil ports and ribs that provide for optimum lubrication and oil circulation.

When filled to the proper level, oil will be circulated within the box to each set of bearings, and across all the pump splines for smooth operation. Because the pump spline adapters and the input shaft are exposed to the oil within the pump drive, do not apply grease or any type of corrosion prevention materials to the splines, as these will contaminate the gear box oil.

DRAIN PLUG IS LOCATED BESIDE DIPSTICK TUBE FITTING IN BOTTOM OF GEARBOX

CHECKING/ADDING OIL

480-220

1) Refer to SECTION 3 of this manual for recommended oil change interval, lubricating oil type and capacity.

PUMP DRIVE GEARBOX DRAIN PLUG

2) Stop engine before attempting to check or add oil.

3) Clean around dipstick and oil fill tube before checking or adding oil.

CAUTION Hot oil can cause severe burns. Use extreme care when removing lubrication drain plugs and vents!

4) If oil is to be changed, drain oil while the unit is still warm.

5) Inspect and clean magnetic drain plug for contamination or metal particles before replacing.

DIPSTICK

CAUTION DO NOT over fill, as this will result in overheating and possible failure of the pump drive!

6) Refill the pump drive gear box to MAX oil level on dipstick.

480-219

11.9

PUMP DRIVE GEARBOX DIPSTICK AND TUBE LOCATION

Tigercat 480 Mulcher

480-141a

Track Drive

TRACK DRIVE CIRCUIT DIAGRAM 11.10

Tigercat 480 Mulcher

480-146

Track Drive

TRACK DRIVE HYDRAULIC SCHEMATIC 11.11

Tigercat 480 Mulcher

Track Drive

DRIVE PUMP CHARGE PRESSURE 1. Connect a 0-1000 psi (0 -70 Bar) gauge to the CHARGE test port on both pumps.

DRIVE MOTOR BEGIN OF STROKE ADJUSTMENT R.H. TRACK DRIVE PUMP

2. Start engine and set idle speed to 850 rpm.

R.H. & L.H. TRACK REVERSE GAUGE PORT

L.H. TRACK DRIVE PUMP

3. Check charge pressure. Refer to section 3 of this manual for pressure setting specifications.

If charge pressure is set to specifications proceed to step 5.

L.H. TRACK FORWARD GAUGE PORT

R.H. TRACK FORWARD GAUGE PORT 480-223

GAUGE TEST PORT LOCATIONS

1. Install 700 bar/10,000 psi gauges on forward gauge port of each pump.

DRIVE

Drive Charge Filter Bypassed

'M1' TEST PORT

480-103

NOTE: If the charge pressure is low check the computer display to determine if the computer is displaying a Drive Charge Filter Bypassed Alert message. If the alert message is present shut engine off and replace charge pressure filters. Refer to section 3 of this manual for filter replacement procedure. If no alert message then proceed to step 4.

R.H. TRACK DRIVE PUMP

CHARGE PRESSURE TEST PORT CONNECTOR

L.H. TRACK DRIVE PUMP

480-224

TRACK DRIVE (l.h.) MOTOR

2. Remove track motor cover plates and install 350 bar / 5000 psi gauges on M1 port of both drive motors.

3. Start the engine and set idle speed to 850 rpm.

CHARGE PRESSURE RELIEF VALVE ADJUSTMENT SCREW 480-223

TRACK DRIVE PUMPS

4. With engine running an set to 850 rpm, adjust the charge pressure adjustment screw.

Set the charge pressure to specifications by turning the screw in to increase pressure or turn the screw out to decrease pressure 5. Shut engine off and remove gauges. Wipe up any oil.

480-043

4. In the main menu, press the F2 button on the computer to select adjustment menu.

11.12

Tigercat 480 Mulcher

Track Drive NOTE: The track brakes will be locked in the ON position when the program mode is set to Setup Drive Motors. The track brakes will only disengage when the program mode is set back to Normal.

480-082

R.H. DRIVE PUMP 'POR' VALVE

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

L.H. DRIVE PUMP 'POR' VALVE 480-151

DRIVE PUMP POR VALVE LOCATION

8. Adjust the POR valve on both drive pumps to obtain a gauge reading of 103 bar/1500 psi.

NOTE: * Refer to section 3, PRESSURE AND SPEED chart in this manual for pressure and speed specifications.

BEGIN OF DISPLACEMENT SCREW

480-135

6. The General Settings menu appears on the display, scroll down and select Program Mode. Press the OK button to select.

480-214

TRACK DRIVE MOTOR

9. With engine at idle push drive joystick fully forward and adjust the BEGIN OF DISPLACEMENT screw on the motors to set both motors to *specifications.

NOTE: The exact value is not critical, but both gauges must read exactly the same value.

10. Reset the POR valve on both drive pumps to *specifications.

480-225

7. In the program menu scroll to Setup Drive Motors selection and press the OK button.

11. Reset the program mode back to Normal.

12. Remove gauges, wipe up any oil and reinstall drive motor cover plates.

11.13

Tigercat 480 Mulcher

Track Drive

drive Pump High Pressure Relief and POR Valve ADJUSTMENT R.H. TRACK DRIVE PUMP

R.H. TRACK FORWARD GAUGE PORT 480-223

R.H. & L.H. TRACK REVERSE GAUGE PORT

L.H. TRACK DRIVE PUMP

L.H. TRACK FORWARD GAUGE PORT

GAUGE TEST PORT LOCATIONS

1. Install 700 bar/10,000 psi gauges on forward and reverse gauge ports of RH drive pump.

2. Start the engine and set idle speed to 850 rpm.

480-135

5. The General Settings menu appears on the display, scroll down and select Program Mode. Press the OK button to select.

480-225

480-043

3. In the main menu, press the F2 button on the computer to select adjustment menu.

6. In the program menu scroll to Setup RH Drive Pump selection and press the OK button.

NOTE: The track brakes will be locked in the ON position when the program mode is set to Setup RH Drive Pump. The drive motors will be held at min displacement and the RH drive pump will only be activated when Setup RH Drive Pump is selected.

480-082

4. Press the F4 button to select the General Settings Menu from the ADJUSTMENT MENU. 11.14

Tigercat 480 Mulcher 'FORWARD' HIGH PRESSURE RELIEF VALVE

'REVERSE' HIGH PRESSURE RELIEF VALVES

Track Drive 'FORWARD' HIGH PRESSURE RELIEF VALVE

R.H. DRIVE PUMP 'POR' VALVE

480-151

L.H. DRIVE PUMP 'POR' VALVE

POR VALVES & HIGH PRESSURE RELIEF VALVES 7. Fully turn in forward high-pressure relief valve.

8. Push drive joystick fully forward and set drive pump POR valve to 21 bar / 300 psi above high pressure relief valve *specification.

NOTE: * Refer to section 3, PRESSURE AND SPEED chart in this manual for pressure and speed specifications.

9. Turn out forward high-pressure relief valve to set pressure to *specifications.

10. Pull drive joystick fully reverse.

11. Adjust reverse high-pressure relief valve to set pressure to *specifications.

12. Set drive pump POR to *specifications.

13. Shut engine off and remove gauges.

14. Install 700 bar/10,000 psi gauges on forward and reverse gauge ports of LH drive pump.

15. Start the engine and set idle speed to 850 rpm.

16. Set Program Mode to “Setup LH Drive Pump”. See steps 4 to 6.

17. Repeat Steps 7-12 from above for LH drive pump.

18. Set program mode back to “Normal” when complete.

19. Shut engine off, remove gauges and wipe up any oil.

11.15

Tigercat 480 Mulcher TEST DRIVE NOTE: Following is to be done using laptop through IQANRun with the user logged in as “Service”.

1. Ensure the machine is on level, flat, hard ground with ample space to drive. Ensure that track tension is correct for both tracks.

Track Drive 8. Using IQANRun, go to “Adjust” and select “Service Adjustments – Drive” 9. Set the RH & LH track pressures and speeds equal (within 300psi) by raising the “Drive Pump Min Value Fwd” for the appropriate pump and lowering this value for the opposite pump.

Example:

2. Set Engine Speed to 1850 rpm.

If the RH track pressure is higher than the LH track pressure, decrease the “RH Drive Pump Min Value Fwd” and increase the “LH Drive Pump Min Value Fwd” by the same amount until both pressures and speeds are equal.

3. Set Speed Control Adjustment to min speed.

4. Using the MD3 press “Menu”, “Measure” and select “Drive Control” and press OK.

10. Repeat Steps 3-9 in the reverse direction.

Note: Adjust the pump “Rev” values when driving in the reverse direction.

Note: Cruise control does not work in reverse so the joystick must be held steady.

11. Repeat Steps 2-10 at the following points: a) RH & LH drive pump output values are between 585-595 mA Example: If the RH track pressure is higher than the LH track pressure, then increase the “LH Drive Pump Max Value Fwd” until both pressures and speeds are equal.

5. Monitor the “RH Drive Pump” and “LH Drive Pump” output values (in mA).

b) Maximum machine speed (joystick fully deflected and speed control at max)

6. Push the drive joystick forward and enable cruise control when both values are between 205-210 mA.

Example: If the RH track pressure is higher than the LH track pressure, decrease the “RH Drive Motor Max Value” and increase the “LH Drive Motor Max Value” by the same amount until both pressures and speeds are equal.

Note: Adjusting motor values affects both forward and reverse speeds.

Note: Ensure motor speeds are between 3200 & 3250 rpm.

7. Set the MD3 to the “Drive Functions” page to monitor RH & LH Track pressures and speeds.

11.16

Tigercat 480 Mulcher

Track Drive

TRACK COMPONENTS IMPORTANT: New machine: Before driving a new machine ensure that track sag is set correctly. Track sag may be set less than specified for shipping purposes.

The correct track sag must be adjusted once a machine has been delivered to the job sight and operating in the accumulated soil build-up in the undercarriage.

Track sag Note: The track sag dimension is very important and should be checked regularly, 50% increase in the life of the track assembly can be realized, particularly bushing O/D wear and track pitch by maintaining the correct amount of track sag.

A track that is too tight will wear out significantly faster due to increased tension in the chain.

TOP ROLLERS

Track components operate under varying terrain conditions, most of which cause excessive wear.

Wear to one component can quickly spread to the rest of the track assembly.

To ensure that the track components are always in good running order, a periodic inspection should be made to ensure that components have not come loose, that bolts are at the correct torque, that components are within the specified wear limits (discussed further in this section) and where applicable, check lubrication points.

For a guide on inspection, refer to the PERIODIC MAINTENANCE SCHEDULE in SECTION 3 OF THIS MANUAL. Refer to MEASURING TRACK SAG in THIS SECTION.

TRACK DRIVE GEARBOX

INSPECTION COVER

DRIVE SPROCKET

SHAFT

TRACK DRIVE GEARBOX WALKING BEAM

LOWER ROLLERS

IDLER ASSEMBLY TRACK ASSEMBLY 480-139

TRACK DRIVE ASSEMBLY 11.17

Tigercat 480 Mulcher

Track Drive

MEASURING TRACK SAG

idler adjusting 4 cylinder

A. Park machine on flat level ground.

B. Place attachment on the ground.

3

C. Place a 1.2 meter (4 foot) straight edge across the tracks over two rollers as shown .

SAG DIMENSION

straight edge

•

DO NOT REMOVE

TIP OF GROUSER

•

straight edge over two rollers

CW001-2A 480-058

CW001-3

1

2

TRACK ADJUSTMENT

TRACK SAG ADJUSTMENT

480-056

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

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.

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 TOO LOOSE TOO MUCH SAG

TRACK CORRECT 30mm - 40mm (11/4" - 15/8") SAG 480-056

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.

Repeat this procedure for the opposite track.

11.18

Tigercat 480 Mulcher

Track Drive

TORQUING UNDERCARRIAGE BOLTS It is important to check the torque values of the track shoe retaining bolts and the bottom roller retaining bolts at the NEW MACHINE MAINTENANCE time period (first 125 hours) and then EVERY 125 HOURS SCHEDULED MAINTENANCE time period.

When installing new components, all traces of paint and dirt must be removed from all mating surfaces including the contact area under the bolt head and nut.

Both the bolt and the nut on the track shoes should be lightly lubricated with SAE 30 oil and tightened using the Torque-turn method.

The torque-turn method involves torquing the bolt to an initial predetermined value, plus an additional 1/3 turn (not the value shown in the torque charts). This ensures a more accurate and consistent torquing of the bolts, with less likelihood of the bolt/nut coming loose later.

When checking the torque values at the first 125 hours and every 125 hours thereafter use the CHECKING TORQUE values listed in the following paragraphs.

If loose shoes or under torqued bolts are discovered during the first 125 hour check, they should be removed, surfaces cleaned, and reused using the torque-turn method. If the shoe is not loose but a single bolt is low on torque, loosen the bolt and re torque-turn.

If loose or under torqued bolts are discovered any time after the 125 hour check, the bolts and nuts must be replaced with new ones, surfaces cleaned, and re torque-turned.

TORQUE 1

TRACK COMPONENT TORQUE VALUES TRACK SHOE RETAINING BOLTS Track shoes must be fastened together applying the exact torque values shown below and using the Torque-turn method described in TORQUING UNDER CARRIAGE BOLTS earlier in this section.

Track shoe bolts and nuts are designed specifically for this purpose and should not be substituted with standard off the shelf hardware.

When checking the torque values at the first 125 hours and every 125 hours thereafter.

Track shoe bolts ~ M20x1.5 TORQUE-TURN......350 Nm/260 LBF-FT. + 1/3 TURN. CHECKING TORQUE (Dry)... 746 Nm/550 LBF-FT. BOTTOM ROLLER RETAINING BOLTS The bottom rollers must be fastened to the lower frame applying the exact torque values shown below.

When installing new rollers, apply "NEVER-SEEZ" to the bolt.

When checking the torque values at the first 125 hours and every 125 hours thereafter use the torque value(s) shown below.

Bottom roller bolts ~ 3/4" UNC TORQUE (Lubricated)...... 407 Nm (300 LBF-FT.) Top roller bolts ~ M16x2 UNC TORQUE (Lubricated)...... 271 Nm (200 LBF-FT.) For a complete maintenance check Refer to the PREVENTIVE MAINTENANCE SCHEDULE in SECTION 3 of this manual.

11.19

Tigercat 480 Mulcher

Track Drive

WEAR LIMITS

PIN AND BUSHING WEAR

TRACK SHOE GROUSER HEIGHT WEAR WEAR LIMITS

To obtain the track internal wear, i.e., the wear between the pin and the internal diameter of the bushing, measure the track pitch over four sections of track (5 pins).

DOUBLE GROUSER BERC-10

TRIPLE GROUSER

MEASURING TRACK PITCH

BERC-3 BERC-1

GROUSER WEAR (Height)

New 70% wear 100% wear Double 1.378" (35mm). 0.748 (19mm)........... 0.43" (10.92mm) Triple 1.102" (28mm) 0.689"(17.5mm) 0.453" (11.5mm) TRACK LINK WEAR WEAR LIMITS

To take this measurement, 1. Remove slack by placing a steel pin between sprocket and chain, then slowly move machine in reverse to tighten chain.

2. Measure pitch across two four link sections, except section on each side of the master pin, to find average chain wear.

INTERNAL PIN & BUSHING WEAR 180°

BERC-2

EXTERNAL BUSHING WEAR

TRACK LINK WEAR (Height)

New link height..........................4.173"(106mm) 50% wear..................................4.028"(102.3mm) 70% wear..................................3.957"(100.5mm) 100% wear................................3.858" (98mm)

BERC-4

ROTATION

TURN PIN & BUSHING 180°

PIN/BUSHING INTERNAL WEAR

NOTE: Wear to the pins and bushings only occurs in a small localised area, to extend the life of these components, the pins and bushings may be turned 180° or replaced provided other components are within specified wear limits: 1. Track link wear is 75% or less.

2. Change in track pitch has not exceeded 100% wear.

3. Bushing external wear less than 100% in soft ground or 75% or less in rocky ground.

4. There is at least 0.008" (0.2mm) press fit available between pin and bushing and link.

WEAR LIMITS New length of four sections............... 29.928"(760.0mm) 70% worn.......................................... 30.319"(770.1mm) 100% worn........................................ 30.472"(774.0mm) NOTE: Allowable wear in rocky ground is 75% NOTE: These wear limits are used as a guide for when to turn the pins and bushings. If pins and bushings are not to be turned, the chain can be run past the 100% wear limit, until chain failure.

11.20

Tigercat 480 Mulcher

Track Drive

BUSHING WEAR, OUTSIDE DIAMETER

BOTTOM ROLLER WEAR Measure the roller diameter on the tread contact surface with a large calliper to obtain the worst wear condition.

45°

45°

FORWARD SIDE vertical WEAR WEAR

REVERSE SIDE WEAR

MEASURING BUSHING WEAR

BERC-5

Use a calliper to measure the wear of the bushing O.D. in three places.

BERC-6

MEASURING BTM. ROLLER WEAR

NOTE: Bushing outside diameter is measured at three places because of the forward and reverse travel of the machine and a vertical wear that takes place.

If accessibility to the rollers is impaired by guards, then concentrate on the front and rear rollers, these will be the most worn.

WEAR LIMITS New bushing O.D......................2.362" (60.0mm) 70% worn..................................2.260" (57.4mm) 100% worn................................2.150" (54.6mm)

WEAR LIMITS New roller............................... 7.992" (203.0mm) 70% worn............................... 7.528" (191.2mm) 100% worn............................. 7.244" (184.0mm)

NOTE: Allowable wear in rocky ground is 75%

IDLER WEAR Measure the idler wheel side diameters (tread contact surface) at several points to obtain the worst wear condition. Position a depth gauge or measuring tape as close as possible toward the centre of the idler with the gauge flat on the centre flange and parallel to the idler shaft.

BERC-7

MEASURING IDLER WEAR

WEAR LIMITS New idler dimension................. 0.787" (20.0mm) 100% wear............................... 1.201" (30.5mm)

11.21

Tigercat 480 Mulcher

Track Drive

11.22

Tigercat 480 Mulcher SECTION 12 - LIFT BOOM MARCH, 2010

CONTENTS - SECTION 12 B

boom lift lock......................................................................................................... 12.6 BOOM VALVE CROSS SECTION OF SPOOL SECTION.................................................................. 12.3 C

CIRCUIT DIAGRAM....................................................................................................... 12.5 J

JOYSTICK CONTROL VALVE....................................................................................... 12.2 OPERATING DESCRIPTION..................................................................................... 12.2 P

PRESSURE SETTINGS................................................................................................. 12.6 PUMP, DESCRIPTION....................................... See SECTION 4 - HYDRAULIC SYSTEM

Tigercat 480 Mulcher LIFT BOOM ELECTRONIC JOYSTICK

Lift Boom

MAIN CONTROL VALVE

480-179

HYDRAULIC VALVE COMPARTMENT

480-163

BOOM LIFT VALVE The main control valve assembly consists of five spool sections and one inlet section.

The boom lift/tilt joystick is an electronic joystick that uses electrical signals to energize electric solenoid controls that activate the control valves for the boom functions.

PILOT RELIEF VALVE

OPERATING DESCRIPTION When not actuated the lever (1) is held in neutral position by the return springs (8). When operating the lever (1), the plunger (5) pushes against return spring (8). The magnet (7) mechanically linked to the plunger (5) moves upward or downward while following the levers actuation direction. The electrical signal generated by the sensor (4) is proportional to the deflection of the lever.

BOOM LIFT VALVE SECTION 480-168A

'PS' PORT

MAIN CONTROL VALVE ASSEMBLY

Moving the joystick forward or back sends an electrical signal to the MD3 computer module. The signal is then sent to the XA2#1 (front module) and from the module the signal is directed to the solenoid control for the selected function.

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve. This shifts the spool of the control valve directing pump oil flow to the boom lift cylinders.

12.2

The boom lift valve section is the 1st section when viewed in the hydraulic valve compartment (as shown in the illustration above).

For a detailed description of the Main Control Valve Assembly Refer to SECTION 4 'Hydraulic System' of this service manual.

Tigercat 480 Mulcher

480-137

Lift Boom

BOOM LIFT AND TILT CIRCUIT SCHEMATIC DIAGRAM 24 VOLT SOLENOID CONTROL

24 VOLT SOLENOID CONTROL LOAD CHECK VALVE

A

B

PILOT END CAP PILOT END CAP

SPOOL CENTERING SPRING RELIEF VALVE PORT 'A'

480-170

SPOOL

TYPICAL CROSS SECTION OF SPOOL SECTION 12.3

RELIEF VALVE PORT 'B'

Tigercat 480 Mulcher LIFT BOOM CIRCUIT DESCRIPTION

Lift Boom

Two cylinders are used to raise and lower the boom. The boom cylinders receive oil from the main pump via the boom lift spool section in the main control valve. The boom lift spool section in the main control valve is equipped with proportional, electro-hydraulic spool actuators.

The actuators are spring centered to the neutral position, and are shifted by sending a 24 volt proportional current signal to the appropriate solenoid.

When the solenoid is activated internal pilot oil shifts the spool. The spool directs oil from the main pump to either end of the cylinders and from the cylinders back to tank via the return filters.

480-170

The spools installed in the main valve are selected specifically for the function it is controlling. These spools cannot be interchanged.

The boom lift valve is equipped with port reliefs on each side of all spool section. The purpose of the port relief is to protect the valve and the function from pressure peaks in the system. The port reliefs also act as anti-cavitation valves, which means they allow oil to flow from the tank gallery in the valve to the service ports in the event of underpressure. The port reliefs cannot be adjusted. Port reliefs installed in each section are specifically designed for use in that section and should not be interchanged with port reliefs from other valve sections .

12.4

spool section

Tigercat 480 Mulcher

480-134

Lift Boom

LIFT BOOM AND TILT CIRCUIT 12.5

Tigercat 480 Mulcher PRESSURE SETTINGS

Lift Boom WARNING

Before starting this procedure, read the following safety precautions:~

Do not stand below the mulching head and lift boom or between the boom and front of the machine during this procedure.

• Never reach between boom crank arms or link arms during machine set-up.

• Wear safety glasses and safety shoes.

• Do not stand on top or inside of boom arms.

MAIN PRESSURE RELIEF VALVE

WARNING

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 1. Park machine on level ground. Completely raise lift boom and install boom lift lock over one of the two cylinder rods with the open side at the bottom and wide end up against the cylinder. Install 'T' handle retaining bolt through center hole. Slowly lower boom until lock is securely held in place.

MAIN PRESSURE RELIEF VALVE

2. Shut OFF engine.

480-167A

CUTTER solenoid CONTROL VALVE (S1)

MAIN PUMP SOLENOID CONTROL VALVE (S2)

4. Turn the main relief adjusting screw on the main control valve all the way IN. 5. Start the engine, and set the throttle control to the 850 rpm.

'B1' TEST PORT

6. Ensure that the hydraulic oil temperature is between 49 °C -60°C (120°F - 140°F).

STANDBY ADJUSTMENT

CUTTER CONTROL VALVE

'POR' ADJUSTMENT

LOCKING SCREWS

MAIN CONTROL VALVE

480-078 480-163

MAIN VALVE

HYDRAULIC VALVE COMPARTMENT

PUMP ADJUSTMENTS

7. While holding the joystick in the lift up position (fully extended), loosen locking screw and adjust POR valve on main pump in to 242 Bar (3500 psi) then turn the adjusting screw in 1/2 turn (aproximately 276 Bar/4000 psi).

3. Connect a 0-350 Bar (0 - 5000 psi) pressure gauge to the 'B1' test port on the cutter control valve.

12.6

Tigercat 480 Mulcher

Lift Boom

IMPORTANT! During the following procedures, DO NOT hold any function control over relief for longer than 5 seconds.

NOTE: The gauge pressure reading will not exceed the boom lift circuit port relief of 242 Bar (3500 psi).

Also, the Port releif valves are not adjustable and must be replaced if the pressure readings do not match specifications.

IMPORTANT! Without a head attached, the tilt function can cause damage to the arms.

Watch the two LINK ARMS very carefully, as they may drop down beside the boom arms and wedge, causing the crank arms to bend.

When necessary, lower the boom DOWN, watching closely and tilt FORWARD, again watching the link arms closely. crank arm link arm

NOTE: * Refer to section 3, PRESSURE AND SPEED chart in this manual for pressure and speed specifications.

8. Remove the boom lift lock.

9. While holding the joystick in the lift down position (fully retracted), check gauge pressure reading. Front of machine may lift off ground. boom arm

480-136

PORT RELIEFS PORT RELIEFS

480-166a

10. Pressure gauge should read *specifications for both lift up and lift down. If pressure is less then or greater then *specifications replace the affected relief valve.

11. If pressure readings are correct reinstall the boom lift lock.

12. While holding the joystick in the lift UP position (fully extended), check gauge pressure reading. Adjust the main relief on the main valve to *specifications and tighten locknut.

13. While holding the joystick in the lift UP position (fully extended), check gauge pressure reading. Adjust the main pump POR valve to *specifications.

14. Remove pressure gauge and wipe up any excess oil from 'B1' test port area.

12.7

crank, link and boom arms

Tigercat 480 Mulcher

Lift Boom

12.8

Tigercat 480 Mulcher SECTION 13 - TILT BOOM MARCH, 2010

CONTENTS - SECTION 13 B

boom cylinder lock.............................................................................................. 13.6 BOOM VALVE CROSS SECTION OF SPOOL SECTION.................................................................. 13.3 C

CIRCUIT DIAGRAM....................................................................................................... 13.5 J

JOYSTICK CONTROL VALVE OPERATING DESCRIPTION..................................................................................... 13.2 P

PRESSURE SETTINGS................................................................................................. 13.6 PUMP, DESCRIPTION....................................... See SECTION 4 - HYDRAULIC SYSTEM

Tigercat 480 Mulcher TILT BOOM ELECTRONIC JOYSTICK

Tilt Boom

MAIN CONTROL VALVE

480-179

HYDRAULIC VALVE COMPARTMENT

480-163

BOOM TILT VALVE The main control valve assembly consists of five spool sections and one inlet section.

The boom lift/tilt joystick is an electronic joystick that uses electrical signals to energize electric solenoid controls that activate the control valves for the boom functions.

PILOT RELIEF VALVE

OPERATING DESCRIPTION When not actuated the lever (1) is held in neutral position by the return springs (8). When operating the lever (1), the plunger (5) pushes against return spring (8). The magnet (7) mechanically linked to the plunger (5) moves upward or downward while following the levers actuation direction. The electrical signal generated by the sensor (4) is proportional to the deflection of the lever.

BOOM TILT VALVE SECTION 480-168A

'PS' PORT

MAIN CONTROL VALVE ASSEMBLY

Moving the joystick RIGHT or LEFT sends an electrical signal to the MD3 computer module. The signal is then directed to the XA2#1 front module and from the module the signal is directed to the solenoid control for the boom tilt function.

The electrical signal activates the solenoid and opens a pilot circuit that directs internal pilot oil to the spool actuator of the control valve. This shifts the spool of the control valve directing pump oil flow to the selected function.

13.2

The boom tilt valve section is the 2nd section when viewed in the hydraulic valve compartment, (as shown in the illustration above).

For a detailed description of the Main Control Valve Assembly Refer to SECTION 4 'Hydraulic System' of this service manual.

Tigercat 480 Mulcher

480-137

Tilt Boom

BOOM TILT AND LIFT CIRCUIT SCHEMATIC DIAGRAM 24 VOLT SOLENOID CONTROL

24 VOLT SOLENOID CONTROL LOAD CHECK VALVE

A

B

PILOT END CAP PILOT END CAP

SPOOL CENTERING SPRING RELIEF VALVE PORT 'A'

480-170

SPOOL

TYPICAL CROSS SECTION OF SPOOL SECTION 13.3

RELIEF VALVE PORT 'B'

Tigercat 480 Mulcher BOOM TILT CIRCUIT DESCRIPTION

Tilt Boom

Two cylinders are used to tilt the attachment.

The tilt cylinders receive oil from the main pump via the boom TILT spool section in the main control valve. The boom tilt spool section in the main control valve is equipped with proportional, electro-hydraulic spool actuators. The actuators are spring centered to the neutral position, and are shifted by sending a 24 volt proportional current signal to the appropriate solenoid.

When the solenoid is activated internal pilot oil shifts the spool. The spool directs oil from the main pump to either end of the cylinders and from the cylinders back to tank via the return filters.

480-170

The spools installed in the main valve are selected specifically for the function it is controlling. These spools cannot be interchanged.

The boom tilt valve is equipped with port reliefs on each side of all spool section. The purpose of the port relief is to protect the valve and the function from pressure peaks in the system. The port reliefs also act as anti-cavitation valves, which means they allow oil to flow from the tank gallery in the valve to the service ports in the event of underpressure. The port reliefs cannot be adjusted. Port reliefs installed in each section are specifically designed for use in that section and should not be interchanged with port reliefs from other valve sections .

13.4

spool section

Tigercat 480 Mulcher

480-134

Tilt Boom

BOOM TILT AND LIFT CIRCUIT 13.5

Tigercat 480 Mulcher PRESSURE SETTINGS

Tilt Boom WARNING

Before starting this procedure, read the following safety precautions:~

Do not stand below the mulching head and lift boom or between the boom and front of the machine during this procedure.

• Never reach between boom crank arms or link arms during machine set-up.

• Wear safety glasses and safety shoes.

• Do not stand on top or inside of boom arms.

MAIN PRESSURE RELIEF VALVE

WARNING

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 1. Park machine on level ground. Completely raise lift boom and install boom lift lock over one of the two lift cylinder rods with the open side at the bottom and wide end up against the cylinder. Install the 'T' handle retaining bolt through center hole. Slowly lower boom until lock is securely held in place.

MAIN PRESSURE RELIEF VALVE

2. Shut OFF engine.

CUTTER solenoid CONTROL VALVE (S1)

480-167A

MAIN PUMP SOLENOID CONTROL VALVE (S2)

MAIN VALVE

4. Turn the main relief adjusting screw on the main control valve all the way IN. 5. Start the engine, and set the throttle control to the 850 rpm.

'B1' TEST PORT

6. Ensure that the hydraulic oil temperature is between 49 °C -60°C (120°F - 140°F).

STANDBY ADJUSTMENT

'POR' ADJUSTMENT

CUTTER CONTROL VALVE LOCKING SCREWS

MAIN CONTROL VALVE

480-078 480-163

PUMP ADJUSTMENTS

7. While holding the joystick in the lift up position (fully extended), loosen locking screw and adjust POR valve on main pump in to 242 Bar (3500 psi) then turn the adjusting screw in 1/2 turn (aproximately 276 Bar/4000 psi).

HYDRAULIC VALVE COMPARTMENT

3. Connect a 0-350 Bar (0 - 5000 psi) pressure gauge to the 'B1' test port on the cutter control valve.

13.6

Tigercat 480 Mulcher

Tilt Boom

IMPORTANT! During the following procedures, DO NOT hold any function control over relief for longer than 5 seconds.

NOTE: The gauge pressure reading will not exceed the boom lift circuit port relief of 242 Bar (3500 psi).

Also, the Port relief valves are not adjustable and must be replaced if the pressure readings do not match specifications.

IMPORTANT! Without a head attached, the tilt function can cause damage to the arms.

Watch the two LINK ARMS very carefully, as they may drop down beside the boom arms and wedge, causing the crank arms to bend.

When necessary, lower the boom DOWN, watching closely and tilt FORWARD, again watching the link arms closely. crank arm link arm

NOTE: * Refer to section 3, PRESSURE AND SPEED chart in this manual for pressure and speed specifications.

8. Hold the joystick in the TILT IN position (fully retracted) and check gauge pressure reading.

9. Hold the joystick in the TILT OUT position (fully extended) and check gauge pressure reading. boom arm

480-136

PORT RELIEFS PORT RELIEFS

480-166a

10. Pressure gauge should read *specifications for both tilt in and tilt out. If pressure is less then or greater then *specifications replace the affected relief valve.

11. If pressure readings are correct hold the lift up joystick in the lift up position (fully extended), check gauge pressure reading. Adjust the main relief on the main valve to *specifications and tighten locknut.

12. Hold the joystick in the lift UP position (fully extended), check gauge pressure reading. Adjust the main pump POR valve to *specifications.

14. Remove pressure gauge and wipe up any excess oil from 'B1' test port area.

13.7

crank, link and boom arms

Tigercat 480 Mulcher

Tilt Boom

13.8

Tigercat 480 Mulcher SECTION 17 - ATTACHMENT DRIVE MARCH, 2010

CONTENTS - SECTION 17 A

ATTACHMENT DRIVE COMPONENTS......................................................................... 17.4 ATTACHMENT HYDRAULIC SCHEMATIC.................................................................... 17.5 ATTACHMENT MOTOR...................... See ATTACHMENT MANUFACTURER'S MANUAL attachment pump.................................................................................................... 17.2 C

CIRCUIT DESCRIPTION............................................................................................... 17.4 P

PRESSURE SETTINGS attachment pump AND attachment:........................... 17.6 S

SAFETY.......................................................................................................................... 17.6 SET CUTTER CONTROL VALVE MAIN RELIEF AND PUMP 'POR'............................. 17.8 SET MOTOR begin of displacement CONTROL................................................. 17.6 SET MOTOR MINIMUM DISPLACEMENT.................................................................... 17.9

Tigercat 480 Mulcher

Attachment Drive

R.H. DRIVE PUMP

L.H. DRIVE PUMP

MAIN PUMP

ATTACHMENT PUMP

480-141

ENGINE AND PUMP INSTALLATION

attachment pump The attachment pump is an axial-piston variable displacement pump controlled by an electrohydraulic solenoid pump control. The pump control is mounted directly onto the pump. The pump is mounted to the bottom pad of the pump drive gearbox. The pump drive shaft is connected to the gearbox via a splined adapter.

The pump is equipped with a suction impeller to provide boost/charge pressure supply to the primary pump. The primary pump is a variable displacement, axial piston type. This pump is made variable by slipping the pump pistons against a tiltable swashplate. The volume of oil flow from the piston pump is determined by the angle of this swashplate. When the swashplate is stroked to a maximum displacement angle, the piston pump will produce maximum flow in one direction in the open loop circuit.

480-230

PUMP CROSS SECTION

The electro-hydraulic solenoid pump controller uses pilot oil supplied by the main control valve and pump oil (whichever is greater pressure) to stroke the pump swashplate to increase pump flow. When the pump controller is de-energized the swashplate is destroked by spring force to shut off pump flow.

Pump oil is supplied to the attachment via the cutter control valve located in the valve compartment in the front of the machine.

480-152

17.2

PUMP SCHEMATIC

Tigercat 480 Mulcher CUTTER solenoid CONTROL VALVE (S1)

Attachment Drive MAIN PUMP SOLENOID CONTROL VALVE (S2)

MAIN PUMP SOLENOID CONTROL VALVE (S2)

CUTTER CONTROL VALVE

CUTTER PUMP SUPPLY

CUTTER solenoid CONTROL VALVE (S1)

CUTTER CONTROL MAIN RELIEF VALVE

CUTTER CONTROL MAIN RELIEF VALVE

MAIN CONTROL VALVE

480-153 480-163

CUTTER CONTROL VALVE SCHEMATIC

HYDRAULIC VALVE COMPARTMENT

CUTTER solenoid CONTROL VALVE (S1)

CUTTER CONTROL VALVE The cutter control valve consists of a steel body which houses six valve cartridges. Two solenoid operated control valves, three pilot operated check valves and a relief valve cartridge.

pressure switch

The cutter solenoid control valve (S1) controls the flow of oil from the attachment pump to the attachment motors.

pressure transducer

OPERATING DESCRIPTION

CUTTER CONTROL MAIN RELIEF VALVE

When the cutter switch is in the OFF position, the solenoid control S1 on the cutter valve and the pump controller are turned OFF. When the pump controller is turned off the swashplate of the attachment pump is at 0° (no oil flow from the pump).

When the cutter switch is turned ON, the pump controller is turned on tilting the attachment pump swashplate to allow the pump to produce oil flow. Also, the cutter solenoid control valve 'S1' is turned ON directing pilot oil to the three pilot operated cartridge valves. Two of the valves direct attachment pump oil to the two cutter motors and the third valve blocks return oil at T2 port.

A pressure switch on the cutter valve, provides a pilot pressure signal for the computer to ensure that the pilot pressure is above 23 bar/330 psi.

This is the minimum pressure that is required to activate the cartridges, if the pressure signal is below this specification the computer will not turn on the attachment pump.

480-229

CUTTER CONTROL VALVE

A pressure transducer mounted on the cutter valve provides a pressure signal for the compter to display the attachment and cutter circuit pressure.

A relief valve mounted in the cutter control valve, protects the pump in case of failure of the 'POR' valve on the pump. Oil is diverted to tank via the 'T1 TANK' port.

The relief valve is adjusted by loosening the locknut and turning the adjusting screw clockwise to increase the pressure value and counterclockwise to decrease the value.

17.3

Tigercat 480 Mulcher

Attachment Drive

ATTACHMENT CIRCUIT DESCRIPTION

CAUTION

The attachment is driven by variable displacement hydraulic motors. A variable displacement hydraulic pump mounted on the pump drive gearbox supplies oil flow to the motors via the cutter control valve. The cutter control valve is solenoid operated with a built in relief and controls the flow of hydraulic oil from the attachment pump to the attachment motors.

Serious component damage will result: • Never stop engine with cutter rotating.

• Always stop cutter with engine at idle.

For additional information, refer to CUTTER SWITCH and INTERLOCK RESET SWITCH in SECTION 2 of the OPERATOR'S MANUAL.

The cutter switch on the control panel in the cab is used to turn the attachment ON or OFF. NOTE: The attachment will not run unless both cab doors are closed and the interlock reset switch is pressed to activate the pilot system.

L.H. ATTACHMENT MOTOR

R.H. ATTACHMENT MOTOR

CUTTER CONTROL VALVE

ATTACHMENT PUMP

PUMP CONTROLLER

480-155

ATTACHMENT DRIVE COMPONENTS 17.4

Tigercat 480 Mulcher

480-152

Attachment Drive

ATTACHMENT HYDRAULIC SCHEMATIC 17.5

Tigercat 480 Mulcher PRESSURE SETTINGS attachment pump AND attachment:

Attachment Drive WARNING

Before starting this procedure, read the following safety precautions:~ Check torque on cutter tool mounting bolts before starting cutter.

• Never assume that other workers are aware of mulching head dangers.

• Do not operate with discharge areas of the mulching head pointed toward people, vehicles, or buildings.

• Guards, wear plates and covers must be properly attached during operation.

• Do not, under any circumstances, overspeed the rotating cutter RPM. • A slowly rotating cutter can crush bones.

Beware of pinch points when rotating cutter by hand.

• Never operate the mulching head inside of a building and always warn others to keep clear of the area.

• Do not reach between boom crank arms or link arms at any time during setup.

• Mulcher door opens and closes quickly.

Keep clear of its operating range.

• Wear safety shoes and safety glasses when working on mulching head.

• Keep mulcher door closed whenever possible during setup.

• If a vibration or imbalance is detected, shut down immediately and check problem.

Do not stand below the attachment and lift boom or between the boom and front chassis during this procedure.

•

3. Rotate slowly by hand and check for damage and "wobble ".

4. Check the torque on both the cutter tool mounting bolts and rotor mounting bolts.

5. Block rotor from rotating as outlined in mulching head manufacturer’s manual.

6. Clear area under the mulcher of all loose dirt, stones, wood and debris.

7. Start the engine and operate machine functions to raise hydraulic oil temperature to 49°C-60°C/120°F - 140°F. 8. Keep mulcher head 6" off the ground (15 cm).

9. Warn all persons to stay clear of area and especially the discharge area.

10. Stop engine.

SET MOTOR begin of displacement CONTROL NOTE: * Refer to section 3, PRESSURE AND SPEED chart in this manual for pressure and speed specifications.

11. Perform steps 1 through 10 above.

WARNING Always allow the rotating cutter to coast to a complete stop before approaching mulching head to make adjustments.

Refer also to SECTION 1 of THIS MANUAL. NOTE: * Refer to section 3, PRESSURE AND SPEED chart in this manual for pressure and speed specifications.

1. Park machine on level ground, close mulcher door and lower mulching head to the ground.

Adjust depth shoes or rest depth shoes on firm blocks so that the rotating cutter is approximately 6" off the ground. Turn off the engine.

2. Remove all guards and check that the area in and around the rotating cutter is free of loose objects (wood, stones, nuts, bolts, etc.). Make sure all tools and spare parts are removed from the area.

480-043

12. In the main menu, press the F2 button on the computer to select adjustment menu.

17.6

Tigercat 480 Mulcher

Attachment Drive CUTTER solenoid CONTROL VALVE (S1) pressure switch

pressure transducer

CUTTER CONTROL MAIN RELIEF VALVE 480-229

480-082

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

CUTTER CONTROL VALVE

16. Turn cutter control valve main relief in fully.

Note: if main relief is already set to 5600 psi it does not need to be turned.

480-135

14. The General Settings menu appears on the display, scroll down and select Program Mode. Press the OK button to select.

attachment pump 'm' test port

17. Install a 700 bar/10,000 psi gauge on test gauge port 'M' on bottom of cutter pump. l.h. motor 'm1' test port

r.h. motor 'm1' test port

480-225

15. In the program menu scroll to Lockout Drives selection and press the OK button.

18. Install 350 bar/5000 psi gauges on test gauge port 'M1' on both motors.

17.7

Tigercat 480 Mulcher 19. Start engine and set engine rpm to 850rpm and turn cutter on.

Attachment Drive SET CUTTER CONTROL VALVE MAIN RELIEF AND PUMP 'POR' 24. Observe gauge on M gauge port on bottom of cutter pump (use a long test hose so that gauge can be read while adjusting main relief valve in front chassis area).

25. Start engine and set engine rpm to 850rpm and turn cutter on.

26. Set cutter pump POR to 5700psi.

CUTTER solenoid CONTROL VALVE (S1) pressure switch

pressure transducer

attachment pump 'por' adjustment

CUTTER CONTROL MAIN RELIEF VALVE

20. Set cutter pump POR to 3000psi.

480-229

motor begin of displacement control

CUTTER CONTROL VALVE

27. Set cutter control valve main relief to *specifications (measured on gauge connected to M port on bottom of cutter pump).

28. Set cutter pump POR to *specifications.

21. Set both motor Begin of Displacement controls to *specifications. This adjustment is very sensitive in the control range. Turn screw in to increase setting and out to decrease setting. Note that the exact value is not critical, but both gauges must read exactly the same value.

22. Turn cutter off.

23. Shut engine off and remove gauges from motors.

17.8

Tigercat 480 Mulcher

Attachment Drive

SET MOTOR MINIMUM DISPLACEMENT

480-225

29. Set program mode to “Normal”.

30. Remove attachment side cover and install photo-tach tape to rotor drive pulley, raise head 1-2ft. motor begin of displacement control

'MIN' displacement ADJUSTMENT SCREW 480-159

ATTACHMENT DRIVE MOTOR

31. Preset both motor 'MIN' displacement screw exposed thread lengths to 4 threads.

32. Set engine rpm to 1850rpm and turn cutter on.

33. Measure rotor speed. Rotor speed setting must be 1550-1565 max rpm.

34. Turn cutter off and adjust min displacement screws as required (turn screw in to increase speed and out to decrease speed).

35. Reinstall attachment side cover.

17.9

Tigercat 480 Mulcher

Attachment Drive

17.10

Tigercat 480 Mulcher SECTION 19 - PUSH BAR & DEBRIS DOOR CONTENTS - SECTION 19

CIRCUIT DESCRIPTION............................................................................................... 19.4 CIRCUIT DIAGRAM....................................................................................................... 19.5 CROSS SECTION OF VALVE SPOOL SECTION......................................................... 19.3 PRESSURE SETTINGS................................................................................................. 19.6 SAFETY.......................................................................................................................... 19.6

MARCH, 2010

Tigercat 480 Mulcher

Push Bar & Debris Door

A

MAIN CONTROL VALVE

B

AM

AL

AI

AH

AJ

AK

AG

AF

AD

AE

34583AUNI R0

HYDRAULIC VALVE COMPARTMENT

480-163

MAIN CONTROL VALVE The main control valve assembly consists of five spool sections and one inlet section. push bar VALVE SECTION

PILOT RELIEF VALVE debris door VALVE SECTION 480-168A

'PS' PORT

MAIN CONTROL VALVE ASSEMBLY The push bar and debris door valve sections are part of the main control valve assembly and are located in the main valve as shown in the illustration above.

For a detailed description of the Main Control Valve Assembly Refer to SECTION 4 'Hydraulic System' of this service manual.

19.2

Tigercat 480 Mulcher

Push Bar & Debris Door

24 VOLT SOLENOID CONTROL

24 VOLT SOLENOID CONTROL LOAD CHECK VALVE

A

B

PILOT END CAP PILOT END CAP

SPOOL CENTERING SPRING RELIEF VALVE PORT 'A'

480-170

SPOOL

TYPICAL CROSS SECTION OF SPOOL SECTION 19.3

RELIEF VALVE PORT 'B'

Tigercat 480 Mulcher CIRCUIT DESCRIPTION

Push Bar & Debris Door

Debris Door

Push Bar

The debris door is operated by hydraulic cylinder(s). The main pump supplies oil to the cylinder(s) via the debris door spool section in the main control valve.

The push bar is operated by two hydraulic cylinders. The main pump supplies oil to the cylinders via the push bar spool section in the main control valve.

The debris door is operated by a thumb switch OPEN/CLOSE (self centering to OFF) located on the right joystick control (Refer to section 2 of the operator's manual for details). The switch operates two solenoid pilot valves on the debris door valve section which direct pilot oil to the debris door spool section of the control valve, to shift the spool. The spool directs oil from the pump to either end of the debris door cylinder to open or close the door. Return oil is directed back to tank via return oil filters.

The push bar is operated by a thumb switch IN/OUT (self centering to OFF) located on the left joystick control (Refer to section 2 of the operator's manual for details). The switch operates two solenoid pilot valves on the push bar valve section which direct pilot oil to the push bar spool section of the control valve, to shift the spool. The spool directs oil from the pump to either end of the push bar cylinders to move the push bar IN or OUT. Return oil is directed back to tank via return oil filters.

PUSH BAR CYLINDER

PUSH BAR

DEBRIS DOOR CYLINDER

DEBRIS DOOR

480-162

DEBRIS DOOR AND PUSH BAR 19.4

PUSH BAR CYLINDER

Tigercat 480 Mulcher

480-161

Push Bar & Debris Door

PUSH BAR AND DEBRIS door CIRCUIT DRAWING 19.5

Tigercat 480 Mulcher

Push Bar & Debris Door

Pressure settings PUSH BAR AND DEBRIS door

Before starting this procedure, read the following safety precautions:~ • Never reach between boom crank arms or link arms during machine setup.

• Wear safety glasses and safety shoes.

• Keep debris door closed whenever possible during setup.

• Keep clear of push bar operating area.

• Debris door opens and closes very rapidly, always keep clear of operating area.

480-135

• Do not stand on top or inside of boom arms.

1. Park machine on level ground. Lower the attachment to the ground and shut off engine.

4. The General Settings menu appears on the display, scroll down and select Program Mode. Press the OK button to select.

480-043 480-225

2. In the main menu, press the F2 button on the computer to select adjustment menu.

5. In the program menu scroll to Lockout Drives selection and press the OK button.

WARNING Do not stand below the attachment and lift boom or between the boom and front chassis during this procedure while boom is elevated and unsupported.

480-082

3. Press the F4 button to select the General Settings Menu from the ADJUSTMENT MENU. 19.6

Tigercat 480 Mulcher CUTTER solenoid CONTROL VALVE (S1)

Push Bar & Debris Door MAIN PUMP SOLENOID CONTROL VALVE (S2) 'B1' TEST PORT

CUTTER CONTROL VALVE

MAIN CONTROL VALVE

5. Start the engine, and set the throttle control to the 850 rpm.

6. Ensure that the hydraulic oil temperature is between 49 °C -60°C (120°F - 140°F).

7. While holding the PUSH BAR function control in the OUT position (cylinders fully extended), loosen locking screw and adjust POR valve on main pump in to 242 Bar (3500 psi) then turn the adjusting screw in 1/2 turn (aproximately 276 Bar/4000 psi).

NOTE: The gauge pressure reading will not exceed the push bar circuit port relief see specification chart in section 3.

Also, the Port releif valves are not adjustable and must be replaced if the pressure readings do not match specifications.

HYDRAULIC VALVE COMPARTMENT CHECK RELIEF VALVE PRESSURE:480-163

NOTE: * Refer to section 3, PRESSURE AND SPEED chart in this manual for pressure and speed specifications.

3. Connect a 0-350 Bar (0 - 5000 psi) pressure gauge to the 'B1' test port on the cutter control valve.

MAIN PRESSURE RELIEF VALVE

PORT RELIEFS PORT RELIEFS

480-166a

8. While holding the PUSH BAR function control in the IN position (cylinders fully retracted), check gauge pressure reading.

9. Pressure gauge should meet specifications for both IN and OUT positions. If pressure is less then or greater then specifications replace the affected relief valve.

10. If pressure readings are correct check debris door pressures.

Debris Door Pressure Test 11. While holding DEBRIS DOOR function control in the CLOSE position (cylinder fully extended), check gauge pressure reading.

12. While holding DEBRIS DOOR function control in the OPEN position (cylinder fully retracted), check gauge pressure reading.

MAIN PRESSURE RELIEF VALVE

480-167A

MAIN VALVE

4. Turn the main relief adjusting screw on the main control valve all the way IN.

13. Pressure gauge should meet specifications for both IN and OUT positions. If pressure is less then or greater then specifications replace the affected relief valve.

14. If pressure readings are correct reset main relief pressure on main valve and main pump POR pressure.

19.7

Tigercat 480 Mulcher

Push Bar & Debris Door

Reset POR and Main Relief Valve STANDBY ADJUSTMENT

'POR' ADJUSTMENT

LOCKING SCREWS

480-078

PUMP ADJUSTMENTS

15. While holding DEBRIS DOOR function control in the OPEN position, check gauge pressure reading. Adjust the main relief valve to specifications.

MAIN PRESSURE RELIEF VALVE

MAIN PRESSURE RELIEF VALVE

480-167A

MAIN VALVE

16. While holding DEBRIS DOOR function control in the OPEN position, check gauge pressure reading. Adjust the main pump POR valve to specifications.

17. Remove pressure gauge and wipe up any excess oil from 'B1' test port area.

19.8

Tigercat 480 Mulcher SECTION 20 - WINCH CONTENTS - SECTION 20

CIRCUIT DESCRIPTION............................................................................................... 20.4 CIRCUIT DIAGRAM....................................................................................................... 20.5 CROSS SECTION OF VALVE SPOOL SECTION......................................................... 20.3 PRESSURE SETTINGS................................................................................................. 20.6

MARCH, 2010

Tigercat 480 Mulcher

Winch

A

MAIN CONTROL VALVE

B

AM

AL

AI

AH

AJ

AK

AG

AF

AD

AE

34583AUNI R0

HYDRAULIC VALVE COMPARTMENT

480-163

MAIN CONTROL VALVE The main control valve assembly consists of five spool sections and one inlet section.

PILOT RELIEF VALVE WINCH VALVE SECTION 480-168A

'PS' PORT

MAIN CONTROL VALVE ASSEMBLY The winch valve section is part of the main control valve assembly and is located in the main valve as shown in the illustration above.

For a detailed description of the Main Control Valve Assembly Refer to SECTION 4 'Hydraulic System' of this service manual.

20.2

Tigercat 480 Mulcher

Winch

WINCH HYDRAULIC SCHEMATIC

480-164

24 VOLT SOLENOID CONTROL

24 VOLT SOLENOID CONTROL LOAD CHECK VALVE

A

B

PILOT END CAP PILOT END CAP

SPOOL CENTERING SPRING RELIEF VALVE PORT 'A'

480-170

SPOOL

TYPICAL CROSS SECTION OF SPOOL SECTION 20.3

RELIEF VALVE PORT 'B'

Tigercat 480 Mulcher

Winch

WINCH DESCRIPTION The Planetary Winch is composed of an input from a hydraulic motor. Input drives through a multiple disc brake that is spring applied and hydraulically released, and then through planet gear sets to the cable drum.

During inhaul, the brake is not released since the load is driven through a one-way cam clutch, bypassing the brake. When the load comes to a stop, the cam clutch locks up and the load is prevented from moving by the brake.

During payout, a brake valve is used to prevent the load from moving faster than desired. This brake valve partially blocks the main line from the motor back to the directional control valve, allowing only a limited amount of oil through the motor. Also, any time there is sufficient pressure to modulate the brake valve, this same pressure releases the multiple disc brake.

480-231

WINCH

The winch is also equipped with a spring applied and pneumatically released clutch. When the clutch is released the drum is disengaged from the drive motor and brake and can free spool the cable.

DRIVE MOTOR

WINCH CS

INPUT SHAFT

bRAKE DISCS

CLUTCH

WINCH CROSS SECTION 20.4

DRUM

Tigercat 480 Mulcher CIRCUIT DESCRIPTION

Winch

WINCH The winch is operated by a hydraulic motor. The main pump supplies oil to the motor via the winch spool section in the main control valve.

The winch function is controlled by a thumb switch FREE SPOOL/WINCH IN/WINCH OUT located on the right joystick control (Refer to section 2 of the operator's manual for details). The switch operates two solenoid pilot valves on the winch valve section which direct pilot oil to the winch spool section of the control valve, to shift the spool. The spool directs oil from the pump to either side of the motor to allow winch IN or OUT operation. Return oil is directed back to tank via return oil filters.

480-163

480-170

WINCH CIRCUIT DRAWING 20.5

spool section

Tigercat 480 Mulcher

Winch

Pressure settings WINCH

1. Park machine on level ground. Lower the attachment to the ground and shut off engine.

480-135

480-043

4. The General Settings menu appears on the display, scroll down and select Program Mode. Press the OK button to select.

2. In the main menu, press the F2 button on the computer to select adjustment menu.

480-225

480-082

5. In the program menu scroll to Lockout Drives selection and press the OK button.

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

20.6

Tigercat 480 Mulcher CUTTER solenoid CONTROL VALVE (S1)

Winch MAIN PUMP SOLENOID CONTROL VALVE (S2) 'B1' TEST PORT

9. Free spool the cable out and attach it to a suitable anchor.

10. Engage the winch IN function, and observe gauge pressure as cable is hauled in. When the cable stops the pressure should rise to specifications. Disengage winch IN function.

11. Pressure gauge should meet specifications.

If pressure is less then or greater then specifications replace the affected relief valve.

CUTTER CONTROL VALVE

MAIN CONTROL VALVE

PORT RELIEFS

HYDRAULIC VALVE COMPARTMENT CHECK RELIEF VALVE PRESSURE:-

PORT RELIEFS

480-163

NOTE: * Refer to section 3, PRESSURE AND SPEED chart in this manual for pressure and speed specifications.

480-166a

NOTE: The relief valves are non adjustable.

12. If pressure readings are correct shut engine off and remove gauge.

6. Connect a 0-350 Bar (0 - 5000 psi) pressure gauge to the 'B1' test port on the cutter control valve.

7. Start the engine, and set the throttle control to the 850 rpm.

8. Ensure that the hydraulic oil temperature is between 49 °C -60°C (120°F - 140°F).

20.7

Tigercat 480 Mulcher

Winch

20.8