Tigercat 6500 MATERIAL PROCESSOR OPERATOR'S MANUAL SN 65000001–65000500 - PDF DOWNLOAD

6500 MATERIAL PROCESSOR

OPERATOR'S MANUAL

SERIAL NUMBER 65000001 – 65000500

ISSUE 1.0, JUNE 2021 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

ii

Tigercat 6500 Material Processor TABLE OF CONTENTS INTRODUCTION................................................................................................................................................. v MACHINE IDENTIFICATION AND SERIAL NUMBERS..................................................................................... vi NON-APPROVED FIELD PRODUCT CHANGES..............................................................................................vii REGULATORY INFORMATION.........................................................................................................................viii SAFETY...............................................................................................................................................................1 CONTROLS AND OPERATION...........................................................................................................................2 LUBRICATION AND MAINTENANCE.................................................................................................................3

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

6500 AVAILABLE LITERATURE Operator's Manual (this manual).....................................................................................................Part No. 62036AENG Service Manual................................................................................................................................Part No. 62037AENG Parts Catalog...................................................................................................................................Part No. 62038A Vehicle Moving and Transporting Instructions.................................................................................Part No. 62034AMUL Engine Operation and Maintenance Manual...................................................................................SEBU9376-05 (en-us) iii

iv

INTRODUCTION................................................................................................................................................. v

Tigercat 6500 Material Processor 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 6500 Material Processor.

SERIAL NUMBERS: 6500

65000001 – 65000500

The 6500 Material Processor is designed to process all types of wood debris.

The Operator's manual will assist the operator with the techniques of proper and safe operation of the 6500 Material Processor. There is also important information regarding the safe operation of accessories (if equipped). The service manual contains safety and servicing procedures and a preventive maintenance schedule to ensure optimum machine performance.

Section 1 in both the Operator's manual and the service manual contains safety information that must be followed.

As well, throughout the rest of the manuals, DANGER, WARNING, and CAUTION notices are displayed where necessary, drawing attention to possible hazards when performing certain procedures.

Only personnel trained on the safe operation of this machine are permitted to operate or service 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 most current information.

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

If the machine in question was built after the release date of this manual and there is a discrepancy, call Tigercat service department.

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

Tigercat Industries Inc.

v

MACHINE IDENTIFICATION AND SERIAL NUMBERS..................................................................................... vi

Introduction

Tigercat 6500 Material Processor

MACHINE IDENTIFICATION AND SERIAL NUMBERS

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for engine serial number plate location.

Please record all serial numbers related to this machine below and have ready before calling for assistance.

Engine Serial Number:___________________________

6000304

Machine Serial Number Plate Location

The machine serial number plate is located at the nondrive side of the machine on the feed conveyor frame.

Machine Model Number:__________________________ Machine Serial Number:__________________________ Model Year:____________________________________

vi

NON-APPROVED FIELD PRODUCT CHANGES..............................................................................................vii

Tigercat 6500 Material Processor

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 its 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: • 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.

• 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.

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 incident 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.

vii

REGULATORY INFORMATION.........................................................................................................................viii

Introduction

Tigercat 6500 Material Processor

REGULATORY INFORMATION The machine is equipped with standard or optional equipment that is capable of emitting radio frequency fields.

Bluetooth and Wi-Fi exposure limits are significantly less than the maximum permitted for public use.

IMPORTANT! The RemoteLog™ telematics satellite antenna is externally mounted to the operator cab. When transmitting, the external antenna should be separated from personnel by a minimum distance of 20 cm (8 in). Transmissions can be silenced by placing the telematics system in repair mode.

FEDERAL COMMUNICATIONS COMMISSION NOTIFICATIONS TO USER INTERNAL (OPERATOR'S CAB): Telematics Module (Wi-Fi)

Contains FCC ID: VPYLB1CL or NCMOCG2101

IQAN-G11 (Bluetooth)

Contains FCC ID: VPYLBZY

Radio (Bluetooth)

Contains FCC ID: OPDJHD36A

Radio (Bluetooth)

Contains FCC ID: OPDJHD1635BT

Radio (Bluetooth)

Contains FCC ID: OPDJHD3630BT

EXTERNAL: Inmarsat Modem (Satellite)

Contains FCC ID: B92IDP1XX

Iridium Modem (Satellite)

Contains FCC ID: Q639603N

Transmitter (Light fob, not part of the machine)

Contains FCC ID: K4E939T4G

These devices comply with part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation.

Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.

This equipment complies with FCC radiation exposure limits set forth for an uncontrolled environment and meets the FCC radio frequency (RF) Exposure Guidelines. This equipment has very low levels of RF energy that is deemed to comply without maximum permissive exposure evaluation (MPE).

INDUSTRY CANADA NOTIFICATIONS TO USER INTERNAL (OPERATOR'S CAB): Telematics Module (Wi-Fi)

Contains IC ID: 772C – LB1CL or NCMOCG2101

IQAN-G11 (Bluetooth)

Contains IC ID: VPYLBZY

EXTERNAL: Inmarsat Modem (Satellite)

Contains IC ID: B92IDP1XX

Iridium Modem (Satellite)

Contains IC ID: Q639603N

Transmitter (Light fob, not part of the machine) Contains IC ID: 23770-K939T4GNUQ These devices comply with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.

This equipment complies with IC radiation exposure limits set forth for an uncontrolled environment and meets RSS102 of the IC radio frequency (RF) Exposure rules. This equipment has very low levels of RF energy that is deemed to comply without maximum permissive exposure evaluation (MPE). viii

SAFETY...............................................................................................................................................................1

Tigercat 6500 Material Processor SECTION 1– SAFETY Read and understand the entire contents of this manual, and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 1

ISSUE 1.0, JUNE 2021

B

BACKOVER ACCIDENTS – AVOIDING...................................................................................................................... 1.9 BATTERY DISCONNECT SWITCH......................................................................................................................... 1.13 BATTERY SAFETY...................................................................................................................................................... 1.8

C

COOLING SYSTEM.................................................................................................................................................. 1.14

E

EXHAUST FUMES.................................................................................................................................................... 1.15

F

FIRE PREVENTION.................................................................................................................................................. 1.22 AFTER A MACHINE FIRE...................................................................................................................................... 1.24 DRY CHEMICAL CLEANUP PROCEDURES...................................................................................................... 1.25 HOW TO PREPARE FOR A MACHINE FIRE....................................................................................................... 1.23 IN CASE OF A MACHINE FIRE............................................................................................................................. 1.23 WET CHEMICAL CLEANUP PROCEDURES...................................................................................................... 1.25 FLUID INJECTION INJURY...................................................................................................................................... 1.17

G

GENERAL SAFETY PRECAUTIONS........................................................................................................................ 1.4 GREASE INJECTION INJURY................................................................................................................................. 1.18

H

HAZARD ZONE........................................................................................................................................................... 1.5

L

LIGHTNING SAFETY AWARENESS....................................................................................................................... 1.19 LIGHTNING SAFETY............................................................................................................................................. 1.19 WHAT IS A LIGHTNING STRIKE?........................................................................................................................ 1.19 LOCKOUT TAGOUT.................................................................................................................................................. 1.13 LOOSE CLOTHING HAZARD.................................................................................................................................. 1.15

M

MACHINE STABILITY AND TRACTION.................................................................................................................. 1.16 MATERIAL PROCESSING SAFETY PRECAUTIONS............................................................................................ 1.12

O

OPERATING SAFETY PRECAUTIONS.................................................................................................................. 1.10

P

PARKING THE MACHINE......................................................................................................................................... 1.11 PNEUMATIC GREASE GUNS, USING.................................................................................................................... 1.18 PROTECTIVE CLOTHING.......................................................................................................................................... 1.4

S

SAFETY HAZARDS OPERATING............................................................................................................................................................. 1.8 VITON SEALS.......................................................................................................................................................... 1.7 SAFETY LABELS...................................................................................................................................................... 1.26 SAFETY PRECAUTIONS GENERAL................................................................................................................................................................. 1.4 MATERIAL PROCESSING.................................................................................................................................... 1.12 OPERATING........................................................................................................................................................... 1.10 SERVICING............................................................................................................................................................ 1.13 SAFETY SIGNAL WORDS.......................................................................................................................................... 1.3 SAFETY SYMBOLS..................................................................................................................................................... 1.3 SERVICING SAFETY PRECAUTIONS.................................................................................................................... 1.13

T

Safety

Tigercat 6500 Material Processor

TRANSPORTING THE MACHINE........................................................................................................................... 1.11 W

WELDING, PRIOR TO............................................................................................................................................... 1.15 WORKING WITH OIL.................................................................................................................................................. 1.7

1.2

Tigercat 6500 Material Processor

Safety

SAFETY SYMBOLS

The safety alert symbol demands immediate attention to a personal safety issue! It identifies important safety messages on machines, on safety signs, in manuals, or elsewhere. Be alert to the possibility of personal injury or death where this symbol appears. Follow the instructions in the safety message that accompanies the symbol.

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

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

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

NOTICE NOTICE indicates a potentially damaging situation which, if not avoided, may result in property damage and is not related to personal injury.

1.3

Safety

Tigercat 6500 Material Processor

GENERAL SAFETY PRECAUTIONS

WARNING

WARNING 24 VOLT ELECTRICAL SYSTEM 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 must be followed and obeyed.

These safety rules highlight both general and specific measures the operator must 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.

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.

DANGER The machine operator is responsible for the safety of persons around the machine. Verify that all personnel remain outside the hazard zone to prevent serious injury or death.

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

• Follow all instructions from safety inspector and supervisors.

• You must be fully trained to operate this piece of equipment. Know the capabilities and the limitations of the equipment. Learn the most efficient operating techniques. Do not let untrained persons operate the machine.

• Use recommended protective clothing and safety devices such as gloves, safety boots, safety hat, goggles, and ear protection when necessary.

1.4

Tigercat 6500 Material Processor

Safety

The following diagram illustrates the HAZARD ZONE. Keep all personnel clear of these zones while the machine is operating.

A

A

WARNING

B

Avoid mounting or dismounting the machine in areas with slippery surfaces. Dry, de-ice, clean up or cover slippery surfaces with an anti-slip material before mounting or dismounting the machine.

6000139

A 50 m (165 ft) B 50 m (165 ft)

Hazard Zone

WARNING

The HAZARD ZONE is off limits to all individuals.

Do not walk on machine surfaces with steel cleated foot wear. Steel cleats on steel surfaces are slippery and do not provide a safe foot hold.

• When approaching an active machine on foot, stay at least 50 m (165 ft) away until the operator recognizes your presence. All equipment must be shut down before advancing to the machine.

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

• Do not jump off the machine at any time.

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

• When mounting or dismounting the machine, use the three point technique. Use one hand with two feet or two hands with one foot.

1.5

Safety

Tigercat 6500 Material Processor

• To reduce risk of fire, completely clean machine of debris daily, particularly around the engine exhaust components. Eliminate hydraulic oil leaks, excess grease, fuel and oil accumulation (including spillage) immediately. Turn OFF the engine and remove the ignition key before cleaning the machine.

• Maintain a clean engine compartment, clear away trash or debris.

• Wash machine completely at every major service.

• Inspect the machine daily for signs of damage or unusual wear to structures.

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

• 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, oil shields, or other devices removed.

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

1.6

Tigercat 6500 Material Processor

Safety

WORKING WITH OIL

SAFETY HAZARDS – VITON SEALS

Direct contact with oil implies a risk of skin complaints (example: eczema). Observe strict hygiene.

O-rings and other seals manufactured of Viton material (fluorine rubber) produce a highly corrosive acid (Hydrofluoric) when subjected to temperatures above 315°C (600°F).

Observe the following when working with oil: • Oils used in this machine may be hot enough to cause serious burns.

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

• Avoid contact with oil, particularly heated oil.

• Wash off oil on the skin immediately with soap and water.

• Wear protective gloves. Clean hands before putting on gloves. Apply protective cream to the hands to make washing easier.

• Don't put oily rags in your pockets.

• Change oil soiled clothing as soon as possible.

• Keep an extra overall handy, but not in the machine where it can become dirty.

• Attend to cuts and abrasions immediately. Clean them and apply first-aid.

• Avoid breathing in oil fumes.

The following procedures are recommended when inspecting equipment subjected to high temperatures such as fire: • Visually inspect any seals or gaskets which have suffered from heat damage. They will appear black and sticky. If these are found, do not touch!

• Determine the material composition of any seals or gaskets, If fluoroelastomer 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).

• Wash hands and arms frequently, for example, at each meal break or as often as possible.

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

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

1.7

Safety

Tigercat 6500 Material Processor

SAFETY HAZARDS – OPERATING • Maintain a charged fire extinguisher near the machine at all times and know how to use it.

• Do not carry passengers anywhere on the machine.

• Do not allow anyone who may be unfit, physically or mentally, or who may be under the influence of alcohol or drugs, to operate the machine.

• Be aware, when performing service and maintenance tasks, surfaces and grab handles in and around the engine and cooling system may become very hot when the engine has been running.

Contact with hot surfaces may cause injury.

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

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

• 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.

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 distance of 3 m (10 ft) between the machine and any power line carrying up to 50,000 V. Add 1.5 m (5 ft)for each 150,000 V increment beyond 50,000 V. For example, if a power line carries 350,000 V, keep back at least 6 m (20 ft).

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

WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

Wash hands after handling.

• If the machine must be transported, it must be adequately secured to the transporting vehicle. Refer to the VEHICLE MOVING AND TRANSPORTING INSTRUCTIONS literature supplied with the machine. Refer to the TABLE OF CONTENTS page in THIS MANUAL for the literature part number if required.

• Stopping the engine immediately after it has been working under load can result in overheating and premature wear of the engine components.

• Reduce engine speed to LOW and let run for approximately five minutes to allow gradual dissipation of heat and also to reduce turbo speed.

This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

1.8

Tigercat 6500 Material Processor

Safety AVOID INJURY FROM BACKOVER ACCIDENTS

CAUTION

Lead-acid batteries contain sulfuric acid which can severely damage eyes or skin on contact.

Wear a safety face shield, rubber gloves and protective clothing to reduce risk of injury.

• Before moving the machine, be sure all persons are clear of the area.

• Be alert for bystanders moving into the work area.

Warn bystanders before moving the machine.

Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, open flames and lighted tobacco a safe distance from the batteries.

• When using a signal person, keep the person in view at all times. Be sure the signal person is clear before backing up.

• To avoid backover accidents: • Look around the entire machine area before backing up the machine.

• If acid is accidentally splashed into your eyes, flush immediately with clean water and get medical attention.

• Keep the motion alarm in proper working order.

The motion alarm must sound when the machine travels in forward or reverse.

• Do not attempt to charge a frozen battery. It can explode.

• Use a signal person when backing up if the view is obstructed. Keep the signal person in view.

• Learn and understand the meaning of all flags, signs, and markings on the job site. Know who is responsible for signalling.

• Keep lights, and cameras in proper working order.

• Before servicing the machine, turn OFF the battery disconnect switch and remove the negative (−) battery terminal cable (to the starter motor) from the battery.

• When service is complete, connect the negative (−) battery terminal cable and turn ON the battery disconnect switch.

• Do not short out the battery terminals for any reason.

Serious burns or an explosion can result.

1.9

Safety

Tigercat 6500 Material Processor

OPERATING SAFETY PRECAUTIONS

• Turn OFF the engine and remove the ignition key when refuelling. Do not refuel the machine while smoking or near an open flame or sparks.

• Attach a grounding strap to an unpainted metal surface on the machine if the refuelling tank or nozzle is so equipped.

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

• Start the engine according to the instructions in this manual. Refer to OPERATING MACHINE in SECTION 2.

• Before moving the machine to the work site, all doors, panels, and access covers must be installed properly and secured.

1.10

Tigercat 6500 Material Processor

Safety

PARKING THE MACHINE Park the machine in a cleared area at least 15 m (50 ft) away from other equipment. In the event of a fire, this distance will minimize the chance of the fire spreading to other equipment.

WARNING

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

• Maintain a safe operating distance between the machine and other personnel.

A slight decline to the discharge end of the machine will improve the performance of the feed conveyor.

Perform the following steps when parking the machine: 1. Park the machine on level ground. Do not park on a slope or hillside.

• Do not travel near co-workers or other pieces of equipment with the machine running.

2. Turn OFF the engine.

3. Remove the ignition key.

• Do not allow people or other pieces of equipment near the processing operation.

4. Wait for the 'Wait to Disconnect' light to go out.

5. Turn OFF the battery disconnect switch.

NOTE: If the battery disconnect switch is used to turn OFF the engine, the engine electronic control unit logs a fault code to record improper shutting/powering down.

This switch completely disconnects all electrical circuits on the machine from the batteries and is located at the front of the machine under the control panel. It is good practice to turn this switch OFF when the machine is left idle for an extended period of time, such as overnight.

WARNING • Use only prearranged and approved signalling practices.

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

• All safety screens and guards, must be installed and properly secured.

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

• Do not work alone. Regularly inform other crew members of your intentions, location and length of time to perform duties.

When transporting the machine, enough clearance must be 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 that all doors, panels, access covers and access stairs are installed properly and secured. Improperly secured doors or panels pose a serious danger to pedestrians and other vehicles.

1.11

Safety

Tigercat 6500 Material Processor

MATERIAL PROCESSING SAFETY PRECAUTIONS WARNING Maintain a safe operating distance of 50 m (165 ft) between the machine and workers and all other personnel. It is the duty of the operator to ensure that no personnel approach the machine while in use.

Failure to follow the above instructions could result in serious injury or death.

• Operators on the ground must maintain a 50 m (165 ft) distance from the machine during operation.

Use the remote to control the machine functions.

• Do not climb on the machine while processing.

• Do not walk or stand on the conveyors when the engine is running or the hog is operating.

WARNING The feed conveyor does not prevent material from discharging in the reverse direction beyond the conveyor. Operator must be aware of the surroundings at all times.

• Do not locate the machine atop combustible materials while in operation or when parked after operations have been completed.

• Keep the area around the machine clear of all debris.

• Maintain correct drive belt tension on hog drive.

Clear debris from drive belt and sheaves.

1.12

Tigercat 6500 Material Processor

Safety

SERVICING SAFETY PRECAUTIONS

LOCKOUT TAGOUT

• Conduct maintenance inspections at least as frequently as recommended in SECTION 3.

C

D

• Read, understand and follow all operating safety precautions specified in all supplementary documentation.

A

B

M00068

• Install a DO NOT START ENGINE sign on the control panel and in the engine compartment when making repairs to the machine. Before performing maintenance or repair work on any equipment, consult the instruction manual provided by the manufacturer and follow the recommended procedures.

A B C D

Battery Disconnect Switch – OFF Position (Switch Open) Battery Disconnect Switch – ON Position (Switch Closed) Lockout Hasp Padlock

• Before performing any service, lockout and tagout the machine to ensure the machine cannot be started by personnel other than those servicing the machine. Follow all lockout tagout rules in accordance with local regulations.

• The use of an industry-standard multiple-hole lockout hasp is recommended, especially when more than one person is servicing the machine. This allows each person to install their own lock and tag.

Close the lockout hasp and place lock(s) through the latch hole(s).

WARNING B

A

6000306

Do not remove a lock that was attached to the battery disconnect switch by someone else.

6000307

Battery Disconnect Switch

A OFF Position (Switch Open) B ON Position (Switch Closed)

• When servicing or repairing equipment, turn OFF the engine, remove the ignition key and turn OFF the battery disconnect switch in accordance with local regulations.

• Before servicing the machine, remove the negative (−) battery terminal cable (to the starter motor) from the battery.

1.13

Safety

Tigercat 6500 Material Processor

• When service is complete, connect the negative (−) battery terminal cable and turn ON the battery disconnect switch.

• Clean and service the cooler package daily to maintain moderate engine temperatures.

WARNING

• 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.

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

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

• Do not begin service work until the surface or system temperature has cooled down to below 38°C (100°F).

• Pressure can be maintained in a hydraulic system long after the power source and pump have been shut down.

WARNING

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

Diesel fuel or hydraulic oil 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.

• Do not use your bare hand to check for fluid leaks.

• Turn OFF the engine. Only remove the coolant fill cap when it is cool enough to touch with bare hands.

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

• Do not change any pressure or relief settings unless Tigercat authorized instruction has been obtained.

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

1.14

Tigercat 6500 Material Processor

Safety PRIOR TO WELDING Special precautions are necessary before undertaking any welding on the machine: 1. Clean up the work area. Remove excess oil or grease, debris, or flammable materials from the vicinity.

2. Keep a fire extinguisher on hand in the work area.

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

• Work in a ventilated area. If it is necessary to run an engine in an enclosed area, use an exhaust pipe extension to allow toxic exhaust fumes to be routed outdoors.

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

3. Situate the welding ground clamp on the machine such that current will not pass through any bearings.

4. Turn OFF the battery disconnect switch.

5. Remove the battery cover and disconnect the negative battery cable from the negative battery terminal. Refer to BATTERY BOOSTING in SECTION 3.

The following steps protect the sensitive electronics on the machine: 6. Disconnect all electronic components on the engine. Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

7. Disconnect the multi-pin connectors from the computer system modules in the electrical panel.

When welding work is complete: 8. Re-connect all connectors.

• 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.

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

• Be aware of machine pinch points that could cause injury. Do not place body parts within the range of motion of the working parts of the machine.

• Do not stand under an object supported with hydraulics. Use safety stands or a locking device.

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

1.15

9. Connect the negative battery cable to the negative terminal. The connection must be tight, clean, and secure.

Safety

Tigercat 6500 Material Processor

MACHINE STABILITY AND TRACTION This machine is designed to operate in rugged terrain.

However, ground conditions vary greatly according to soil type, slope, moisture level, temperature, season, geology, and vegetation. These factors affect the machine's stability and tractive capabilities. The machine may not be suitable for some ground conditions. Use caution when assessing the terrain in the work area Observe the following approaches to minimize the risk of tipping: • Do not operate this machine on slopes.

• Do not travel across a steep slope or hillside.

• When crossing obstacles (boulders, stumps, or ditches) the machine can shift rapidly, greatly affecting its stability. Move slowly over obstacles to reduce the risk of the machine shifting rapidly.

1.16

Tigercat 6500 Material Processor

Safety

FLUID INJECTION INJURY

Prevention is the best defence against fluid injection injuries.

WARNING

When searching for possible fluid leaks:

Diesel fuel or hydraulic oil under pressure can penetrate the skin and could result in serious injury or death. 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.

• Do not use bare hands. Wear thick protective gloves at all times.

• Wear safety goggles; a face shield is also recommended.

• Keep all body parts well away from the potential leak zone.

Hydraulic oil and diesel fuel systems in forestry equipment operate at very high pressures —often above 200 bar (3000 psi).

If a hose fitting becomes loose or a hose ruptures, the leak point will emit a fine, high velocity stream of fluid.

Even in systems that operate at pressures as low as 7 bar (100 psi), a fluid stream can penetrate human skin as if it were hypodermic needle.

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

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

An accidental hypodermic fluid injection may, at first, create only slight stinging sensation. Within a short time, however, the wound will begin to throb painfully, indicating that tissue has already been damaged.

If fluid injection penetrates a blood vessel, it can rapidly spread throughout the body's circulatory system. The body is unable to purge this toxin.

Time is a critical factor that influences fluid injection injuries. If a fluid injection injury occurs, or is suspected, it is vitally important to seek medical attention immediately. Tissue damage will continue to occur until the injury is treated.

Although fluid injection injuries are relatively rare, the resulting injuries have, on occasion, resulted in the amputation of fingers, hands, or entire limbs. The longer the delay in seeking medical attention, the further up the limb the tissue damage will reach. An injury of this nature can have extremely grievous consequences —including death —if not treated promptly and correctly.

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

• Seek professional medical attention immediately.

1.17

• Recognize that the leak source and the fluid stream itself may be nearly invisible. Pooling of fluid may be the clearest evidence of a leak.

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

• Do not grab hold of any hydraulic or diesel fittings or hoses that are pressurized.

• Use the correct hoses and fittings for repairs; they must be rated for the pressures to which they will be subjected.

• Do not use hoses or fittings if defects or damage are suspected.

Safety

Tigercat 6500 Material Processor

GREASE INJECTION INJURY– PNEUMATIC GREASE GUNS Pneumatic grease guns can pump grease at pressures ranging from 17 – 400 bar (245-5800 psi). Fluids at pressures as low as 7 bar (100 psi) can penetrate human skin.

Seek professional medical attention immediately in the event of a grease injection injury. Provide the attending physician with as much information as possible: the type of grease, the pressure setting of the gun, and related details.

In the event of a grease injection injury, the volume of material injected, the pressure at which it was injected, and the time elapsed between injection and medical treatment will influence the chance of successful recovery.

Before using a pneumatic grease gun: • All users must be trained to operate it properly.

• All users must be familiar with the hazards involved, and necessary safety precautions.

When using a pneumatic grease gun: • Wear protective clothing, such as gloves, safety goggles, and safety helmet.

• Inspect the grease gun equipment for damage or wear; replace damaged or worn parts.

• Verify that protective shrouds are installed at the grease gun nozzles.

• Remove dirt and old grease from grease fittings prior to pumping fresh grease.

• Replace any defective or damaged grease fitting on equipment with new fittings.

• Replace awkwardly situated fittings with angled or swivel fittings for ease of access.

1.18

Tigercat 6500 Material Processor

Safety

LIGHTNING SAFETY AWARENESS

LIGHTNING SAFETY

WHAT IS A LIGHTNING STRIKE? 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.

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.

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.

Personnel can increase their chances of avoiding a lightning strike by following a few simple safety practices: • Designate a member of your crew to: • Monitor daily weather forecasts • Observe local weather conditions • Alert all other members of the crew when a possible lightning threat develops • Do not start or continue any work that cannot be stopped immediately, when a storm moves nearby.

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 ft) within the soil around the strike point.

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.

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.

1.19

• 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.

• Obey the rule - If you see lightning, flee. If you hear thunder, Clear. 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.

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

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 they contain. Should lightning strike, the electrical current will travel through the wiring or plumbing into the ground.

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

Unfortunately personnel do not often work close to buildings and therefore other alternatives need to be considered.

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.

Safety 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.

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

Tigercat 6500 Material Processor IF YOU ARE CAUGHT OUTSIDE AND HAVE NOWHERE TO GO: • Avoid wide-open areas where you project above the surrounding landscape.

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

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

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

WHAT TO DO IF YOU ARE OUTSIDE AND SEE LIGHTNING OR HEAR THUNDER

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

IF YOU CAN, GET INSIDE:

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

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

IF INSIDE A BUILDING:

• Avoid entering any small enclosures or shelters.

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

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

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

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

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

IF INSIDE A MOTOR VEHICLE OR FULLY ENCLOSED ROPS EQUIPMENT CAB: • 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 use the telephone except for emergencies.

WHAT TO DO IF YOU FEEL YOUR SKIN TINGLING, YOUR HAIR STANDS ON END, LIGHT METAL OBJECTS VIBRATE OR YOU HEAR A CRACKLING SOUND: • Lightning is probably about to strike. You only have a few seconds to act.

• 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.

• 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.

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

1.20

Tigercat 6500 Material Processor

Safety

WHAT TO DO IF A CO-WORKER HAS BEEN STRUCK BY LIGHTNING: • The victim does not carry any electrical charge.

There is no danger to anyone helping this person.

You can touch him or her immediately.

• Call your local emergency response telephone number immediately.

• If the victim has no pulse, their heart has stopped or they have stopped breathing, call for professional medical help immediately and then begin administering appropriate first aid. Use a portable defibrillator if one is available (as required).

• 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.

1.21

Safety

FIRE PREVENTION

Tigercat 6500 Material Processor • Power wash the engine, hydraulic pumps, transmission, brake, fuel and hydraulic oil tank compartments at least once each month, or more frequently when working in conditions with high volumes of forest debris • Use only non-flammable solutions for cleaning the machine and components.

When working in a forest environment, combustible debris will collect in tight corners of the machine. Left unchecked, this debris may cause a fire; when mixed with fuel, oil, or grease in a hot or confined place, the danger of fire greatly increases.

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.

• Maintain a charged fire extinguisher on the machine at all times. Know how to use it.

• Remove dust and debris regularly from the cooling system components to prevent engine and hydraulic system overheating and to maintain efficient operation. Refer to CLEANING COOLER PACKAGE in SECTION 3 .

• Remove all forest debris and fine organic material around engine intake and exhaust components (turbocharger, exhaust manifold, exhaust pipes, muffler) at the end of each shift, or more frequently when working in conditions with high volumes of combustible forest debris. Check carefully in small pockets and cavities around the engine enclosure where smouldering debris may gather.

NOTE: Minor debris accumulations near hot components can ignite and smoulder. Smouldering debris may shift and cause fire to spread.

• Clean out all accumulated forest debris (twigs, needles, branches, bark, leaves, saw dust, wood chips) and any other combustible materials from inside the lower machine structures, and engine, hydraulic, and fuel system areas no less frequently than at the completion of each work shift.

• Inspect the machine regularly for evidence of diesel fuel or hydraulic system leakage. Check for worn or damaged hydraulic and fuel lines before turning on the engine.

• Inspect the exhaust system daily for evidence of leakage. Check for worn, cracked, broken, or otherwise damaged pipes or muffler, and missing or damaged bolts or clamps. Make repairs immediately. Engine exhaust leaks can cause fires.

Do not operate the machine until exhaust leaks are repaired.

NOTE: Changes or increases in engine exhaust noise levels often indicate exhaust leaks. Do not ignore these warnings. Shut down the machine immediately and complete repairs.

• Park the machine at least 15 m (50 ft) away from other equipment at the end of each shift.

• Turn OFF the battery disconnect switch when parking the machine.

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

• Remove the ignition key and lock the fuel cap at the end of shift to reduce the risk of vandalism or theft.

• Do not smoke in the vicinity of the machine.

• Do not smoke during fuelling operations, when the fuel system is open to the atmosphere, or when servicing the batteries. Exercise caution if smoking in the woods.

• After transporting a machine by road, remove any debris that may have settled around the engine and exhaust system during the journey.

• Before undertaking repair work or welding, clean the surrounding area and place a fire extinguisher within easy reach.

• Store rags and other combustible materials safely in a fireproof location.

• Do not operate the machine near burning timber.

• There is no substitute for fire prevention. Time invested in prevention is repaid through productivity on the job site.

• Clean up any grease, diesel fuel, or oil spillage (hydraulic or lubricating) immediately.

1.22

Tigercat 6500 Material Processor

Safety IN CASE OF A MACHINE FIRE

NOTICE

If a machine fire occurs: 1. Turn OFF the engine.

Equipment fires undermine productivity, may increase your insurance premiums dramatically, or prevent you from obtaining insurance coverage. Make fire prevention a priority.

2. Radio or call for help. Report a fire immediately.

3. Turn OFF the battery disconnect switch if it safe to do so.

HOW TO PREPARE FOR A MACHINE FIRE • Inspect and maintain all machine systems on a routine basis.

• Maintain fire extinguishers in proper working order. Follow the manufacturer’s instructions for inspection and maintenance (on the label of the fire extinguisher and in the user's manual).

• Verify the correct types of fire extinguishers are available at the work 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.

• Class C fires apply to energized electrical equipment.

• Know the recommended fire procedures in your organization's emergency action plan.

• Follow all national, state/provincial, and local fire fighting regulations. Regulations will vary from region to region but most will require that: • Workers assigned to fire fighting duties must be physically capable of performing them safely and effectively.

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

• 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.

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

• Know how to use the fire extinguisher on your machine. There is no time to read instructions during a fire emergency. Be prepared to act.

• Keep emergency contact information readily available in case of fire.

1.23

4. Put your personal safety and the safety of other persons first. Approach any fire with extreme caution. All fires are potentially very dangerous and life threatening.

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

2. There is a clear, safe escape route.

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

If in doubt about your ability to fight the fire, do not attempt to fight it. Stay well back. Wait for help to arrive.

NOTE: Engine coolant, diesel fuel, or hydraulic hoses may fail during a fire. Hot coolant, fuel, or oil could be ignited, or may spray at high velocity from damaged hoses.

Safety

Tigercat 6500 Material Processor

When fighting a fire:

AFTER A MACHINE FIRE

1. If possible, use a dry chemical fire extinguisher or fire suppression system first.

Before returning a machine to operations:

2. Immediately afterwards use a pressurized water extinguisher (if available). A fire suppressed by dry chemical may re-ignite from the heat retained by debris or hot machine components in the area.

Water cools the area, reducing the chances of reignition.

1. Determine the cause of the fire.

2. Complete all necessary repairs.

3. Service and recharge the fire suppression and detection systems as applicable.

4. Report the fire to your dealer.

3. Use the fire extinguisher PASS method: Pull the safety pin at the top of the extinguisher that prevents the discharge lever 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. To put out the fire, the fuel must be extinguished, not the flames. Hose nozzles are often clipped to the extinguisher body. Release the hose before taking aim.

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

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

4. If it is safe to do so, open any access panels in the area of the fire and aim the extinguisher directly at the base of the flames.

5. Monitor the machine after extinguishing a fire in case of re-ignition; remain until help arrives.

1.24

Tigercat 6500 Material Processor

Safety

DRY CHEMICAL CLEANUP PROCEDURES

WET CHEMICAL CLEANUP PROCEDURES

ABC dry chemical fire extinguishers and fire suppression systems discharge a chemical powder. The powder comprises very fine particles that penetrate and cover all components in the vicinity of the discharge.

The wet chemical suppression fluid contains frost protection, rust inhibitor, and film-forming liquids that are broken down by natural organisms. When the fluid dries, the corrosion protection loses its effect. Clean up wet chemical discharges as soon as possible to avoid corrosion on metal parts.

Areas in contact with dry chemical power must be neutralized and cleaned after a fire. Wear protective clothing, safety goggles, and a fine particle dust mask.

1. De-energize electrical systems prior to any cleanup.

2. In areas that remained cool and dry during the fire, the dry chemical remains in powder form.

Clean these areas immediately to prevent residual powder from coming into contact with water or ambient moisture.

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.

Wipe all surfaces with a damp cloth.

3. In areas exposed to moisture during the fire, the dry chemical powder combines with water to form a paste that is mildly acidic. All surfaces covered in dry chemical paste, including electrical contacts, are vulnerable to corrosion.

Neutralize the acidic paste on large surfaces by spraying or washing these areas with a mixture of three parts hot water to one 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.

Clean electrical contacts with a contact cleaner that has no flash or fire point and is non-corrosive and non-conductive, such as CRC Contact Cleaner 2000.

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

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.

When exposed to moisture the caked dry chemical is also mildly acidic. When the breakdown procedure has been completed, follow this immediately with the neutralizing procedure as described in step 3.

1.25

If the suppression fluid is sucked into the engine air intake, it will not significantly change engine functioning.

However, starting difficulties may occur with diesel engines because the suppression fluid contains water.

The suppression fluid also may cause corrosion damage if the engine is not cleaned soon after a fire.

Clean affected areas promptly to protect electrical system functions and prevent short circuits.

To clean affected areas: 1. Flush the affected area with pressurized fresh water.

2. Use an alkaline washing detergent to remove the film. (Film residue attracts dirt and other impurities on affected surfaces.)

3. Flush affected areas a second time to remove detergent residue.

NOTICE To protect engines, electrical installations, and other metal parts against corrosion, flush the remains of dried or moist suppression fluid as soon as possible after the release of the piston accumulator (use a high pressure washer if possible).

Safety

SAFETY LABELS Inspect and clean safety labels to preserve legibility.

Replace any illegible, damaged, or missing labels immediately.

Tigercat 6500 Material Processor REMOVE IGNITION KEY BEFORE SERVICING THE MACHINE

OPERATOR'S MANUAL LOCATION

This label shows where the operator's manual is stored.

The label is placed on the outside of the operator's manual case.

Read and understand the operator's manual before operating the machine. Take note of the warnings and hazard identifications. Study all safety messages in the manual and on machine labels.

Before performing maintenance or service work on the machine, turn OFF the engine, remove the ignition key, and store it in a safe place. Follow lockout tagout procedures before performing maintenance or service work on the machine.

1.26

Tigercat 6500 Material Processor

Safety

CRUSH HAZARD

THROWN OBJECT HAZARDS

This label warns of a crush hazard.

High speed ejection of heavy logs and branches, wood chips, and debris could strike personnel resulting in death or serious injury.

Make sure all personnel are clear when opening and closing the hog box. Operating the hog box with personnel in the crush zone could result in death or serious injury.

Do not operate machine unless the hog box is closed.

Keep all personnel clear of the machine before opening the hog box.

Never position the feed conveyor or discharge conveyor in line with any bystanders, other machines or buildings.

Maintain a safe operating distance between the machine and workers and all other personnel. It is the duty of the operator to ensure that no personnel approach the machine while in use. The risk zone is 50 m (150 ft).

1.27

Safety

Tigercat 6500 Material Processor

ELECTRICAL SHOCK HAZARD

CUTTING HAZARD

This label indicates a severe electrical shock hazard.

This label indicates cutting hazards around the cooling fan blades when the engine is running.

Do not place hands, fingers, hair, or clothing near the fan. Rotating parts such as cooling fan blades can entangle body parts, resulting in death or serious injury.

Turn OFF the battery disconnect switch before accessing the battery compartment. Disconnect the positive battery cables before servicing the electrical system.

Do not short the battery terminals for any reason. An explosion and/or serious burns can result.

Before performing any service work on the fan, cooling system, or fan area, turn the engine OFF and wait for rotating parts to come to a complete stop.

1.28

Tigercat 6500 Material Processor

Safety

STORED ENERGY HAZARD

KEEP BACK 50 M/165 FT

43424BUNI R0

This label warns personnel to keep back at least 50 m (165 ft) from a working machine due to the risk of high velocity flying debris.

When approaching an operating machine on foot, stay at least 50 m (150 ft) away until the operator recognizes your presence. Make certain that all equipment has been shut down before advancing any closer to the machine.

This label indicates a stored energy hazard.

The hydraulic system stores energy in the form of hydraulic pressure. Servicing a pressurized hydraulic oil tank, or any pressurized hydraulic components can result in death or serious injury.

Release hydraulic pressure before servicing any hydraulic components.

1.29

Safety

Tigercat 6500 Material Processor

CRUSH HAZARD

NO RIDERS

This label warns of a crush hazard.

Do not carry passengers anywhere on the machine.

Make sure all personnel are clear when tilting the tracks.

Operating the track tilt with personnel in the crush zone could result in death or serious injury.

Personnel riding on the outside of the machine are subject to a range of hazards, including: falls, crush hazards, thrown objects, falling objects, and others that can result in death or serious injury.

Keep all personnel clear of the machine before operating the track tilt.

If any person approaches or attempts to climb on to the machine during operation, stop the machine immediately.

Clear all personnel beyond the hazard zone before operating the machine.

1.30

Tigercat 6500 Material Processor

Safety

FIRE PREVENTION

CRUSH HAZARD

This label describes essential fire prevention measures:

This label indicates a vertical crush zone.

Read, understand, and follow the fire prevention guidelines in this manual.

Clear all personnel from the machine area before tilting the tracks, or raising or lowering the toolbox. Do not allow any personnel in areas where crush hazards exist while the machine is running.

Do not allow combustible material to build up in the machine.

Do not service the machine until the machine is correctly parked, and the engine is turned OFF.

Repair and clean up fluid leaks and spills immediately.

Inspect exhaust components for wear or damage.

1.31

Safety BURN HAZARD

Tigercat 6500 Material Processor ENTANGLEMENT HAZARD

This label indicates hot machine and/or component surfaces. Surfaces and grab handles in and around the engine, hydraulic oil tank, and cooling system can become very hot when the machine has been running.

Do not touch these surfaces; contact with hot surfaces can cause injury.

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

Use a thermometer to check surface and system temperatures. Do not begin service work until the surface or system temperature has cooled below 38°C (100°F).

36779BUNI R0

This label indicates an entanglement hazard around rotating parts.

Do not place hands, fingers, hair, or clothing near rotating parts such as pulleys, belts, and drives. Rotating parts can entangle body parts or clothing, resulting in death or serious injury.

Before performing any service work on these parts or in this area, turn the engine OFF and wait for rotating parts to come to a complete stop.

1.32

Tigercat 6500 Material Processor

Safety

PORTABLE FIRE EXTINGUISHER

EXPLOSIVE RELEASE OF COOLING SYSTEM FLUID

This label indicates portable fire extinguisher storage locations.

33952AUNI R0

This label indicates a pressure and fluid spray hazard when the coolant is hot.

Do not loosen the radiator cap when the radiator and coolant are hot. The explosive release of pressurized fluids can cause serious burns.

Turn OFF the engine and allow the radiator to cool to the point that it can be touched with bare hands before removing the cap. Slowly loosen the cap to the first stop.

Allow pressure to release. When the hissing stops, press down on the cap and continue turning to remove.

1.33

Safety

Tigercat 6500 Material Processor

1.34

CONTROLS AND OPERATION...........................................................................................................................2

Tigercat 6500 Material Processor SECTION 2 – CONTROLS AND OPERATION Read and understand the entire contents of this manual, and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 2

ISSUE 1.0, JUNE 2021

A

AIR COMPRESSOR – AIR SUPPLY (OPTIONAL)................................................................................................... 2.87 DRAINING THE SYSTEM...................................................................................................................................... 2.87 ALARMS EMERGENCY STOP ACTIVE............................................................................................................................... 2.14

B

BATTERIES................................................................................................................................................................ 2.20 BATTERY BOOSTING.............................................................................................................................................. 2.85 BATTERY BOOSTER CABLE WITH CLAMPS.................................................................................................... 2.85 BATTERY DISCONNECT SWITCH......................................................................................................................... 2.20

C

COMPUTER............................................................................................................................................................... 2.21 COOLING SCREEN............................................................................................................................................... 2.39 FAN CLEAN DURATION.................................................................................................................................... 2.39 FAN CLEAN FREQUENCY................................................................................................................................ 2.39 FAN START TEMPERATURE............................................................................................................................ 2.39 HYDRAULIC OIL COOLING FAN CLEAN MODE – MANUAL OPERATION................................................... 2.40 ENGINE MENU....................................................................................................................................................... 2.24 COOLANT LEVEL............................................................................................................................................... 2.25 COOLANT TEMPERATURE............................................................................................................................... 2.25 ENGINE FAILURE OR MALFUNCTION INDICATOR...................................................................................... 2.25 ENGINE % LOAD................................................................................................................................................ 2.25 ENGINE SPEED.................................................................................................................................................. 2.25 ENGINE SPEED ADJUST.................................................................................................................................. 2.25 FUEL CONSUMPTION....................................................................................................................................... 2.25 FUEL CONSUMPTION RESET BUTTON......................................................................................................... 2.25 FUEL LEVEL GAUGE......................................................................................................................................... 2.25 FUEL PRESSURE............................................................................................................................................... 2.25 FUEL TEMPERATURE....................................................................................................................................... 2.25 HOME SCREEN BUTTON................................................................................................................................. 2.25 MACHINE VOLTAGE.......................................................................................................................................... 2.25 OIL PRESSURE.................................................................................................................................................. 2.25 TOTAL FUEL CONSUMPTION.......................................................................................................................... 2.25 TURBOCHARGER BOOST PRESSURE.......................................................................................................... 2.25 HOME SCREEN..................................................................................................................................................... 2.21 MAIN MENU SCREEN BUTTON....................................................................................................................... 2.21 AUTO MODE/SERVICE MODE BUTTON......................................................................................................... 2.21 IMPACT DETECTION............................................................................................................................................ 2.41 MACHINE FUNCTIONS......................................................................................................................................... 2.26 DISCHARGE CONVEYOR................................................................................................................................. 2.27 ENGINE PTO PRESSURE................................................................................................................................. 2.27 ENGINE PTO TEMPERATURE......................................................................................................................... 2.27 FEED CONVEYOR............................................................................................................................................. 2.27 FEED CONVEYOR SPEED............................................................................................................................... 2.27 MACHINE SETUP SCREEN BUTTON.............................................................................................................. 2.27 ROTOR BEARING TEMPERATURE................................................................................................................. 2.27 TOP FEED ROLL HEIGHT................................................................................................................................. 2.27 TOP FEED ROLL SPEED................................................................................................................................... 2.27 TOP FEED ROLL UP/DOWN............................................................................................................................. 2.27

Controls and Operation

Tigercat 6500 Material Processor

MACHINE SETUP.................................................................................................................................................. 2.30 FEED CONVEYOR SPEED............................................................................................................................... 2.32 FORWARD FEED RESUME.............................................................................................................................. 2.33 FORWARD FEED STOP.................................................................................................................................... 2.33 PIN CODE............................................................................................................................................................ 2.30 REVERSE FEED START.................................................................................................................................... 2.34 SETUP SCREEN................................................................................................................................................. 2.31 TOP FEED ROLL DOWNFORCE...................................................................................................................... 2.36 TOP FEED ROLL HOLD HEIGHT...................................................................................................................... 2.38 TOP FEED ROLL LOCK..................................................................................................................................... 2.37 TOP FEED ROLL SPEED................................................................................................................................... 2.32 TOP FEED ROLL UP STOP HEIGHT................................................................................................................ 2.35 MACHINE WARMUP.............................................................................................................................................. 2.28 WARMUP BY TEMPERATURE.......................................................................................................................... 2.29 WARMUP BY TIME............................................................................................................................................. 2.29 MAIN MENU............................................................................................................................................................ 2.52 ADJUST MENU................................................................................................................................................... 2.56 MEASURE MENU............................................................................................................................................... 2.55 PREFERENCES.................................................................................................................................................. 2.56 DATE/TIME....................................................................................................................................................... 2.57 DISPLAY........................................................................................................................................................... 2.57 SYSTEM MENU.................................................................................................................................................. 2.53 INFO.................................................................................................................................................................. 2.53 LOGS MENU.................................................................................................................................................... 2.54 MODULES MENU............................................................................................................................................ 2.54 MESSAGES............................................................................................................................................................ 2.59 MESSAGES – CRITICAL AND ALARM................................................................................................................. 2.60 CONTROLLED SHUTDOWN............................................................................................................................. 2.63 CONTROLLED STOP......................................................................................................................................... 2.63 DISCHARGE HIGH PRESSURE....................................................................................................................... 2.63 DRIVE BELT FAILED TO ENGAGE................................................................................................................... 2.62 DRIVE SIDE BEARING HIGH TEMPERATURE............................................................................................... 2.64 ENGINE COOLANT TEMPERATURE HIGH.................................................................................................... 2.64 E-STOP ALARM.................................................................................................................................................. 2.62 FEED CONVEYOR HIGH PRESSURE............................................................................................................. 2.65 HYDRAULIC OIL TANK HIGH TEMPERATURE............................................................................................... 2.65 HYDRAULIC OIL TANK LOW OIL LEVEL......................................................................................................... 2.66 METAL DETECTION SYSTEM.......................................................................................................................... 2.62 NON-DRIVE SIDE BEARING HIGH TEMPERATURE..................................................................................... 2.64 TETHERED REMOTE SHORT.......................................................................................................................... 2.66 TOP FEED ROLL AFTER METAL DETECTED................................................................................................. 2.62 TOP FEED ROLL HIGH PRESSURE................................................................................................................ 2.66 WIRELESS REMOTE SHORT........................................................................................................................... 2.66 MESSAGES – ERROR............................................................................................................................................ 2.67 COMPUTER MODULE BLANK SCREEN......................................................................................................... 2.69 CURRENT OUTPUT ERROR (COUT).............................................................................................................. 2.69 DIGITAL INPUT ERROR (DIN)........................................................................................................................... 2.68 DIGITAL OUTPUT ERROR (DOUT).................................................................................................................. 2.68 MODULE NO CONTACT ERROR...................................................................................................................... 2.67 MODULE VREF ERROR.................................................................................................................................... 2.67 VOLTAGE INPUT ERROR (VIN)........................................................................................................................ 2.68 MESSAGES – WARNING....................................................................................................................................... 2.70 AUTO BELT ENGAGE........................................................................................................................................ 2.72 BAD BELT PRESSURE SENSOR..................................................................................................................... 2.72 BAD DISCHARGE PRESSURE SENSOR........................................................................................................ 2.73 BAD DRIVE SIDE BEARING SENSOR............................................................................................................. 2.73 2.2

Tigercat 6500 Material Processor

Controls and Operation

BAD DRIVE SIDE BOX POSITION SENSOR................................................................................................... 2.72 BAD DRIVE SIDE LOCK PIN POSITION SENSOR......................................................................................... 2.74 BAD DRIVE SIDE TOP FEED ROLL POSITION SENSOR............................................................................. 2.75 BAD DRIVE SIDE TRACK POSITION SENSOR.............................................................................................. 2.74 BAD FEED CONVEYOR PRESSURE SENSOR.............................................................................................. 2.75 BAD HYDRAULIC TEMPERATURE SENSOR................................................................................................. 2.75 BAD NON-DRIVE SIDE BEARING SENSOR................................................................................................... 2.73 BAD NON-DRIVE SIDE BOX POSITION SENSOR......................................................................................... 2.72 BAD NON-DRIVE SIDE LOCK PIN POSITION SENSOR............................................................................... 2.74 BAD NON-DRIVE SIDE TOP FEED ROLL POSITION SENSOR................................................................... 2.75 BAD NON-DRIVE SIDE TRACK POSITION SENSOR.................................................................................... 2.74 BAD TOP ROLL PRESSURE SENSOR............................................................................................................ 2.76 COUT HARDWARE FAULT................................................................................................................................ 2.80 DIN HARDWARE FAULT.................................................................................................................................... 2.80 DOUT HARDWARE FAULT................................................................................................................................ 2.80 FEEDS STOPPED FOR LOAD SENSE............................................................................................................ 2.76 GO TO SERVICE MODE.................................................................................................................................... 2.76 HARDWARE FAULT – MD4................................................................................................................................. 2.79 HARDWARE FAULT – XC43[1]............................................................................................................................ 2.79 HARDWARE FAULT – XC43[2]............................................................................................................................ 2.79 HOG BOX OPEN................................................................................................................................................. 2.76 HYDRAULIC OIL TANK HIGH TEMPERATURE............................................................................................... 2.77 LOCK PIN START BLOCKED............................................................................................................................ 2.77 MODULE HIGH SUPPLY VOLTAGE................................................................................................................. 2.84 MODULE HIGH SUPPLY VOLTAGE – WARNING............................................................................................. 2.82 MODULE HIGH TEMPERATURE...................................................................................................................... 2.84 MODULE HIGH TEMPERATURE – WARNING................................................................................................. 2.81 MODULE LOW SUPPLY VOLTAGE.................................................................................................................. 2.84 MODULE LOW SUPPLY VOLTAGE – WARNING............................................................................................. 2.83 SERVICE MODE START BLOCKED................................................................................................................. 2.77 START DISABLED.............................................................................................................................................. 2.78 TOP FEED ROLL START BLOCKED................................................................................................................ 2.78 VIN HARDWARE FAULT.................................................................................................................................... 2.80 OPERATIONAL DATA............................................................................................................................................ 2.22 ENGINE COOLANT TEMPERATURE............................................................................................................... 2.23 ENGINE FAILURE/MALFUNCTION INDICATOR............................................................................................. 2.23 ENGINE FUEL CONSUMPTION........................................................................................................................ 2.23 ENGINE MENU BUTTON................................................................................................................................... 2.23 ENGINE SPEED.................................................................................................................................................. 2.23 ENGINE SPEED ADJUST.................................................................................................................................. 2.23 FUEL LEVEL GAUGE......................................................................................................................................... 2.23 HYDRAULIC OIL TEMPERATURE.................................................................................................................... 2.23 MACHINE VOLTAGE.......................................................................................................................................... 2.23 ROTOR DRIVE BELT PRESSURE.................................................................................................................... 2.23 SERVICE MODE.................................................................................................................................................... 2.43 ANVILS EXTEND................................................................................................................................................ 2.50 ANVILS RETRACT.............................................................................................................................................. 2.50 CLOSE MACHINE AFTER MAINTENANCE..................................................................................................... 2.46 DRIVE BELT DISENGAGE................................................................................................................................. 2.51 DRIVE BELT ENGAGE....................................................................................................................................... 2.51 GRATE EXTEND................................................................................................................................................. 2.49 GRATE RETRACT.............................................................................................................................................. 2.49 OPEN MACHINE FOR MAINTENANCE........................................................................................................... 2.44 SERVICE FUNCTIONS SCREEN...................................................................................................................... 2.43 TOOLBOX DOWN............................................................................................................................................... 2.48 TOOLBOX UP...................................................................................................................................................... 2.48 TELEMATICS.......................................................................................................................................................... 2.42 2.3

Controls and Operation

Tigercat 6500 Material Processor

COMPUTER AND DISPLAY..................................................................................................................................... 2.14 CONTROLS............................................................................................................................................................... 2.14 EMERGENCY STOP ACTIVE............................................................................................................................... 2.15 EMERGENCY STOP BUTTONS........................................................................................................................... 2.15 MAIN ELECTRICAL PANEL.................................................................................................................................. 2.14 COMPUTER AND DISPLAY............................................................................................................................... 2.14 ENGINE DIAGNOSTICS CONNECTION.......................................................................................................... 2.14 IGNITION SWITCH............................................................................................................................................. 2.14 SYSTEM RESET BUTTON................................................................................................................................ 2.14 REMOTE................................................................................................................................................................. 2.16 DATA SCREEN.................................................................................................................................................... 2.17 DISCHARGE CONVEYOR................................................................................................................................. 2.17 ENGINE SPEED.................................................................................................................................................. 2.17 FEED CONVEYOR............................................................................................................................................. 2.17 FEED RATE......................................................................................................................................................... 2.17 STOP BUTTON................................................................................................................................................... 2.17 STORAGE AND CHARGING LOCATION......................................................................................................... 2.18 TOP FEED ROLL................................................................................................................................................ 2.17 TRACK MODE..................................................................................................................................................... 2.17 TRACK SPEED................................................................................................................................................... 2.17 TRACK UP/DOWN.............................................................................................................................................. 2.17 E

EMERGENCY STOP BUTTONS.............................................................................................................................. 2.15 ENGINE DIAGNOSTICS CONNECTION................................................................................................................ 2.14

F

FIRE EXTINGUISHER.............................................................................................................................................. 2.19 FUEL, REFUELLING PROCEDURE........................................................................................................................ 2.86

I

IGNITION SWITCH.................................................................................................................................................... 2.14

M

MACHINE OPERATING ANGLE.............................................................................................................................. 2.95 MACHINE OVERVIEW.............................................................................................................................................. 2.11 MOVING THE MACHINE.......................................................................................................................................... 2.96 USING TETHERED CONTROLLER..................................................................................................................... 2.96 USING WIRELESS REMOTE............................................................................................................................... 2.96

O

OPERATING MACHINE............................................................................................................................................ 2.88 PRE-START CHECKS........................................................................................................................................... 2.88 SHUTDOWN PROCEDURE.................................................................................................................................. 2.93 STARTUP PROCEDURE....................................................................................................................................... 2.92

P

PICTOGRAMS............................................................................................................................................................. 2.7

R

REFUELLING PROCEDURE................................................................................................................................... 2.86

S

2.4

Tigercat 6500 Material Processor

Controls and Operation

SERVICE MODE........................................................................................................................................................ 2.43 ANVILS EXTEND................................................................................................................................................... 2.50 ANVILS RETRACT................................................................................................................................................. 2.50 CLOSE MACHINE AFTER MAINTENANCE........................................................................................................ 2.46 DRIVE BELT DISENGAGE.................................................................................................................................... 2.51 DRIVE BELT ENGAGE.......................................................................................................................................... 2.51 GRATE EXTEND.................................................................................................................................................... 2.49 GRATE RETRACT.................................................................................................................................................. 2.49 OPEN MACHINE FOR MAINTENANCE............................................................................................................... 2.44 TOOLBOX DOWN.................................................................................................................................................. 2.48 TOOLBOX UP......................................................................................................................................................... 2.48 STARTING ENGINE.................................................................................................................................................. 2.94 STOPPING ENGINE................................................................................................................................................. 2.94 SYSTEM RESET BUTTON....................................................................................................................................... 2.14 T

TRACK OPERATION AND WEAR PREVENTION.................................................................................................. 2.97 PROTECTING STEEL TRACKS........................................................................................................................... 2.97 TRANSPORTING THE MACHINE........................................................................................................................... 2.95

2.5

Controls and Operation

Tigercat 6500 Material Processor

2.6

Tigercat 6500 Material Processor

Controls and Operation

PICTOGRAMS Diagrams in pictorial form are used to represent machine function operation. They are a simple universal language of symbols or pictograms that illustrate a function or component without the use of words.

Drive Belt Cylinder Engage

Examples of these pictograms are the turtle and the rabbit that are often used to describe speed such as SLOW = or FAST = .

Drive Belt Cylinder Extend 12V, Power 24V, Power Drive Belt Cylinder Retract

Adjustment Menu Icon

Alert Message Symbol

Electric Service Pump

Anvil Cylinders Extend Engine Boost Pressure Anvil Cylinders Retract Engine Charge Air Pressure Filter Battery Connect Engine Charge Air Temperature

Battery Disconnect

Engine Coolant Level

Bearing Temperature

Cooling Adjust

Engine Coolant Temperature

Discharge Conveyor On/Off

Engine Diagnostics

Discharge Conveyor Pressure

Engine Fan Cooling Duration

Engine Fan Temperature Enable

2.7

Controls and Operation

Tigercat 6500 Material Processor

Engine Fan Manual Purge

Feed System Stop

Engine Fan Purge Duration Fuel Consumption Engine Percentage of Load Fuel Consumption – 1 hour Engine Oil Pressure Fuel Consumption – 12 hours

Engine Oil Temperature

Fuel – Diesel Engine Run Fuel Information Engine Speed – rpm Fuel Level Engine Start Fuel Pressure Engine Stop Fuel Rate Engine Wait to Start Fuel Reset

Feed Conveyor

Fuel – Temperature

Feed Conveyor Forward

Fuel – Total Consumed

Feed Conveyor Pressure Feed Conveyor Reverse

Fuel – Water in Fuel

Feed System Forward

Grate Extend

Feed System Reverse

Grate Retract

2.8

Tigercat 6500 Material Processor

Controls and Operation

Hog Box Close

Hydraulic Oil Temperature

Hog Box Lock Pin Extend

Hydraulic Oil Warmup

Hog Box Lock Pin Retract

Hydraulic Oil Warmup Mode

Hog Box Open

Hydraulic Oil Cooling Fan Purge

Home

Impact Detection Menu

Hours – Engine

Metric/Imperial Toggle

Hours – Machine

Peak Value

Hydraulic Oil Filter Bypass

Play

Hydraulic Oil Tank

Reset

Hydraulic Oil Grade

Rotor Hydraulic Oil Level Run Mode Hydraulic Oil Temperature Run Mode Adjust Hydraulic Oil Cooling Enable Save to File Hydraulic Oil Fan Cooling Duration Serial Number Hydraulic Oil Fan Purge Duration Service Mode

2.9

Controls and Operation

Tigercat 6500 Material Processor Top Feed Roll Pressure

Settings

Top Feed Roll Reverse Speed Fast or Hi Speed Slow or Low

Top Feed Roll Stop Rotation

Switch OFF Top Feed Roll Up Switch ON Top Feed Roll Up Cancel Temperature Top Feed Roll Up Pressure Toolbox

Track Mode On

Toolbox Down

Track LEFT FORWARD/REVERSE and TRAVEL

Toolbox Up Track RIGHT FORWARD/REVERSE Top Feed Roll

Top Feed Roll Down

Top Feed Roll Down Cancel

Top Feed Roll Down Pressure

Top Feed Roll Forward

Top Feed Roll Height

2.10

Tigercat 6500 Material Processor

Controls and Operation

MACHINE OVERVIEW

F

G

H

I

A E D

C B

6000308

A B C D E

Approximate Overall Dimensions– Machine at Level Setting

Height – 4.88 m (16 ft) Length – 16.15 m (53 ft) Track Contact Length – 3.66 m (12 ft) Feed Conveyor Frame Height – 2.74 m (9 ft) Engine Compartment Height – 4.27 m (14 ft)

F G H I

2.11

Feed Conveyor Frame Width – 2.69 m (8 ft 10 in) Feed Conveyor Chains Width – 1.45 m (4 ft 9 in) Track Contact Width – 3.05 m (10 ft) Discharge Conveyor Belt Width – 1.22 m (4 ft)

Controls and Operation

Tigercat 6500 Material Processor

A

B

N

C

M

D

L

E

F

K

J

G

I

H

6000311

A B C D E F G

Feed Conveyor Rotor Top Feed Roll/Top Feed Roll Arm Engine/Hydraulic Compartment Hydraulic Oil Tank Fuel Tank Discharge Conveyor

Non-drive Side H I J K L M N

2.12

Engine/Hydraulic Compartment Service Platform Cooler Package Right Track Hog Box Service Platform Discharge Conveyor Tail Pulley Toolbox Feed Conveyor Tail Pulley

Tigercat 6500 Material Processor

A

Controls and Operation

B

N

C

M

D

L

E

K

F

J

G

I

H

6000312

A B C D E F G

Discharge Conveyor Hydraulic Oil Tank Fuel Tank Engine/Hydraulic Compartment Service Platform Cooler Package Upper Hog Box Hog Box Service Platform

Drive Side

H I J K L M N

2.13

Feed Conveyor Tail Pulley Discharge Conveyor Tail Pulley Feed Conveyor Drive Motor Left Track Drive Belt (Guard Not Shown) Main Electrical Panel Hydraulic Oil Cooler and Engine PTO Oil Cooler

Controls and Operation

Tigercat 6500 Material Processor

CONTROLS

IGNITION SWITCH

MAIN ELECTRICAL PANEL

A

B

C

D 800590

6000406

A B C D E

A

B

C

D

E

Main Electrical Panel– Drive Side of Machine

Ignition Switch Engine Diagnostics Connection System Reset Button Computer and Display Emergency Stop Button

COMPUTER AND DISPLAY The computer and display module is the operator's principal interface with the machine's electronic control system. The computer has a 254 mm (10 in) backlit colour graphic touchscreen display for reading system information.

Refer to COMPUTER in THIS SECTION for operating instructions and system details.

SYSTEM RESET BUTTON Press and release the system reset button after engine is running to activate all machine functions. Screen icon will change from orange to green.

NOTE: If the system reset button icon remains orange after pressing, check for an emergency stop button that is still pressed or refer to the computer display for active alarm messages.

A B C D E

E

Stop Position Run Position Start Position Mounting Nut Ignition Key

This is a three-position switch with STOP/RUN/START positions.

STOP POSITION – All electrical power through the key switch is turned OFF. RUN POSITION – The battery is connected to all functions. Used for normal machine operation.

START POSITION – Turning the key to this position starts the engine by connecting the battery to the start relay. The key will return to the RUN position when released.

ENGINE DIAGNOSTICS CONNECTION Plug a remote electronic diagnostic device into this connection such as a laptop computer with appropriate engine manufacturer’s programming to perform engine performance analysis and tuning.

IMPORTANT! This operation can only be performed by a trained service technician.

Refer to OPERATING MACHINE– STARTUP PROCEDURE in THIS SECTION.

2.14

Tigercat 6500 Material Processor

Controls and Operation

EMERGENCY STOP BUTTONS

There are two emergency stop (E-stop) buttons on the machine: • Main electrical panel – drive side of machine • Non-drive side near hog box service platform Press any of the emergency stop buttons DOWN, to immediately turn OFF the engine and all machine systems.

To turn the power back ON, turn the knob clockwise and allow the button to pop up.

A

NOTICE Do not use the emergency stop button to turn OFF the engine during normal operation.

6000385

EMERGENCY STOP ACTIVE B

6000194

When an emergency stop button is pressed, an alarm warning message will appear on the computer display advising that one of the buttons is active.

6000170

The machine will not start until all emergency stop buttons are popped up.

Emergency Stop Buttons

A Main Electrical Panel B Non-Drive Side of Machine Near Feed Conveyor

2.15

Controls and Operation

Tigercat 6500 Material Processor

WIRELESS REMOTE

A

B

D

C

F

E

H

G

J

I

L

K

N

M

P

O

6000325

A B C D E F G H

Main Function

Stop Button Data Screen 2nd Function Button Power ON/OFF Engine Speed UP Engine Speed DOWN Discharge Conveyor ON/OFF Top Feed Roll REVERSE

2nd Function– Fn Button – – – – Feed Rate Discharge Speed UP Discharge Speed DOWN

I J K L M N O P

2.16

Main Function

Feed FORWARD Feed REVERSE Top Feed Roll UP Top Feed Roll DOWN – – Track UP Track DOWN

2nd Function– Fn Button Track Range LOW/HIGH Track Mode ON/OFF Right Track FORWARD Left Track FORWARD Right Track REVERSE Left Track REVERSE – –

Tigercat 6500 Material Processor

Controls and Operation

STOP BUTTON

FEED RATE Momentarily press Feed Rate to select from three preset rates.

C

DISCHARGE CONVEYOR Press Discharge ON/OFF button to activate the discharge conveyor. Press the button again to deactivate.

Press and hold Discharge Speed UP to increase the speed of the discharge conveyor. Release the button when desired speed is attained.

Press and hold Discharge Speed DOWN to decrease the speed of the discharge conveyor. Release the button when desired speed is attained.

TOP FEED ROLL

6000325

A Stop Button – Remote

Press the button to stop the machine. To reset, twist the button until it pops up.

DATA SCREEN The data screen shows the following information: Screen Parameter

Description

1

Engine Speed (rpm)

2

Engine Load (%)

3

Fuel Rate – L/h (US gph)

4

Engine Hours

5

Coolant Temperature °C (°F)

6

Fuel Pressure – bar (psi)

7

Oil Pressure – bar (psi)

8

Boost Pressure – bar (psi)

Press and hold Top Feed Roll REVERSE to reverse the direction of the top feed roll.

Press and hold Top Feed Roll UP to raise the top feed roll. Release the button when top feed roll is in the desired position.

Press and hold Top Feed Roll DOWN to lower the top feed roll. Release the button with top feed roll is in the desired position.

TRACK MODE Momentarily press Track Mode ON/Off to engage the tracks. Track alarm will sound. The machine can now be moved using the track forward and reverse buttons.

Press the Track Mode ON/OFF button again to turn OFF track mode. Track alarm will continue to sound until track mode is turned OFF.

ENGINE SPEED

TRACK SPEED

Press and hold Engine Speed UP to increase engine speed. Release the button when desired speed is attained.

Momentarily press Track Range LOW/HIGH to set track speed range at HIGH or LOW. The low setting provides the slowest travel speed with maximum torque or driving force. The high setting provides a faster travel speed range but with lower driving force.

Press and hold Engine Speed DOWN to decrease engine speed. Release the button when desired speed is attained.

FEED CONVEYOR Momentarily press Feed FORWARD to operate the feed conveyor and top feed roll in the forward direction.

Momentarily press Feed REVERSE to stop the feed conveyor. Press and hold Feed REVERSE to reverse the direction of the conveyor.

2.17

TRACK UP/DOWN Press and hold Track UP to raise the tracks off the ground or Track DOWN to lower the tracks.

Controls and Operation

Tigercat 6500 Material Processor

REMOTE STORAGE AND CHARGING LOCATION

A

B

6000407

A Wireless Remote B Charging Station

Main Electrical Panel

The remote is attached magnetically to a charging station inside the main electrical panel. When not in use, return the remote to the charging station to maintain maximum charge during operation.

NOTE: Use only rechargeable Nickel Metal Hydride (NiMH) batteries in the remote.

NOTICE Failure to use rechargeable batteries in the remote will damage the remote and the machine electrical system.

2.18

Tigercat 6500 Material Processor

Controls and Operation

FIRE EXTINGUISHER

A

6000188

Non-Drive Side of Machine

A Fire Extinguisher

The machine is equipped with a fire extinguisher mounted on the non-drive side of the machine, beside the engine/hydraulic compartment service platform.

Keep the fire extinguisher fully charged in its proper storage location.

2.19

Controls and Operation

Tigercat 6500 Material Processor

BATTERY DISCONNECT SWITCH

BATTERIES Two 12 V batteries are located in a tray under the hydraulic oil tank on the drive side of the machine.

The batteries are wired in series to produce a 24 V supply. Access to the batteries is by removing the battery compartment cover.

If the batteries require boosting, refer to BATTERY BOOSTING in THIS SECTION. If the batteries need charging, refer to BATTERY CARE in SECTION 3.

6000585

Drive Side of Machine

B

A

6000306

6000307

Battery Disconnect Switch

A OFF Position (Switch Open) B ON Position (Switch Closed)

This manually-operated switch is located on the drive side of the machine behind the main electrical panel. It completely disconnects most electrical circuits from the battery.

Turn OFF the battery disconnect switch if the machine is to be parked for an extended period of time, such as overnight.

IMPORTANT! Use the battery disconnect switch to turn OFF a running machine in an emergency only. A fault code will be logged by the ECU on the engine for improper shut down and power down.

2.20

Tigercat 6500 Material Processor

Controls and Operation

COMPUTER HOME SCREEN

B

C

A

6000382

A Main Menu Screen Button B Auto Mode/Service Mode Button

C Imperial/Metric Units Selection Button

This home screen appears at the start-up of the machine. The touch screen allows navigation through the computer.

AUTO MODE/SERVICE MODE BUTTON Momentarily press to change the machine from auto mode (operation) to service mode. Perform all machine service and maintenance in this mode. Momentarily press the button again to return machine to auto mode.

MAIN MENU SCREEN BUTTON Momentarily press to access the Main menu.

2.21

Controls and Operation

Tigercat 6500 Material Processor

OPERATIONAL DATA B

C

D

A

E

F

G

H

I

J

K

L

M

N

O

6000382

A B C D E F G H

Engine Status Icon Engine Failure or Malfunction Indicator – Yellow Engine Failure or Malfunction Indicator – Red Interlock System Indicator Engine Speed Digital Readout and Gauge Engine Speed Adjust Button – FAST Engine Speed Adjust Button – SLOW Machine Voltage

I J K L M N O

2.22

Hydraulic Oil Temperature Fuel Level Gauge Rotor Drive Belt Pressure Engine Oil Pressure Engine Coolant Temperature Engine Fuel Pressure Engine Menu Button

Tigercat 6500 Material Processor

Controls and Operation

ENGINE FAILURE/MALFUNCTION INDICATOR

HYDRAULIC OIL TEMPERATURE This display indicates hydraulic oil temperature in the hydraulic oil tank.

FUEL LEVEL GAUGE This display indicates the percentage of maximum capacity of the fuel tank.

ROTOR DRIVE BELT PRESSURE This display indicates the load (pressure) on the rotor drive belt.

6000196

The yellow or red indicator will illuminate when an engine fault occurs. Depending on the nature of the fault, the machine will go into a controlled shutdown and a warning message will appear on the computer display.

This display indicates the total fuel consumption of the engine.

ENGINE SPEED

ENGINE COOLANT TEMPERATURE

ENGINE FUEL CONSUMPTION

This display indicates the operating engine coolant temperature.

This display provides a digital readout of the engine speed in rpm. The gauge indicates the percentage of HIGH engine speed where the engine is operating.

If temperature rises above the recommended temperature check the following:

MAINTAINING CORRECT ENGINE RPM It is important that engine speeds be correct at all times: LOW: 700 rpm (No Load) HIGH: 2050 rpm (No Load)

• Plugged cooler package air intake screens in doors and access panels.

• Plugged oil cooler.

Do not continue to operate machine.

NOTE: The above values are measured with the hydraulic and engine oil at normal operating temperatures and no functions activated.

Refer to CLEANING COOLER PACKAGE in SECTION 3.

Engine speed defaults to LOW at startup.

ENGINE MENU BUTTON

ENGINE SPEED ADJUST

For additional engine operation information, press to display the engine menu.

To increase engine speed, press and hold the FAST button until the desired speed is attained. To decrease engine speed, press and hold the SLOW button until the desired speed is attained.

MACHINE VOLTAGE

IMPORTANT! 24 VOLT ELECTRICAL SYSTEM This display indicates machine voltage levels.

Normal operating range for the electrical system is between 20 and 30 V. A reading in excess of 30 V indicates a possible faulty voltage regulator. A reading less than 20 V indicates a possible faulty battery or alternator.

2.23

Controls and Operation

Tigercat 6500 Material Processor

ENGINE MENU B

C

A

D

E

F

S

G

H

I

R

J

Q

K

L

M

N

O

P

6000327

A B C D E F G H I J

Status Icon (Check Engine Light) Failure or Malfunction Indicator – Yellow Failure or Malfunction Indicator – Red Time of Operation – Hours Speed Digital Readout and Gauge Speed Adjust Button – FAST Speed Adjust Button – SLOW Engine % Load Turbocharger Boost Pressure Machine Voltage

K L M N O P Q R S

2.24

Fuel Consumption Coolant Temperature Fuel Pressure Fuel Temperature Fuel Consumption Reset Button Home Screen Button Fuel Level Gauge Engine Oil Pressure Total Fuel Consumption

Tigercat 6500 Material Processor

Controls and Operation

ENGINE FAILURE OR MALFUNCTION INDICATOR

FUEL PRESSURE This display indicates operating engine fuel pressure.

Refer to COMPUTER – OPERATIONAL DATA for information.

FUEL TEMPERATURE

ENGINE SPEED

This display indicates operating engine fuel temperature.

Refer to COMPUTER – OPERATIONAL DATA for information.

FUEL CONSUMPTION RESET BUTTON Press to reset the fuel consumption to zero.

ENGINE SPEED ADJUST

HOME SCREEN BUTTON

Refer to COMPUTER – OPERATIONAL DATA for information.

Press to return to the home screen.

ENGINE % LOAD

FUEL LEVEL GAUGE

This display indicates the percentage of full load the machine is operating.

Refer to COMPUTER – OPERATIONAL DATA for information.

TURBOCHARGER BOOST PRESSURE

ENGINE OIL PRESSURE

This display indicates air intake manifold boost pressure. This reading is an absolute value and includes atmospheric pressure.

MACHINE VOLTAGE Refer to COMPUTER – OPERATIONAL DATA for information.

FUEL CONSUMPTION This display indicates the total fuel consumption of the engine.

COOLANT TEMPERATURE This display indicates the operating engine coolant temperature.

If temperature rises above the recommended temperature check the following: • Plugged cooler package air intake screens in doors and access panels.

• Plugged oil cooler.

Do not continue to operate machine.

Refer to CLEANING COOLER PACKAGE in SECTION 3.

2.25

This display indicates operating engine oil pressure.

TOTAL FUEL CONSUMPTION This display indicates total fuel consumption of the machine.

Controls and Operation

Tigercat 6500 Material Processor

MACHINE FUNCTIONS A

B

E

C

F D G

H

I

J

K

L

M

N

6000382

A B C D E F G

Rotor Non-drive Side Bearing Temperature Rotor Drive Side Bearing Temperature Engine PTO Oil Temperature Engine PTO Oil Pressure Top Feed Roll Height Top Feed Roll Speed Feed Conveyor Speed

Buttons and Readouts H I J K L M N

2.26

Feed Conveyor – Feed FORWARD Button Discharge Conveyor Pressure Discharge Conveyor Speed – % of Maximum Discharge Conveyor – FAST Speed Button Discharge Conveyor – SLOW Speed Button Discharge Conveyor ON/OFF Button Machine Setup Screen

Tigercat 6500 Material Processor

Controls and Operation

ROTOR BEARING TEMPERATURE Displays the drive side and non-drive side rotor bearing temperatures during operation.

ENGINE PTO TEMPERATURE Displays the operating temperature of the engine PTO oil.

ENGINE PTO PRESSURE Displays the operating pressure of the engine PTO oil circuit.

TOP FEED ROLL HEIGHT Displays the operating top feed roll height.

TOP FEED ROLL SPEED Displays the operating top feed roll rotational speed.

FEED CONVEYOR SPEED Displays the operating feed conveyor speed.

FEED CONVEYOR Momentarily press the Feed FORWARD button to turn ON the feed conveyor. Momentarily press the button again to turn OFF the feed conveyor.

DISCHARGE CONVEYOR Momentarily press the Discharge Conveyor ON/OFF button to turn ON the discharge conveyor. Momentarily press the button again to turn OFF the discharge conveyor.

Press and hold the Discharge Conveyor FAST button to increase the speed. Press and hold the Discharge Conveyor SLOW button to reduce the speed.

The percentage of maximum speed is displayed on the screen. The operating pressure of the discharge conveyor is also displayed.

MACHINE SETUP SCREEN BUTTON Press to display the machine setup screen. Use this screen to make adjustments to machine settings suitable to operating conditions.

2.27

Controls and Operation

Tigercat 6500 Material Processor

MACHINE WARMUP

6000328 6000382

Home Screen – Machine Warmup Screen

When machine warmup is activated, the following functions are automatically turned ON: • Feed system (top feed roll and feed conveyor) in reverse direction.

• Downforce applied to the top feed roll.

• Discharge conveyor.

NOTE: Engine speed is limited to 1100 rpm maximum when cold.

6000247

When the machine is started from cold, the hydraulic oil temperature cold warning will appear on the screen.

2.28

Tigercat 6500 Material Processor

Controls and Operation

WARMUP BY TEMPERATURE

WARMUP BY TIME

A

A

B

B

6000328

6000467

A Temperature Warmup Button B Hydraulic Warmup Button

A Time Warmup Button B Hydraulic Warmup Button

Press the temperature warmup button to set the warmup cycle by temperature.

Press the time warmup button to set the warmup cycle by duration.

Press the hydraulic warmup button to start the warmup cycle. The button will illuminate green.

Press the hydraulic warmup button to start the warmup cycle. The button will illuminate green.

A

6000468

A Time Countdown

The time will count down on the screen.

NOTE: Warmup temperature and warmup time are factory preset values.

2.29

Controls and Operation MACHINE SETUP

6000382

Tigercat 6500 Material Processor PIN CODE

6000329

Home Screen Press the Machine Setup Screen button.

6000330

The machine setup is controlled by a PIN code.

Press the Enter PIN button.

Enter the PIN code and press

2.30

to accept.

Tigercat 6500 Material Processor

Controls and Operation

SETUP SCREEN

6000471 6000469

Home Screen – Machine Setup Screen Three machine setup modes are available to group the machine settings for various operating conditions.

Press the run mode button to select mode 1, 2 or 3, before starting the machine setup.

6000470

2.31

Controls and Operation

Tigercat 6500 Material Processor

TOP FEED ROLL SPEED

FEED CONVEYOR SPEED

A

6000469

A Top Feed Roll Speed

A

6000469

A Feed Conveyor Speed

Home Screen – Machine Setup Screen

Home Screen – Machine Setup Screen

This window shows the top feed roll speed as the machine is operating.

This feature shows the feed conveyor speed as the machine is operating.

2.32

Tigercat 6500 Material Processor

Controls and Operation

FORWARD FEED STOP

FORWARD FEED RESUME

6000472

6000473

Home Screen – Machine Setup Screen

Home Screen – Machine Setup Screen

This feature stops the top feed roll and the feed conveyor when the engine speed drops to the set value during operation.

This feature starts the top feed roll and the feed conveyor when the engine speed increases to the set value during operation.

Press the Forward Feed Stop button to select.

Press the Forward Feed Resume button to select.

Press and hold the slider to select the desired engine speed for the forward feed function to stop. The maximum value for this setting is 1975 rpm.

Press and hold the slider to select the desired engine speed for the forward feed function to resume.

NOTE: When setting this speed, the speeds for Forward Feed Resume and Reverse Feed Start will automatically be adjusted.

2.33

NOTE: This setting can be increased above the value set when adjusting Forward Feed Stop but cannot be adjusted to a value lower than 100 rpm above Forward Feed Stop. The maximum value for this setting is 2025 rpm.

Controls and Operation REVERSE FEED START

6000474

Tigercat 6500 Material Processor ON/OFF

6000475

Home Screen – Machine Setup Screen

This feature can be turned OFF.

This feature reverses the direction of the top feed roll and the feed conveyor when the engine speed drops lower than the Forward Feed Stop speed.

Press the Reverse Feed ON/OFF button to turn ON or turn OFF this feature.

Press the Reverse Feed Start button to select.

NOTE: This setting can be set lower than the value set when adjusting Forward Feed Stop but cannot be adjusted to a value higher than 50 rpm below Forward Feed Stop. The minimum value for this setting is 1450 rpm.

The ON/OFF and Reverse Feed buttons will illuminate red when the feature is turned OFF. NOTE: This value is linked to the Forward Feed Stop feature. It can only be adjusted on this screen if Forward Feed Stop has been increased above its minimum setting. The minimum value for this setting is 1450 rpm.

2.34

Tigercat 6500 Material Processor

Controls and Operation

TOP FEED ROLL UP STOP HEIGHT

6000479

Home Screen – Machine Setup Screen This feature sets the maximum height the top feed roll can operate above the feed conveyor.

Press the Top Feed Roll Up Stop Height button to select.

Press and hold the slider to select the desired maximum height for the feature to activate.

NOTE: This setting can be adjusted after setting the Top Feed Roll Down Stop Height. The minimum value for this setting is 25 mm (1 in) higher than the Top Feed Roll Down Stop Height.

2.35

Controls and Operation

Tigercat 6500 Material Processor

TOP FEED ROLL DOWNFORCE

6000482

Home Screen – Machine Setup Screen This feature sets the top feed roll downforce value.

Press the Top Feed Roll Downforce button to select.

Press and hold the slider to select the desired force value.

2.36

Tigercat 6500 Material Processor

Controls and Operation

TOP FEED ROLL LOCK

ON/OFF

6000484

6000483

Home Screen – Machine Setup Screen

This feature can be turned OFF.

This feature locks the top feed roll when the engine speed drops below the set value.

Press the Top Feed Roll Lock ON/OFF button to activate this feature.

Press the Top Feed Roll Lock to select.

The ON/OFF and Top Feed Roll Lock buttons will illuminate red when the feature is turned OFF.

Press and hold the slider to select the desired engine speed for the top feed roll lock feature to activate.

2.37

Controls and Operation TOP FEED ROLL HOLD HEIGHT

6000485

Tigercat 6500 Material Processor ON/OFF

6000486

Home Screen – Machine Setup Screen

This feature can be turned OFF.

This feature sets the top feed roll minimum operating height above the feed conveyor when the machine is operating. This feature limits the vertical travel of the top feed roll when processing large continuous stock.

Press the Top Feed Roll Hold Height ON/OFF button to activate this feature.

Press the Top Feed Roll Down Hold Height button to select.

The ON/OFF and Top Feed Roll Lock buttons will illuminate red when the feature is turned OFF.

Press and hold the sliders to select the desired minimum hold height or the percentage of full travel.

2.38

Tigercat 6500 Material Processor

Controls and Operation

COOLING SCREEN

B A C

D

6000487

A B C D

6000469

Home Screen – Machine Setup Screen

Hydraulic Oil Cooler Fan Start Temperature Fan Clean Frequency Fan Clean Duration

Home Screen – Machine Setup Screen – Cooling Screen

FAN START TEMPERATURE This is the temperature the hydraulic oil must reach before the corresponding fan will turn ON. Press and hold the slider to select the desired temperature.

FAN CLEAN FREQUENCY This is the frequency in minutes the fan will operate before the clean function will activate.

Press and hold the slider to select the desired frequency time.

FAN CLEAN DURATION This is the duration in seconds the fan clean (reverse) will operate.

Press and hold the slider to select the desired duration time.

2.39

Controls and Operation

Tigercat 6500 Material Processor

HYDRAULIC OIL COOLING FAN CLEAN MODE – MANUAL OPERATION

B

C A D

6000487

A Hydraulic Oil Cooler Fan Reverse Button

Momentarily press the Hydraulic Cooling Fan Reverse button to manually reverse the fan. The fan will reverse for the set duration time.

When the button is pressed momentarily, the fan direction is reversed to help clean the hydraulic oil cooler. By reversing the fan blade direction, air flow is propelled in the opposite direction, thereby helping to force dust and debris off the heat exchanger core and screen.

2.40

Tigercat 6500 Material Processor

Controls and Operation

IMPACT DETECTION

A

B

B

C

6000489 6000469

Home Screen – Machine Setup Screen This feature sets the maximum impact load value where: • The machine will go into controlled shutdown.

• Feed system (top feed roll and feed conveyor will reverse.

A B C D E F

D

E

F

Current Reading Peak Value Peak Value Saved Settings Button Impact Detection ON/OFF Button Reset Button

Home Screen – Machine Setup Screen – Impact Detection Screen

• Top feed roll will go up.

This feature can be turned OFF.

• Engine will idle down and go into a controlled shutdown.

Three settings are available to set the maximum value to suit various operating conditions.

Press the settings button to select setting 1, 2 or 3, before setting the maximum impact value.

Press the Impact Detection ON/OFF button to turn ON or turn OFF this feature.

The ON/OFF button will illuminate green and the slider will be visible when the feature is turned ON. The ON/OFF button will illuminate red and the slider will not be visible when the feature is turned OFF. Press and hold the slider to set the desired value.

The current reading is graphically displayed on the left side of the gauge. The peak value is graphically displayed on the right side of the gauge.

2.41

Controls and Operation

Tigercat 6500 Material Processor

TELEMATICS

6000490 6000469

Home Screen – Machine Setup Screen

Home Screen – Machine Setup Screen – Telematics Menu The Telematics menu displays the machine location and operating status of the system.

2.42

Tigercat 6500 Material Processor

Controls and Operation

SERVICE MODE

SERVICE FUNCTIONS SCREEN

The Service Mode prevents the engine from starting.

In Service Mode, the electric service pump is utilized to operate the functions required for servicing the machine.

A A

B

D

C

E

G

F

H

I L J

K

M N

P O

6000582

6000491

B

A Auto/Service Mode Button B Service Mode Button

Home Screen Momentarily press the Auto/Service Mode button. The Service Mode button will appear at the bottom left of the screen.

Momentarily press the Service Mode button to display the Service Functions screen.

A B C D E F G H I J K L M N O P Q

Initial Service Functions Screen

Toolbox UP Button Top Feed Roll UP Button Top Feed Roll REVERSE Button Grate RETRACT Button Anvils RETRACT Button Rotor Drive Belt Pressure Top Feed Roll Pressure Feed Conveyor REVERSE Button Discharge Conveyor Pressure Rotor Drive Belt DISENGAGE Button Rotor Drive Belt ENGAGE Button Feed Conveyor Pressure Anvils EXTEND Button Grate EXTEND Button Top Feed Roll DOWN Button Toolbox DOWN Button Return to Home Screen

Home Screen – Service Functions Screen

2.43

Q

Controls and Operation

Tigercat 6500 Material Processor

OPEN MACHINE FOR MAINTENANCE

B

A

B

1

1 6000391

A Top Feed Roll B Top Feed Roll Safety Pin

2. Install the top feed roll safety pin.

3. Press the top feed roll DOWN button to lower the top feed roll arm to rest on the safety pin.

6000582

Home Screen – Service Functions Screen 1. Press and hold the top feed roll UP button to raise the feed roll to the maximum height.

WARNING Engage the top feed roll safety pin before proceeding further.

When the top feed roll is at maximum height, the hog box locking pins RETRACT button will appear on the screen.

NOTE: Raise the top feed roll as part of routine maintenance to inspect the rotor tips and hammers.

Refer to ROTOR VISUAL INSPECTION in SECTION 3 for details.

2.44

Tigercat 6500 Material Processor

Controls and Operation

6000583

6000584

4. Press and hold the hog box locking pins RETRACT button to retract the hog box retaining pins.

When the hog box retaining pins are fully retracted, the hog box UP button will appear on the screen.

5. Press and hold the hog box UP button until the upper hog box is in the resting place (over-centre).

WARNING Make sure all personnel are clear of the hog box service platform and feed conveyor before raising the upper hog box.

2.45

Controls and Operation

Tigercat 6500 Material Processor

CLOSE MACHINE AFTER MAINTENANCE

6000583 6000584

Home Screen – Service Functions Screen 1. Press and hold the hog box DOWN button to lower upper hog box until it is in the closed position.

2. Press and hold the hog box locking pins EXTEND button to extend the retaining pins into the locked position.

NOTE: The hog box locking pins EXTEND button will disappear from the screen when pins are fully extended.

NOTE: The hog box DOWN button will disappear from the screen when the hog box has reached the closed position.

WARNING Make sure all personnel are clear of the hog box service platform and feed conveyor before closing the upper hog box.

CAUTION Do not operate the machine until the hog box locking pins are in the extended position.

2.46

Tigercat 6500 Material Processor B

A

Controls and Operation

B

1

1 6000391

A Top Feed Roll B Top Feed Roll Safety Pin

3. Press the top feed roll UP button to raise the top feed roll and remove the safety pin.

6000582

4. Press and hold the top feed roll DOWN button to lower the top feed roll to the desired height.

WARNING Make sure all personnel are clear of the hog box service platform and feed conveyor before lowering the top feed roll.

2.47

Controls and Operation TOOLBOX UP

Tigercat 6500 Material Processor TOOLBOX DOWN

NOTE: The toolbox functions can be activated at any time during maintenance.

6000582

Home Screen – Service Functions Screen 6000582

Home Screen – Service Functions Screen

Press and hold the toolbox DOWN button until the toolbox is in the bottom position.

Press and hold the toolbox UP button until the toolbox is in the top position.

WARNING

WARNING Make sure all personnel are clear of the machine before lowering the toolbox.

Make sure all personnel are clear of the machine before raising the toolbox.

2.48

Tigercat 6500 Material Processor

Controls and Operation

GRATE RETRACT

GRATE EXTEND

NOTE: The grate functions can be activated at any time during maintenance.

6000582

Home Screen – Service Functions Screen 6000582

Press and hold the grate EXTEND button until the grate is in the desired position.

Home Screen – Service Functions Screen Press and hold the grate RETRACT button until the grate is in the desired position.

2.49

Controls and Operation ANVILS RETRACT

Tigercat 6500 Material Processor ANVILS EXTEND

NOTE: The anvils functions can be activated at any time during maintenance.

6000582

Home Screen – Service Functions Screen 6000582

Home Screen – Service Functions Screen

Press and hold the anvils EXTEND button until the grate is in the desired position.

Press and hold the anvils RETRACT button until the grate is in the desired position.

2.50

Tigercat 6500 Material Processor

Controls and Operation

DRIVE BELT DISENGAGE

DRIVE BELT ENGAGE

NOTE: The drive belts functions can be activated at any time during maintenance.

6000582

Home Screen – Service Functions Screen 6000582

Press and hold the drive belt ENGAGE button to raise the belt idler to apply pressure to the drive belt.

Home Screen – Service Functions Screen Press and hold the drive belt DISENGAGE button to lower the belt idler to relieve the pressure on the drive belt.

2.51

Controls and Operation

Tigercat 6500 Material Processor

MAIN MENU

6000335 6000382

Home Screen – Main The Main menu displays the following selections: • System • Measure • Adjust • Preferences The back button

returns to the previous screen.

The home button

returns to the home screen.

2.52

Tigercat 6500 Material Processor

Controls and Operation

SYSTEM MENU

INFO

6000337

6000336

Home Screen – Main – System

Home Screen – Main – System– Info

The System menu displays the following selections:

The info page provides system information, such as the program name and version.

• Info • Modules • Logs

2.53

Controls and Operation MODULES MENU

6000338

Tigercat 6500 Material Processor LOGS MENU

6000339

Home Screen – Main – System– Modules

Home Screen – Main – System– Logs

The Modules menu displays the information and status of the installed machine modules that form the computer system.

The Logs menu displays the following options:

Tap on the desired module to view the module details, status and alert messages relative to each module.

• MD4 • Fuel • Motor Faults • Alarms Tap the above selections to view the history of each log.

2.54

Tigercat 6500 Material Processor

Controls and Operation

MEASURE MENU

EXAMPLE

6000344

6000342

Home Screen – Main – Measure

Home Screen – Main – Measure – (Selection)

NOTE: Slide your finger up or down on the screen to view all entries.

The menu displays the value of all active inputs.

NOTE: If required, slide your finger up or down on the screen to view all entries.

The menu displays the following selections: • • • • • • • • • •

MD40701 Inputs MD40701 Outputs XC430801 Inputs XC430801 Outputs XC430101 Inputs XC430101 Outputs Remote Modules Remote Diagnostics Belt

2.55

Controls and Operation ADJUST MENU

6000345

Tigercat 6500 Material Processor PREFERENCES

6000493

Home Screen – Main – Adjust

Home Screen – Main – Preferences

The Adjust menu displays the following selections:

The preferences menu displays the following functions:

• Remote

• Display

• Adjustments

• Date/Time

• Cooler NOTE: These operations can only be performed by a trained service technician. A PIN is required.

2.56

Tigercat 6500 Material Processor

Controls and Operation

DISPLAY

DATE/TIME

6000061

6000064

Home Screen – Main – Preferences – Date/Time The date/time menu displays the following functions: • Date • Time DATE

6000062

6000065

6000063

Home Screen – Main – Preferences – Display Tap the / buttons to change the value for the following information: • Backlight (20 – 100% in increments of 10%) • Screen saver (Screen: Off– Dimmed – Black)

2.57

Controls and Operation

Tigercat 6500 Material Processor TIME

6000066 6000069

6000067 6000070

6000068

Home Screen – Main – Preferences – Date/Time – Date Settings Tap the day.

/

buttons to change the year, month, or

Tap the check mark button cancel button to exit.

6000071

Home Screen – Main – Preferences – Date/Time – Time Settings Tap the

to accept or tap the

/

buttons to change the hour and minute.

Tap the check mark button cancel button to exit.

2.58

to accept or tap the

Tigercat 6500 Material Processor

Controls and Operation

COMPUTER MESSAGES The computer displays messages when a system fault occurs.

There are different types of messages and alarms. They appear on the screen as a block message.

Message Header Message Text

The types of messages are: • CRITICAL MESSAGE – RED header • ERROR MESSAGE – RED header • ALARM MESSAGE – YELLOW header • WARNING MESSAGE – YELLOW header

Message Header Message Text

All messages can be hidden or acknowledged by tapping the Hide or Close button.

In some instances it is necessary to immediately stop the machine. Turn OFF the engine and repair the problem causing the message.

Message Header Message Text

Message Header Message Text

6000496

Active messages that have been hidden can be reviewed by accessing the Main menu and selecting System– Logs – Alarms. Refer to COMPUTER – MAIN MENU – SYSTEM MENU– LOGS MENU in THIS SECTION.

2.59

Controls and Operation

Tigercat 6500 Material Processor

CRITICAL AND ALARM MESSAGES Critical and alarm messages advise the operator that a machine fault is about to occur or a system fault has occurred.

Critical and alarm 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 or alarm message is displayed, the message remains on the screen until it is hidden by the operator.

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

In some instances the machine requires immediate action to correct the problem which requires the operator to STOP machine operation, turn OFF the engine 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 make the machine safe, then STOP machine operation and turn OFF the engine before serious machine damage can occur!

Messages can be hidden by tapping the Hide, OK or Close button.

6000495

Active messages that have been hidden can be reviewed by accessing the Main menu and selecting System– Logs – Alarms. Refer to COMPUTER – MAIN MENU – SYSTEM MENU– LOGS MENU in THIS SECTION.

2.60

Tigercat 6500 Material Processor

Controls and Operation

Critical and Alarm messages: • Metal Detection System • Top Feed Roll After Metal Detected • E-Stop Alarm • Drive Belt Failed to Engage • Controlled Shutdown • Controlled Stop • Discharge High Pressure • Drive Side Bearing High Temperature • Non-Drive Side Bearing High Temperature • Engine Coolant Temperature High • Feed Conveyor High Pressure • Hydraulic Oil Tank High Temperature • Hydraulic Oil Tank Low Oil Level • Wireless Remote Short • Tethered Remote Short • Top Feed Roll High Pressure

2.61

Controls and Operation METAL DETECTION SYSTEM

Tigercat 6500 Material Processor E-STOP ALARM

E-STOP ACTIVE Check all E-stops.

TRAMP MATERIAL DETECTED The system has detected a metal impact and is now shutting down.

This message will be displayed when a metal impact to the rotor has been detected.

Stop the engine immediately when this alarm is activated. Raise the top feed roll, install the top feed roll safety pin and inspect the top feed roll, rotor and feed conveyor for damage.

Refer to COMPUTER – MACHINE FUNCTIONS – TOP FEED ROLL UP/DOWN in THIS SECTION.

TOP FEED ROLL AFTER METAL DETECTED

This message will be displayed when an attempt to start the engine is made while an emergency stop button has been pressed.

Check all emergency stop buttons and return to popped up position.

Refer to CONTROLS – EMERGENCY STOP ACTIVE in THIS SECTION.

DRIVE BELT FAILED TO ENGAGE

LOW PRESSURE Belt engage pressure too low to engage.

TOP ROLL Lower the Top Roll before starting.

This message will be displayed to advise the operator that the top roll has not been lowered.

Refer to COMPUTER – MACHINE FUNCTIONS – TOP FEED ROLL UP/DOWN in THIS SECTION.

This message will be displayed when the drive belt does not automatically engage.

Stop the engine immediately when this alarm is activated. Inspect the condition of the drive belt and drive belt activation cylinder.

2.62

Tigercat 6500 Material Processor

Controls and Operation

CONTROLLED SHUTDOWN

DISCHARGE HIGH PRESSURE

CONTROLLED SHUTDOWN The machine has gone into a controlled shutdown.

HIGH PRESSURE The Top Feed Roll is in a High Pressure Condition.

The following operating conditions can activate a controlled shutdown:

This message will be displayed when the discharge conveyor is in an active high pressure condition.

• Drive belt failed to engage

Stop the engine immediately when this alarm is activated. Inspect the discharge conveyor for damage or jammed material.

• Drive side rotor bearing high temperature • Non-drive side rotor bearing high temperature • Hydraulic oil tank level low • Hydraulic oil tank high temperature Investigate and correct the problem(s) before restarting the engine.

CONTROLLED STOP

CONTROLLED STOP The machine has gone into a controlled stop.

This message will be displayed when high engine coolant temperature is detected.

The following conditions can activate a controlled stop: • Engine coolant temperature high.

Refer to COMPUTER – MESSAGES– CRITICAL AND ALARM – ENGINE COOLANT TEMPERATURE HIGH in THIS SECTION for corrective action.

2.63

Controls and Operation DRIVE SIDE BEARING HIGH TEMPERATURE

Tigercat 6500 Material Processor ENGINE COOLANT TEMPERATURE HIGH

HIGH TEMPERATURE The Drive Side Bearing temperature is too high.

This message will be displayed when a high temperature is detected on the drive side rotor bearing.

Stop the engine immediately when this alarm is activated. Check the rotor bearing for damage or inadequate lubrication.

NON-DRIVE SIDE BEARING HIGH TEMPERATURE

HIGH TEMPERATURE The Non-Drive Side Bearing temperature is too high.

HIGH TEMPERATURE High Engine Coolant Temperature.

This message will be displayed when engine temperature exceeds recommended engine temperature.

When this alarm is activated check for: • Plugged cooler package air intake screens in doors and access panels • Plugged radiator • Malfunction of the engine cooling fan Refer to CLEANING COOLER PACKAGE in SECTION 3.

WARNING

This message will be displayed when a high temperature is detected on the non-drive side rotor bearing.

Stop the engine immediately when this alarm is activated. Check the rotor bearing for damage or inadequate lubrication.

Do not remove the radiator cap when the engine is hot, release of pressurized coolant can cause serious burns.

Turn OFF the engine. Only remove the coolant fill cap when it is cool enough to touch with bare hands.

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

2.64

Tigercat 6500 Material Processor

Controls and Operation

FEED CONVEYOR HIGH PRESSURE

HYDRAULIC OIL TANK HIGH TEMPERATURE

HIGH PRESSURE The Feed Conveyor is in a High Pressure Condition.

HIGH TEMPERATURE The oil temperature in the Hydraulic Tank is too high.

This message will be displayed when the feed conveyor is in an active high pressure condition.

Stop the engine immediately when this alarm is activated. Inspect the feed conveyor for damage or jammed material.

This message will be displayed when the oil temperature exceeds the recommended operating range for the type of hydraulic oil in use.

If the temperature rises above the recommended operating range for the type of hydraulic oil in use check the following: • Plugged cooler package air intake screens in doors and access panels • 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 screen, together with the HYDRAULIC OIL OPERATING RANGE CHART in SECTION 3 to prevent damage to the hydraulic system.

Operating outside the recommended operating range shortens hydraulic component life.

Refer to APPROVED HYDRAULIC OILS in SECTION 3 for hydraulic oil operating range information.

2.65

Controls and Operation HYDRAULIC OIL TANK LOW OIL LEVEL

Tigercat 6500 Material Processor TETHERED REMOTE SHORT

LOW HYDRAULIC OIL LEVEL Hydraulic Tank Oil Level is too low.

TETHER TRACK LOCKED OUT Inputs are pressed down prior to going into Track Mode.

This message will be displayed when the main hydraulic oil tank level is low.

This message will be displayed when a signal from the tethered remote is not being received by the computer.

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

TOP FEED ROLL HIGH PRESSURE

Inspect the hydraulic system for signs of broken hoses or other leaks. Repair leaks and refill the main hydraulic oil tank to FULL mark on the sight gauge. Restart engine and inspect for leaks.

HIGH PRESSURE The Top Feed Roll is in a High Pressure Condition.

WIRELESS REMOTE SHORT

TRACK LOCKED OUT Inputs are pressed down prior to going into Track Mode.

This message will be displayed when the track mode signal from the wireless remote is not being received by the computer.

This message will be displayed when the top feed roll is in an active high pressure condition.

Stop the engine immediately when this alarm is activated. Raise the top feed roll, install the top feed roll safety pin and inspect the top feed roll, rotor and feed conveyor for damage or jammed material.

Refer to COMPUTER – MACHINE FUNCTIONS – TOP FEED ROLL UP/DOWN in THIS SECTION.

2.66

Tigercat 6500 Material Processor

Controls and Operation

ERROR MESSAGES (RED)

MODULE NO CONTACT ERROR

Telematics No contact J1939-D71

Error messages are activated when an electrical connection is broken/disconnected. Most error messages are due to computer system hardware or connection faults.

The module no contact error message indicates a loss of communication with, or power to, a module. The module is identified on the display screen.

When a module loses contact all machine functions controlled by that module cease and all messages associated with that module are activated. If the problem is with the CAN wires, all modules beyond the module in question will also be affected.

Error messages are the second highest priorities (after critical and alarm messages). The operator must take immediate to prevent damage to machine or to ensure operator safety.

If the computer display module loses power or otherwise malfunctions, the screen may go blank and all machine functions controlled by the computer system will be affected.

When an error message displays, the message remains on the screen until it is hidden by the operator.

When this message is acknowledged, hidden, and recalled to the screen, it will be replaced with a hardware fault message for the corresponding module.

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

The message gives brief details of the fault and advises what action is necessary.

When immediate action is necessary to correct the problem the operator must stop machine operation, turn OFF the engine, and service the machine to correct the problem.

If the machine cannot be stopped immediately for safety reasons, the operator can hide the message. In this instance the machine should be operated only long enough to move the machine to a safe location.

Messages can be hidden by tapping the Hide or Close button.

MODULE VREF ERROR

MD40701 VREF error value 0.012 V MD40701

The module VREF message indicates a problem with the 5 V reference signal coming from the module. The source of the problem may involve a sensor, connecting wires, or the 5V reference signal itself.

Examples of error messages: • Module No Contact Error • Module VREF Error

The module is identified on the display screen.

• Voltage Input Error (VIN)

When this message is acknowledged, hidden, and recalled to the screen, it will be replaced with a hardware fault message for the corresponding module.

• Digital Input Error (DIN) • Digital Output Error (DOUT) • Current Output Error (COUT) NOTE: Not all error messages are shown.

2.67

Controls and Operation

Tigercat 6500 Material Processor

VOLTAGE INPUT ERROR (VIN)

DIGITAL OUTPUT ERROR (DOUT)

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

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 module and pin number are identified on the display screen.

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

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

An example of a voltage input error message is shown above.

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

DIGITAL INPUT ERROR (DIN) Digital input error messages will be displayed to indicate a problem with a digital input signal to a computer system module.

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

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

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

2.68

Tigercat 6500 Material Processor

Controls and Operation

CURRENT OUTPUT ERROR (COUT)

COMPUTER MODULE BLANK SCREEN

Current output error messages will be displayed to indicate a problem with a current output signal from a computer system module.

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

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.

Likely causes are: • Power – Fuse (Computer) • Ground • LCD display settings too light to read • Faulty computer

Once acknowledged these message will be replaced with a hardware failure message for the corresponding module when active faults recalled to the screen.

2.69

Controls and Operation

Tigercat 6500 Material Processor

WARNING MESSAGES Warning messages advise the operator that machine operation will be compromised.

Warning messages have the third highest level of priority and are used to indicate to the operator that action is required to prevent future damage to the machine.

All warning messages 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.

There are two types of warning messages: 1. Programmed messages – generally activated by machine function related conditions.

2. Computer system generated messages – generally initiated by computer error and fault related conditions.

When a warning message is displayed, the alert message remains on the screen until it is hidden by the operator.

Messages can be hidden by tapping the Hide, OK or Close button.

Active messages that have been hidden can be reviewed by accessing the Main menu and selecting System– Logs – Alarms. Refer to COMPUTER – MAIN MENU – SYSTEM MENU– LOGS MENU in THIS SECTION.

6000494

2.70

Tigercat 6500 Material Processor

Controls and Operation

Warning messages: • Auto Belt Engage • Bad Belt Pressure Sensor • Bad Drive Side Box Position Sensor • Bad Non-drive Side Box Position Sensor • Bad Discharge Pressure Sensor • Bad Drive Side Bearing Sensor • Bad Non-drive Side Bearing Sensor • Bad Drive Side Lock Pin Position Sensor • Bad Non-Drive Side Lock Pin Position Sensor • Bad Drive Side Track Position Sensor • Bad Non-drive Side Track Position Sensor • Bad Feed Conveyor Pressure Sensor • Bad Hydraulic Temperature Sensor • Bad Drive Side Top Feed Roll Position Sensor • Bad Non-drive Side Top Feed Roll Position Sensor • Bad Top Roll Pressure Sensor • Feeds Stopped for Load Sense • Go To Service Mode • Hog Box Open • Hydraulic Oil Tank High Temperature • Lock Pin – Start Blocked • Service Mode – Start Blocked • Start Disabled • Top Roll – Start Blocked • Hardware Fault – MD4 • Hardware Fault – XC43[1] • Hardware Fault – XC43[2] • COUT Hardware Fault • DOUT Hardware Fault • DIN Hardware Fault • VIN Hardware Fault • Module High Temperature • Module High Supply Voltage • Module Low Supply Voltage • Module High Temperature • Module High Supply Voltage • Module Low Supply Voltage

2.71

Controls and Operation AUTO BELT ENGAGE

Tigercat 6500 Material Processor BAD DRIVE SIDE BOX POSITION SENSOR

ROTOR AUTOMATIC ENGAGE The rotor will automatically engage, stay clear.

This message will be displayed to advise the operator the drive belt has automatically engaged.

BAD BELT PRESSURE SENSOR

BAD SENSOR The BOX DS position sensor is faulty. Check wiring and replace as necessary.

This message will be displayed when the drive side box position sensor signal is not being received by the computer.

Check sensor and replace if faulty.

NOTE: The system will rely on the non-drive side sensor until the issue is resolved.

BAD SENSOR The Belt Engage Pressure Sensor has failed.

BAD NON-DRIVE SIDE BOX POSITION SENSOR

BAD SENSOR The BOX NDS position sensor is faulty. Check wiring and replace as necessary.

This message will be displayed when the drive belt pressure sensor signal is not being received by the computer.

Check sensor and replace if faulty.

This message will be displayed when the drive side box position sensor signal is not being received by the computer.

Check sensor and replace if faulty.

NOTE: The system will rely on the drive side sensor until the issue is resolved.

2.72

Tigercat 6500 Material Processor

Controls and Operation

BAD DISCHARGE PRESSURE SENSOR

BAD DRIVE SIDE BEARING SENSOR

BAD SENSOR The discharge pressure sensor has failed.

BAD SENSOR The DS bearing sensor has failed.

This message will be displayed when the discharge conveyor pressure sensor signal is not being received by the computer.

This message will be displayed when the drive side bearing temperature sensor signal is not being received by the computer.

Check sensor and replace if faulty.

Check sensor and replace if faulty.

BAD NON-DRIVE SIDE BEARING SENSOR

BAD SENSOR The NDS bearing sensor has failed.

This message will be displayed when the non-drive side bearing temperature sensor signal is not being received by the computer.

Check sensor and replace if faulty.

2.73

Controls and Operation BAD DRIVE SIDE LOCK PIN POSITION SENSOR

Tigercat 6500 Material Processor BAD DRIVE SIDE TRACK POSITION SENSOR

BAD SENSOR The DS Track position sensor is faulty, check wiring and replace as necessary.

BAD SENSOR The DS Lock Pin position sensor is faulty, check wiring and replace as necessary.

This message will be displayed when the drive side lock pin sensor signal is not being received by the computer.

This message will be displayed when the drive side track position sensor signal is not being received by the computer.

Check sensor and replace if faulty.

Check sensor and replace if faulty.

NOTE: The system will rely on the non-drive side sensor until the issue is resolved.

NOTE: The system will rely on the non-drive side sensor until the issue is resolved.

BAD NON-DRIVE SIDE LOCK PIN POSITION SENSOR

BAD NON-DRIVE SIDE TRACK POSITION SENSOR

BAD SENSOR The NDS Lock Pin position sensor is faulty, check wiring and replace as necessary.

BAD SENSOR The NDS Track position sensor is faulty, check wiring and replace as necessary.

This message will be displayed when the non-drive side lock pin sensor signal is not being received by the computer.

This message will be displayed when the non-drive side track position sensor signal is not being received by the computer.

Check sensor and replace if faulty.

Check sensor and replace if faulty.

NOTE: The system will rely on the drive side sensor until the issue is resolved.

NOTE: The system will rely on the drive side sensor until the issue is resolved.

2.74

Tigercat 6500 Material Processor

Controls and Operation

BAD FEED CONVEYOR PRESSURE SENSOR

BAD SENSOR The Feed Conveyor Pressure Sensor has failed.

BAD DRIVE SIDE TOP FEED ROLL POSITION SENSOR

BAD SENSOR The TFR DS position sensor is faulty, check wiring and replace as necessary.

This message will be displayed when the feed conveyor pressure sensor signal is not being received by the computer.

Check sensor and replace if faulty.

This message will be displayed when the drive side top feed roll position sensor signal is not being received by the computer.

Check sensor and replace if faulty.

BAD HYDRAULIC TEMPERATURE SENSOR

NOTE: The system will rely on the non-drive side sensor until the issue is resolved.

BAD NON-DRIVE SIDE TOP FEED ROLL POSITION SENSOR

BAD SENSOR The hydraulic temperature sensor has failed.

BAD SENSOR The TFR NDS position sensor is faulty, check wiring and replace as necessary.

This message will be displayed when the hydraulic temperature sensor signal is not being received by the computer.

Check sensor and replace if faulty.

This message will be displayed when the non-drive side top feed roll position sensor signal is not being received by the computer.

Check sensor and replace if faulty.

NOTE: The system will rely on the drive side sensor until the issue is resolved.

2.75

Controls and Operation BAD TOP ROLL PRESSURE SENSOR

Tigercat 6500 Material Processor GO TO SERVICE MODE

BAD SENSOR The Top Roll Pressure Sensor has failed.

This message will be displayed when the top feed roll pressure sensor signal is not being received by the computer.

Check sensor and replace if faulty.

FEEDS STOPPED FOR LOAD SENSE

BELT DISENGAGE DISABLED Must be in Service Mode and Engine not running.

This message will be displayed when the following conditions are present: • Drive belt is disengaged • Engine rpm drops to zero Investigate cause of problem before attempting to restart engine.

HOG BOX OPEN FEEDS STOPPED Increase Engine Speed.

HOG BOX OPEN Close hog box to start.

This message will be displayed when engine speed has dropped too low to support machine operation. Increase the engine speed to restart the feed system.

This message will be displayed when attempting to start the engine with the hog box open. Close the upper hog box. Refer to SERVICE MODE in THIS SECTION.

2.76

Tigercat 6500 Material Processor

Controls and Operation

HYDRAULIC OIL TANK HIGH TEMPERATURE

HIGH TEMPERATURE Hydraulic Tank temperature is too high.

LOCK PIN – START BLOCKED

LOCK PIN RETRACTED Extend lock pin to start.

This message will be displayed when the oil temperature exceeds the recommended operating range for the type of hydraulic oil in use.

This message will be displayed when attempting to start the machine with the hog box pins retracted. Extend lock pins. Refer to SERVICE MODE in THIS SECTION.

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

SERVICE MODE – START BLOCKED

• Plugged cooler package air intake screens in doors and access panels.

• Malfunction in a hydraulic system

SERVICE MODE ON Exit Service Mode to Start.

• High loads on the hydraulic system • Malfunction of the cooling fan • Low hydraulic oil level • Correct hydraulic oil grade selection

This message will be displayed when attempting to start the machine in service mode. Exit service mode. Refer to SERVICE MODE in THIS SECTION.

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 screen, together with the HYDRAULIC OIL OPERATING RANGE CHART in SECTION 3 to prevent damage to the hydraulic system.

Operating outside the recommended operating range shortens hydraulic component life.

Refer to APPROVED HYDRAULIC OILS in SECTION 3 for hydraulic oil operating range information.

2.77

Controls and Operation START DISABLED

Tigercat 6500 Material Processor TOP FEED ROLL – START BLOCKED

START DISABLED The rotor will not engage, lower top feed roll, or disable the belt to start.

This message will be displayed to advise the operator the machine cannot be started.

TOP FEED ROLL OPEN Close top feed roll to start.

This message will be displayed to advise the operator the machine cannot be started with the top feed roll open. Close top feed roll. Refer to ROTOR VISUAL INSPECTION in THIS SECTION.

2.78

Tigercat 6500 Material Processor

Controls and Operation

HARDWARE FAULT – MD4

HARDWARE FAULT – XC43[1]

Hardware Fault - MD4 Active fault has been hidden.

Turn key off and on to recall active hidden hardware faults

Hardware Fault - XC43[1] Active fault has been hidden.

Turn key off and on to recall active hidden hardware faults

This message will be displayed when an alert level active hardware fault related to the MD4 module has been hidden.

This message will be displayed when an alert level active hardware fault related to theXC43[1] module has been hidden.

To recall the original active fault(s) the operator must turn the ignition key OFF and ON.

To recall the original active fault(s) the operator must turn the ignition 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 activate 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 activate this message.

HARDWARE FAULT – XC43[2]

Hardware Fault - XC43[2] Active fault has been hidden.

Turn key off and on to recall active hidden hardware faults

This message will be displayed when an alert level active hardware fault related to the XXC43[2] module has been hidden.

To recall the original active fault(s) the operator must turn the ignition 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 activate this message.

2.79

Controls and Operation COUT HARDWARE FAULT

Tigercat 6500 Material Processor DIN HARDWARE FAULT

Hardware Fault - COUT Active fault has been hidden.

Turn key off and on to recall active hidden hardware faults.

Hardware Fault - DIN Active fault has been hidden.

Turn key off and on to recall active hidden hardware faults.

This message will be displayed when a current output error message has been hidden.

This message will be displayed when a digital input error message 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.

DOUT HARDWARE FAULT

VIN HARDWARE FAULT

Hardware Fault - VIN Active fault has been hidden.

Turn key off and on to recall active hidden hardware faults.

Hardware Fault - DOUT Active fault has been hidden.

Turn key off and on to recall active hidden hardware faults.

This message will be displayed when a digital output error message has been hidden.

This message will be displayed when a voltage input error message 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.

2.80

Tigercat 6500 Material Processor

Controls and Operation

MODULE HIGH TEMPERATURE Module high temperature message will be displayed to indicate the computer control system has detected high temperature readings in a system module.

The module is identified on the display screen. The temperature reading value is also displayed.

Display High Temperature Value 73°C MD4

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– ALERT– HARDWARE FAULT in THIS SECTION. XC43[1] High Temperature Value 81°C XC43[1]

XC43[2] High Temperature Value 81°C XC43[2]

2.81

Controls and Operation

Tigercat 6500 Material Processor

MODULE HIGH SUPPLY VOLTAGE Module high supply voltage alert message will be displayed to indicate the computer control system has detected high supply voltage readings in a system module.

Display High supply voltage Value 33.32 V MD4

The module is identified on the display screen. The voltage reading value is also displayed.

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– WARNING – HARDWARE FAULT in THIS SECTION.

XC43[1] High supply voltage Value 33.32 V XC43[1]

XC43[2] High supply voltage Value 33.32 V XC43[2]

2.82

Tigercat 6500 Material Processor

Controls and Operation

MODULE LOW SUPPLY VOLTAGE Module low supply voltage alert message will be displayed to indicate the computer control system has detected low supply voltage readings in a system module.

Display Low supply voltage MD4

The module is identified on the display screen.

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– WARNING – HARDWARE FAULT in THIS SECTION.

XC43[1] Low supply voltage XC43[1]

XC43[2] Low supply voltage XC43[2]

2.83

Controls and Operation MODULE HIGH TEMPERATURE

Tigercat 6500 Material Processor MODULE HIGH SUPPLY VOLTAGE

Module High Temperature High temperature.

Module high temperature alert message will be displayed to indicate the computer control system has detected high temperature readings in a system module.

The module is identified on the display screen. The temperature reading value is also displayed.

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 – ALERT – HARDWARE FAULT in THIS SECTION.

Module High Supply Voltage High supply voltage.

Module high supply voltage alert message will be displayed to indicate the computer control system has detected high supply voltage readings in a system module.

The module is identified on the display screen. The voltage reading value is also displayed.

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 – ALERT – HARDWARE FAULT in THIS SECTION.

MODULE LOW SUPPLY VOLTAGE

Module Low Supply Voltage Low supply voltage.

Module low supply voltage alert message will be displayed to indicate the computer control system has detected low supply voltage readings in a system module.

The module is identified on the display screen.

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 – ALERT – HARDWARE FAULT in THIS SECTION.

2.84

Tigercat 6500 Material Processor

Controls and Operation

BATTERY BOOSTING

BATTERY BOOSTER CABLE WITH CLAMPS

NOTICE

1. Situate the boosting source as close to the machine as possible without touching.

This machine has a 24 V starting system. Only use the same voltage when boosting with an auxiliary battery. Using a higher or lower voltage will cause serious damage to the electrical system. Only a compatible (same) voltage is permissible.

2. Confirm the boosting source uses a 24 V battery/ electrical system.

3. Turn OFF the ignitions of both machines.

A

A

B

6000462

Battery Terminals

A Positive (Red) Battery Terminal B Negative (Black) Battery Terminal

6000461

A Batteries

4. Locate the red positive (+) and black negative ( – ) battery terminals.

Drive Side of Machine

The batteries are located in a tray under the hydraulic oil tank on the drive side of the machine.

5. Connect the clamp of the red booster cable to the positive (+) terminal of the dead battery.

6. Connect the other clamp of the red booster cable to the positive (+) terminal of the good battery.

7. Connect the clamp of the black booster cable to the negative ( – ) terminal of the good battery.

8. Connect the other clamp of the black booster cable to the negative ( – ) terminal of the dead battery.

9. Turn ON the engine with the good battery.

10. Turn ON the engine with the dead battery.

11. Disconnect the clamp of the black booster cable from the negative ( – ) terminal of the dead battery.

12. Disconnect the clamp of the black booster cable from the negative ( – ) terminal of the good battery.

13. Disconnect the clamp of the red booster cable from the positive (+) terminal of the good battery.

14. Disconnect the clamp of the red booster cable from the positive (+) terminal of the dead battery.

2.85

Controls and Operation

REFUELLING PROCEDURE

IMPORTANT!

Tigercat 6500 Material Processor 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Allow machine to cool.

3. Clear obstructions from steps and handles needed to access the fuel tank.

4. Attach a grounding strap to an unpainted metal surface on the machine if the refuelling tank or nozzle is so equipped.

5. Clear any debris from around the fuel fill cap.

S≤15 mg/kg ULTRA LOW SULFUR FUEL ONLY 36686AUNI R0

Use only ultra low sulfur diesel (ULSD) fuel in engines equipped with Tier 4f aftertreatment systems. Using fuel with sulfur levels greater than 15 ppm (S≤15 mg/kg) maximum will permanently damage the engine and aftertreatment system within a short period of time.

6. Remove the fuel fill cap slowly to allow pressure to escape from the tank.

7. Inspect the fuel fill cap gasket.

8. Inspect the fuel strainer located under the fuel fill cap for debris or damage.

9. Insert the fuel nozzle into the fuel fill tube.

10. Fill the tank until the fuel level reaches the bottom of the fuel fill tube. Do not leave the fuel nozzle unattended or spillage may occur.

11. Remove the fuel nozzle and the ground strap (if applicable).

12. Install fuel fill cap hand-tight.

WARNING

NOTE: Before restarting the machine, Refer to STARTING ENGINE in SECTION 2.

CAUTION

Do not smoke while refuelling. Do not refuel near sparks or open flame.

CAUTION Do not leave the machine unattended during the refuelling process.

Fuel or oil-soaked rags may spontaneously combust. Do not leave fuel or oil-soaked rags around the machine or work area. Dispose properly in a certified container according to local regulations.

2.86

Tigercat 6500 Material Processor

Controls and Operation

AIR COMPRESSOR – AIR SUPPLY (OPTIONAL) An air compressor and air tank are provided as an air supply for air tools.

A

6000458

Bottom of Compressor Compartment

A Air Tool Supply Quick Connector A

The air tool supply quick connector is accessible through an opening in the bottom of the compressor compartment.

B

A

6000457

Non-drive Side of Machine

A Air Compressor Unit B Battery Location

The optional gasoline-powered, belt-driven air compressor unit is mounted in a compartment on the non-drive side of machine.

The latch for the compartment lid is accessible via the rear ladder. When opened, the lid is supported by two gas-filled struts.

6000460

A Air Hose Mounting Brackets

A 114 L (30 US gal) air supply tank is part of the compressor unit. A 12 V battery in the compartment provides power to the electric starter for the compressor engine.

Mounting brackets are provided on the bottom of the compartment to store an air hose.

Refer to the COMPRESSOR OWNER'S MANUAL supplied with the machine for SAFETY WARNINGS and information on operating and maintaining the compressor unit.

To remove moisture from the system, drain the air supply at the drain valve daily. Refer to the COMPRESSOR OWNER'S MANUAL for drain valve location.

DRAINING THE AIR SUPPLY

Refer to SECTION 25 of the SERVICE MANUAL for additional information on the compressed air system.

WARNING Do not run compressor engine with compartment lid closed. Read the COMPRESSOR OWNER'S MANUAL before operation.

2.87

Controls and Operation

Tigercat 6500 Material Processor

OPERATING MACHINE The appropriate lubrication and maintenance schedule must been performed prior to operating the machine.

Refer to SCHEDULED MAINTENANCE in SECTION 3.

Refer to the ENGINE OPERATION AND MAINTENANCE MANUAL supplied with the machine.

Personnel who are to operate this machine must be fully trained in safety and operating procedures by a competent person.

PRE-START CHECKS

A 6000382

A Fuel Level Gauge

3. Turn the ignition key to the RUN position to check fuel level on the computer display main screen. Fill fuel to the required level. Refer to REFUELLING PROCEDURE in THIS SECTION. A A

6000386

Main Electrical Panel– Drive Side of Machine

B

A Ignition Key

1. Set the ignition key to the STOP position.

A

B C

6000310

Drive Side of Machine

A Oil Level Sight Gauge B Hydraulic Oil Level High Limit C Hydraulic Oil Level Low Limit

6000188

Non-drive Side of Machine

4. Check the hydraulic oil level.

A Fire Extinguisher B Charge Gauge

2. Check portable fire extinguisher for sufficient charge.

2.88

The level should be between the HIGH and LOW marks on the level gauge with all cylinders fully retracted. Refer to HYDRAULIC SYSTEM – REFILLING in SECTION 3.

Tigercat 6500 Material Processor

Controls and Operation

A

6000250

ADD

A 6000132

ADD

Engine/Hydraulic Compartment Service Platform

FULL

FULL

ENGINE STOPPED

ENGINE LOW IDLE

6000251

A Fuel Filter/Water Separator Drain Plug

5. Check the fuel filter/water separator and drain any accumulated water into a bowl and clean up any spills. Refer to FILTERS– FUEL – PRIMARY FUEL FILTER/WATER SEPARATOR in SECTION 3.

B

6000252

Engine/Hydraulic Compartment Service Platform

A Engine Oil Dipstick B Engine Oil Fill Cap

6. Check the engine oil level. Dipstick is located at the rear of the engine.

Oil level can be checked with engine stopped or engine running at LOW speed. The level of the oil must be between the ADD and FULL marks on the dipstick. Refer to the ENGINE OPERATION AND MAINTENANCE MANUAL.

2.89

Controls and Operation

Tigercat 6500 Material Processor A

A

6000148

6000249

Engine/Hydraulic Compartment Service Platform

A Engine Air Precleaner

7. Check the engine air precleaners. Remove any blockages or obstructions. Refer to AIR INTAKE SYSTEM– ENGINE AIR PRECLEANERS in SECTION 3.

Top of Radiator

A Engine Coolant Fill Cap

9. Check engine coolant level on the radiator. Fill as required.

WARNING

Do not remove the engine coolant fill cap when the engine is hot, release of pressurized coolant can cause serious burns.

Turn OFF the engine. Only remove the coolant fill cap when it is cool enough to touch with bare hands.

B

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

A 6000253

Fan and Guard Not Shown for Clarity

A Serpentine Belt B Engine Fan Drive Belts

8. Check the condition and tension of the engine serpentine belt and the engine fan drive belts. Refer to BELTS– ENGINE in SECTION 3.

2.90

Tigercat 6500 Material Processor B

A

Controls and Operation B

C

E

A

D

B

C

830-02

6000151

Non-drive Side of Machine

A B C D E

A Radiator (Engine Coolant Core) B Charge Air Cooler

Cracked Bent Worn Edge Broken Edge Worn Holes

11. Inspect track shoes for wear, bends, breaks, or cracks.

B

12. Inspect machine for leaks, damaged or loose components or any other abnormal conditions.

13. Fasten all doors, covers and access panels securely.

A

6000152

Drive Side of Machine

A Hydraulic Oil Cooler B Engine PTO Cooler

10. Clean the cooler package, hydraulic oil cooler, and engine PTO cooler if required. Refer to CLEANING COOLER PACKAGE in SECTION 3.

2.91

Controls and Operation

Tigercat 6500 Material Processor

STARTUP PROCEDURE

NOTE: No screen or remote functions will operate until the system reset button is cleared.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

B

A

6000306

6000307

Battery Disconnect Switch

A OFF Position (Switch Open) B ON Position (Switch Closed)

2. Turn ON the battery disconnect switch.

6000325

6. Press I/O (Power ON/OFF) to turn ON the remote.

7. Set the machine to the desired operating angle.

Refer to MACHINE OPERATING ANGLE in THIS SECTION. 8. Press Feed FORWARD to start the feed conveyor and top feed roll in the forward direction.

9. Press Discharge Conveyor ON/OFF to start the discharge conveyor.

A

6000387

B

C

Main Electrical Panel– Drive Side of Machine

A Ignition Key B System Reset Button C Computer Display

3. Start the engine. Refer to STARTING ENGINE in THIS SECTION.

10. Press and hold Engine Speed UP to set engine speed at 1200 rpm for 10 minutes.

11. Press and hold Engine Speed UP to set engine speed at HIGH. 12. Commence loading material onto the feed conveyor.

13. The following functions are available during operation:

4. Maintain engine speed at LOW for 10 minutes.

• Feed Reverse – Stops or reverses the feed conveyor and top feed roll simultaneously.

5. Press the system reset button.

• Roll Reverse – Reverses top feed roll only.

NOTE: If the system reset button remains illuminated, check for an emergency stop button that is still pressed or refer to the computer display for active alarms. Once the engine is running check if the system reset button is illuminated. If it is illuminated, press it to clear.

• Roll Up – Raises top feed roll. Use this function to feed large logs or piles into the hog box.

• Roll Down – Applies downward pressure on top feed roll. Use this function to increase pressure on material that is not feeding properly.

Refer to CONTROLS – REMOTE in THIS SECTION. 2.92

Tigercat 6500 Material Processor

Controls and Operation

SHUTDOWN PROCEDURE 1. Stop loading material into the feed conveyor.

2. Allow all material to be processed until the discharge conveyor is empty.

3. Set engine speed at LOW. 4. Momentarily press Top Feed Roll REVERSE to turn OFF the feed conveyor and top feed roll.

5. Momentarily press Discharge Conveyor ON/OFF on the remote to turn OFF the discharge conveyor.

6. Turn OFF the engine. Refer to STOPPING ENGINE in THIS SECTION. 7. Turn OFF the battery disconnect switch.

Refer to CONTROLS – REMOTE in THIS SECTION for additional details.

2.93

Controls and Operation

STARTING ENGINE

1. Complete all prestart checks before starting the engine. Refer to OPERATING MACHINE – PRESTART CHECKS in THIS SECTION. 2. Clear personnel from the area before starting the engine.

3. Turn the battery disconnect switch to the ON position.

4. Turn the ignition key to the START position to crank the engine.

Tigercat 6500 Material Processor

STOPPING ENGINE NOTICE Turning off the engine immediately after it has been working under load can result in overheating and premature wear of the engine components. Follow the stopping procedure below to allow the engine to cool. The important benefits are: • Extended life of engine, cooling and exhaust systems.

5. When the engine starts, release the ignition key to the RUN position.

• Reduced risk of post shutdown fires.

NOTE: If the engine does not start after three attempts, check the fuel supply system.

6. Set engine speed at LOW. Wait three to five minutes before operating with a load.

7. Increase engine speed gradually to adequately lubricate the bearings and stabilize the oil pressure.

If the engine stalls while operating the machine, turn the ignition key to the STOP position and repeat steps 1 – 6.

CAUTION Do not attempt to start the engine by shorting across the starter terminals. Personal injury can occur.

NOTICE Allow a cold engine to warm up at LOW speed for at least 5 minutes before applying any load.

Monitor all measured values on the computer display during warmup.

• Interior of machine cools significantly reducing risk of touching hot surfaces.

1. Turn OFF all machine functions.

2. Set engine speed at LOW and run the engine at LOW for three minutes minimum to dissipate heat and reduce the turbocharger speed. This will also prevent loss of coolant by after boil and possible hot spot damage to the engine.

Do not increase engine speed before turning it off.

3. Turn OFF the engine.

4. Remove the ignition key.

5. Turn OFF the battery disconnect switch if required by the servicing procedure or if the machine is to be parked for an extended period of time, such as overnight.

6. Perform EVERY 8 HOURS maintenance at the end of the shift (greasing, clean engine compartment, etc.). This allows the machine time to cool down while under the watchful eye of the operator.

2.94

Tigercat 6500 Material Processor

Controls and Operation

MACHINE OPERATING ANGLE

A

B

6000309

A Maximum Tilt Towards Discharge Conveyor – 8°

B Maximum Tilt Towards Feed Conveyor – 4°

For mulch and stumps, set machine operating angle (tilt) towards the discharge conveyor ('A' angle 0 to 8°).

For long trees, set machine operating angle towards the feed conveyor ('B' angle 0 to 4°).

NOTE: Press and hold Track DOWN or Track UP to change the tilt of the machine.

Refer to CONTROLS – REMOTE– TRACK UP/DOWN in THIS SECTION.

2.95

TRANSPORTING THE MACHINE Set the machine to the maximum tilt towards the discharge conveyor before transporting the machine.

Refer to MACHINE OPERATING ANGLE in THIS SECTION. The overall height of the machine in this position is approximately 3.7 m (12 ft).

Controls and Operation

Tigercat 6500 Material Processor

MOVING THE MACHINE

USING TETHERED CONTROLLER

USING WIRELESS REMOTE

A

B

D

C

F

E

6000175

6000325

A B C D E F

2nd Function Track Mode ON/OFF Right Track FORWARD Left Track FORWARD Right Track REVERSE Left Track REVERSE

1. Press and release 2nd Function button.

2. Press and release Track Mode ON/OFF to activate the track function.

3. Press and hold Right Track FORWARD and Left Track FORWARD simultaneously to move the machine forward in a straight direction. Press and hold Right Track REVERSE and Left Track REVERSE simultaneously to move the machine backwards in a straight direction.

A tethered controller is provided for moving the machine.

The connector for the controller is located on the nondrive side of the machine under the engine/hydraulic compartment service platform.

1. Press and release TRACK MODE ON to activate the track function.

2. Press and hold RIGHT FORWARD and LEFT FORWARD simultaneously to move the machine forward in a straight direction. Press and hold RIGHT REVERSE and LEFT REVERSE simultaneously to move the machine backwards in a straight direction.

3. To turn the machine, press and hold RIGHT to turn left or LEFT to turn right.

4. To turn the machine, press and hold Right Track to turn left or Left Track to turn right.

Refer to CONTROLS – REMOTE– TRACK UP/DOWN in THIS SECTION for instructions.

2.96

Tigercat 6500 Material Processor

Controls and Operation

TRACK OPERATION AND WEAR PREVENTION

Alternate turning directions:

NOTE: The following illustrations are presented for illustrative purposes only and may not necessarily depict your machine or model.

If you're turning in the same direction, the undercarriage components on one side of the machine will wear at a different rate than those on the other side. Pay attention to the way you're turning and changing directions whenever possible to ensure even wear.

Make gradual turns instead of counter-rotations: Counter-rotating accelerates wear on the tracks and other undercarriage components. Don't use that technique unless job conditions demand it. Instead, turn the machine gradually while slowly moving forward or reverse. Gradual turns minimize cuts, tears and excessive wear in the undercarriage. They also reduce damage to soft or sensitive work surfaces.

R7150L2-7

Extended Machine Travel:

PROTECTING STEEL TRACKS Steel tracks are designed to perform in tough underfoot conditions. Take these steps to maximize service life and reduce operating costs.

Start every shift with a clean undercarriage: When mud and debris build up on the lower part of your machine, components wear at a faster rate. Do not begin work until the undercarriage area is clean.

Inspect the undercarriage before you start working: In addition to ensuring the undercarriage is clean, spend a couple of minutes on a visual inspection. Check for loose bolts, leaky seals and abnormal wear patterns.

When you spot potential problems early, you can often prevent them from turning into bigger issues that reduce component life significantly or cause expensive unscheduled downtime.

Don't spin the tracks:

Avoid machine travel over distances of 1 km (0.60 mi) or greater. Extended travel, especially in warm weather, risks overheating the track rollers and burning the oil inside the roller assemblies. The rollers on new machines are especially vulnerable to overheating (the break-in period for rollers is approximately 200 hr).

If it is absolutely necessary to drive the machine over an extended distance, observe the following essential precautions: 1. Stop the machine frequently.

2. At each stop, use a suitable hand-held temperature sensor to measure the surface temperatures of the rollers.

3. If any roller surface temperature reaches or exceeds 80°C (175°F), pause for at least 30 minutes to permit cooling.

Completing just one extended travel without suitable precautions can ruin the oil inside the roller assemblies and cause roller failure. Replace rollers immediately in the event of failure. Operating the machine with failed rollers places excessive strain on other drive train components.

Track spinning reduces production, it increases fuel consumption, without a corresponding increase in productivity, and it accelerates undercarriage wear, so your costs escalate. Grouser bars are especially prone to wear problems associated with track slippage.

Watch your speed: Links, rollers and idlers are particularly vulnerable. Keep them working longer by controlling your speed.

Avoid unnecessary reverse operation: Operating in reverse, even at slow speeds, compounds bushing and sprocket wear as the track tension loads are applied to the top side of the chain. So avoid an unproductive reverse operation.

2.97

Controls and Operation

Tigercat 6500 Material Processor

Other factors: • Material type is another key contributor to undercarriage wear that is outside your control, the more abrasive the material, the more rapid the wear rate.

• Maintenance discipline plays a big role in undercarriage component life. One of the most critical maintenance practices is track adjustment.

Tight track is the number-one 'track killer'. But whether your track is too loose or too tight, improper adjustment accelerates wear which can increase downtime and repair costs. Follow the manufacturer's recommendations for track adjustment, and perform the adjustment in the machine's working environment. A second important maintenance process is cleaning the undercarriage.

To maximize wear life, remove mud and debris at the end of every shift, or more frequently if necessary.

To reduce and prevent track chain joint seizing, move the machine at least once per week, in order to articulate each joint. Avoid long stops in wet environments, for example wet soil or in water.

Talk to the experts: Undercarriage components are expensive! To get long life and maximum value from your investment, consult with a dealer or factory rep that really knows the undercarriage business. Ask for advice on operating techniques. Explore relevant application, material and terrain issues. Fine-tune your maintenance processes.

Working together with an undercarriage expert, you can manage your equipment investment over the long term.

2.98

LUBRICATION AND MAINTENANCE.................................................................................................................3

Tigercat 6500 Material Processor SECTION 3– LUBRICATION AND MAINTENANCE Read and understand the entire contents of this manual, and all manuals for any attachments or accessories associated with this machine, prior to operating or servicing this equipment.

CONTENTS – SECTION 3

ISSUE 1.0, JUNE 2021

A

ACCESS LADDERS.................................................................................................................................................. 3.20 LOWERING/RAISING............................................................................................................................................ 3.21 AIR INTAKE SYSTEM............................................................................................................................................... 3.50 AIR CLEANERS..................................................................................................................................................... 3.52 AIR CLEANER UNLOADER VALVES................................................................................................................... 3.53 AIR FILTER RESTRICTION INDICATOR............................................................................................................. 3.53 AIR FILTER RESTRICTION SWITCH.................................................................................................................. 3.53 AIR INTAKE TUBING AND JOINTS...................................................................................................................... 3.51 CHANGING FILTER ELEMENTS.......................................................................................................................... 3.52 ENGINE AIR PRECLEANER................................................................................................................................. 3.50 IMPROPER SERVICING....................................................................................................................................... 3.52 OVER SERVICING................................................................................................................................................. 3.52 ANVIL ADJUSTMENT............................................................................................................................................... 3.61 APPROVED HYDRAULIC OILS............................................................................................................................... 3.17

B

BATTERY CARE........................................................................................................................................................ 3.42 BELTS, ENGINE........................................................................................................................................................ 3.43 ENGINE FAN DRIVE BELTS................................................................................................................................. 3.43 SERPENTINE BELT............................................................................................................................................... 3.43

C

CARE OF THE MACHINE......................................................................................................................................... 3.63 CLEANING COOLER PACKAGE............................................................................................................................. 3.65 CLEANING PROCEDURE..................................................................................................................................... 3.68 COOLER PACKAGE SCREENS........................................................................................................................... 3.66 ENGINE PTO COOLER......................................................................................................................................... 3.67 HYDRAULIC OIL COOLER................................................................................................................................... 3.67 HYDRAULIC OIL COOLER SCREEN................................................................................................................... 3.67 COMMON CONVERSIONS...................................................................................................................................... 3.77 CONVEYORS AND CHAINS.................................................................................................................................... 3.54 CHAINS................................................................................................................................................................... 3.54 DISCHARGE CONVEYOR BELT TENSION........................................................................................................ 3.56 FEED CONVEYOR CHAIN TENSION.................................................................................................................. 3.55 GENERAL............................................................................................................................................................... 3.54 SPROCKETS.......................................................................................................................................................... 3.54 TRACKS AND TROUGHS..................................................................................................................................... 3.54

E

ENGINE COOLANT ADDING................................................................................................................................................................... 3.26 DRAINING............................................................................................................................................................... 3.27 ENGINE/HYDRAULIC COMPARTMENT................................................................................................................. 3.22 ENGINE PTO............................................................................................................................................................. 3.28 LOW PRESSURE FILTER..................................................................................................................................... 3.30

F

FILTERS ENGINE OIL............................................................................................................................................................ 3.44 ENGINE PTO – LOW PRESSURE FILTER........................................................................................................... 3.30 FUEL........................................................................................................................................................................ 3.44

Lubrication and Maintenance

Tigercat 6500 Material Processor

PRIMARY FUEL FILTER/WATER SEPARATOR.............................................................................................. 3.45 SECONDARY FUEL FILTERS........................................................................................................................... 3.46 HYDRAULIC OIL RETURN.................................................................................................................................... 3.37 FILTER CHANGE PROCEDURE....................................................................................................................... 3.38 FIRE PREVENTION.................................................................................................................................................... 3.9 FLUID ANALYSIS PROGRAM.................................................................................................................................... 3.6 FLUID ANALYSIS KITS............................................................................................................................................ 3.6 FLUID SAMPLING PROGRAM.................................................................................................................................. 3.7 FLUID SAMPLE COLLECTION PROCEDURES................................................................................................... 3.7 FUEL TANK................................................................................................................................................................ 3.47 CAPACITY............................................................................................................................................................... 3.47 FILL CAP................................................................................................................................................................. 3.47 FILL STRAINER..................................................................................................................................................... 3.47 IN-TANK FUEL STRAINER.................................................................................................................................... 3.48 CHANGING OR CLEANING............................................................................................................................... 3.48 FUSES AND RELAYS............................................................................................................................................... 3.41 MAIN ELECTRICAL PANEL.................................................................................................................................. 3.41 H

HYDRAULIC OIL OPERATING RANGE CHART.................................................................................................... 3.17 HYDRAULIC SYSTEM.............................................................................................................................................. 3.31 CASE DRAIN STRAINER...................................................................................................................................... 3.39 FILTER CHANGE PROCEDURE.......................................................................................................................... 3.38 FILTER RESTRICTION PRESSURE SWITCH.................................................................................................... 3.37 FILTERS, HYDRAULIC OIL RETURN.................................................................................................................. 3.37 HYDRAULIC OIL TANK.......................................................................................................................................... 3.32 ADDING OIL........................................................................................................................................................ 3.34 CLEAN OUT COVER.......................................................................................................................................... 3.33 DRAINING........................................................................................................................................................... 3.33 OIL LEVEL SIGHT GAUGE................................................................................................................................ 3.32 OIL LOW LEVEL SWITCH.................................................................................................................................. 3.32 OIL TEMPERATURE SENDING UNIT............................................................................................................... 3.32 RETURN DIFFUSER/STRAINER...................................................................................................................... 3.40 REFILLING.............................................................................................................................................................. 3.36

N

NEW MACHINE MAINTENANCE FIRST 125 HOUR INSPECTION REPORT............................................................................................................ 3.5 INITIAL PRE-DELIVERY INSPECTION................................................................................................................. 3.5 TIGHTENING POINTS............................................................................................................................................. 3.5

P

PRESSURE AND SPEED SETTINGS..................................................................................................................... 3.78 PRESSURE WASHING............................................................................................................................................. 3.64 PREVENTIVE MAINTENANCE SCHEDULE............................................................................................................ 3.5

R

REFILLING THE HYDRAULIC SYSTEM................................................................................................................. 3.34 ROTOR DRIVE GEARBOX....................................................................................................................................... 3.29 CHECKING OIL LEVEL......................................................................................................................................... 3.28 DRAINING AND REFILLING................................................................................................................................. 3.29 ROTOR MAINTENANCE.......................................................................................................................................... 3.58 ROTOR VISUAL INSPECTION................................................................................................................................ 3.57

S

3.2

Tigercat 6500 Material Processor

Lubrication and Maintenance

SCHEDULED MAINTENANCE GENERAL................................................................................................................................................................. 3.8 FREQUENTLY........................................................................................................................................................ 3.10 8 HOURS................................................................................................................................................................. 3.11 40 HOURS............................................................................................................................................................... 3.12 125 HOURS............................................................................................................................................................. 3.13 250 HOURS............................................................................................................................................................. 3.13 500 HOURS............................................................................................................................................................. 3.14 1000 HOURS........................................................................................................................................................... 3.14 2000 HOURS........................................................................................................................................................... 3.15 EVERY 2 YEARS.................................................................................................................................................... 3.16 SEASONAL............................................................................................................................................................. 3.16 STRAINERS CASE DRAIN.......................................................................................................................................................... 3.39 FUEL TANK............................................................................................................................................................. 3.48 HYDRAULIC OIL RETURN.................................................................................................................................... 3.40 T

TOOLBOX.................................................................................................................................................................. 3.62 LOWERING............................................................................................................................................................. 3.63 RAISING.................................................................................................................................................................. 3.63 TORQUE CHART, FLUID CONNECTIONS................................................................................................... 3.74 – 3.76 TORQUE CHART, GENERAL................................................................................................................................... 3.73 TORQUE CHART, SPECIFIC................................................................................................................................... 3.72 TRACK DRIVE GEARBOX....................................................................................................................................... 3.24 FILLING................................................................................................................................................................... 3.24 OIL DRAINING AND REPLACEMENT................................................................................................................. 3.25 TRACKS IMPORTANT TRACK DRIVE NOTES................................................................................................................... 3.69 MEASURING TRACK SAG.................................................................................................................................... 3.69 TRACK SAG........................................................................................................................................................... 3.69 TRACK SAG ADJUSTMENT................................................................................................................................. 3.70 TRACK SHOE RETAINING BOLTS...................................................................................................................... 3.71 UNDERCARRIAGE BOLTS – TORQUING............................................................................................................ 3.71

3.3

Lubrication and Maintenance

Tigercat 6500 Material Processor

3.4

Tigercat 6500 Material Processor

Lubrication and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE

IMPORTANT! Before moving the machine, the track tension (sag) must be set correctly. Track sag may be set less than specified for shipping purposes. Refer to TRACKS – TRACK SAG ADJUSTMENT in THIS SECTION.

NEW MACHINE MAINTENANCE INITIAL PRE-DELIVERY INSPECTION Perform the initial pre-delivery inspection using Tigercat form numbers 5434 and 5347: 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 numbers 5434 and 5347: PDI and 125 hour inspection report.

HOUR METER – MAINTENANCE Check the machine hour meter on a regular basis to determine your scheduled maintenance times.

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

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

WARNING

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 the Tigercat Industries Inc. Warranty department.

Hot fluids and hot machine surfaces can cause serious burns!

TIGHTENING POINTS: All hydraulic connections

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

Hose clamps All cylinder pin retainers Engine mounting bolts Pump mounting bolts

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

Track shoe bolts Track roller retaining bolts Track sprocket retaining bolts

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

Track drive gearbox mounting bolts Track drive motor mounting bolts Any other loose nut, bolt or fitting

CAUTION

All hydraulic connections NOTE: Use of filters other than genuine Tigercat replacement filters is not recommended.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL and ATTACHMENT MANUFACTURER'S DOCUMENTATION for additional required maintenance at this scheduled time period.

3.5

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.

Lubrication and Maintenance

Tigercat 6500 Material Processor

TIGERCAT FLUID ANALYSIS PROGRAM

TIGERCAT FLUID ANALYSIS KITS

Using the Tigercat Advanced Fluid Analysis Program on a regular basis is an excellent preventative maintenance tool.

Each kit includes a Prepaid Sample Bottle and Sample Information Form. Preprinted 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.

Studies have shown that it is possible to receive a 10 to 1 payback when looking at the amount saved on repair costs in relation to the amount invested in a scheduled fluid analysis program. Some of the benefits of a sampling program include: • Detecting problems early and before they become major catastrophic failures.

• Better ability to schedule downtime and forecast cost of repairs.

• Monitoring maintenance schedules and practices and confirming the required maintenance is being done on time.

The same type of sample bottle can be used for all types of fluid testing including Hydraulic Circuits, Final Drives, Axles, Gearboxes, Engines, etc.

To ensure accurate and meaningful results are obtained, each kit also includes detailed instructions on how to properly collect, prepare and ship the fluid samples.

Contact your Tigercat Dealer Parts Department to order kits.

• Increase used equipment value by providing proof of proper maintenance.

This Program uses the most modern technology available to analyze all fluid 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. The report is available as a mailed or faxed hardcopy, sent via e-mail or it can be viewed on the Internet.

This program will provide Tigercat machine owners access to an Advanced Fluid Analysis Program for all major machine components including Engines, Hydraulic Circuits, Axles, Final Drives, Gearboxes, etc.

Tigercat Fluid 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 follow-up fluid samples.

Refer to FLUID SAMPLING PROGRAM in THIS SECTION for sample valve and drain plug locations.

6000 Series Location

First Sample

Follow-up Samples

Hydraulic Oil

125 hours

Every 1000 hours or 6 months

Track Drive Gearboxes

125 hours

Every 1000 hours or 6 months

Rotor Drive Gearbox

125 hours

Every 1000 hours or 6 months

Pump Drive Gearbox (if applicable)

125 hours

Every 1000 hours or 6 months

3.6

Tigercat 6500 Material Processor

Lubrication and Maintenance

TIGERCAT FLUID SAMPLING PROGRAM

HYDRAULIC OIL SAMPLES

FLUID SAMPLE COLLECTION PROCEDURES

A

Fill out the Sample Information Form (SIF) completely and accurately. When taking multiple fluid samples, fill out all of the required SIF`s in their entirety, prior to taking any fluid samples. Then, immediately package each completed SIF together with the matching fluid 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`s and fluid 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 fluid sample taken.

Collection of clean fluid samples that are representative of the main body of fluid 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 followup samples should be consistently taken from the same location using the same techniques as all previous samples.

• All sample valves and drain plugs must be clean and free of debris.

• Remove the dust cover from the sample valve and attach the bleed hose (supplied with the machine) to the sample valve connection.

• Remove the sample bottle cap only when ready to obtain 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.

6000174

A Hydraulic Oil Sample Valve – On Hydraulic Oil Return Manifold

• 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.

• Purge the bleed hose before taking a representative oil sample. Drain a minimum of 90 – 120 ml (3 – 4 oz) of oil into a separate container and discard this oil using approved recycling methods.

• Remove the bleed hose and 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.

• To obtain a representative oil sample, the oil must be warm and must not have settled (within 30 minutes of shutdown).

• Avoid contamination of the sample – replace the sample bottle cap immediately after filling the bottle to approximately ¾ full.

• Place the required drain container under the machine to capture the used oil to be discarded using approved recycling methods.

All samples taken should be immediately forwarded to the lab for processing.

Contact your Tigercat dealer to purchase additional or replacement hydraulic sample valves or drain plugs.

• 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.

In cases where fluid samples must be pumped or otherwise drawn out of a tank or housing, a hand operated fluid suction pump is also available from your Tigercat dealer.

3.7

Lubrication and Maintenance

Tigercat 6500 Material Processor

GENERAL

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

CAUTION

• Clean away all branches, bark and chips. Clean up all traces of oil to avoid fires.

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

• 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. Repair all exhaust leaks or defective parts immediately. Engine exhaust leaks can cause fires. Do not operate the machine until the exhaust leak is repaired.

• Clean around fill caps before checking or adding fluids.

• Clean around hydraulic fittings before breaking connection. Plug or cap immediately.

• 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. When exhaust leaks occur during operation, shut down the machine immediately and do not put it back to work until the necessary repairs have been completed.

• Clean up spills as soon as possible.

• Use clean oil and containers.

• 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.

• Keep a fire extinguisher on hand at all times.

• Install door safety struts when working on the machine.

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

• Check and clean fire suppression system sensors on a regular basis.

• Clean up oil spills in engine enclosure immediately.

• Before welding on machine, disconnect all electrical connections and follow all servicing safety precautions as outlined in the WELDING, PRIOR TO in SECTION 1.

* Oil Lost From Leakage Lost Oil (Litres) Leakage Rate

Lost Oil (US Gallons)

Per Day

Per Month

Per Year

Per Day

Per Month

Per Year

One drop In TEN Seconds

0.424

12.72

152

0.112

3.36

40

One drop In FIVE Seconds

0.852

25.6

306.6

0.225

6.75

81

One drop per second

4.26

127.76

1533.1

1.125

33.75

405

Three Drops per Second

14.2

425.86

5110.31

3.75

112.5

1350

Drops Break Into Stream

90.83

2725.5

32706

24.0

720

8640

3.8

Tigercat 6500 Material Processor

Lubrication and Maintenance

FIRE PREVENTION

FIRE EXTINGUISHER

Proper maintenance of your machine will greatly extend its life and reduce your operating costs.

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

A

CAUTION After transporting (trucking) a machine from one jobsite 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 during the journey.

1. When allowed to accumulate, forest debris and fine organic material (twigs, pine needles, branches, bark, leaves, sawdust, small wood chips, etc.) and any other combustible materials form a fuel source that is extremely difficult to extinguish when ignited. 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 routes during maintenance. ALL wiring harnesses and hydraulic hoses must be 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, turn OFF the engine before discharging the fire suppression system.

Refer to FIRE PREVENTION in SECTION 1 for additional information.

3.9

6000188

Non-Drive Side of Machine

A Fire Extinguisher

Maintain a charged fire extinguisher close to the machine at all times and know how to use it.

Refer to the manufacturer's use and information manual for proper usage, additional information and recommended inspection and maintenance intervals.

Lubrication and Maintenance

Tigercat 6500 Material Processor

SCHEDULED MAINTENANCE

WARNING

For service and replacement intervals see SERVICE AND LUBRICATION POINTS in THIS SECTION.

FREQUENTLY • Check for water in fuel filter/water separator.

• Visual engine check.

• Check the engine cooling air intake screens for possible restriction.

• Check for debris, snow and ice buildup on service platforms and remove accumulation immediately.

Hot fluids and hot machine surfaces can cause serious burns!

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

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

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

3.10

Tigercat 6500 Material Processor

Lubrication and Maintenance

EVERY 8 HOURS

CLEAN • Hydraulic oil cooler, engine PTO cooler, engine radiator and charge air cooler.

PERFORM • FREQUENTLY Maintenance.

• Remove potentially damaging limbs or sticks and all debris.

• Drain fuel filter/water separator.

• Conduct an overall visual inspection.

VISUALLY INSPECT

CHECK

• Rotor bearings for noise and temperature.

• Engine coolant level.

• Knives.

• Engine oil level at dipstick.

• Liners.

• Air intake precleaners.

• Anvil.

• Air intake filter restriction indicators.

Complete repairs immediately.

• Replace primary filter if indicator is in red zone.

LUBRICATE

• Replace secondary (safety) filter every third primary filter change to guarantee maximum performance and reliability.

• Rotor bearings – 6 shots – Use Mobil CMS grease.

• 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.

• Top feed roll arm pivot points – purge.

• Top feed roll end plate bearing – purge.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

• Hydraulic oil level.

• Rotor drive gearbox oil level.

• Visually check condition of tracks.

• For leakage around hydraulic components and flexible hoses.

• For loose nuts, bolts and fittings.

• Condition and tension of belts.

• Exhaust system for leaks.

• Fire extinguisher for sufficient charge.

* Use of filters other than genuine Tigercat replacement filters is not recommended.

3.11

Lubrication and Maintenance

Tigercat 6500 Material Processor

EVERY 40 HOURS PERFORM • FREQUENTLY Maintenance.

• 8 HOURS Maintenance.

LUBRICATE • Feed conveyor tail pulley bearings – purge.

• Feed conveyor head pulley bearing – purge.

• Upper hog box lifting cylinders pivot pins – purge.

• Upper hog box pivot pins – purge.

• Upper hog box locking cylinder pins – purge.

• Top feed roll lifting cylinder pivot pins – purge.

• Shear grate frame pivot pins – purge.

• Shear grate cylinder pins – purge.

• Discharge conveyor tail pulley bearings – purge.

• Discharge conveyor support pins – purge.

• Discharge conveyor head pulley bearing – purge.

• Track pivot pins – purge.

• Track tilt cylinder pins – purge.

• Tension cylinder pins – purge.

• Storage box cylinder pins – purge.

NOTE: Use Mobil CMS grease at all points.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

3.12

Tigercat 6500 Material Processor

Lubrication and Maintenance

EVERY 125 HOURS

EVERY 250 HOURS

PERFORM

PERFORM

• FREQUENTLY Maintenance.

• FREQUENTLY Maintenance.

• 8 HOURS Maintenance.

• 8 HOURS Maintenance.

• 40 HOURS Maintenance.

• 40 HOURS Maintenance.

• 125 HOURS Maintenance.

CHECK

CHECK

• Fuel fill strainer (cap screen).

• Hydraulic oil return filters restriction indicator on filter head with engine speed at HIGH with oil flow.

• Oil level in track drive gearbox. Check with level plug at nine o'clock position and drain plug at six o'clock position. Fill with SAE 75W-90 gear oil.

• Fluid level in batteries unless maintenance free.

• Engine serpentine belt.

• Fire extinguisher and turn it to mix contents.

REPLACE • Engine oil and filter. * • Engine fuel filter. *

• Engine speed.

• Fuel filter/water separator filter. *

• All hydraulic pressures.

DRAIN AND REFILL

• Hydraulic pump and motor securing bolts.

• Oil in track drive gearboxes with level plug at nine o'clock position and drain plug at six o'clock position.

Fill with SAE 75W-90 oil.

• Torque tightening points as per new machine maintenance.

VISUALLY INSPECT FOR DAMAGE TO

• Oil in rotor drive gearbox. Fill with SAE 75W-90 oil Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

• Tracks, track frames.

• Hardfacing wear due to abrasion.

• Conveyor components.

Complete repairs immediately.

VISUALLY INSPECT FOR • Frayed electrical wiring and hydraulic hoses.

• Wear in any other components.

NOTE: Neglecting the proper maintenance of these items can result in fire.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

* Use of filters other than genuine Tigercat replacement filters is not recommended.

3.13

Lubrication and Maintenance

Tigercat 6500 Material Processor

EVERY 500 HOURS

EVERY 1000 HOURS

PERFORM

PERFORM

• FREQUENTLY maintenance.

• FREQUENTLY maintenance.

• 8 HOURS Maintenance.

• 8 HOURS Maintenance.

• 40 HOURS Maintenance.

• 40 HOURS Maintenance.

• 125 HOURS Maintenance.

• 125 HOURS Maintenance.

• 250 HOURS Maintenance.

• 250 HOURS Maintenance.

• 500 HOURS Maintenance.

CHECK • Track rollers and idlers for oil leakage. These components are filled with oil and considered maintenance free. If oil leakage is detected repair of component(s) will be necessary.

• Torque on track drive gearboxes and motor mounting bolts.

REPLACE • Hydraulic oil return filters. * • Low pressure filter. *

CHECK • In-tank fuel strainer.

REPLACE • Air cleaner unloader valve.

• Engine serpentine belt.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

• Engine crankcase ventilation filter. * (Tier 4f machines only.)

Refer to the ENGINE OPERATION AND MAINTENANCE MANUAL for replacement instructions.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

* Use of filters other than genuine Tigercat replacement filters is not recommended.

3.14

Tigercat 6500 Material Processor

Lubrication and Maintenance

EVERY 2000 HOURS

REPLACE • All air intake rubber components such as elbows and connectors – High temperatures in this area can cause the rubber to harden.

PERFORM • FREQUENTLY Maintenance.

• 8 HOURS Maintenance.

NOTE: High-temperature silicone connectors do not need to be replaced unless they are damaged.

• 40 HOURS Maintenance.

• 125 HOURS Maintenance.

NOTE: Refer to AIR INTAKE SYSTEM in THIS SECTION.

• 250 HOURS Maintenance.

• 500 HOURS Maintenance.

• Hydraulic oil tank breather.

• 1000 HOURS maintenance.

CHECK • All hydraulic system components especially cooling fan for proper operation after hydraulic oil has been replaced.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

• Air intake precleaners.

DRAIN AND REFILL • Hydraulic oil tank with recommended hydraulic oil.

Refer to APPROVED HYDRAULIC OILS in THIS SECTION. It is strongly recommended that a program of regular oil testing be used. Oil change intervals can be established from oil test results.

Make sure the hydraulic oil type selected on the computer display matches the oil type being used.

Adjust oil type if needed.

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 diffuser/strainers, filters and replacing the hydraulic oil tends to aerate the oil.

For maximum pump life, do not operate the machine for one hour after servicing to allow entrained air to escape from the oil prior to applying working pressures to the pumps.

* Use of filters other than genuine Tigercat replacement filters is not recommended.

3.15

Lubrication and Maintenance

Tigercat 6500 Material Processor

EVERY 2 YEARS

SEASONAL

REPLACE

REPLACE

• Engine coolant. Antifreeze must comply with international specifications ASTM D-6210.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for additional required maintenance at this scheduled time period.

• Drain and refill hydraulic oil tank with recommended hydraulic oil if required to meet operating temperature range.

Refer to APPROVED HYDRAULIC OILS in THIS SECTION.

3.16

Tigercat 6500 Material Processor

Lubrication and Maintenance

APPROVED HYDRAULIC OILS Use one of the following oils to fill or replenish the hydraulic system:

3.17

Lubrication and Maintenance

Tigercat 6500 Material Processor

4 5

1

13 30

6

13

8 9

11

7

14

3

15

36

17 22 28

21

11

7

26

26

35

21 28

25 29

12

20

14 10 33 16

26

23 24

26

22

34 4 5

27 32

15

17 29

30

2

28

19

33

36

29

32

27

18

21

6000571

3.18

16

23

29

31

19

Tigercat 6500 Material Processor

Lubrication and Maintenance

COOLING SYSTEM

2

ENGINE OIL/FILTERS

DESCRIPTION QTY

USG

LITRES

2000 

1000 

500 

250 

125 

40 

8

ITEM

1

3

CAPACITY

SERVICE EVERY

POINT NO.

SERVICE

Tigercat Model 6500 SERVICE AND LUBRICATION POINTS REFER TO Tigercat OPERATOR'S MANUAL FOR FURTHER INFORMATION

CHANGE COOLANT EVERY 2 YEARS

CHK CHK

REFER TO ENGINE OPERATION AND MAINTENANCE MANUAL FOR REQUIRED ANTIFREEZE SOLUTION AND MIXTURE.

REP

•

•

•

•

REP •

CRANKCASE VENTILATION FILTERS

2

REP

4

FUEL FILTERS (ENGINE)

5

FUEL FILTER/WATER SEPARATOR

6

IN-TANK FUEL STRAINER

7

AIR INTAKE PRECLEANER

CHK

8

AIR INTAKE PRIMARY ELEMENT

CHK

2

9

AIR INTAKE SAFETY ELEMENT

CHK

2

10

AIR CLEANER UNLOADER VALVE

CHK

11

AIR INTAKE CONNECTIONS

CHK

REP

12

HYDRAULIC OIL TANK (LEVEL INDICATOR ON TANK)

CHK

D/R

13

HYDRAULIC OIL TANK BREATHER

14

HYDRAULIC OIL RETURN FILTERS 1 BLUE WATER ABSORBING ELEMENT 3 WHITE HIGH PERFORMANCE ELEMENTS

15

ENGINE PTO LOW PRESSURE FILTER

16

TRACK DRIVE GEARBOXES

17

ROTOR DRIVE GEARBOX (DIPSTICK IN GEARBOX)

CHK

18

ROTOR BEARINGS

LUB

19

FEED CONVEYOR TAIL PULLEY BEARINGS

20

DRN

•

2

REP

1 CHK

1 CHK

2

REP

CLEAN AS REQUIRED. INSPECT IMPELLER FOR WEAR OR DAMAGE. REPLACE AS NECESSARY. CHECK FILTER RESTRICTION INDICATOR. REFER TO 8 HOUR SCHEDULED MAINTENANCE IN SECTION 3 OF THE MANUAL FOR DETAILS.

2

REFER TO ENGINE OPERATION AND MAINTENANCE MANUAL.

1

CHECK FOR LOOSE CLAMPS AND DAMAGED RUBBER COMPONENTS. REPLACE RUBBER COMPONENTS. DRAIN AND REFILL AS REQUIRED BY SEASONAL OIL CHANGE. SEE APPROVED HYDRAULIC OILS IN SECTION 3 OF THE MANUAL.

REP

1

REP

CHK

• REFER TO ENGINE OPERATION AND MAINTENANCE MANUAL FOR PROCEDURES, CAPACITIES AND REPLACEMENT INTERVALS.

4

†

REP

CHECK FILTER RESTRICTION INDICATOR ON FILTER HEADS WITH ENGINE RUNNING AT HIGH SPEED AND WITH OIL FLOW. SEE SECTION 3 OF MANUAL FOR DETAILS.

1

†

2

FILL WITH API GL-5, 75W-90. SYNTHETIC GEAR OIL IS RECOMMENDED FOR SEVERE DUTY APPLICATIONS. †† CHECK OIL WITH PLUGS AT 6 AND 9 O'CLOCK POSITIONS.

5.3

1

FILL WITH API GL-5, 75W-90 GEAR OIL.

15 SHOTS

2

LITHIUM BASE EP2 GREASE 

LUB

PURGE

2

LITHIUM BASE EP2 GREASE 

FEED CONVEYOR HEAD PULLEY BEARING

LUB

PURGE

1

LITHIUM BASE EP2 GREASE 

21

UPPER HOG BOX LIFTING CYLINDER BARREL

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

22

UPPER HOG BOX PIVOT PINS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

23

UPPER HOG BOX LOCKING CYLINDER PINS

LUB

PURGE

2

LITHIUM BASE EP2 GREASE 

24

TOP FEED ROLL ARM PIVOT POINTS

LUB

PURGE

2

LITHIUM BASE EP2 GREASE 

25

TOP FEED ROLL END PLATE BEARING

LUB

PURGE

1

LITHIUM BASE EP2 GREASE 

26

TOP FEED ROLL LIFTING CYLINDER ROD PIN

LUB

PURGE

2

LITHIUM BASE EP2 GREASE 

27

SHEAR GRATE FRAME PIVOT PINS

LUB

PURGE

2

LITHIUM BASE EP2 GREASE 

28

SHEAR GRATE CYLINDER PINS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

29

DISCHARGE CONVEYOR TAIL PULLEY BEARINGS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

30

DISCHARGE CONVEYOR SUPPORT PINS

LUB

PURGE

2

LITHIUM BASE EP2 GREASE 

31

DISCHARGE CONVEYOR HEAD PULLEY BEARING

LUB

PURGE

1

LITHIUM BASE EP2 GREASE 

32

TRACK PIVOT PINS

LUB

PURGE

2

LITHIUM BASE EP2 GREASE 

33

TRACK TILT CYLINDER PINS

LUB

PURGE

4

LITHIUM BASE EP2 GREASE 

34

TENSION CYLINDER PINS

LUB

PURGE

2

LITHIUM BASE EP2 GREASE 

35

ANVIL CYLINDER PINS

LUB

PURGE

8

LITHIUM BASE EP2 GREASE 

36

STORAGE BOX CYLINDER PINS

LUB

PURGE

2

LITHIUM BASE EP2 GREASE 

CHK ††

D/R D/R

20

3.19

Lubrication and Maintenance

Tigercat 6500 Material Processor

ACCESS LADDERS

A

B

6000155

Stored Position

6000154

A Front Ladder B Rear Ladder

Non-drive Side of Machine

Folding ladders on the non-drive side of the machine provide access for servicing the machine.

The front ladder provides access to inspect and perform maintenance on the rotor, and to access lubrication points.

The rear ladder provides access to service the engine, and hydraulic system, and to refuel the machine.

NOTICE Place ladders in the stored position prior to moving the machine.

6000156

Servicing Position

3.20

Tigercat 6500 Material Processor

Lubrication and Maintenance

LOWERING/RAISING THE LADDERS

CAUTION

WARNING

Pinch Hazard. Keep hands clear of ladder pivot points and hinge points when lowering or raising ladder.

Raising and lowering the ladders represents a potential pinch hazard. Use caution when lowering or storing the ladders.

A A B B

6000456

A Lynch Pin B Snapper Pin

Ladder Brace 6000455

1. Remove the snapper pin from the lynch pin.

A Lynch Pin B Snapper Pin

2. Press on the ladder to support it and to take the weight off the lynch pin.

6. Reinstall the lynch pin and secure with the snapper pin.

3. Remove the lynch pin.

6000454

4. Carefully unfold and guide the ladder to the servicing position.

3.21

Lubrication and Maintenance

Tigercat 6500 Material Processor

ENGINE/HYDRAULIC COMPARTMENT E

B

A

C

B

D

H

6000313

A B C D

Radiator Charge Air Cooler Air Cleaners Engine Air Precleaners

Non-Drive Side View– Roof Removed for Clarity E F G H

3.22

Catalytic Converter (SCR) Hydraulic Oil Cooler Fuel Tank Fill Cap Engine

F

G

Tigercat 6500 Material Processor G

I

B

A

Lubrication and Maintenance H

M

D

C

F

J

E

L

N

6000314

A B C D E F G

Drive Side View– Roof and Drive Belt Guard Removed for Clarity

Radiator and Charge Air Coolers Hydraulic Oil Tank Air Cleaners Engine Air Precleaners Catalytic Converter (SCR) Hydraulic Oil Cooler and Engine PTO Cooler Fuel Tank Fill Cap

H I J K L M N

3.23

Engine Hydraulic Oil Return Filters Pump Drive Gearbox Hydraulic Pumps Engine PTO Hydraulic Oil Tank Level Gauge Rotor Drive

K

Lubrication and Maintenance

Tigercat 6500 Material Processor

TRACK DRIVE GEARBOX Check the oil level in the track drive gearboxes every 125 hours.

FILLING THE GEARBOX B

800372

Track Drive Gearbox Fill Level

6. Fill from the upper port 'B' until gear oil flows out of port 'B'. Use 75W-90 gear oil.

A 800371

Track Drive Gearbox

A Track Drive Gearbox Plug 'A' (6 o'clock position) B Track Drive Gearbox Plug 'B' (9 o'clock position)

7. Install plug 'B'.

8. Operate the gearbox for a few minutes, stop and check the oil level.

Refer to SECTION 11 of the SERVICE MANUAL for further information.

To top up the track drive gearboxes: 1. Park the machine on level ground with the track drive gearbox drain plug 'A' at the six o'clock position and the fill plug 'B' at the 9 o'clock position.

2. Park the machine on level ground.

3. Turn OFF the engine.

4. Remove the ignition key.

5. Remove plug 'B'.

3.24

Tigercat 6500 Material Processor

Lubrication and Maintenance

OIL DRAINING AND REPLACEMENT B

800372

A

Track Drive Gearbox Fill Level

800371

7. Fill from the upper port 'B' until gear oil flows out of port 'B'.

Track Drive Gearbox

A Track Drive Gearbox Plug 'A' (6 o'clock position) B Track Drive Gearbox Plug 'B' (9 o'clock position)

8. Install plug 'B'.

9. Operate the gearbox for a few minutes, stop and check the oil level.

Drain and replace the gear oil in the track drive gearboxes every 250 hours. Use 75W-90 gear oil.

To drain the track drive gearboxes: 1. Park the machine on level ground with the track drive gearbox drain plug 'A' at the six o'clock position and the fill plug 'B' at the 9 o'clock position.

2. Park the machine on level ground.

3. Turn OFF the engine.

4. Remove the ignition key.

5. Remove plugs 'A' and 'B' and allow oil to drain into a suitable container.

NOTE: Dispose of waste oil according to local regulations.

6. Install plug 'A'.

3.25

Refer to SECTION 11 of the SERVICE MANUAL for further information.

Lubrication and Maintenance

Tigercat 6500 Material Processor

ADDING ENGINE COOLANT

WARNING

Do not remove the engine coolant fill cap when the engine is hot, release of pressurized coolant can cause serious burns.

A

Turn OFF the engine. Only remove the coolant fill cap when it is cool enough to touch with bare hands.

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

6000249

Top of Radiator– Non-drive Side of Machine

A Engine Coolant Fill Cap

Engine coolant is added to the system through the engine coolant fill cap at the top of the cooling package.

NOTE: A proper solution of coolant antifreeze must be used when filling the surge tank.

3.26

Tigercat 6500 Material Processor

Lubrication and Maintenance

DRAINING ENGINE COOLANT Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION SCHEDULE in THIS SECTION for maintenance and service intervals.

Use a 5/8 in drain hose of suitable length to drain engine coolant from the system.

To drain the engine coolant from the system: 1. Slowly loosen the engine coolant fill cap to the first stop to relieve pressure before removing completely.

A

WARNING

B

6000401

Do not remove the engine coolant fill cap when the engine is hot, release of pressurized coolant can cause serious burns.

Underside of Cooler Package

A Coolant Drain Shut-off Valve B Threaded cap

Turn OFF the engine. Only remove the coolant fill cap when it is cool enough to touch with bare hands.

2. Remove the threaded cap from the coolant drain shut-off valve.

3. Attach a drain hose to the end of the coolant drain shut-off valve.

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

4. Place the end of the drain hose into a suitably sized container.

5. Open the coolant drain shut-off valve.

6. Drain the engine coolant.

7. Close the coolant drain shut-off valve.

8. Install the threaded cap.

9. Fill the cooling system. Refer to ENGINE COOLANT – ADDING in THIS SECTION. 10. Replace the engine coolant fill cap.

3.27

Lubrication and Maintenance

Tigercat 6500 Material Processor

ENGINE PTO A

6000315

A Engine PTO Lube Pump B Engine PTO C Engine Drive Sheave

Engine PTO (Drive Belt Guard Not Shown)

The engine PTO is located on the rear of the engine.

The PTO receives lubrication from a lube pump mounted on the engine which circulates gear oil from the rotor drive gearbox.

3.28

B

C

Tigercat 6500 Material Processor

Lubrication and Maintenance

ROTOR DRIVE GEARBOX

DRAINING AND REFILLING NOTE: Drain the rotor drive gearbox when the oil is cold. This will allow particulate that has settled to the bottom of the gearbox to be removed when the gear oil is drained.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

A

NOTE: The machine must be level when draining and refilling the rotor drive gearbox.

B

2. Clean around and remove the fill cap.

NOTE: Do not remove the drain plug until the fill cap has been removed.

6000573

Rotor Drive Gearbox – Drive Side of Machine

A Gearbox Dipstick B Gearbox Fill Cap

Check the gearbox oil level every 8 hours.

Drain and replace the rotor drive gearbox gear oil every 250 hours.

The gearbox has a usable capacity of 20 L (5.3 US gal).

The fill cap is located on the side of the gearbox. Use 75W-90 gear oil.

A

6000574

Rotor Drive Gearbox – Drive Side of Machine

A Gearbox Drain Plug

CHECKING OIL LEVEL

3. Remove the drain plug.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

4. Drain the gear oil into a suitable container.

NOTE: The machine must be level when checking the gearbox oil level.

NOTE: Dispose of the waste gear oil according to local regulations.

2. Wait at least 5 minutes after stopping the engine before checking the level.

5. Install the drain plug.

6. Fill the gearbox with the correct quantity of gear oil.

3. Clean around the gearbox dipstick.

Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION for rotor drive gearbox oil capacity and recommended gear oils.

4. Remove the dipstick and read the level.

5. If the gearbox oil level is low, clean around and remove the fill cap. Carefully add oil, checking the level regularly with the dipstick. Do not overfill.

7. Install and tighten the fill cap.

Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION for recommended oils.

6. Install and tighten the fill cap.

3.29

Lubrication and Maintenance

Tigercat 6500 Material Processor

LOW PRESSURE FILTER C

E

B

FILTER CHANGE PROCEDURE

F

A

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

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

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

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

5. Dispose of old filter and any oil properly.

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

7. The new filter has an attached gasket, apply clean oil to the gasket surface.

8. Screw on the new filter until the gasket makes contact.

9. Tighten filter an additional 1⁄4 – 1⁄2 turn, by hand.

D 6000463

A B C D E F

Drive Side of Machine

Low Pressure Filter – Engine PTO Pressure Switch Engine PTO Lube Pump From Rotor Drive Gearbox to Lube Pump From Lube Pump to Filter head From Filter Head to Engine PTO Cooler

10. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

IMPORTANT! Contaminated gear oil can lead to premature failure of components and costly repairs. Filter must be replaced at the recommended time intervals, Refer to SCHEDULED MAINTENANCE in THIS SECTION.

The low pressure filter is located at the front of the engine on the drive side of the machine.

Gear oil from the rotor drive gearbox passes through the PTO lube pump, a spin-on low pressure filter mounted on a filter head, a cooler located behind the hydraulic oil cooler, to the engine PTO and back to the rotor drive gearbox.

For service and replacement intervals refer to SCHEDULED MAINTENANCE in THIS SECTION.

3.30

Tigercat 6500 Material Processor

Lubrication and Maintenance

HYDRAULIC SYSTEM

IMPORTANT! Before servicing the hydraulic system, park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

NOTICE

Tigercat does not recommend the pre-filling 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 system components.

The cleanliness of hydraulic oil cannot be guaranteed unless it is pre-filtered before use.

Use of filters other than genuine Tigercat replacement filters is not recommended. Replace filters at the recommended time intervals.

Refer to SCHEDULED MAINTENANCE in THIS SECTION.

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 verify it is safe to begin service work.

• Do not begin service work until the surface or system temperature has cooled down to below 38°C (100°F).

3.31

Lubrication and Maintenance

Tigercat 6500 Material Processor

HYDRAULIC OIL TANK C

D

E

OIL LEVEL SIGHT GAUGE F

An oil level sight gauge, on the drive side of the tank indicates the HIGH and LOW levels of the hydraulic oil.

This gauge is located to monitor hydraulic oil level when filling the hydraulic oil tank.

A

Maintain the hydraulic oil between the HIGH and LOW level marks on the gauge label. Check oil level with all cylinders fully retracted to obtain an accurate level reading. Overfilling the tank may cause excess oil to discharge from the breather vent.

B

LOW LEVEL SENDING UNIT A low level sending unit is incorporated into the hydraulic oil level sight gauge. A message is sent to the computer display when the hydraulic oil tank level is low. The alarm light will flash and the alarm will also sound.

Refer to COMPUTER – MESSAGES– CRITICAL AND ALARM – HYDRAULIC OIL TANK LOW OIL LEVEL in SECTION 2.

6000317

A B C D E F

Hydraulic Oil Tank – Drive Side of Machine

Hydraulic Oil Return Filter (White) – Quantity 3 Water Absorbent Filter (Blue) – Quantity 1 Hydraulic Oil Level Sight Gauge Hydraulic Oil Low Level Sending Unit Breather Hydraulic Oil Temperature Sending Unit

The hydraulic oil tank is located on the drive side of the machine. The tank has a capacity of 435 L (115 US gal).

Return oil passes through a return manifold and four filters before entering the tank.

Allowing the level to drop below the LOW limit can result in severe damage to hydraulic components.

If the oil level drops, inspect the machine including all fittings and hydraulic components for leaks. Once the source of the oil loss is located and repaired, oil can be added to the tank.

TEMPERATURE SENDING UNIT A temperature sending unit activates the hydraulic oil temperature gauge on the computer display main screen. A message is sent to the computer display when the hydraulic oil temperature exceeds the recommended operating range for the type of hydraulic oil in use. The alarm light will flash and the alarm will also sound.

Refer to COMPUTER – MESSAGES– CRITICAL AND ALARM – HYDRAULIC OIL TANK HIGH TEMPERATURE in SECTION 2.

3.32

Tigercat 6500 Material Processor

Lubrication and Maintenance

DRAINING

CLEAN OUT COVER

To drain the hydraulic oil tank:

C

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

B

A

6000319

A Clean Out Cover B Fastener (Qty 10) C O-ring

A 6000318

The clean out cover is located on the drive side of the hydraulic oil tank.

Hydraulic Oil Tank – Drive Side of Machine

A Environmental Drain Plug

2. Remove the dust cap from the environmental drain plug on the bottom of the tank.

3. Thread the drain hose onto the environmental drain plug.

NOTE: Once the drain hose seats itself, the valve will open and hydraulic oil will begin to drain through the hose.

Removing the clean out cover provides access into the hydraulic oil tank for cleaning, inspection and mounting of components.

IMPORTANT! Remove the clean out cover only when the hydraulic oil tank has been completely drained of hydraulic oil.

Refer to HYDRAULIC OIL TANK – DRAINING in THIS SECTION. To remove the clean out cover:

CAUTION

1. Remove the clean out cover fasteners.

Drain the hydraulic oil tank when the hydraulic oil temperature is below 38°C (100°F), but warm enough to be less viscous.

2. Remove the clean out cover.

3. Remove the O-ring.

NOTE: Install a new O-ring when reinstalling the clean out cover.

4. Drain the hydraulic oil into a suitable container.

NOTE: Dispose of the waste hydraulic oil according to local regulations.

5. Remove and store the drain hose.

6. Install the environmental drain plug dust cap.

3.33

Lubrication and Maintenance

Tigercat 6500 Material Processor

ADDING OIL Prior to adding oil to the tank, determine and repair the source of the oil loss.

The hydraulic oil hand-fill pump is used to add oil to the hydraulic oil tank. The hand fill pump is located in the engine/hydraulic compartment. The oil is pumped directly into the tank through the return filters.

A

B

C

6000322

2. Clean the fill hose and insert it into the supply drum.

A

6000464

Engine/Hydraulic Compartment Service Platform

A Hand Fill Pump Shut-Off Valve B Hand Fill Pump C Fill Hose

1. Remove fill hose from stored position.

6000323

A Hand Fill Pump Shut-off Valve

3. Open the shut-off valve above the hand fill pump.

3.34

Tigercat 6500 Material Processor

Lubrication and Maintenance 6. Close the shut-off valve.

7. Remove the suction hose from the supply drum and wipe clean.

8. Install the hose in the storage position.

IMPORTANT! Failure to keep the fill hose clean will significantly reduce the life of the filter elements.

CAUTION Direct contact with oil implies a risk of skin complaints. Wash off oil on skin immediately with soap and water. Refer to WORKING WITH OIL in SECTION 1.

6000324

4. Operate the hand fill pump at a medium speed with steady motion to fill the tank.

A

B

C

6000310

Drive Side of Machine

A Oil Level Sight Gauge B Hydraulic Oil Level High Limit C Hydraulic Oil Level Low Limit

5. Pump the oil until the level is at the FULL mark on the oil level sight gauge.

Check the oil level with all cylinders fully retracted to obtain an accurate level reading.

3.35

Lubrication and Maintenance

Tigercat 6500 Material Processor

REFILLING THE HYDRAULIC SYSTEM When filters are replaced, there is a nominal amount of oil loss through leakage and oil contained in the filters.

This requires a hydraulic system top-up or refill.

Before refilling, verify which oil type is selected to ensure the same type and grade of oil is used to refill the system.

It is strongly recommended that a program of regular oil testing be used. Oil change intervals can be established from oil test results.

Refer to HYDRAULIC SYSTEM – HYDRAULIC OIL TANK – ADDING OIL in THIS SECTION. NOTE: Changing strainers, filters and replacing the hydraulic oil tends to aerate the oil. For maximum pump life, the machine should sit for one hour after servicing to allow entrained air to escape from the oil prior to applying working pressures to the pumps.

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.

Check all hydraulic system components especially the cooling fan for proper operation after hydraulic oil has been replaced.

3.36

Tigercat 6500 Material Processor

Lubrication and Maintenance

HYDRAULIC OIL RETURN FILTERS

FILTER RESTRICTION PRESSURE SWITCH A filter restriction pressure switch is installed at the inlet of one of the filter heads. When an oil pressure in excess of 1.4 bar (20 psi) is encountered at the inlet, this pressure switch closes and a warning message appears on the computer display. The alarm will sound and the alarm light will flash continuously.

A B

FILTER/DIFFUSER SERVICE: The return filters should be checked/changed when the warning message appears on the computer display. If the message continues to display after the filters have been changed, the diffuser/strainer attached to the base of the return tube in the hydraulic oil tank should be examined for possible obstruction.

C

Refer to HYDRAULIC SYSTEM – HYDRAULIC OIL TANK – HYDRAULIC OIL RETURN DIFFUSER/ STRAINER in THIS SECTION.

6000174

A Return Filter Manifold B Water Absorbing Return Filter (Blue) – Quantity 1 C Hydraulic Oil Return Filters (White) – Quantity 3

The return oil entering the hydraulic oil tank passes through four spin-on hydraulic oil filters mounted on two filter heads. One of the filters is a water absorbing (blue) filter which is in place to assist with the removal of unwanted moisture from the hydraulic oil.

IMPORTANT! Do not use these warnings as a substitute for changing the hydraulic oil return filters at regular intervals as per SCHEDULED MAINTENANCE in THIS SECTION. This information is assuming that operating conditions and running temperatures are normal.

RETURN FILTER RESTRICTION INDICATOR

For service and replacement intervals refer to SCHEDULED MAINTENANCE in THIS SECTION. There is a bypass valve, preset at 1.7 bar (25 psi), built into each filter head, which will open when the filters become restricted.

A

Before the valve is activated a filter restriction pressure switch on one filter head will send a warning message to the computer display. Refer to HYDRAULIC SYSTEM – FILTER RESTRICTION PRESSURE SWITCH in THIS SECTION.

B

6000174

A Return Filter Restriction Indicator B Return Lines

The IN side of the return filter heads are connected to a return manifold. A return filter restriction indicator is mounted on the manifold.

With the hydraulic oil at normal operating temperature, the engine speed at HIGH and with rotor operating, the return filter restriction indicator should be in the GREEN zone. If the pointer is in the RED zone, replace all four hydraulic oil return filters.

3.37

Lubrication and Maintenance

Tigercat 6500 Material Processor

FILTER CHANGE PROCEDURE – RETURN FILTERS

 'O' RING GASKET

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

A

2. Open the pump compartment access door to access the return filters.

B

3. Wipe clean the area around the filters and filter head.

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

C FILTR_SEALS 2

5. Wearing eye and face protection (in case of an oil spray), unscrew the old filter.

6. Dispose of old filter and any oil properly.

A Filter Head B Gasket C Filter Element

a. Remove the used gasket and clean the gasket seat in the head.

7. The new Tigercat filter is supplied with two gaskets enclosed. Examine the filter head closely to determine which gasket to use and follow the instructions for proper installation.

b. Apply clean oil to the new gasket surfaces. c.

 SQUARE SECTION GASKET

d. Screw on the new filter until the gasket makes contact.

A

e. Tighten the filter until the top edge makes metal to metal contact with the filter head (approximately 11⁄2 additional turns after gasket contact).

B C FILTR_SEALS 2

A Filter Head B Gasket C Filter Element

a. Remove the used gasket and clean the groove in the head. b. Apply clean oil to new gasket surfaces. c.

Install the new gasket into the groove in the filter head.

d. Screw on the new filter until the gasket makes contact.

Install the new gasket on the inside lip of the filter.

8. Use the fill pump to raise the hydraulic oil level up to the FULL line, replacing oil lost during filter change.

Refer to HYDRAULIC SYSTEM–HYDRAULIC OIL TANK–ADDING OIL in THIS SECTION. 9. Clean up any spilled oil.

10. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

11. Run engine at LOW speed for at least five minutes to purge any remaining air from the filter system.

Then turn OFF the engine for 15 minutes to allow air bubbles in the hydraulic oil tank to rise.

12. Re-check hydraulic oil level and top-up as needed.

e. Tighten the filter an additional 3⁄4 turn.

3.38

Tigercat 6500 Material Processor

Lubrication and Maintenance

CASE DRAIN STRAINER

A

6000171

Drive Side of Machine

A Case Drain Strainer

The case drain strainer is located on the drive side of the machine, under the hydraulic oil cooler.

Case drain return oil from hydraulic pumps, motors and other components flows through the case drain strainer before returning directly to the hydraulic oil tank.

The strainer element requires no regular maintenance over the life of the machine. This element requires maintenance only in the event of damage or contamination duel to a hydraulic pump or motor failure.

IMPORTANT! The case drain strainer element is not a filter element.

Use the correct replacement element. Use of an incorrect (filter type) element will result in pump damage.

3.39

Lubrication and Maintenance HYDRAULIC OIL DIFFUSER/STRAINER C

B

A

Tigercat 6500 Material Processor CHANGING OR CLEANING THE DIFFUSER/ STRAINER This should only be performed in the event of a pump or motor catastrophic failure or hydraulic oil contamination.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Install a Do Not Start Engine sign on the machine near the engine compartment.

3. Turn OFF and lock out the battery disconnect switch.

4. Drain the hydraulic oil tank into a suitable container.

Refer to HYDRAULIC SYSTEM – HYDRAULIC OIL TANK – DRAINING in THIS SECTION. 5. Remove the cleanout cover and O-ring.

IMPORTANT! Remove the clean out cover only after the hydraulic oil tank has been completely drained of hydraulic oil.

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

6000129

A Clean Out Cover B Fastener (Qty 10) C O-ring

6000128

Diffuser/Strainer Removal

7. Remove the diffuser/strainer.

8. Carefully clean the diffuser/strainer as it is easily damaged by rough handling.

9. Check for a buildup of foreign materials where the diffuser screws onto the pipes and cover plate.

10. Re-install the diffuser/strainer.

NOTE: Repair any burrs created when removing the diffuser/strainer before reinstalling.

A 6000320

A Diffuser/Strainer Inside Hydraulic Oil Tank

There is one reusable diffusers/strainer on the return tube inside the hydraulic oil tank. Inspect whenever the hydraulic oil tank is drained. See SCHEDULED MAINTENANCE in THIS SECTION.

11. Reinstall the clean out cover with a new O-ring.

12. Refill the hydraulic oil tank and check for leaks.

Refer to HYDRAULIC OIL TANK – ADDING OIL and REFILLING THE HYDRAULIC SYSTEM in THIS SECTION.

3.40

Tigercat 6500 Material Processor

Lubrication and Maintenance

FUSES AND RELAYS Each circuit of the machine is protected against current overload by fuses. If a fuse is blown it must be replaced by one of the same value. If the fuse blows again, the circuit should be inspected for possible short circuit or other malfunction.

FUSE AND RELAY PANEL – MAIN ELECTRICAL PANEL The cab fuse and relay panel is located below the right console and can be accessed by opening the right cab door.

6000388

3.41

Lubrication and Maintenance

Tigercat 6500 Material Processor

BATTERY CARE Tigercat uses two types of batteries dependent on the machine application, model and design.

• Absorbed Glass Mat (AGM) • Flooded Lead Acid (FLA).

NOTICE Before charging the battery, it is important to identify which type of battery you have.

Read and follow the battery and charger manufacturer's instructions prior to connecting or charging a battery.

All batteries are sensitive to overcharging. Charging or maintaining AGM batteries requires the use of a smart charger with an AGM setting. The peak charging voltage for AGM batteries varies slightly between battery manufacturer's. Exceeding this voltage can cause permanent battery damage. Refer to the BATTERY MANUFACTURER'S charging instructions for more information.

Refer to BATTERY MANUFACTURER'S instructions for charging or maintaining FLA batteries.

3.42

Tigercat 6500 Material Processor

Lubrication and Maintenance

ENGINE BELTS

ENGINE FAN DRIVE BELTS

SERPENTINE BELT

A B

B

6000466

A

Drive Belt Guard Not Shown for Clarity

6000253

A Hex Nuts (Qty 4) B Sliding Bracket

Fan and Drive Belt Guard Not Shown for Clarity

A Serpentine Belt B Engine Fan Drive Belts

The alternator is driven by the serpentine belt. Belt tension is controlled by a spring-loaded tensioner.

Check the condition and tension of the serpentine belt every 250 hours. Replace the serpentine belt every 1000 hours.

Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for details of the engine belt.

3.43

The engine fan drive belts are tensioned by a sliding bracket held by four hex nuts on studs on the engine.

Loosen the nuts and pry the bracket upwards to increase tension on the belts.

Lubrication and Maintenance

ENGINE FILTERS – REMOVE AND REPLACE

IMPORTANT! Failure to service and replace engine filters at the proper intervals specified in the ENGINE OPERATION AND MAINTENANCE MANUAL, could cause damage to the machine and result in the product warranty becoming NULL and VOID. Check the Tigercat parts catalog for replacement filters.

Tigercat 6500 Material Processor FUEL FILTERS These engines use filters with a very fine micron rating.

If the fuel supply is dirty, the fuel filter must be replaced more frequently than recommended in SCHEDULED MAINTENANCE in THIS SECTION. Operating the machine with a clogged fuel filter will result in low engine power. It is also recommended to drain the fuel filter/ water separator bowl daily.

NOTICE

Refer to the ENGINE OPERATION AND MAINTENANCE MANUAL for the oil and fuel filter replacement procedure. Read and understand the SAFETY section in each of THESE MANUALS.

ENGINE OIL FILTERS

Tigercat does not recommend the pre-filling of spin-on filters due to the risk of damage to the fuel system caused by unfiltered fuel. Unfiltered fuel used to pre-fill filters enters directly into the fuel circuit. Contaminants in unfiltered fuel can cause significant and costly damage to fuel system components. The cleanliness of fuel cannot be guaranteed unless it is pre-filtered before use.

Use of filters other than genuine Tigercat replacement filters is not recommended. Replace filters at the recommended time intervals.

Refer to SCHEDULED MAINTENANCE in THIS SECTION. A 6000465

Engine/Hydraulic Compartment Service Platform

A Engine Oil Filters

The engine oil filters are remotely located in the engine/ hydraulic compartment service platform, on the drive side of the machine.

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

When installing a new oil filter, do not pre-fill with engine oil as this may result in engine damage. This type of failure is not warrantable by the engine manufacturer.

For service and replacement intervals refer to SERVICE AND LUBRICATION POINTS in THIS SECTION. Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for more detailed information.

3.44

Tigercat 6500 Material Processor

Lubrication and Maintenance

PRIMARY FUEL FILTER/WATER SEPARATOR

CHANGING FUEL FILTER/WATER SEPARATOR Refer to SCHEDULED MAINTENANCE and SERVICE AND LUBRICATION POINTS in THIS SECTION for filter replacement intervals.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Drain the fuel from the filter/water separator as described previously in this section.

3. Wearing eye and face protection (in case of a fuel spray) remove the fuel filter/water separator bowl from the filter. Dispose of any fuel properly.

4. Clean the separator bowl with clean diesel fuel.

5. Remove the filter cartridge and discard properly.

6. Discard the gasket from the filter cartridge.

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

8. Lubricate the filter gasket with clean diesel fuel and install at the top of the filter cartridge.

B

A

9. Screw the new filter onto the filter head as specified in the ENGINE OPERATION AND MAINTENANCE MANUAL. Note: Mechanical over tightening can damage the filter element.

C

6000132

10. Prime the fuel system following the instructions in the ENGINE OPERATION AND MAINTENANCE MANUAL.

A Primary Fuel Filter/Water Separator B Drain C Secondary Fuel Filters

11. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

The fuel filter/water separator is located on the front of the engine on the non-drive side of the machine.

WARNING

DRAINING PRIMARY FUEL FILTER/WATER SEPARATOR

To lower the risk of causing accidental fires, do not leave fuel or oil soaked rags laying around.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

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

WARNING

3. Place a suitable container under the filter and/or place rags below to catch the spillage of fuel.

4. Refer to ENGINE OPERATION AND MAINTENANCE MANUAL for draining instructions.

NOTE: A drain hose can be attached to the drain valve if required.

5. Close the drain valve.

For service and replacement intervals, refer to SERVICE AND LUBRICATION POINTS in THIS SECTION.

3.45

Drain fuel filter into a container and dispose of all fluids properly.

Lubrication and Maintenance

Tigercat 6500 Material Processor

CHANGING SECONDARY FUEL FILTERS

WARNING The fuel pump high-pressure fuel lines and fuel rail contain very high pressure fuel. Do not loosen any fittings while the engine is running.

Personal injury and property damage can result.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Allow machine to cool.

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

4. Place rags below to catch the spillage of fuel.

WARNING

Drain fuel filter into a container and dispose of all fluids properly.

5. Wearing face protection (in case of a fuel spray) unscrew the old fuel filter. Dispose of any fuel and the fuel filter properly.

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

7. Lubricate the gasket on top of the new filter with clean diesel fuel. Do not pre-fill the new filter.

8. Screw the new filter onto the filter head as specified in the ENGINE OPERATION AND MAINTENANCE MANUAL. Note: Mechanical over tightening can damage the filter element.

9. Prime the fuel system following the instructions in the ENGINE OPERATION AND MAINTENANCE MANUAL. 10. Start the engine and check for leaks. Refer to STARTING ENGINE in SECTION 2.

3.46

Tigercat 6500 Material Processor

Lubrication and Maintenance

FUEL TANK COMPONENTS FUEL FILL CAP AND FILL STRAINER

A

B

C

6000321

A Fuel Fill Cap B Fuel Level Sender

Engine/Hydraulic Compartment Service Platform C Fill Strainer

FUEL LEVEL SENDER

The fuel tank is located on the non-drive side of the machine. The fuel fill cap is located at the top of the tank. The fuel tank has a usable capacity of 2080 L (550 US gal).

A fill strainer is fitted to the fuel tank fill neck to prevent foreign matter from entering the tank during refuelling.

Remove and clean the fuel fill strainer every 125 hours.

Replace the fuel fill strainer if damaged.

3.47

The fuel level sender is mounted at the top of the tank in the cleanout cover, along with an manual fuel shutoff valve. The fuel level sender sends a signal to the computer which displays an on-screen fuel level gauge.

When the engine runs, fuel is supplied to the engine via the fuel filter/water separator and the engine fuel filter.

The amount of fuel supplied to the engine is more than required as the fuel is also used to cool some of the fuel system parts. The unused fuel is pumped back to the fuel tank via the fuel return line.

Lubrication and Maintenance IN-TANK FUEL STRAINER

Tigercat 6500 Material Processor CHANGING OR CLEANING IN-TANK FUEL STRAINER Replace the fuel tank strainer only if excessive foreign material has accumulated inside the fuel tank.

CAUTION

B

A

Do not smoke while filling or servicing the fuel tank. Do not fill or service the tank near sources of sparks or open flame. Allow the engine to cool before adding fuel or servicing the tank. Do not fill or service the tank with the engine running.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

6000402

A In-tank Fuel Strainer B Fuel Supply Line

A stainless steel 150 micron fuel strainer is fitted at the end of the fuel supply pipe inside the tank. The in-tank fuel strainer is accessed by removing the fuel tank cleanout cover.

A

B

6000403

Fuel Tank Drain – Non-drive Side of Machine

A Fuel Tank B Fuel Tank Drain Plug

2. Place a suitable clean container below the fuel tank drain plug and remove the fuel tank drain plug. Do not allow fuel to spill on the ground. The fuel may be reused.

3.48

Tigercat 6500 Material Processor

Lubrication and Maintenance CAUTION A

B

Fuel or oil-soaked rags may spontaneously combust. Do not leave fuel or oil-soaked rags around the machine or work area. Dispose properly in a certified container according to local regulations.

C

6000404

Fuel Tank Cleanout Cover

A Cover Plate B O-Ring C In-tank Fuel Strainer

3. Remove the fuel tank cover plate and O-ring.

4. Remove the fuel strainer using the hex collar on the end of strainer.

5. Inspect the bottom of the fuel tank for debris. Wipe clean and dispose of debris according to local regulations.

6. Clean the strainer carefully (it can easily be damaged by rough handling).

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

8. Reinstall the strainer.

9. Reinstall the fuel tank cover plate with a new O-ring.

10. Reinstall the fuel tank drain plug.

11. Refuel and check for leaks at the drain plug and the cleanout cover.

12. Turn ON the battery disconnect switch.

13. Check that all personnel are clear of the machine before starting engine.

14. Sound horn to warn personnel of machine start-up 15. Start the engine.

16. Check for fuel leaks again.

3.49

Lubrication and Maintenance

Tigercat 6500 Material Processor

AIR INTAKE SYSTEM

C

C

ENGINE AIR PRECLEANERS

D A B A E

480-017

A B C D E

Dirty Air Specially-designed Vanes Stainless Steel One Piece Impeller Foreign Particles Cleaned Air

HOW IT WORKS 1. Dirty air (A) enters the precleaner, which is clamped onto the engine air intake.

6000148

A Engine Air Precleaners

The engine air precleaners clean 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.

IMPORTANT! Check the precleaner every 8 hours for foreign materials that may have plugged the intake area or the discharge louvre area. Clean as required.

2. Specially-designed vanes (B), curved and angled to precisely direct air flow, move the dirty air toward the stainless steel impeller (C).

3. The dynamically balanced, one piece impeller (C) (only moving part) creates a tornado inside the housing.

4. The centrifugal force of the tornado expels the heavier than air dirt particles (D), chaff, dust, snow, rain, etc., out the discharge louvre.

5. Cleaned air (E) enters the engine air cleaner intake pipe, and the filter element has only the very light particles to remove.

A plugged precleaner will create a restriction to airflow, resulting in reduced engine performance and increased fuel consumption.

If the machine is operated with a plugged precleaner, excessive air intake restriction will damage the air intake tube which will lead to ingestion of dirt into the engine resulting in engine failure. The air intake filter restriction indicator may not function properly if the air intake tube is damaged.

3.50

Tigercat 6500 Material Processor

Lubrication and Maintenance

AIR INTAKE TUBING AND JOINTS C

E

A

B

C

D

E

D

6000405

A Engine Air Precleaner B Air Cleaner C Air Intake Rubber Elbow

D Air Intake Rubber Connector E Air Intake Tube

Check all air intake system components, rubber elbows, connector hoses, tubes and clamps every eight hours 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.

NOTE: High-temperature silicone connectors do not need to be replaced unless they are damaged.

3.51

E

C

Lubrication and Maintenance

Tigercat 6500 Material Processor

AIR CLEANERS A

In addition to the SCHEDULED MAINTENANCE in THIS SECTION, the following instructions should also be noted: NOTE: Replace secondary (safety) filter every third primary filter change.

The most common and most damaging air intake servicing problems are over servicing and improper servicing.

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

IMPROPER SERVICING Engine exposure to dust during servicing is the largest single factor contributing to engine damage due to dust. Abrasive dust can easily enter the intake system once the air cleaner element has been removed for replacement. The safety element reduces the risk, however it must also be replaced at every third primary element change.

6000149

A Air Cleaners

B

IMPORTANT STEPS TO FOLLOW WHEN CHANGING FILTER ELEMENTS 1. Release the cover latches gently to reduce the amount of dust dislodged.

2. Avoid dislodging dust from filter element(s) by gently pulling the element out of the housing.

3. Check your old filter sealing surfaces, This will help detect foreign material on the sealing surface that is causing leakage.

A 726D-006

A Primary Element B Secondary (Safety) Element

NOTE: Do not clean and reuse filter elements.

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.

4. Clean the inside of the housing.

5. Clean the sealing surface before inserting a new filter element.

6. Inspect the new filter for damage.

The air cleaners on this machine use two filter elements; a primary element and a secondary (safety) element.

7. Insert the new filter properly. Apply pressure to the filter frame not the pleated filter surface.

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

8. Check connections hoses and tubes for an air tight fit. All clamps, bolts and connections must be tight.

Check rubber elbows for splits or wear points. Leaks in these locations send dust directly to the engine.

3.52

Tigercat 6500 Material Processor

Lubrication and Maintenance

AIR CLEANER UNLOADER VALVES

AIR FILTER RESTRICTION SWITCH The engine is also equipped with an engine air filter restriction switch which continually sends the intake restriction level to the computer display. The sensor will send an alert message to the computer in the event of filter restriction.

Refer to AIR INTAKE SYSTEM– AIR CLEANER – OVER SERVICING and AIR INTAKE SYSTEM– AIR CLEANER – IMPROPER SERVICING in THIS SECTION.

A

6000150

A Air Cleaner Unloader Valves

Check the rubber air cleaner unloader valve on the air cleaner housing every 8 hours. If this valve is missing, damaged or has become hard, it will cause the air cleaner to become ineffective.

Replace the unloader valve every 1000 hours.

Remove the unloader valve from the tube of the air cleaner housing. A good valve should be soft and flexible. Check and clean the valve. If it is plugged, check the filter elements as they may also need to be replaced. Reattach the valve to the tube. The valve should suck closed at about one-third of HIGH engine speed. When operating in high dust conditions this valve should be checked and squeezed every two hours to release dust buildup.

Refer to SERVICE AND LUBRICATION POINTS in THIS SECTION.

3.53

Lubrication and Maintenance

Tigercat 6500 Material Processor

CONVEYORS AND CHAINS

SPROCKETS

GENERAL

TEETH

• Inspect conveyor in both operating and stationary positions.

• Check for irregular wear on chains, sprockets and tracks.

• Check for unusual sounds during operation.

• Check for chain snaking, snapping or hang ups.

• Check for hooked and worn teeth.

POCKETS • Check for material buildup fin pockets.

DRUM FLANGES • Check for grooves

• Maintain chain drop between 5% and 10% of the centres range. Tighten mechanical take-ups to allow chain to operate smoothly.

TEETH

• To avoid accelerated chain and sprocket wear, do not overtighten chain.

NOISE

CHAINS ELONGATION • Replace chain when length has grown by 5% due to joint wear. Chain riding high on sprockets indicates an elongated chain.

SIDEBARS • Check for wear due to sliding in trough.

• Check for wear on inside of links due to misalignment.

• Check for wear or damage to bottom side of drag chain due to contact from drum flanges.

BARRELS

• Check for scrubbing on sides.

• Check that chain is not snapping or popping in sprocket. In normal operation a metal on metal clicking sound should be observed.

TRACKS AND TROUGHS WEAR PLATES • Check for wear on sides due to misaligned conveyor or worn chain.

TRACK WEAR AT ENDS • Check for excessive wear at terminals due to sprockets set too low.

OBSTRUCTIONS • Check for loose liner plates and joints.

• Check for wear at sprocket tooth contact areas.

Barrels should appear polished.

RIVETS • Check for torsional failure.

• Check for wear on head or tail due to rubbing on sides of trough

3.54

Tigercat 6500 Material Processor

Lubrication and Maintenance

FEED CONVEYOR CHAIN TENSION NOTE: Check chain tension monthly. Chains will stretch from regular use.

B

D

E

C

F

A

6000389

A Feed Conveyor Roller B Feed Conveyor Bearing C Feed Conveyor Adjusting Stud

Feed Conveyor

D Outer Adjusting Nut E Inner Adjusting Nut F Bearing Guard

Tension the conveyor chains so the sprockets are freemoving and not binding.

5. Repeat the adjustment on the opposite side of the machine.

To tension chains:

6. Replace the bearing guards.

NOTE: If conveyor roller has reached maximum travel (no further adjustment), remove one link from each row of the conveyor chain.

1. Remove the bearing guards on both sides of the feed frame.

2. Loosen the inner and outer adjusting nuts on the adjusting stud.

3. Turn the hex end of the adjusting stud clockwise to move the conveyor roller away from the machine.

4. Tighten the inner and outer adjusting nuts.

3.55

Lubrication and Maintenance

Tigercat 6500 Material Processor

DISCHARGE CONVEYOR BELT TENSION NOTE: Check belt tension monthly. Belt will stretch from regular use.

B

E

D

C

A

6000390

A Discharge Conveyor Roller B Discharge Conveyor Bearing C Discharge Conveyor Adjusting Stud

Discharge Conveyor

D Adjusting Nut E Bearing Guard

Tension the conveyor belt such that belt is free-moving and not binding.

NOTE: If belt has reached maximum travel (no further adjustment), replace the belt.

To tension belt:

The discharge belt when tensioned properly will lay down on its supporting surfaces including pan in impact area, side supports and support rollers. If belt is tensioned too much, the belt will come off these surfaces and not track properly.

1. Remove the bearing guards on both sides of the discharge frame.

2. Turn the adjusting nut clockwise to move the conveyor roller away from the machine.

3. Repeat the adjustment on the opposite side of the machine.

4. Replace the bearing guards.

3.56

Tigercat 6500 Material Processor

Lubrication and Maintenance

ROTOR VISUAL INSPECTION Inspect the rotor daily to check for damaged knives and counterknives. Also check the condition of the anvils.

10. Remove the lockout hasp and turn ON the battery disconnect switch. Refer to BATTERY DISCONNECT SWITCH in SECTION 1.

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Set the machine operating angle to zero (level).

Refer to MACHINE OPERATING ANGLE in SECTION 2.

11. Raise the top feed roll and remove the safety pin.

Refer to SERVICE MODE– OPEN MACHINE FOR MAINTENANCE in SECTION 2.

3. Place the machine in service mode. Refer to SERVICE MODE in SECTION 2.

B

A

9. From the hog box service platform, visually inspect the rotor knives and counterknives for damage.

Refer to ROTOR MAINTENANCE in THIS SECTION if damage is observed.

12. Lower the top feed roll. Refer to SERVICE MODE– CLOSE MACHINE AFTER MAINTENANCE in SECTION 2.

B

WARNING Make sure all personnel are clear of the hog box service platform and feed conveyor before lowering the top feed roll.

1

NOTE: The top feed roll can also be raised from the hog box service platform by using the top feed roll up push button. It cannot be lowered using this button.

1 6000391

A Top Feed Roll B Top Feed Roll Safety Pin

4. Raise the top feed roll. Refer to SERVICE MODE– OPEN MACHINE FOR MAINTENANCE in SECTION 2.

A

5. Install the top feed roll safety pin.

6. Lower the top feed roll arm to rest on the safety pin.

7. Turn OFF the battery disconnect switch. Refer to BATTERY DISCONNECT SWITCH in SECTION 1.

8. Perform lockout tagout procedure. Refer to LOCKOUT TAGOUT in SECTION 1.

WARNING Do not inspect the rotor until lockout tagout procedure has been performed.

3.57

6000248

A Top Feed Roll UP Push Button

Lubrication and Maintenance

Tigercat 6500 Material Processor

ROTOR MAINTENANCE

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

A

2. Set the machine operating angle to zero (level).

Refer to MACHINE OPERATING ANGLE in SECTION 2.

B

3. Place the machine in service mode. Refer to SERVICE MODE in SECTION 2.

C

A

B

6000393

A Clamp B Knife C Counterknife

9. Rotate the rotor to inspect all knives and counterknives.

10. Remove and sharpen or replace dull knives or counterknives.

NOTE: Knives can be sharpened up to 10 times.

Counterknives can only be sharpened once.

6000392

A Upper Hog Box B Rotor

4. Raise the top feed roll. Refer to ROTOR VISUAL INSPECTION in THIS SECTION.

11. Remove the lockout hasp and turn ON the battery disconnect switch. Refer to BATTERY DISCONNECT SWITCH in SECTION 1.

5. Unlock the upper hog box. Refer to SERVICE MODE– OPEN MACHINE FOR MAINTENANCE in SECTION 2.

12. Close the upper hog box. Refer to SERVICE MODE– CLOSE MACHINE AFTER MAINTENANCE in SECTION 2.

6. Raise the upper hog box. Refer to SERVICE MODE– OPEN MACHINE FOR MAINTENANCE in SECTION 2.

13. Lock the upper hog box. Refer to SERVICE MODE– CLOSE MACHINE AFTER MAINTENANCE in SECTION 2.

7. Turn OFF the battery disconnect switch. Refer to BATTERY DISCONNECT SWITCH in SECTION 1.

14. Lower the top feed roll. Refer to SERVICE MODE– CLOSE MACHINE AFTER MAINTENANCE in SECTION 2.

8. Perform lockout tagout procedure. Refer to LOCKOUT TAGOUT in SECTION 1

WARNING Do not service the rotor until lockout tagout procedure has been performed.

WARNING Make sure all personnel are clear of the hog box service platform and feed conveyor before closing the hog box.

3.58

Tigercat 6500 Material Processor

Lubrication and Maintenance

ROTOR KNIFE REPLACEMENT

A

1. Thoroughly clean all components, surfaces and threads.

B

C

2. If rotor studs require replacement, install the studs into the rotor using blue Loctite® 242. Tighten and torque to 136 N-m (100 lbf-ft).

A

6000577

A Counterknife B Spring C Socket Head Bolt – M8-1.25 x 12 mm lg

6000581

A 194 mm (7.656 in) – Back of Setscrew to Tip of Counterknife

3. Install two M12-1.75 x 40 mm lg square head setscrews into back of counterknife to dimension shown. Lightly oil the setscrews prior to installation.

B

5. Apply red Loctite® to two M8-1.25 x 12 mm lg socket head bolts and install into the counterknife. Tighten and torque to 27 N-m (20 lbf-ft).

6. Install a spring over both M8-1.25 socket head bolts.

B

C

A

A 6000578

6000576

A Knife B Square Head Setscrew – M12-1.5 x 60 mm lg

A Counterknife B Square Head Setscrew – M12-1.75 x 40 mm lg C Socket Head Bolt – M10-1.5 x 25 mm lg

4. Apply red Loctite® to two M10-1.5 x 25 mm lg socket head bolts and fasten counterknife to rotor shelf.

Tighten and torque to 54 N-m (40 lbf-ft).

3.59

7. Install two M12-1.5 x 60 mm lg square head setscrews into the back face of each knife. Lightly oil the setscrews prior to installation.

Refer to ROTOR MAINTENANCE – ROTOR KNIFE REPLACEMENT – KNIFE SETTING DIMENSION in THIS SECTION for setting dimension of setscrew for desired chip size.

Lubrication and Maintenance

Tigercat 6500 Material Processor E

KNIFE SETTING DIMENSION

D

C

A

A

600580

B

Chip Size

6000579

Knife Setting Dimension 'A'

mm

mm

Inches

30

220.4

8.677

31

221.9

8.738

32

223.5

8.799

8. Mount knife and clamp onto counterknife. Install clamp nuts onto rotor studs and tighten hand-tight.

33

225.0

8.860

34

226.6

8.921

9. Repeat steps 3 – 8 on the opposite knife on the rotor shelf.

35

228.1

8.982

36

229.7

9.042

37

231.2

9.103

38

232.7

9.163

39

234.3

9.223

40

235.8

9.283

A B C D E

Counterknife Knife Clamp Washer (Qty 7) Nut (Qty 7)

10. Bring both knives together to minimize the gap between them and align knife edges. Ensure that knives are in line and parallel to each other.

7

5

3

1

2

4

6

6

4

2

1

3

5

7

6000575

Clamp Nut Torquing Sequence

11. Tighten and torque clamp nuts to 880 N-m (650 lbf-ft) in the torquing sequence shown. Do not over-tighten.

3.60

Tigercat 6500 Material Processor

Lubrication and Maintenance

ANVIL ADJUSTMENT

A

1. Retract the anvil cylinders. Refer to SERVICE MODE– ANVIL CYLINDERS RETRACT in SECTION 2.

B

A

6000408

A Anvil Stop B Anvil Stop Shims

3. Slide the anvil stop back towards the cylinders.

6000426

4. Install or remove an equal number of shims on both sides of the machine to obtain the desired chip size.

Drive Side of Machine

5. Reinstall the anvil stop covers.

A

B

C

D

A

E F

6000427

Non-drive Side of Machine

6000410

A Anvil Stop Cover

2. Remove the anvil stop covers on both sides of the machine.

A B C D E F

3.61

Anvil Components

Anvil Cylinder (Qty 4) Anvil Wearplate (Qty 4) Anvil Base (Qty 4) Anvil (Qty 4) Anvil Stop Anvil Stop Shims (As Required)

Lubrication and Maintenance

Tigercat 6500 Material Processor

TOOLBOX

A

6000394

A

B

6000396

A Toolbox Lid

When servicing the rotor and hog box, the toolbox can be raised for ease of access to tools. In this position, the toolbox lid can be opened outwards.

6000395

A Toolbox B Front Door

The toolbox is located on the non-drive side of the machine beside the feed conveyor.

To load from ground level, open the front door of the toolbox. Press the latches down and rotate 90° clockwise to open the door. Once the latches are released, carefully lower the door downward until it is in the vertical position.

3.62

Tigercat 6500 Material Processor

Lubrication and Maintenance

CARE OF THE MACHINE

RAISING THE TOOLBOX 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

• All fluid levels must be at the proper level. Refer to the LUBRICATION AND MAINTENANCE SCHEDULE in THIS SECTION.

2. Set the machine operating angle to zero (level).

Refer to MACHINE OPERATING ANGLE in SECTION 2.

• Lubricate all grease points at the required intervals as specified in the LUBRICATION AND MAINTENANCE SCHEDULE in THIS SECTION.

3. Place the machine in service mode. Refer to SERVICE MODE in SECTION 2.

• Do not allow branches, twigs, leaves or pine needles to build up around radiator intake doors or anywhere else on the machine. Clean as operating conditions warrant but at least once a day all debris must be remove from the machine interior.

4. Raise the toolbox using one of the following methods:

• Do not apply load to a cold engine.

• SAFETY FIRST! Follow all safety rules and regulations as outlined in SECTION 1.

IMPORTANT! When cleaning the machine with pressurized water it is important to avoid getting water directly or indirectly into the exhaust tube. Water in the exhaust tube will damage sensors and SCR system components and affect the proper operation of the after treatment system and the engine.

A

6000248

A Toolbox Switch

• Toolbox switch (hogbox service platform). Turn the switch to the Tool UP position and hold until toolbox is at desired height.

• Computer display. Refer to SERVICE MODE– TOOLBOX UP in SECTION 2.

LOWERING THE TOOLBOX 1. Lower the toolbox using one of the following methods: • Toolbox switch (hogbox service platform). Turn the switch to the Tool DOWN position and hold until toolbox is at desired height.

2. Computer display. Refer to SERVICE MODE– TOOLBOX DOWN in SECTION 2.

NOTE: Close the toolbox lid before lowering the toolbox.

WARNING Make sure all personnel are clear of the machine before raising or lowering the toolbox.

3.63

Lubrication and Maintenance PRESSURE WASHING Pressure washing is one of the easiest and most economical ways to preserve your investment.

Accumulated mud can damage track rollers, sand will grind down pins and bearings and wood debris buildup in machine enclosures is a serious fire hazard. Pressure washing is also good practice before and after servicing equipment.

CAUTION To avoid slips, trips or falls, all handles, steps and platforms must be kept free of grease, oil, fuel, mud, snow, ice, and forest debris.

CAUTION

Tigercat 6500 Material Processor PRESSURE WASHING PROCEDURE

IMPORTANT! Allow the engine to cool down before pressure washing the engine compartment. Pressure washing a hot engine with cold water could crack the engine block or other components.

To avoid damaging sensitive machine components, do not allow water to come in contact with electrical/ electronic components or air ducts and filters inside the vehicle.

Due to the sensitive electronics on this machine use only warm water, a mild detergent and a gentle pressure wash setting.

1. Start the engine. Maintain engine speed at LOW. 2. Set machine angle fully towards the feed conveyor.

Refer to MACHINE OPERATING ANGLE in SECTION 2.

3. Clean the undercarriage and tracks with a shovel and a broom to remove all debris before pressure washing.

4. Pressure wash the tracks and undercarriage.

Use personal protective equipment to guard against flying debris.

IMPORTANT! Use a high volume, low pressure fan nozzle or nozzle setting for all equipment cleaning. High pressure spray can damage paint, penetrate electrical connections and remove labels. Use a mild detergent and make sure pressure settings are below 83 bar (1200 psi).

A

B

5. Set machine angle fully towards the discharge conveyor. Refer to OPERATING THE MACHINE – SETTING MACHINE OPERATING ANGLE in SECTION 2.

6. Repeat steps 3 and 4.

7. Pressure wash the drive motor compartments.

8. Pressure wash debris from top of hog box. Open upper hog box.

9. Pressure wash hog box internals.

10. Pressure wash all upper hog box mating surfaces.

Close upper hog box.

11. Pressure wash the cooler package, hydraulic oil cooler and enclosure screens.

12. Pressure wash the engine/hydraulic compartment.

13. Pressure wash the control valve areas.

845C-242

A Pressure Washer Extension B Platform Ladder

To clean hard-to-reach areas, use a platform ladder or attach an extension wand to your pressure washer, extend it to the desired height and lock it in place.

3.64

Tigercat 6500 Material Processor

Lubrication and Maintenance

CLEANING COOLER PACKAGE Check the cooler package every 8 hours or more often where conditions cause accumulation of twigs, leaves, pine needles and dust. Also check all engine enclosure doors.

B

A

B

6000151

A Radiator

B Charge Air Cooler

The cooler package is located at the non-drive side of the machine.

The cooler package consists of the radiator and two charge air coolers (CAC). The cooler package is cooled by the engine fan.

3.65

In normal operation, the engine fan draws air from outside of the machine through the cooler package into the engine compartment.

Lubrication and Maintenance

Tigercat 6500 Material Processor

COOLER PACKAGE SCREENS

A

6000397

A Removable Screen – Cooler Package

There are two cooler screens in the front of the cooler package.

To clean the cooler package screens, open the latches on the cooler package frame and swing open the door.

Pull out the top and bottom cooler screens.

3.66

Tigercat 6500 Material Processor

Lubrication and Maintenance

HYDRAULIC OIL COOLER

ENGINE PTO/ROTOR DRIVE GEARBOX COOLER The engine PTO/rotor drive gearbox cooler is mounted behind the hydraulic oil cooler. Refer to ENGINE PTO in THIS SECTION for additional details.

B

HYDRAULIC OIL COOLER SCREEN A

A

6000152

C 6000398

A Removable Screen – Hydraulic Oil Cooler

There is one cooler screen in the front of the hydraulic oil cooler.

D

To clean the hydraulic oil cooler screen, lift the screen from the top of the hydraulic cooler frame.

6000153

A B C D

Hydraulic Oil Cooler Engine PTO Cooler Hydraulic Oil Cooler Fan Hydraulic Oil Cooler Fan Motor

The hydraulic oil cooler with motor-driven fan is located on the drive side of the machine.

In normal operation, the fan draws air from outside of the machine through the hydraulic oil cooler.

3.67

Lubrication and Maintenance

Tigercat 6500 Material Processor

CLEANING PROCEDURE 1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Remove any accumulated debris.

3. Use compressed air or water for cleaning.

CAUTION Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris being blown into contact with hot surfaces.

If using compressed air for cleaning, use at 2 bar (30 psi) or less.

Use personal protective equipment (eye wear) to guard against flying debris.

CAUTION Avoid the risk of fire caused by debris accumulating on surfaces that may become hot during machine operation. Use care when cleaning to ensure debris removed from one area of the machine does not accumulate on other areas of the machine.

NOTE: The cooler package and hydraulic oil cooler must be checked daily and may have to be thoroughly cleaned on a daily, weekly or monthly basis, depending on operating conditions. Use personal protective equipment (eye wear) to guard against flying debris. Use compressed air for cleaning only when the machine is cold to avoid the risk of fire caused by debris contacting hot surfaces. Care must be taken not to set the pressure too high otherwise damage to the components could result.

Pay particular attention to cleaning in the corners of the cooler as these areas usually plug deeply. For more information on fire prevention refer to FIRE PREVENTION in SECTION 1.

If an oil leak occurs in this area it should be thoroughly power-washed with a mild soap to ensure all of the oil is removed. The presence of oil causes dust and dirt to cling to surfaces which will impair the ability of the fans to remove dust and dirt particles.

3.68

Tigercat 6500 Material Processor

Lubrication and Maintenance

IMPORTANT TRACK DRIVE NOTES NEW MACHINE

A

Set track sag correctly before driving a new machine.

Track sag may be factory set at less than the specified value for shipping purposes. It must be adjusted before beginning operations.

During the initial operating period, frequent track sag adjustments are necessary.

B

TRACK SAG Inspect track sag often. Maintaining correct track sag increases track assembly life by as much as 50%. A track that is set too tight will wear out prematurely due to excessive chain tension.

400487

MEASURING TRACK SAG

A No Sag – Track Too Tight B Too Much Sag – Track Too Loose C Sag 40 mm (1.57) – Track Correct

1. Park the machine on level ground. Refer to PARKING THE MACHINE in SECTION 1.

2. Place a 1.2 m (4 ft) straight edge on top the track over two rollers as shown.

B

A

C

4. The measured dimension must be 50 mm (1.97 in) for normal operations.

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.

C

Refer to TRACKS – TRACK SAG ADJUSTMENT in THIS SECTION for the track chain tension adjustment procedure.

5. Repeat this procedure for the opposite track.

D

6000399

A B C D E

E

Straight Edge Tip of Grouser Sag Dimension Straight Edge Over Two Rollers Rollers

3. Measure the distance from the bottom surface of the straight edge to the tip of the grouser closest to the middle distance between the track rollers.

3.69

Lubrication and Maintenance

Tigercat 6500 Material Processor

TRACK SAG ADJUSTMENT

TIGHTEN TRACK 1. Attach the valve coupler onto the fill valve.

WARNING

2. Connect a grease gun to the grease fitting on the coupler.

Hydraulic oils or grease under pressure can penetrate the skin and could result in death or serious injury.

3. Add grease until the track sag dimension is within recommended limits.

Refer to TRACKS – MEASURING TRACK SAG in THIS SECTION for recommended limits.

CAUTION

4. Remove the grease gun from the coupler fitting.

5. Store the valve coupler in a safe place.

Do not remove the fill valve. The grease in the idler is under very high pressure.

LOOSEN TRACK 1. Slowly loosen the fill valve until grease begins to escape through the vent passage in the valve body housing.

Grease will vent around the valve body threads.

Remove grease until the track sag dimension is within recommended limits.

Refer to TRACKS – MEASURING TRACK SAG in THIS SECTION for recommended limits.

A

2. Tighten the valve body when the track sag is correct.

NOTE: The track sag fill valve is not mechanically restricted from being removed completely.

D

C

B

6000400

A B C D

Track Sag Fill Valve

Track Valve Coupler Fill Valve Grease Fitting Fill Valve (do not remove)

CAUTION The grease is under very high pressure. Do not remove the adjustment fitting valve body from the idler adjusting cylinder.

3.70

Tigercat 6500 Material Processor

Lubrication and Maintenance

TORQUING UNDERCARRIAGE BOLTS

TRACK SHOE RETAINING BOLTS

It is important to check the torque values of the master track shoe retaining bolts, track shoe retaining bolts, and the top and bottom roller retaining bolts at the NEW MACHINE MAINTENANCE time period (first 125 hours) and then every 125 hours. Refer to SCHEDULED MAINTENANCE – EVERY 125 HOURS in SECTION 3.

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 ⅓ turn (not the value shown in the torque charts) to ensure 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.

860C-333

Torque Procedure

Track shoes must be fastened together applying the exact torque values and using the torque-turn method described in TORQUE CHART, SPECIFIC in SECTION 3.

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

Once checked, 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 repeat the torque-turn method.

CAUTION The torque-turn method involves torquing the bolt to an initial predetermined value, plus an additional ⅓ turn (not the value shown in the torque charts) to ensure a more accurate and consistent torquing of the bolts, with less likelihood of the bolt/nut coming loose later.

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 repeat the torque-turn method.

Only bolts with grade 12.9 or 170 designation forged in the head are approved.

When checking the torque values at the first 100 hours and every 125 hours thereafter use the checking torque values.

Refer to SECTION 11 of the SERVICE MANUAL for torquing procedure and torque values.

3.71

Lubrication and Maintenance

Tigercat 6500 Material Processor

TORQUE CHART – 6500

INFORMATION NOT AVAILABLE AT TIME OF PRINTING

3.72

Tigercat 6500 Material Processor

Lubrication and Maintenance

GENERAL TORQUE SPECIFICATIONS IMPERIAL GRADE 5 BOLTS

The torque values listed below are for general use only.

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

GRADE 8 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 5 BOLTS GRADE 8 BOLTS LUBRICATED COARSE N-m lbf-ft THREAD 1/4" - 20 9-9 6-7 5/16" - 18 18 - 19 13 - 14 3/8" - 16 31 - 35 23 - 25 7/16" - 14 50 - 55 37 - 41 1/2" - 13 77 - 84 57 - 62 9/16" - 12 111 - 122 82 - 90 5/8" - 11 153 - 168 113 - 124 3/4" - 10 271 - 298 200 - 220 7/8" - 9 437 - 480 322 - 354 1" - 8 654 - 720 483 - 531 1 1/8" - 7 808 - 888 596 - 655 1 1/4" - 7 1139 - 1253 840 - 924 FINE LUBRICATED THREAD N-m lbf-ft 1/4" - 28 10 - 11 7-8 5/16" - 24 20 - 22 14 - 16 3/8" - 24 36 - 39 26 - 29 7/16" - 20 56 - 62 41 - 46 1/2" - 20 86 - 95 64 - 70 9/16" - 18 123 - 136 91 - 100 5/8" - 18 173 - 190 127 - 140 3/4" - 16 302 - 332 223 - 245 7/8" - 14 482 - 530 355 - 391 1" - 14 735 - 808 542 - 596 1 1/8" - 12 906 - 996 668 - 735 1 1/4" - 12 1262 - 1388 930 - 1023

DRY N-m lbf-ft 11 - 13 8-9 24 - 26 17 - 19 42 - 46 31 - 34 67 - 74 49 - 54 102 - 112 75 - 83 147 - 162 109 - 120 203 - 224 150 - 165 361 - 397 267 - 293 582 - 640 429 - 472 873 - 960 644 - 708 1077 - 1185 794 - 874 1519 - 1671 1121 - 1233 DRY N-m lbf-ft 13 - 14 10 - 11 26 - 29 19 - 21 47 - 52 35 - 38 75 - 82 55 - 61 115 - 127 85 - 93 164 - 181 121 - 133 230 - 253 170 - 187 403 - 443 297 - 327 642 - 706 474 - 521 979 - 1077 722 - 795 1207 - 1328 890 - 980 1682 - 1850 1241 - 1365

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

LUBRICATED DRY N-m lbf-ft N-m lbf-ft 12 - 13 9 - 10 16 - 18 12 - 13 25 - 27 18 - 20 33 - 37 25 - 27 44 - 49 33 - 36 59 - 65 44 - 48 71 - 78 52 - 58 95 - 104 70 - 77 108 - 119 80 - 88 144 - 159 106 - 117 156 - 172 115 - 127 208 - 229 154 - 169 215 - 237 159 - 175 287 - 316 212 - 233 383 - 421 282 - 310 510 - 561 376 - 414 616 - 678 455 - 500 822 - 904 606 - 667 924 - 1016 681 - 750 1232 - 1355 909 - 999 1310 - 1441 966 - 1063 1746 - 1921 1288 - 1417 1848 - 2033 1363 - 1499 2464 - 2710 1817 - 1999 LUBRICATED DRY N-m lbf-ft N-m lbf-ft 14 - 15 10 - 11 18 - 20 14 - 15 28 - 30 20 - 22 37 - 41 27 - 30 50 - 55 37 - 41 67 - 74 49 - 54 79 - 87 58 - 64 106 - 116 78 - 86 122 - 134 90 - 99 163 - 179 120 - 132 174 - 192 128 - 141 232 - 255 171 - 188 244 - 268 180 - 198 325 - 358 240 - 264 427 - 469 315 - 346 569 - 626 420 - 462 680 - 748 502 - 552 907 - 997 669 - 736 1037 - 1141 765 - 841 1383 - 1521 1020 - 1122 1468 - 1615 1083 - 1191 1958 - 2154 1444 - 1588 2046 - 2250 1509 - 1660 2728 - 3000 2012 - 2213

METRIC

METRIC BOLT TORQUE SPECIFICATIONS CLASS 8.8

SIZE PITCH LUBRICATED mm N-m lbf-ft M6 1 8-9 6-7 M8 1.25 20 - 22 15 - 16 M10 1.5 39 - 43 29 - 32 M12 1.75 68 - 75 50 - 55 M14 2 109 - 120 80 - 89 M16 2 169 - 186 125 - 137 M18 2.5 234 - 257 172 - 190 M20 2.5 330 - 364 244 - 268 M22 2.5 451 - 496 332 - 366 M24 3 571 - 628 421 - 463 M27 3 837 - 921 618 - 679 M30 3.5 1135 - 1249 837 - 921 M33 3.5 1545 - 1699 1139 - 1253 M36 4 1985 - 2183 1464 - 1610

CLASS 10.9 LUBRICATED DRY N-m lbf-ft N-m lbf-ft N-m lbf-ft 11 - 12 8-9 11 - 12 8-9 15 - 17 11 - 12 26 - 29 19 - 21 27 - 30 20 - 22 36 - 40 27 - 30 52 - 57 38 - 42 54 - 60 40 - 44 72 - 79 53 - 59 91 - 100 67 - 74 94 - 104 70 - 77 126 - 138 93 - 102 145 - 160 107 - 118 151 - 166 111 - 122 201 - 221 148 - 163 226 - 248 166 - 183 234 - 257 173 - 190 312 - 343 230 - 253 312 - 343 230 - 253 323 - 356 239 - 262 431 - 474 318 - 350 441 - 485 325 - 357 457 - 503 337 - 371 610 - 670 450 - 495 601 - 661 443 - 487 623 - 686 460 - 506 831 - 914 613 - 674 761 - 838 562 - 618 790 - 869 583 - 641 1053 - 1159 777 - 855 1116 - 1228 823 - 906 1158 - 1274 854 - 940 1544 - 1699 1139 - 1253 1514 - 1665 1116 - 1228 1570 - 1727 1158 - 1274 2094 - 2303 1544 - 1699 2060 - 2266 1519 - 1671 2137 - 2351 1576 - 1734 2849 - 3134 2102 - 2312 2646 - 2911 1952 - 2147 2745 - 3020 2025 - 2227 3661 - 4027 2700 - 2970 DRY

3.73

CLASS 12.9 LUBRICATED DRY N-m lbf-ft N-m lbf-ft 13 - 14 10 - 11 18 - 19 13 - 14 32 - 35 24 - 26 43 - 47 31 - 35 63 - 70 47 - 51 84 - 93 62 - 68 110 - 121 81 - 90 147 - 162 109 - 119 176 - 194 130 - 143 235 - 259 173 - 191 274 - 301 202 - 222 365 - 401 269 - 296 378 - 416 279 - 307 504 - 554 372 - 409 534 - 588 394 - 433 712 - 784 525 - 578 728 - 801 537 - 591 971 - 1068 716 - 788 923 - 1016 681 - 749 1231 - 1354 908 - 999 1354 - 1489 998 - 1098 1805 - 1985 1331 - 1464 1835 - 2019 1354 - 1489 2447 - 2692 1805 - 1985 2498 - 2747 1842 - 2026 3330 - 3663 2456 - 2702 3208 - 3529 2366 - 2603 4278 - 4706 3155 - 3471

Lubrication and Maintenance

Tigercat 6500 Material Processor

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 onto 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.

A B C

D E F

FLANGE PORT ASSEMBLY The steps to properly assemble the flange port clamping bolts are:

FLANGE.JPG

A B C D E F

4-Bolt Split Flange Components

1. Make sure sealing surfaces are free of burrs, nicks, scratches or any foreign particles.

Washers Bolts Flange Clamp Flange Head O-Ring Tapped Holes

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.

• 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 washers Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque Nm

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

FLANGE2.JPG

A

Flange Bolt Tightening Sequence

6. Torque bolts in diagonal sequence in small increments to the appropriate torque level listed in Table T6 or Table T7 on this page.

Table T6– Code 61 Flange Recommended Bolt Torque

NOTE: Does not meet ISO 6162 specification.

Dash Size

Flange Size

Inch Bolt (J518)

Torque lbf-ft

Metric Bolt (ISO 6162)

Torque N-m

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

Table T7– Code 62 Flange Recommended Bolt Torque

NOTE: Does not meet ISO 6162 specification.

3.74

Tigercat 6500 Material Processor

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

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

Thread Size

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

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

BSPT

Tube Connection Swivel or Hose Connection FFWR FFWR

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

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

Tube Connection Swivel or Hose Connection TFFT TFFT

Thread Size

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

Thread Size

-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

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

THREAD SIZE

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

SEAL-LOK lbf-ft (lbf-in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

Nm 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (lbf-in) (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

PLUGS

ADJUSTABLE

NON-ADJUSTABLE

SEAL-LOK lbf-ft (lbf-in) (310) (310) (310) (360) (420) 60 100 135 175 200 250 305 375

3.75

Nm 20 20 20 40 46 80 135 185 235 270 340 415 510

TRIPLE-LOK FERULOK PIPE FITTINGS lbf-ft Nm (lbf-in) (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

HOLLOW HEX

HEX HEAD

HP5ON-S

P5ON-S

lbf-ft (lbf-in) (30) (55) (120) (170) (410) 60 100 135 175 200 250 305 375

Nm 3.5 6 13.5 19 46 80 135 185 235 270 340 415 510

lbf-ft (lbf-in) (85) (155) (260) (280) (350) (620) 85 135 175 200 250 305 375

Nm 10 18 29 32 40 70 115 183 237 271 339 414 509

Lubrication and Maintenance

Tigercat 6500 Material Processor

EATON Aeroquip

ASSEMBLY TORQUE

3.76

Tigercat 6500 Material Processor

Lubrication and Maintenance

COMMON CONVERSIONS To Convert...

Into...

Multiply By

To Convert...

Into...

Multiply By

bar

psi

14.5

in3

cm3

16.39

cm

in

0.06102

°F

°C

(°F − 32) / 1.8

3

3

°C

°F

(°C × 1.8) + 32

lb

kg

0.4535

kg

lb

2.205

hp

kW

0.7457

kW

hp

1.341

US Gal

L

3.785

L

US Gal

0.2642

in

mm

25.4

mm

in

0.03937

lbf•ft

N-m

1.356

N-m

lbf•ft

0.7375

lbf

N

4.4482

N

lbf

0.22481

in Hg

psi

0.4912

psi

bar

0.06896

in H2O

psi

0.03613

3.77

Lubrication and Maintenance

Tigercat 6500 Material Processor

PRESSURE AND SPEED SETTINGS – 6500

INFORMATION NOT AVAILABLE AT TIME OF PRINTING

3.78