Tigercat BUNCHING AND FELLING SAWS OPERATOR AND SERVICE MANUAL - PDF DOWNLOAD

BUNCHING AND FELLING SAWS

OPERATOR AND SERVICE MANUAL

ISSUE 2.0, AUGUST 2019 Tigercat Industries Inc. P.O. Box 637 Brantford, Ontario Canada N3T 5P9 Tel: (519) 753-2000 Fax: (519) 753-8272

ii

Tigercat Bunching and Felling Saws TABLE OF CONTENTS INTRODUCTION................................................................................................................................................. v NON-APPROVED FIELD PRODUCT CHANGES.............................................................................................viii SAFETY...............................................................................................................................................................1 USING HIGH-SPEED DISC SAWS SAFELY.............................................................APPENDIX TO SECTION 1 OPERATING, SERVICE AND MAINTENANCE...................................................................................................2

BUNCHING AND FELLING SAW AVAILABLE LITERATURE Operator and Service Manual (This Manual), English.....................................................................Part No. 59003AENG Parts Catalog, 5000.........................................................................................................................Part No. 55542A Parts Catalog, 5300.........................................................................................................................Part No. 55543A Parts Catalog, 5400.........................................................................................................................Part No. 55544A Parts Catalog, 5500.........................................................................................................................Part No. 55545A Parts Catalog, 5600.........................................................................................................................Part No. 55546A Parts Catalog, 5700.........................................................................................................................Part No. 55547A iii

iv

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

Tigercat Bunching and Felling Saws INTRODUCTION An Operator and Service manual and a Parts catalog are provided by Tigercat to assist the dealer, customer and operator in becoming familiar with the features of the Tigercat Bunching and Felling Saws serial numbers: DT5003 – 50T0101 DT5301 – 53T0101 DW5003 – 50W0101 DW5502 – 55W0101 DW5603 – 56W0101 ST5401 – 54T0101 ST5702 24” and 26” – 57T0101 SW5702 – 57W0101 The Operator and Service manual will assist the operator with the techniques of proper and safe operation of the Bunching and Felling Saws. It contains important information regarding the safe operation of the saw head, a preventive maintenance schedule and servicing procedures to ensure optimum felling performance. Also included are disassembly and assembly instructions.

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

The operator of this equipment must be made aware of the fact that; The safety of the people on the ground i.e., workers or bystanders is the responsibility of the machine operator.

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

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

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

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

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

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

Tigercat Industries Inc.

v

NON-APPROVED FIELD PRODUCT CHANGES.............................................................................................viii

Introduction

Tigercat Bunching and Felling Saws

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

IT IS Tigercat POLICY THAT NO CHANGES ARE TO BE MADE TO ITS PRODUCTS INCLUDING DELETIONS OR ADDITIONS OTHER THAN A Tigercat APPROVED OPTION FITTED IN THE FACTORY APPROVED MANNER. Official approval to make changes or install options is only to be undertaken as follows: • 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.

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

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

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

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

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

Tigercat Industries Inc.

vi

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

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

CONTENTS – SECTION 1

ISSUE 2.0, AUGUST 2019

B

BACKOVER ACCIDENTS – AVOIDING...................................................................................................................... 1.8 BATTERY DISCONNECT SWITCH......................................................................................................................... 1.18 BATTERY SAFETY...................................................................................................................................................... 1.8

C

CAB EXITS................................................................................................................................................................. 1.11 CABLE ASSIST CABLE ASSIST MOUNT........................................................................................................................................ 1.15 CABLE TENSION................................................................................................................................................... 1.16 DAILY CHECKS...................................................................................................................................................... 1.15 LOADING DIRECTIONS........................................................................................................................................ 1.16 COOLING SYSTEM.................................................................................................................................................. 1.21

D

DIESEL EXHAUST FLUID (DEF)............................................................................................................................. 1.11 DURING OPERATION................................................................................................................................................ 1.9

E

EMERGENCY CAB EXITS....................................................................................................................................... 1.11 ENGINE DOORS....................................................................................................................................................... 1.24 ER BOOM FUNCTION, SWITCHABLE................................................................................................................... 1.23 ER BOOM SYSTEM PRECAUTIONS...................................................................................................................... 1.23 EXHAUST FUMES.................................................................................................................................................... 1.24

F

FELLING TREES....................................................................................................................................................... 1.17 FIRE PREVENTION.................................................................................................................................................. 1.30 DRY CHEMICAL CLEANUP PROCEDURES...................................................................................................... 1.34 FIRE PREVENTION GUIDELINES....................................................................................................................... 1.30 WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED.............................................................................. 1.33 WHAT TO DO TO PREPARE FOR A MACHINE FIRE........................................................................................ 1.31 WHAT TO DO WHEN A MACHINE FIRE OCCURS............................................................................................. 1.32 FLUID INJECTION INJURY...................................................................................................................................... 1.25 FLUID LEAKS............................................................................................................................................................ 1.21

G

GENERAL SAFETY PRECAUTIONS........................................................................................................................ 1.3 GREASE INJECTION INJURY................................................................................................................................. 1.26

H

HAZARD ZONE........................................................................................................................................................... 1.4 HYDRAULIC PRESSURE HAZARD........................................................................................................................ 1.21

L

LIGHTENING SAFETY AWARENESS LIGHTNING SAFETY............................................................................................................................................. 1.27 WHAT IS A LIGHTNING STRIKE?........................................................................................................................ 1.27 LIQUID STARTING AID............................................................................................................................................. 1.10 LOOSE CLOTHING HAZARD.................................................................................................................................. 1.21

M

MACHINE STABILITY AND TRACTION WITH A LEVELER.................................................................................................................................................. 1.12 WITHOUT A LEVELER.......................................................................................................................................... 1.12

O

OPERATING SAFETY PRECAUTIONS.................................................................................................................... 1.9

Safety

Tigercat Bunching and Felling Saws

P

PARKING HAZARDS................................................................................................................................................. 1.18 PARKING THE MACHINE......................................................................................................................................... 1.18 PNEUMATIC GREASE GUNS, USING.................................................................................................................... 1.26 PRESSURIZED HYDRAULIC TANK........................................................................................................................ 1.19 PROTECTIVE EQUIPMENT....................................................................................................................................... 1.3

R

REFUELING............................................................................................................................................................... 1.10

S

SAFETY HAZARDS – OPERATING............................................................................................................................ 1.7 SAFETY HAZARDS – VITON SEALS......................................................................................................................... 1.7 SAFETY PRECAUTIONS, GENERAL....................................................................................................................... 1.3 BACKOVER ACCIDENTS........................................................................................................................................ 1.8 HAZARD ZONE........................................................................................................................................................ 1.4 PROTECTIVE CLOTHING...................................................................................................................................... 1.3 VITON SEALS.......................................................................................................................................................... 1.7 SAFETY PRECAUTIONS, OPERATING................................................................................................................... 1.9 CAB EXITS..............................................................................................................................................................1.11 LIQUID STARTING AID......................................................................................................................................... 1.10 MACHINE STABILITY AND TRACTION............................................................................................................... 1.12 PARKING THE MACHINE..................................................................................................................................... 1.18 SEAT BELT.............................................................................................................................................................. 1.10 SAFETY PRECAUTIONS, SERVICING................................................................................................................... 1.19 ER BOOM SYSTEM............................................................................................................................................... 1.23 FLUID INJECTION INJURY.................................................................................................................................. 1.25 GREASE INJECTION INJURY.............................................................................................................................. 1.26 LEVELING SYSTEM.............................................................................................................................................. 1.24 PRIOR TO WELDING............................................................................................................................................ 1.20 SAFETY SYMBOLS..................................................................................................................................................... 1.3 SEAT BELT................................................................................................................................................................. 1.10 SEPARATION DISTANCE........................................................................................................................................... 1.4 SERVICING SAFETY PRECAUTIONS.................................................................................................................... 1.19 SIGNAL WORDS......................................................................................................................................................... 1.3

V

VITON SEALS.............................................................................................................................................................. 1.7

W

WELDING, PRIOR TO............................................................................................................................................... 1.20 WORKING WITH OIL.................................................................................................................................................. 1.6

1.2

Tigercat Bunching and Felling Saws

Safety

GENERAL SAFETY PRECAUTIONS

SAFETY SYMBOLS

Remember that safety is a prime responsibility of all.

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

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

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

The safety alert symbol identifies important safety messages on machines, safety signs, in manuals, or elsewhere. When you see this symbol, be alert to the possibility of personal injury or death. Follow the instructions in the safety message.

UNDERSTANDING SIGNAL WORDS DANGER

Follow all instructions from safety inspector and supervisors.

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

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

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

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

NOTICE Do not let untrained persons operate the machine.

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

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

These safety rules highlight both general and specific measures that the operator should be familiar with and adhere to. More specific measures are illustrated with pictograms which may also be attached to the machine in locations pertinent to their respective message.

Keep safety labels in good condition. Repair or replace damaged labels.

1.3

Safety

Tigercat Bunching and Felling Saws

KEEP BACK 150 m (500 ft)

WARNING Before using the saw blade guard and locking bolt the engine must be shutdown, the saw blade must have come to a complete stop and the felling head must be supported.

The guard must be installed when working on the saw motor hydraulic circuit or when the saw head is not being used. Refer to SAW BLADE GUARD AND LOCKING PIN SECTION 2 of THIS MANUAL for instructions on the proper use of this safety device.

The following diagram illustrates the HAZARD ZONE. All personnel should be kept clear of this zone while the harvesting equipment is operating.

The HAZARD ZONE should be considered off limits to all individuals.

WARNING Before using the saw blade lock pin the engine must be shutdown, the saw blade must have come to a complete stop and the felling head must be supported.

A

The saw blade lock pin must be used for all maintenance procedures requiring access to the exposed portion of the blade and teeth, such as saw tooth replacement and saw tooth sharpening. Refer to SAW BLADE LOCK PIN in SECTION 2 of THIS MANUAL for instructions on the proper use of this safety device.

A

A

A

822D-117

A 150 m (500 ft)

Hazard Zone

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

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

Always avoid the discharge side of a felling saw head. A saw head's high-velocity discharge of debris requires a safe separation distance.

1.4

Tigercat Bunching and Felling Saws

Safety WARNING DO NOT walk on machine surfaces with steel cleated foot wear. Steel cleats on steel surfaces are slippery and do not provide a safe foothold.

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. This machine exceeds 70 dB(A) in the cab and exceeds 85 dB(A) when servicing m achine engine.

Always use the handrails and steps provided when mounting and dismounting from the machine.

WARNING It is not recommended to walk on machine surfaces that are not designated walking areas.

No attempt should be made to walk on angled steel surfaces or surfaces that are irregular in shape.

Walking surfaces on the machine must be covered with anti-slip materials to provide a safe foot hold and prevent slipping.

Do not jump off the machine at any time.

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

Do not use the seat armrest or joystick as handles when entering or leaving the cab.

Do not use the machine foot controls as steps.

These anti-slip surfaces should be maintained on a regular basis. If the surface shows signs of wear, the anti-slip material must be replaced immediately.

To reduce risk of fire, machines should be completely cleaned of debris at least daily, particularly around the engine exhaust components. Hydraulic oil leaks, excess grease, fuel and oil accumulation (including spillage) should be eliminated immediately, always shut off engine before cleaning machine.

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

When mounting or dismounting the machine always use the three point technique; use one hand with two feet or two hands with one foot.

Machine should be washed 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.

WARNING

Check windows and door guards for damage.

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

All damaged windows must be replaced with original equipment.

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

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

1.5

Safety 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.

Tigercat Bunching and Felling Saws

WORKING WITH OIL Direct contact with oil implies a risk of skin complaints (example: eczema). Strict hygiene should always be observed.

Some advice which should be observed: • Oils used in this machine may be hot enough to cause serious burns.

• Avoid contact with oil, particularly heated oil.

• Oil on the skin should be washed off immediately with soap and water.

• Wear protective gloves. Hands should be clean before putting on gloves. Apply protective cream to the hands to make washing easier.

• Do not put oily rags in your pockets.

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

• Soiled clothing should be changed as soon as possible.

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

• Cuts and abrasions must be attended to immediately. Clean them and apply first-aid.

• Avoid breathing in oil fumes.

• Wash hands and arms frequently (example: at each meal break or as often as possible).

• Oily rags and gloves must be safely discarded after use.

1.6

Tigercat Bunching and Felling Saws

Safety

SAFETY HAZARDS – VITON SEALS

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.

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).

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

Maintain a distance of 3 m (10 ft) between the machine or boom and any power line carrying up to 50,000 volts or less plus 10 mm (½ in.) for each additional 1,000 volts above the 50,000 volt level.

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

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

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

• If these are found, Do Not Touch!

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

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

If the machine must be transported, make sure that it is adequately secured to the transporting vehicle. Refer to appropriate machine vehicle moving instructions MANUAL. 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 IDLE 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.

• Any soiled rags 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.

SAFETY HAZARDS – OPERATING Maintain a charged fire extinguisher on the vehicle at all times and KNOW HOW TO USE IT. Do not carry passengers either in the cab or anywhere else on the machine. The vehicle is provided and approved with seating for the operator only.

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.

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

1.7

Be aware when performing service and maintenance tasks that 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.

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

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.

Safety

Tigercat Bunching and Felling Saws 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 acid is accidentally splashed into your eyes, flush immediately with clean water and get medical attention.

Do not attempt to charge a frozen battery; it can explode.

Disconnect battery before working on electrical systems as follows:

AVOID INJURY FROM BACKOVER ACCIDENTS

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

Always be alert for bystanders moving into the work area. Use the horn to warn bystanders before moving the machine.

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

To avoid backover accidents: • Always look around before you back up. Be sure that everyone is clear.

• Turn off battery disconnect switch in the cab

• Keep motion warning alarm in working condition.

The motion warning alarm must sound when the machine is moving in forward or reverse.

• Disconnect negative starter motor cable from both battery posts • Disconnect positive solenoid cable from both battery posts

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

Connect ground terminal last when reconnecting.

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

Do not short out battery terminals for any reason.

Serious burns or an explosion can result.

• Keep windows, mirrors and lights in good condition.

• Dust, heavy rain, fog, snow etc. can reduce visibility.

As visibility decreases, reduce speed and use proper lighting

CAUTION Lead-acid batteries contain sulphuric acid which can severely damage eyes or skin on contact. Always wear a safety face shield, rubber gloves and protective clothing to reduce risk of accidents.

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

1.8

Tigercat Bunching and Felling Saws

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

OPERATING SAFETY PRECAUTIONS

Use only prearranged and approved signalling practices.

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

Do not turn on saw blade until machine is at cutting site.

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

Read and understand "Using high speed disc saws safely" section of this book (or Tigercat safety bulletin No. SFB-001).

Read, understand and follow all operating and general safety precautions specified in this manual. Remember at all times that the disc saw blade at operational speed carries a tremendous amount of stored energy. Flying chips or other debris can cause serious injury. DO NOT APPROACH THE FELLING HEAD UNLESS THE DISC SAW BLADE HAS COME TO A COMPLETE STOP AND THE ENGINE HAS BEEN SHUT DOWN. CAREFULLY INSPECT THE CONDITION OF THE SAW BLADE AND TEETH at the start of every shift and immediately following contact with a rock or other foreign material.

Check for fatigue cracks in the teeth and saw blade and replace or repair any defective saw components.

Check tooth fastener torques daily.

SHUT SAW OFF IMMEDIATELY IF AN IMBALANCE OCCURS. Do not operate saw blade in an unbalanced condition - repair as necessary to achieve balanced condition.

During operation of the disc saw felling head, all personnel not in the cab of the machine should REMAIN AT LEAST 150 m (500 ft) AWAY AND NEVER CROSS IN FRONT OF THE SAW OPENING. Do not allow people or other pieces of equipment near the harvesting operation.

All observers should stand on the opposite side of the machine to where chips are being directed from the saw opening.

Always wait until disc saw achieves full speed before proceeding to cut. Turn saw controls on only when engine is at idle.

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

Never operate on steep slopes.

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

NEVER travel across a STEEP slope or side hill: See MACHINE STABILITY AND TRACTION in THIS SECTION

Never operate the saw blade at a higher speed than the maximum upper limit.

WARNING

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

If saw guard has been installed DO NOT remove until at the cutting site. Remove guard before starting engine.

Sound the machine horn before starting the machine.

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

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

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

1.9

Safety

Tigercat Bunching and Felling Saws

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

Secure loose items in the cab.

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

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

S≤15 mg/kg

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

Turn OFF the engine when refuelling - DO NOT refuel ULTRA the engine while smoking or near openLOW flameSULFUR or sparks.

FUEL ONLY 36686AUNI R0 Attach a grounding strap to an unpainted metal surface on the machine if the refuelling tank or nozzle is so equipped.

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

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

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

Sound the machine horn before starting the machine.

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

CAUTION Do not open cab doors or window screens when cab is on a slope. The doors and screens are heavy and could swing out with considerable force. Anyone in the path of swing could be injured. Anyone opening the door or screen and holding on to it could be pulled out of the cab and injured.

The operator’s seat is equipped with lap and shoulder harness belts. Use both of these restraint systems at all times when operating the machine.

Start the engine according to the instructions in the machine specific manual. Refer to OPERATING MACHINE in SECTION 2 of the MACHINE OPERATOR'S MANUAL.

WARNING Never use a liquid starting aid to start an engine.

This machine is equipped with a computer controlled heating element in the engine intake system. Starting fluids will explode on contact with the heating element.

1.10

Tigercat Bunching and Felling Saws

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

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

All operators should practice using all the cab exits to become familiar with escape procedures should they need to perform them in the dark, when the machine is in a rolled position, or other possible adverse conditions.

41581AUNI R0

Diesel Exhaust Fluid (DEF) may irritate eyes or skin. Do not get in eyes. Do not get on skin.

First Aid treatment: DEF Contains Urea. If swallowed call a Poison Control Centre or doctor immediately.

Do not induce vomiting. If in eyes rinse with water for 15 minutes. If on skin rinse well with water. If irritation persists seek medical treatment.

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

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

WARNING Use only diesel exhaust fluid (DEF) which meets ISO 22241 specifications. Never fill the DEF tank with any other fluid.

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

DEF is injected into the exhaust gas stream during normal operation of the Selective Catalytic Reduction (SCR) aftertreatment system.

Use of other fluids may cause component damage, or a fire risk which could result in death or serious injury.

1.11

Safety

MACHINE STABILITY AND TRACTION

Tigercat Bunching and Felling Saws MACHINES WITH A LEVELER

1. As a load is added to the attachment the handling and the stability of the machine will change.

This machine is designed to operate on rough terrain and slopes commonly found in forestry applications.

However, ground conditions vary greatly with changing soil types, slope angles, moisture, snow and ice, rocks, boulders and stumps, and fallen trees. All of these factors affect the machine’s stability against tip-over and traction to resist slipping. This machine may not be capable of operating on some ground conditions, and must be used with caution.

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

Whenever possible work within the normal working range of the boom system as shown in FIG. 1.

MACHINES WITHOUT A LEVELER When working on slopes, travel straight up or down the slope to prevent roll-over.

Never travel across a STEEP slope or side hill:

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

4. Do not overload the machine as this can create an unstable condition and cause a roll-over.

NOTE: In any boom position, both inside and outside of the normal operating range, there is a risk of instability and tipping.

When it is necessary to work outside of the normal working range, be aware that the stability of the machine is reduced. The risk of tipping is increased while operating in the reduced stability working range.

Be aware that the machine is in its least stable position on a slope with the boom to the rear.

A

B

D

C

860C-030

A B C D

Working Ranges

Normal Working Range of Boom System Reduced Stability Working Range Track Gear Box at Rear of Undercarriage Uphill

All efforts have been made in the design of the machine to reduce the risk of tipping, however it is not possible to eliminate the risk of tipping.

1.12

Tigercat Bunching and Felling Saws

Safety Never travel across a STEEP slope or side hill.

• Always carry any load on the uphill side of the machine.

• Do not lift or move objects that exceed machine stability.

• Always be prepared to release the load in case it causes the machine to tip.

• Always position the cab so that you have a clear view in the direction of travel. Be aware of ground conditions and obstacles in the machine’s path before moving the machine.

• When crossing obstacles (boulders, stumps, ditches etc.) the machine can shift rapidly, greatly affecting the stability of the machine. Move slowly over obstacles, and position the boom against the ground to reduce the risk of the machine shifting rapidly.

20°

• Backing over obstacles unexpectedly while travelling down a slope poses a tipping risk. Know the path of the tracks whenever the machine is moved.

16° 845C-005 845C-004

Undercarriage Leveling Angles

To minimize the risk of tipping observe the following:

845C-007

• Do not attempt to operate this machine on slopes without first receiving proper training.

A

B

Climbing a Slope

• Learn the stability limits or “feel” of the machine by first working on gentle slopes and by positioning the boom to reduce the risk of tipping. Gain experience over time by gradually increasing the angle of the slopes on which you are working.

• Keep the attachment as close to the ground as possible to increase machine stability, and to allow the boom to be quickly lowered to the ground should the machine begin to tip.

• Always use the LOW speed setting for the track drives when on slopes.

• Travelling at an angle to the slope other than straight up and down decreases the traction of the tracks. Increasing the angle to the slope away from straight up and down can cause the machine to slide sideways downhill and/or possibly tip over.

1.13

A Keep the Attachment Close to the Grade B Track Gear Box at the Rear of the Undercarriage

• When climbing a slope the boom should face uphill and the attachment should be kept close to the ground.

Safety

845C-006

Tigercat Bunching and Felling Saws

A

Descending a Slope

A Keep the Attachment Close to the Ground

• When descending a slope the boom should face down hill and the attachment should be kept close to the ground (FIG. 4). Be particularly aware of machine stability when changing directions on, or travelling back down a slope.

• As you gain experience, recognize that the maximum slope on which the machine can operate cannot be defined simply by an angle value.

Variables in surface terrain, soil types, rocks, boulders, stumps, and fallen trees, changing weather conditions, and first and foremost the operator’s experience and skill levels greatly affect the maximum slope limitations. Be aware that these factors can result in a shallow slope posing greater risk than a relatively steeper slope. DO NOT attempt to work on slopes beyond your personal capability level.

1.14

Tigercat Bunching and Felling Saws

Safety

CABLE ASSIST

CABLE ASSIST MOUNT The cable assist mount can be used with a single or double shackle configuration depending on the winch system. Use only shackles with a pin diameter of 21⁄2 in. and rated for 55,000 kgf (121,000 lbf).

The leveler cable assist mount may improve machine maneuverability on steep slopes when attached to a suitable winching device.

Factors that will affect the safety of the machine as it works on steep slopes are: • Direction of machine travel • Limitations of machine tractive effort and soil conditions • Experience of the operator • Weather • Load sizes (boom position and load) • Poor visibility/lighting conditions

B

DAILY CHECKS On a daily basis prior to operating the equipment check:

A

855D-036

Single Shackle Configuration

A Shackle B Cable Assist Mount

• All equipment fluid levels.

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

• Secure loose items in the cab.

• Do not store tools, oil containers or other equipment in the cab • Functional check of all escape hatches.

• All covers, roof and doors are closed and latched.

• The cable assist mount for structural cracks and loose or missing bolts.

On a weekly basis check the torque tightening points on the cable assist mount. Make sure the M24 bolts have a torque value of 915 Nm (675 lbf-ft).

For additional information refer to MACHINE STABILITY AND TRACTION – MACHINES WITH LEVELER in THIS SECTION.

855D-037

A

B

Double Shackle Configuration

A Shackle B Cable Assist Mount

WARNING

CAUTION Do not open cab doors or window screens when cab is on a slope. The doors and screens are heavy and could swing out with considerable force. Anyone in the path of swing could be injured. Anyone opening the door or screen and holding on to it could be pulled out of the cab and injured.

The lifting bail on the cable assist mount is for installation of the cable assist mount only. Do not use the lifting bail for anything other than its intended use.

1.15

Safety

Tigercat Bunching and Felling Saws

CABLE TENSION To prevent damaging the cable assist mount and undercarriage the following acceptable maximum continuous cable tensions must not be exceeded.

• Maximum continuous cable tension for a single shackle configuration is 18,000 kgf (40,000 lbf).

• Maximum continuous cable tension for a double shackle configuration is 9,000 kgf (20,000 lbf) for each cable.

WARNING Always use the proper equipment. Always inspect the cable and cable assist mount for damage before using. Never use equipment that shows signs of poor maintenance or damage.

Repairs should only be made by qualified personnel.

LOADING DIRECTIONS To prevent damaging the cable assist mount and undercarriage the following acceptable loading directions must not be exceeded

855D-038

1.16

Tigercat Bunching and Felling Saws

Safety

FELLING TREES Pieces of wood, debris from the ground and even teeth separating from the saw blade become potentially dangerous missiles when thrown from these machines.

Debris shoots away from the cutting disc at very high speed. The debris pattern gets wider as it gets further away from the machine.

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

WARNING Do not use this machine for anything other than its intended use.

• Do not use the boom to service other equipment.

Inspect saw teeth, tooth retaining bolts, saw disc and felling head.

• Do not use the boom to lift items such as tires, engines, cylinders, boom components, etc.

Ensure that all saw tooth retaining bolts are at correct torque value. Refer to section 2 of THIS MANUAL for correct values.

Replace all worn saw teeth or rotate worn teeth to align unused cutting tips.

Always replace saw tooth retaining bolts when replacing saw teeth.

Inspect saw disc for stress cracks and that saw disc does not wobble due to worn saw shaft bearings.

Never start the machine if saw blade has missing teeth, teeth retaining bolts or a bent saw disc.

Shut down machine immediately if vibration occurs during cutting.

• Do not modify the boom system.

• Do not add hooks or lugs to the boom for the purpose of attaching lifting rigging.

• Do not use the attachment for anything other than its intended use.

Maintain a safe operating distance between the workers and equipment. It is the duty of the operator to ensure that no person approach the machine while in use.

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

Check that the saw discharge area is clear and undamaged.

Never use this machine to clear a logging deck on a new tract of timber when the rest of the equipment and operator's are also moving in. Preplan to clear decks in advance before other equipment arrives.

When moving from tree to tree with the saw blade turning, take care not to make contact with other vegetation or debris.

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

Know where your co-workers are. Make sure that they are always out of harms way before beginning the cut.

Stop the saw blade before leaving the cutting area.

Run saw disc only at recommended cutting speed.

NOTE: The saw blade will continue to free wheel for several minutes after the saw switch has been turned OFF.

Do not over load felling head.

Work within your operating skills, do not attempt to cut down a tree that is too large for the felling head.

To stop the blade from rotating, CAREFULLY lower the saw blade onto a stump gently to prevent unnecessary loading of the saw blade, saw housing and bearings.

Be alert for dead or decaying trees. Tops can break off while cutting.

As debris is always being released from the saw housing, the operator must remain in the cab until the blade has stopped rotating completely.

Operate so that the chip discharge area of the felling head (where applicable) is not directed at people, livestock, buildings or other machines.

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

When cutting, properly position felling head in front of tree and have saw blade running at full speed.

Always know and control the direction the tree will fall to prevent injury to co-workers or damage other vehicles.

When backing away from a cut, watch out for obstacles in your path.

1.17

Safety

Tigercat Bunching and Felling Saws

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

Before leaving operator's cab, lower the attachment onto the ground.

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. Never operate the boom or attachment over the heads of bystanders.

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

1. Park on level ground only and engage the swing brake.

2. Do not park on a hillside or incline.

3. Lower attachment onto level ground.

Use only prearranged and approved signalling practices.

4. Stop the engine.

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

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

24863A

OFF OFF

ON ON 24863A R0

Before transporting the machine check to ensure that all doors, panels and access covers are installed properly and secured. Improperly secured doors or panels pose a serious danger to pedestrians and other vehicles.

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

1.18

Tigercat Bunching and Felling Saws

Safety

SERVICING SAFETY PRECAUTIONS

WARNING Before using the saw blade lock pin the engine must be turned OFF, the saw blade must have come to a complete stop and the felling head must be supported.

Conduct maintenance inspections at least as frequently as recommended in SECTION 2 of THIS MANUAL.

The saw blade lock pin must be used for all maintenance procedures requiring access to the exposed portion of the blade and teeth, such as saw tooth replacement and saw tooth sharpening. Refer to SAW BLADE LOCK PIN in SECTION 2 of THIS MANUAL for instructions on the proper use of this safety device.

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

WARNING 24863A

OFF OFF

ON ON 24863A R0

When servicing or repairing equipment, turn OFF the engine and remove the ignition key. Turn battery disconnect switch OFF and lock out the switch in accordance with local regulations. Some machines are equipped with a remotely operated battery disconnect relay. Some wiring on the machine is live even when the battery disconnect switch is OFF. When servicing the electrical system, remove the battery cables from the batteries disconnecting the negative cables first.

Follow applicable lock-out procedures. Install a 'DO NOT OPERATE' tag on the cab door and in the engine compartment when making repairs to the machine.

Install saw guard.

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)!

WARNING Before using the saw blade guard and locking bolt the engine must be turned OFF, the saw blade must have come to a complete stop and the felling head must be supported.

IMPORTANT! PRESSURIZED HYDRAULIC TANK.

The guard must be installed when working on the saw motor hydraulic circuit or when the saw head is not being used. Refer to SAW BLADE GUARD AND LOCKING PIN SECTION 2 of THIS MANUAL for instructions on the proper use of this safety device.

34.5 kPa (5 psi) MAXIMUM. Before servicing hydraulic system, wearing eye protection, release air pressure from tank using air vent valve.

After service is completed, close air vent valve and add air pressure from a clean air source to the hydraulic tank via the Schrader valve. Do not exceed 34.5 kPa (5 psi). Refer to HYDRAULIC TANK PRESSURIZATION INSTRUCTIONS in the MACHINE MANUAL for details.

1.19

Safety

Tigercat Bunching and Felling Saws

Prior to Welding on any part of the machine, it should be cleaned and a fire extinguisher must be made available at the welding location.

Care must be taken in attaching the welding machine grounding clamp so current does not pass through bearings, especially the wrist and swing bearings.

A

Turn OFF the battery disconnect switch before removing the battery compartment cover.

Remove the positive (+) and negative ( – ) battery cables from the batteries disconnecting the negative ( – ) cables first.

Disconnect Engine ECU. Due to the sensitive electronics on some machines the following additional precautions must be taken. A typical Tigercat machine is shown here as an example:

A

B

H845D-018

Cab Fuse and Relay Panel

B

A Multi-Pin Connector at the XS2 Module B Multi-Pin Connector in the Harness

H845C-001

Engine ECU Disconnect

A Multi-Pin Connector B Four-Pin Engine Power Connector

Disconnect the multi-pin connector from the XS2 computer module in the cab electrical compartment.

Disconnect the 2multi-pin connectors in the harness.

Disconnect the engine ECU (Electronic Control Unit) by unplugging the four-pin engine power connector and the 2 multi-pin connectors from the left side of the engine.

A

855D-025

Battery Compartment

A Multi-Pin Connector at the XA2 Module

Disconnect the multi-pin connectors from the XA2 computer modules in the battery compartment.

1.20

Tigercat Bunching and Felling Saws

Safety

Never use your bare hand to check for fluid leaks.

WARNING

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

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

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

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.

Do not change any pressure or relief setting 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.

A

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.

B 845C-002

Parking the Boom

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

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

Lower the attachment to the ground, stop engine and relieve trapped pressure before performing work on components, or disconnecting any hoses. Refer to the PARKING THE BOOM diagram. Accumulators will selfdrain within two minutes of stopping the engine.

Never stand under an object supported with hydraulics.

Always use safety stands or a locking device.

A Stick Cylinders Fully Extended B Tip of Stick Boom Fully Supported

Never stand on the felling head butt plate, either with the clamping arms open or closed.

WARNING Failure to follow these instructions could result in serious injury or death from crushing.

1.21

Safety

Tigercat Bunching and Felling Saws

FOR WHEEL FELLER BUNCHERS

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

Always install 'T' handle retainer bolt.

Use only to support boom and felling head.

Do not use to set hydraulics pressures. Always wear proper safety equipment such as safety glasses and gloves during blade service.

1.22

Tigercat Bunching and Felling Saws

Safety

MACHINE MODELS EQUIPPED WITH AN ER BOOM SYSTEM

SWITCHABLE ER BOOM FUNCTION

WARNING Some Tigercat machines are equipped with an ER boom system. Because of this, it may behave in an unexpected manner compared to a conventional boom system.

Pay attention to the following when servicing the ER Boom System. Certain hydraulic circuits are interconnected in order to provide level head-travel and to recirculate hydraulic oil to reduce heat generation and fuel consumption. As a result, disconnecting hydraulic lines from one cylinder may release pressure in a different cylinder at the same time. Before attempting to disconnect hydraulic hoses or perform work on the boom system, ensure that: 55987BUNI R0

A

Some Tigercat machines are equipped with a switchable ER valve to provide ER boom function or non-ER boom function. This function is switched on or off by a button switch and the Computer Controller. For complete details refer to ER BOOM SYSTEM, SPECIAL OPERATING INSTRUCTIONS in section 2 of the MACHINE OPERATOR'S manual.

B 845C-002

Parking the Boom

A Stick Cylinders Fully Extended B Tip of Stick Boom Fully Supported

845C-003

A

B

ER Boom System

A Hoist Cylinder Fully Retracted B Tip of Stick Boom Fully Supported

1. The machine is parked on level ground with the attachment on the ground (FIG. 1).

2. The stick cylinders are fully extended (FIG. 1) or the hoist cylinder fully retracted (FIG. 2).

3. If the attachment has been removed make sure the tip of the stick boom is supported.

1.23

Safety

Tigercat Bunching and Felling Saws

Before performing work under the boom system ensure it is firmly supported.

WARNING Always follow the instructions and safety warnings in THIS MANUAL before approaching the felling head to make adjustments.

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

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

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

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

CAUTION Do not open cab doors or window screens when cab is on a slope. The doors and screens are heavy and could swing out with considerable force. Anyone in the path of swing could be injured.

Anyone opening the door or screen and holding on to it could be pulled out of the cab and injured.

When opening or closing power operated engine door, watch for personnel in door areas.

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

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.

NEVER SERVICE BLADE OR ANY PART OF FELLING HEAD WITH ENGINE RUNNING. When performing required hydraulic checks and blade speed adjustments. Install the saw blade guard. Refer to SECTION 2 of THIS MANUAL for instructions.

As with any attachment device NEVER ACCESS THE MACHINE UNDER THE ATTACHMENT in the raised position.

The saw blade is very heavy. Use a lifting device of suitable capacity when moving the blade.

MACHINE MODELS EQUIPPED WITH A LEVELING SYSTEM

Always install support braces in the leveling mechanism while performing service and maintenance tasks. This area is a crush zone. Keep clear to avoid personal injury or death.

1.24

Tigercat Bunching and Felling Saws

Safety

FLUID INJECTION INJURY

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

WARNING

When searching for possible fluid leaks:

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

• NEVER search for leaks with your bare hands.

Always wear thick protective gloves.

Hydraulic and diesel fuel systems on forestry machines operate at very high pressures, often 207 bar (3000 psi) and above. If a loose connection or a defect in a hose should occur, a fine, high velocity stream of fluid will result.

Even for systems pressurized to as little as 7 bar (100 psi), this fluid stream can penetrate human skin as if it were a hypodermic needle.

• Be sure to wear safety goggles for eye protection.

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

Initially, an accidental fluid injection beneath the skin may only produce a slight stinging sensation. There is a danger that you will tend to ignore this, thinking that it will get better with time. Most often, it does not. Within a very short time the wound may begin to throb painfully, indicating that tissue damage has already begun.

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

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

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

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

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

In the event of any suspected fluid injection injury:

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

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

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

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

• Report the injury to your supervisor immediately.

• Seek professional medical attention immediately.

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

1.25

Safety

Tigercat Bunching and Felling Saws

GREASE INJECTION INJURY WHEN USING PNEUMATIC GREASE GUNS Pneumatic grease guns can deliver grease at pressures from 17 – 400 bar (246 – 5801 psi). It takes less than 7 bar (100 psi) to inject a substance through human skin.

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

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

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

Prior to using a high pressure pneumatic grease gun perform the following: • All operators of high pressure pneumatic grease guns MUST be trained in the hazards of its operations and the treatment for such injuries.

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

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

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

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

• Remove dirt and grease from grease fittings prior to greasing.

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

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

1.26

Tigercat Bunching and Felling Saws

Safety

LIGHTNING SAFETY

LIGHTNING SAFETY AWARENESS 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.

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.

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

1. Designate a member of your crew to: • Monitor daily weather forecasts • Observe local weather conditions • Alert all other members of the crew when a possible lightning threat develops

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.

2. Don’t 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 feet) within the soil around the strike point.

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

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

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.

1.27

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

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

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

Safety Unfortunately loggers 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.

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

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

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

Note that the rubber tires on motor vehicles and heavy equipment do not increase safety from lightning strikes.

Lightning has already travelled a great distance through the air to strike the vehicle. In comparison a few inches of rubber in a tire offers absolutely no additional insulation.

Tigercat Bunching and Felling Saws

WHAT TO DO IF YOU ARE OUTSIDE AND SEE LIGHTNING OR HEAR THUNDER IF YOU CAN, GET INSIDE: Run to the nearest building, motor vehicle or fully enclosed ROPS equipment cab immediately. Being anywhere outside is not safe.

IF INSIDE A BUILDING: • Don’t watch the lightning storm from open windows or doorways. Stay in inner rooms.

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

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 touch any radio or telephone connected to an outside antenna.

1.28

Tigercat Bunching and Felling Saws

Safety

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.

WHAT TO DO IF YOU FEEL YOUR SKIN TINGLING, YOUR HAIR STANDS ON END, LIGHT METAL OBJECTS VIBRATE OR YOU HEAR A CRACKLING SOUND:

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

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

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

• 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.

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

• Avoid entering any small enclosures or shelters.

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

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

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

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

• 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.

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, start cardiopulmonary resuscitation (CPR) or mouth – to-mouth resuscitation immediately. Use a portable defibrillator if one is available.

• Do not use the telephone except for emergencies.

• 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.

• To further increase your awareness about lightning safety, see the following web sites: • National Weather Service Lightning Safety http://www.lightningsafety.noaa.gov • National Lightning Safety Institute http://www.lightningsafety.com

1.29

Safety

FIRE PREVENTION

Tigercat Bunching and Felling Saws 4. Clean out all accumulated forest debris (twigs, pine needles, branches, bark, leaves, saw dust, small wood chips) and any other combustible materials from inside the machine belly pans or lower machine structures as well as from areas in proximity to the engine, fuel and hydraulic oil systems no less frequently than at the completion of each work shift.

5. Inspect the machine regularly for any signs of diesel fuel or hydraulic system leakage. Check for worn or eroded fuel or hydraulic lines before starting up any equipment.

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

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

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

1. Maintain a CHARGED fire extinguisher on the machine at all times and KNOW HOW TO USE IT. 2. Remove debris and blow out dust regularly from the air intake doors, engine radiator and charge air cooler, hydraulic oil cooler, diesel fuel cooler and air conditioning condenser core to prevent overheating of the engine and hydraulics and to maintain efficient operation of the machine. Refer to CLEANING A/C CONDENSER, OIL COOLER AND RADIATOR in SECTION 2 of the MACHINE OPERATOR’S MANUAL. 3. Blow off all forest debris and fine organic material accumulated near hot engine exhaust components (turbocharger and exhaust manifold as well as exhaust pipes and muffler) at the completion of each work shift or more frequently when working in logging conditions where large amounts of combustible forest debris are present.

Visual inspection after blow off to ensure thorough cleanliness is vital. Engine exhaust systems provide numerous small pockets where saw dust, small wood chips and other flammable forest debris can gather. Even small accumulations close to hot exhaust components can ignite and smoulder. If dislodged this smouldering debris can fall into other areas of the machine and thereby spread a fire.

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

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

8. Use only non-flammable solutions for cleaning the machine and components.

9. Inspect the exhaust system daily for any signs of leakage. Check for worn, cracked, broken or damaged pipes or muffler. Also check for missing or damaged bolts or clamps. Should any exhaust leaks or defective parts be found, repairs must be made immediately. Engine exhaust leaks can cause fires.

Do not operate the machine until the exhaust leak is repaired.

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

11. Park the machine at least 15 METERS (50 feet) away from other equipment at the end of each shift.

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

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

1.30

Tigercat Bunching and Felling Saws

Safety

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

WHAT TO DO TO PREPARE FOR A MACHINE FIRE

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

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

• Ensure that any pressurized water systems on the machine (if applicable) are charged and in working order. Refer to PRESSURIZED WATER SYSTEM MAINTENANCE in SECTION 3 of the MACHINE MANUAL. • Ensure that you have the proper fire extinguishers on site. Most fires involving mobile forestry equipment will be Class A or B. Dry chemical extinguishers should be rated ABC and pressurized water extinguishers should be rated A.

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

Class A fires involve ordinary combustibles such as wood, cloth, paper, rubber and many plastics, Class B fires occur with flammable liquids such as diesel fuel, oil and grease and Class C fires apply to energized electrical equipment.

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

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

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

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

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

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

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

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

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

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

1.31

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

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

• Ensure that after you have received the training as outlined above, that you know how to use the fire extinguisher, the pressurized water system (if applicable) and the fire suppression system** on your machine. There is not enough time available to read instructions during a fire emergency.

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

Tigercat Bunching and Felling Saws

WHAT TO DO WHEN A MACHINE FIRE OCCURS If operating the machine when a fire occurs: 1. Lower all working attachments to the ground.

2. Turn OFF the engine.

3. Activate the fire suppression system**.

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

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

6. At all times ensure your own personal safety and the safety of anyone that may be in the area. Approach any fire with extreme caution. All fires can be very dangerous and life threatening.

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

Before deciding to fight the fire, be certain that: 8. The fire is small and not rapidly spreading.

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

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

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

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

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

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

• Pull the pin at the top of the extinguisher that keeps the handle from being pressed. Break the plastic seal as the pin is pulled.

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

1.32

Tigercat Bunching and Felling Saws

Safety

• Squeeze the handle 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

WHAT TO DO AFTER A MACHINE FIRE HAS OCCURRED • Before returning the machine to work.

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

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

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

• Notify your equipment dealer and / or Tigercat Industries Inc. by completing an incident report, Tigercat form number 5101. *NOTE: Fire detection systems are offered by Tigercat as an optional installation on some Tigercat product lines. Please disregard any references made to fire detection systems if not installed on your machine. **NOTE: Dry chemical fire suppression systems are offered by Tigercat as an optional installation on some Tigercat product lines. Please disregard any references made to fire suppression systems if not installed on your machine.

822C-190

Typical Fire Extinguisher Access Hole

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

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

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

• Ensure that the machine and all components have cooled down sufficiently after a fire so that reignition does not occur.

• Remain with the machine until help arrives.

1.33

Safety

DRY CHEMICAL CLEANUP PROCEDURES Both ABC dry chemical fire extinguishers and fire suppression systems discharge a chemical powder to extinguish the fire. The chemical makeup and the small particle size of the powder as well as the force of the discharge all contribute to the fire fighting capability.

These same characteristics also permit the powder to penetrate into and fully cover all components in the vicinity of the discharge.

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

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

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

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

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

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

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

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

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

Then wipe all surfaces with a damp cloth.

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

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

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

1.34

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

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

DANGER

CONTENTS – APPENDIX TO SECTION 1 C

COMMENTS AND INSTRUCTIONS..........................................................................................................................A.7 ASSESSING THE POTENTIAL DANGERS ON THE JOB SITE..........................................................................A.7 DIRECTION OF THROW.........................................................................................................................................A.7 HIGH ANGLE WRIST ROTATION ABILITY............................................................................................................A.8 RECOGNIZING THE DANGERS............................................................................................................................A.7 REGULAR MAINTENANCE....................................................................................................................................A.7 SAFE OPERATING AREAS.....................................................................................................................................A.7 THROW DISTANCE.................................................................................................................................................A.7 THROWING LONG WOOD PIECES....................................................................................................................A.10

D

DANGERS....................................................................................................................................................................A.3

F

FOREWORD................................................................................................................................................................A.2 BE AWARE OF THE HAZARDS..............................................................................................................................A.3 OTHER INSTRUCTIONS.........................................................................................................................................A.3 SAFE PRACTICES...................................................................................................................................................A.3 SEVERAL TYPES OF HEADS INVOLVED............................................................................................................A.2 STORED ENERGY...................................................................................................................................................A.3

H

HOUSING TYPES.......................................................................................................................................................A.4 HOUSING WITH ADDITIONAL OPENING.............................................................................................................A.6 HOUSING WITH LONGER INGOING SNOUT......................................................................................................A.5 HOUSING WITH NO SNOUTS...............................................................................................................................A.5 HOUSING WITH SNOUTS......................................................................................................................................A.4

S

SAW HEAD DO NOT'S..............................................................................................................................................A.14

T

TYPE OF HOUSING MAKES A DIFFERENCE.........................................................................................................A.4

5211A • R5-1116

Using High-Speed Disc Saws Safely

Tigercat

FOREWORD SEVERAL TYPES OF HEADS INVOLVED

SAW25A

Wheel Feller Buncher– Broadside Saw Contact with a Log Could Produce a Throw

SAW24

Track Feller Buncher – Sudden Machine Movement May Cause and Unexpected Throw at the Cab

Tigercat wheel feller bunchers and track feller bunchers can be supplied with several optional makes and models of high speed disc saw tree felling heads. Because each head has unique characteristics, advantages and disadvantages, they are chosen based on the specific types of work they were designed to complete.

A.2

Tigercat

Using High-Speed Disc Saws Safely

STORED ENERGY

OTHER INSTRUCTIONS

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

All instructions contained in the operator and service manuals for use and maintenance of Tigercat disc saw heads and other disc saw heads installed on Tigercat machines must be read, understood and followed.

BE AWARE OF THE HAZARDS

Here are the most common means by which a rotating disc saw can cause harm by throwing:

DANGERS

Users of machines with disc saw felling heads must be aware of all safety precautions. In this section, some previously unknown, unexpected safety hazards are illustrated and explained. These should be studied before use of the machine and then reviewed again after use has begun.

• The normal throwing of chips from the cut.

• Soil particles are thrown from the ground.

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

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

SAFE PRACTICES It is understood and expected that logging organizations and operators must develop and practice additional rules to suit particular conditions of terrain, trees, soil and job requirements. The information provided in this section is intended to assist towards a quicker understanding of how and why things can happen when a high speed disc saw is in use and to assist in the development of safe operating practices.

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

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

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

It should not be assumed that all possible dangers have been discovered and described in this section.

A.3

Using High-Speed Disc Saws Safely

Tigercat

HOUSING TYPES TYPE OF HOUSING MAKES A DIFFERENCE Since the configuration of the saw housing can affect the safety of its use, we need to identify some particular types of housing shapes and guarding being used.

HOUSING WITH SNOUTS A

B

SAW13

A Throw Angle

SAW17

Saw Housing with Snouts B Snouts

This commonly used saw housing is designed with a continuous skirt around the saw except at a mouth opening where the trees are cut and taken. The skirt extends below the saw enough to intercept tangential throws. There are snouts on both sides of the mouth to prevent the saw teeth from making contact with the wood if pushed against the side of a felled tree or log.

A.4

Tigercat

Using High-Speed Disc Saws Safely

HOUSING WITH NO SNOUTS A

B

SAW14

SAW15

Saw Housing with No Snouts

A Throw Angle

B Housing Plan with No Snouts

This housing has no blade-guarding snouts. This allows the saw blade teeth to protrude ahead of the housing.

This may be preferred for dexterity in tree getting.

HOUSING WITH LONGER INGOING SNOUT A

C

B

B

SAW12

A Throw Angle B Long Snout

SAW18

Saw Housing with a Longer Snout on the housing Ingoing Side C Short Snout

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

A.5

Using High-Speed Disc Saws Safely

Tigercat

HOUSING WITH ADDITIONAL OPENING

B

C

A

A

E

D A

SAW19

A Throw Angle B Rear C Front

A

SAW20

A SAW26

Saw Housing with Additional Opening

D Opening in Housing Skirt E Guard for Chip Escape Port in Housing

This housing incorporates an additional opening (chip escape port) in the housing skirt to allow for the discharge of wood chips produced by the saw teeth in the cut and being taken into the housing.

A guard is available to close the chip escape port so tangential travel of chips and other material is intercepted as soon as it leaves the housing.

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

IMPORTANT! The operator must be familiar with the blade rotation direction, the effectiveness of any snout on the in-going side and which direction a chip escape port allows material to discharge.

A.6

Tigercat

Using High-Speed Disc Saws Safely

COMMENTS AND INSTRUCTIONS

ASSESSING THE POTENTIAL DANGERS ON THE JOB SITE

RECOGNIZING THE DANGERS

The extent of danger from high speed disc saws on a logging operation must be assessed on the job site, depending on how much other work activity is in the area and whether the operator can do their job of cutting and bunching with good control of throw patterns. Danger is greater if the saw is equipped with detachable, or fragile, or brittle teeth, or if the site contains stones or abandoned metal.

While it may appear the illustrated danger areas (throw angle) can be visually recognized on the job by observing how far chips are discharged during a cut, this only holds true for chips and other light weight materials.

Metal parts and wooden spears can be thrown to surprisingly greater distances. Even distant personnel on the ground, in other vehicles, or in buildings are at risk if the throw is in their direction.

REGULAR MAINTENANCE

DIRECTION OF THROW

Poor saw maintenance increases possible dangers.

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

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

THROW DISTANCE The throw distance for metal pieces and stones, can be many times the distance shown by the pattern for chips.

More testing and data collection is needed to pin down a 'safe distance' but if someone or something is in a place that can be seen by the operator and in the throw direction of a high speed disc saw, then the operation is not safe regardless of the distance.

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

A.7

Using High-Speed Disc Saws Safely

Tigercat

HIGH ANGLE WRIST ROTATION ABILITY

B

A

C

SAW21A

A Short Snouts B Chip Escape Port Discharge Path

C Chip Escape Port

The limits of the boom, stick, tilt, wrist, upper leveling and any other freedoms, must not permit a direct throw at the operators cab during normal operation, on felling machines equipped with a high-speed disc saw head with high-angle wrist rotation ability.

A

B

SAW23

B C

SAW23

A Clockwise (CW) Blade Saw Rotation B Discharge Path

C Counterclockwise (CCW) Saw Blade Rotation

The discharge path exists in both the clockwise (CW) and counterclockwise (CCW) blade rotation (relative to the machine).

A.8

Tigercat

Using High-Speed Disc Saws Safely

B

A

SAW21A

Disc Saw Felling Head with High Angle Wrist Rotation Capability

A Long Snout on Outgoing Side

B Discharge Paths

It is essential that the housing have a long snout on the ingoing side and, if equipped with a chip escape port, it should be guarded.

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

A.9

Using High-Speed Disc Saws Safely

Tigercat

THROWING LONG WOOD PIECES

A

Dangers from throws of long wood pieces are illustrated throughout this portion of the document.

Tests and experience have shown that, when a high speed rotating saw is applied to a loose piece of wood, the wood is either blown or pushed away, without a throw.

C

If the wood is held firmly in all directions, and the saw is advanced into the wood at any feed speed, cutting will take place. If the wood is only restrained against the saw radially, but not restrained tangentially, then the wood will be both partly cut and partly moved tangentially.

If the piece of wood is backed-up by a solid slippery surface, the feed in is very fast, and the piece of wood is long enough, the tangential movement is a dangerous spear-like throw.

B

SAW2

A Slab B Throw Direction C Radial Feed In

The slab can be thrown from the side of a log. Although the saw housing has skis, there are no snouts and the blade teeth protrude ahead of the housing.

A

B

C

E

F

SAW7A

D A

SAW10

A Slab SAW8A

A slab, which could later be thrown, might occur when there is not enough room in the head to completely cut the last tree.

A B C D E F

Throw Engagement– Side View

Felling Head Moving Radially Into the Slab/Log Slab Log Felling Head Moving Radially Into the Small Log/Pile Small Log Log Pile

A slab, still partly attached to a well backed-up tree bole and wet with sap, makes an ideally bad throw situation which could unintentionally occur in woods work.

If the side of a log can contact the saw blade, the throw engagement distance can be long.

A.10

Tigercat

Using High-Speed Disc Saws Safely A

B

A

B SAW7

SAW6

C

Felling Head with Snouts

A Thrown Engagement Distance B Uncut tree or stump backup C Radial Feed In

A

A head with snouts does not allow a long throw contact.

Although tests show that a short contact length on a long log or tree butt does not result in a spear like throw, this action should nevertheless be avoided because abnormally large chips are sometimes produced and thrown.

C SAW8

Throw Engagement– Top View

A Thrown Engagement Distance B Felling Head Moving Into the Slab/Log C Felling Head Moving Into the Small Log/Pile

A housing without snouts can create a long throw engagement distance which, in turn, can cause a dangerous spear throw.

B

A SAW3

C

How a Log Can Be Thrown Like a Spear

A Felling Head Moving Into the Small Log/Pile B Small Log C Saw Housing Without Snouts

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

A.11

Using High-Speed Disc Saws Safely

Tigercat SAW BLADE THROW GAP A

A

SAW122

SAW11

A Saw Throw Gap

A Felling Head Moving Into Stump (Feed Speed)

Blocks of wood can be tossed in any direction when improvising with a disc saw to trim over-size stumps. A long snout and a slow feed speed lessen danger during stump trimming. A similar danger of throw may exist when clearing small brush with multiple pass cuts.

Saw blades have gaps between adjacent teeth and holders to permit installation and removal of the teeth and to provide spaces to accumulate chips in the cut.

Fallen sticks and debris, or sticks and debris sliding across the saw blade, can enter these gaps when the blade is rotating and may be struck by the teeth. This will cause the sticks and debris to be tossed or thrown.

Larger gaps and lower rotation speeds increase these dangers.

A.12

Tigercat

Using High-Speed Disc Saws Safely

SAW HOUSING ENTRANCE AND EXIT SPACE

A

B

SAW22 SAW22A SAW22B

A Ingoing Opening of the Saw Blade Housing

Saw Bade Entrance and Exit Space

B Outgoing Opening of the Saw Blade Housing

To avoid the ingestion of materials into the housing space above the disc (and later ejection) the ingoing entrance for the saw rim of teeth is kept as small as practical. It is important that this high wear area be maintained at its original size and shape.

The outgoing opening is large enough to allow the housing to clean itself and allows most things inside to be thrown out. Its throw direction and angle must be respected. A long snout on the ingoing side reduces this danger.

A.13

Using High-Speed Disc Saws Safely

Tigercat

This information is offered by Tigercat as part of interim action to make saw heads safer. It is based on what has recently been reported from the field and on tests conducted on proving grounds.

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

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

Tigercat continues to design and test tree felling machinery towards achieving greater safety in the woods. Tigercat would be thankful for written reports describing any unsafe happenings, including near misses, in the use of felling heads and their carriers.

• Do not select and operate heads that throw rearward.

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

THE FOLLOWING ARE SOME SAW HEAD DO NOT'S THAT APPLY PARTICULARLY TO THROW PREVENTION:

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

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

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

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

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

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

• Do not over speed the blade rpm.

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

• Do not neglect tooth fastening inspection, maintenance and replacement.

• Do not neglect to repair worn or damaged saw housings.

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

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

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

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

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

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

A.14

OPERATING, SERVICE AND MAINTENANCE...................................................................................................2

Tigercat Bunching and Felling Saws SECTION 2 – OPERATING, SERVICE, AND MAINTENANCE Read and understand the entire contents of this manual, and all manuals for any attachments or accessories associated with this equipment, prior to operating or servicing.

CONTENTS – SECTION 2

ISSUE 2.0, AUGUST 2019

B

BUTT PLATE REPLACEMENT MODELS DT/DW5003, DT5301, ST5401, DW5502, AND DW5603..................................................................... 2.61 MODEL SERIES 5702............................................................................................................................................ 2.65

C

CYLINDER SEALS CLAMP ARM AND ACCUMULATING ARM CYLINDERS.................................................................................... 2.69 WRIST CYLINDERS.............................................................................................................................................. 2.70

F

FELLING TECHNIQUES............................................................................................................................................. 2.8 FIXED-DISPLACEMENT MOTOR. SEE MOTOR, FIXED DISPLACEMENT

L

LUBRICATION POINTS MODELS DT5003 AND DT5301............................................................................................................................ 2.23 MODELS DW5003, DW5502, AND DW5603......................................................................................................... 2.21 MODEL ST5401...................................................................................................................................................... 2.25 MODEL ST5702...................................................................................................................................................... 2.27 MODEL ST5702-26................................................................................................................................................. 2.29 MODEL SW5702..................................................................................................................................................... 2.31

M

MOTOR, FIXED-DISPLACEMENT ANTI-CAVITATION CHECK VALVE...................................................................................................................... 2.86 MANIFOLD-MOUNTED ANTI-CAVITATION CHECK VALVE TEST................................................................... 2.87 MOTOR CASE DRAIN FLOW CHECK................................................................................................................. 2.88

N

NEW SAW MAINTENANCE FIRST 125-HOUR INSPECTION........................................................................................................................... 2.17 PRE-DELIVERY INSPECTION............................................................................................................................. 2.17 START-UP OF A NEW SAW HEAD....................................................................................................................... 2.17

O

OPERATING PRINCIPLE........................................................................................................................................... 2.5

P

PART NAMES DOUBLE-POST FELLING SAW.............................................................................................................................. 2.6 SINGLE-POST FELLING SAW................................................................................................................................ 2.7 PREVENTIVE MAINTENANCE SCHEDULE.......................................................................................................... 2.17

S

SAW BLADE IDENTIFICATION................................................................................................................................................... 2.36 INSPECTION.......................................................................................................................................................... 2.37 INSTALLATION USING CHAIN HOIST AND SLING........................................................................................... 2.44 INSTALLATION USING THREADED RODS........................................................................................................ 2.43 REMOVAL............................................................................................................................................................... 2.40 ALTERNATIVE METHOD FOR TRACK FELLER BUNCHERS....................................................................... 2.42 REMOVAL TOOLKIT.............................................................................................................................................. 2.40 RUNOUT CHECK................................................................................................................................................... 2.39 SERIAL NUMBER.................................................................................................................................................. 2.36 SERIES NUMBER.................................................................................................................................................. 2.36 STOPPING THE SAW BLADE.............................................................................................................................. 2.16 WEAR LIMITS......................................................................................................................................................... 2.38

Operating Instructions

Tigercat Bunching and Felling Saws

SAW BLADE GUARD AND LOCKING BOLT........................................................................................................... 2.35 SAW BLADE LOCK PIN............................................................................................................................................ 2.34 SAW DRIVE ANTI-CAVITATION AND MOTOR CONTROL CHECK VALVES TEST.................................................... 2.82, 2.83 BEGIN OF REGULATION PRESSURE, SETTING MOTOR............................................................................... 2.76 BLADE SPEED ADJUSTMENT............................................................................................................................. 2.78 BLADE SPEED TROUBLESHOOTING................................................................................................................ 2.79 DESCRIPTION....................................................................................................................................................... 2.72 MOTOR CASE DRAIN FLOW CHECK................................................................................................................. 2.84 SAW CIRCUIT PRESSURE CHECK.................................................................................................................... 2.80 START-UP PROCEDURE...................................................................................................................................... 2.74 SAW DRIVE HOUSING TEMPERATURE CHECK................................................................................................. 2.85 SAW DRIVE SPINDLE ASSEMBLY COMPONENTS................................................................................................................................. 2.56 END PLAY ADJUSTMENT..................................................................................................................................... 2.54 END PLAY DAILY CHECK..................................................................................................................................... 2.50 END PLAY DEFINITION........................................................................................................................................ 2.50 END PLAY DETAILED CHECK............................................................................................................................. 2.51 INSTALLATION....................................................................................................................................................... 2.60 REMOVAL............................................................................................................................................................... 2.58 SAW DRIVE SPINDLE PULLER........................................................................................................................... 2.59 SAW HOUSING WEAR LINER................................................................................................................................. 2.68 SAW TEETH INSPECTING.......................................................................................................................................................... 2.45 REPLACING........................................................................................................................................................... 2.48 ROTATING.............................................................................................................................................................. 2.47 SCHEDULED MAINTENANCE EVERY 175 HOURS............................................................................................................................................... 2.19 EVERY 500 HOURS............................................................................................................................................... 2.19 EVERY DAY............................................................................................................................................................ 2.19 EVERY WEEK........................................................................................................................................................ 2.19 T

TORQUE CHART....................................................................................................................................................... 2.32 TORQUE SPECIFICATIONS – GENERAL............................................................................................................... 2.33 TROUBLESHOOTING SAW BLADE SPEED.............................................................................................................................................. 2.79 WRIST – 340°......................................................................................................................................................... 2.100

W

WEAR LINER............................................................................................................................................................. 2.68 WRIST CYCLE TIMES...................................................................................................................................................... 2.117 OIL FLOW ADJUSTMENT................................................................................................................................... 2.117 SPECIAL TOOLS.................................................................................................................................................. 2.121 WRIST – 30° DESCRIPTION....................................................................................................................................................... 2.89 DESCRIPTION – HYDRAULIC CIRCUIT.............................................................................................................. 2.90 WRIST – 110º CYLINDER ATTACHMENT POINTS..................................................................................................................... 2.91 DESCRIPTION....................................................................................................................................................... 2.91 DESCRIPTION – HYDRAULIC CIRCUIT.............................................................................................................. 2.93

2.2

Tigercat Bunching and Felling Saws

Operating Instructions

WRIST – 340° CONTROL MANIFOLD.......................................................................................................................................... 2.99 DESCRIPTION – HIGH TORQUE.......................................................................................................................... 2.96 DESCRIPTION – HYDRAULIC CIRCUIT.............................................................................................................. 2.98 DESCRIPTION – STANDARD TORQUE............................................................................................................... 2.94 GENERAL SETUP PROCEDURE....................................................................................................................... 2.100 CASE PRESSURE CHECK.............................................................................................................................. 2.102 COUNTERBALANCE VALVE (HOLDING) PRESSURE ADJUSTMENT...................................................... 2.103 START-UP PROCEDURE................................................................................................................................. 2.101 MOTOR AND OUTPUT SHAFT SEAL REPLACEMENT (HIGH TORQUE WRIST)........................................ 2.109 MOTOR AND PINION ASSEMBLY DISASSEMBLY/ASSEMBLY (HIGH TORQUE WRIST)...........................2.111 MOTOR RIGHT/LEFT RECONFIGURATION (HIGH TORQUE WRIST)......................................................... 2.116 OUTPUT SHAFT ASSEMBLY DISASSEMBLY/ASSEMBLY (STANDARD TORQUE WRIST)....................... 2.106 TROUBLESHOOTING......................................................................................................................................... 2.100 WRIST BEARING RADIAL CLEARANCE CHECK........................................................................................................................... 2.120 SEAL REPLACEMENT........................................................................................................................................ 2.118 TILT CLEARANCE CHECK................................................................................................................................. 2.120 WEAR LIMITS....................................................................................................................................................... 2.119

2.3

Operating Instructions

Tigercat Bunching and Felling Saws

2.4

Tigercat Bunching and Felling Saws

Operating Instructions

OPERATING PRINCIPLE

SAW CONTROLS

Tigercat saws are high speed continuous motion type disc saw felling heads designed to be more productive by accumulating larger bunches of trees with faster cycle times. Larger felling head bunches makes it easier to build large neatly aligned skidder piles reducing the amount of manoeuvring required by the skidder.

All Tigercat machines (sold with saw attachments) are equipped with the following:

The harvesting concept employed here is generally referred to as “High speed continuous motion felling”. In the case of drive to tree felling, this involves lining up the felling head with the tree and travelling or driving forward with both the clamp and accumulating arms open and the saw blade turning at full speed, and without stopping, continuing to drive into the tree with the saw blade to cut the tree. The butt of the tree slides onto a butt plate, positioned just above the blade, which supports the tree.

Immediately after the tree is cut both clamp arms close, transferring the tree to the pocket and holding it secure, as the process repeats itself.

In the case of swing and boom to tree felling, the procedure is the same except that the blade is fed into the tree by combining the boom, stick and tilt controls.

The saw blade is a high inertia type blade. Cutting is done with the inertia (stored energy) in the rotating blade. The hydrostatic drive motor brings the blade back up to speed after each cut is made.

Tigercat saws can be installed on either a wheel (drive to tree) or track (swing and boom to tree) type machine.

2.5

• Saw switch • Saw pressure gauge (wheel feller bunchers only) • Accumulator arm control • Clamp arm control • Wrist control (track feller bunchers only) • Control valve • Pump The location and type of saw controls varies according to machine model.

For specific information on saw operating controls refer to SECTION 2 of the MACHINE OPERATOR'S MANUAL.

Operating Instructions

Tigercat Bunching and Felling Saws

A

B

M

C L

K D J E I

F

F

E

SAW30

A B C D E F G

Upper Horn Structure Accumulating Arm Clamp Arm Saw Drive Motor (Under Cover) Snout Skis Saw Blade

Double-Post Felling Saw H I J K L M

2.6

Tooth Housing Skirt Butt Plate Drive Spindle Log Pocket Frame

H

G

Tigercat Bunching and Felling Saws

Operating Instructions A

B

C D

B

E K F

J

G

F G

SAW87

A B C D E F

Upper Horn Structure Clamp Arm Link Accumulating Arm Saw Drive Motor and Spindle (Under Cover) Snout

Single-Post Felling Saw G H I J K

2.7

Skis Saw Blade Butt Plate Housing Skirt Saw Housing

I

H

Operating Instructions

Tigercat Bunching and Felling Saws

TIGERCAT SAW FELLING TECHNIQUES

A

1. Before operating any Tigercat Saw read and understand the SAFETY PRECAUTIONS at the beginning of this manual.

2. Start engine and ensure that hydraulic oil is at operating temperature.

3. Ensure that all personnel are clear of the cutting area.

4. Turn saw blade on and bring it up to operating speed: It takes approximately 25 to 35 seconds for the saw blade to reach full speed from the stationary position.

SAW84

5. Open both the clamp arm(s) and the accumulating arm(s).

Swing-and-Boom-to-Tree Felling-Head Position

A Tilt the Felling Head Forward 3 – 5°

6. Place the felling head in the slightly tilted forward position (no more than 5°).

• Swing and Boom to Tree Assuming the tree is within reach, swing the boom around and line up the felling head with the tree, then use a combination of the machine's boom, stick and tilt controls (non ER booms) to feed the saw blade through the tree with a smooth horizontal action and at a steady speed. The correct blade feed speed for a 12" tree is approximately 1/2 second.

7. Position the head and start cutting using the correct method for the machine model: A

Moving the head up or down during the cut will cause the blade to undergo unnecessary stress and it may stall before the cut is complete. The correct technique is quickly learned.

Feeding too fast makes a poor cut and stalls the blade. Feeding too slow creates excessive heat.

SAW36

Drive-to-Tree Felling-Head Position

A Tilt the Felling Head Forward 3 – 5°

• Drive to Tree Drive the machine forward toward the tree and feed the saw blade into the tree at a steady speed.

The correct blade feed speed for a 12" tree is approximately 1/2 second.

8. As the cut is being made, begin to close both the clamp and accumulating arms around the tree.

Immediately after the cut is complete, close the clamp arm(s) tightly. This will transfer the severed tree into the back of the log storage pocket making room for additional trees.

IMPORTANT! Do not clamp the tree until after the cut is complete.

IMPORTANT! Do not hold the clamp arm control switch in the close position once the tree is pulled into the log storage pocket. This will cause the hydraulic oil temperature to rise and result in hydraulic component wear.

9. To avoid stalling the blade on the stump, raise the felling head as soon as the cut is complete.

NOTE: If stalling does occur part way through the cut, do not move or tilt the head up or down to pry it loose, this could damage the head or bend the blade. Pull the blade straight back out of the cut and allow the blade to reach full rotational speed before continuing to cut.

2.8

Tigercat Bunching and Felling Saws

Operating Instructions

WARNING Do not leave the operator's cab until the partially cut tree has been felled TO ACCUMULATE ADDITIONAL TREES IN THE LOG STORAGE POCKET: 1. Close accumulating arm(s) and hold first tree in pocket. Completely open clamp arm(s) and position felling head in front of the next tree.

2. Cut second tree and close clamp arm(s).

3. Open the accumulating arm(s). The accumulating arm(s) will slide out from between the first and second tree. Close accumulating arm(s) to hold both trees in the pocket.

4. Fully open clamp arm(s) and proceed to third tree and repeat steps 11, 12, and 13 until pocket is full.

2.9

Operating Instructions

Tigercat Bunching and Felling Saws

FELLING TECHNIQUES – MODELS DT/DW5003, DT5301, DW5502, AND DW5603 A

B

SAW32

SAW30

3. Immediately after completion of cut, both sets of arms close on tree.

A Accumulating Arm B Clamp Arm

1. Open both clamp and accumulating arms. Advance to cut first tree.

SAW33

4. Hold first tree with accumulating arm, advance to cut second tree and close clamp arm.

SAW31

2. Cut continues and clamp arm begins to close on tree, immediately followed by accumulating arm.

2.10

Tigercat Bunching and Felling Saws

Operating Instructions

SAW34

5. With both trees held with clamp arm, withdraw accumulating arm.

SAW34

6. Hold two trees with accumulating arm, advance to cut third tree and close clamp arm. Repeat steps 4 and 5 until log pocket is full.

2.11

Operating Instructions

Tigercat Bunching and Felling Saws

FELLING TECHNIQUES – MODEL ST5401

A

A

B

SAW89 SAW87

A Clamp Arm B Accumulating Arm

3. Immediately after completion of cut, both sets of arms close on tree.

1. Open both clamp and accumulating arms. Advance to cut first tree.

SAW90

4. Hold first tree with accumulating arm, advance to cut second tree and close clamp arms.

SAW88

2. Cut continues and clamp arms begins to close on tree, immediately followed by accumulating arm.

2.12

Tigercat Bunching and Felling Saws

Operating Instructions

SAW91

5. With both trees held with clamp arms, withdraw accumulating arm.

SAW92

6. Hold two trees with accumulating arm, advance to cut third tree and close clamp arms. Repeat steps 4 and 5 until accumulation area is full.

2.13

Operating Instructions

Tigercat Bunching and Felling Saws

FELLING TECHNIQUES – 5702 SERIES

A

A B B

SAW78 SAW76

A Clamp Arm B Accumulating Arm

3. Immediately after completion of cut, both sets of arms close on tree.

1. Open both clamp and accumulating arms. Advance to cut first tree.

SAW81

4. Hold first tree with accumulating arms, advance to cut second tree and close clamp arms.

SAW77

2. Cut continues and clamp arms begins to close on tree, immediately followed by accumulating arm.

2.14

Tigercat Bunching and Felling Saws

Operating Instructions

SAW82

5. With both trees held with clamp arms, withdraw accumulating arms.

SAW83

6. Hold two trees with accumulating arms, advance to cut third tree and close clamp arms. Repeat steps 4 and 5 until accumulation area is full.

2.15

Operating Instructions

Tigercat Bunching and Felling Saws

STOPPING THE SAW BLADE IN A BUSH CUTTING AREA To stop the blade from rotating, set engine speed at LOW idle. Turn OFF the saw switch and carefully lower the saw blade onto a stump. This should be done gently to prevent unnecessary loading of the saw blade, saw housing and bearings.

Do not let it free wheel, the saw blade will take several minutes to come to a complete stop.

IN A SHOP AREA

WARNING Before installing or removing saw blade guard or locking bolt, saw must be at a complete stop and engine must be turned OFF. Saw guard MUST BE INSTALLED when working on the saw motor hydraulic circuit or when the saw head is not being used.

Refer to individual procedures in THIS MANUAL for proper use of saw blade guard and locking bolt.

Set engine speed at LOW idle, wait (approximately 30 seconds) for saw blade to slow down sufficiently that a pressure of less than 500 psi shows on the pressure gauge. Turn OFF the saw and wait until the saw blade has stopped turning before turning OFF the engine. If the saw blade guard is not installed, cordon off the blade area to protect other personnel in the area.

WARNING Never leave a saw head unattended with the saw blade running, or the boom in the raised position. Always rest the felling head on the ground and stop the blade.

WARNING Never leave the operator's cab until the saw blade has stopped rotating.

WARNING Never turn OFF the engine until the saw blade has come to a complete stop.

2.16

Tigercat Bunching and Felling Saws

Service and Maintenance

PREVENTIVE MAINTENANCE SCHEDULE FOR TIGERCAT SAWS

START-UP OF A NEW SAW HEAD

NEW SAW MAINTENANCE PRE-DELIVERY INSPECTION Perform the pre-delivery inspection of the felling head in conjunction with the machine inspection according to the Tigercat inspection report for the applicable machine.

FIRST 125-HOUR INSPECTION AND SERVICE REPORT With the owner’s mechanic present, perform an inspection and service of the felling head in conjunction with the machine inspection and service according to the Tigercat inspection report for the applicable machine.

This must be completed within the first 125-hour time frame.

The following procedure should be performed whenever a new saw head is installed (or major maintenance has been done to a saw head). This procedure will ensure that the spindle bearings have been properly set before operating the saw under load. Refer also to SAW DRIVE, HYDRAULIC: HYDRAULIC SETUPS AND ADJUSTMENTS: START-UP PROCEDURE and WRIST ASSEMBLY - 340º: INITIAL START-UP PROCEDURE (if applicable).

DANGER Observe all safety precautions outlined in this manual and the MACHINE SERVICE MANUAL when performing this procedure.

1. Get the hydraulic oil up to operating temperature.

2. Park machine on firm level ground, lower felling head to the ground, engage parking brake or swing brake (as applicable) and turn OFF the engine.

Block wheels or tracks. Properly install the saw blade guard using all hardware provided. Guard must be secure.

IMPORTANT! To qualify for continued warranty, this report must be completed and returned to Tigercat Industries Inc. warranty department.

3. Check saw motor minimum displacement adjusting screw as follows: Note: This step applies only to saw heads with a variable-displacement motor where the saw blade speed has not yet been set. Fixed-displacement motors have no displacement screw. If your saw head is equipped with a fixed-displacement motor, proceed to step 4. a. Remove saw motor cover.

2.17

Service and Maintenance

Tigercat Bunching and Felling Saws WARNING

A

Never leave the operator's cab until the saw blade has stopped rotating.

WARNING Never turn OFF the engine until the saw blade has come to a complete stop.

4. Clear area under saw of all loose dirt, stones, wood and debris.

5. Raise saw head 6" off the ground and position wrist in the vertical plane (if applicable).

B C

6. Warn all persons to stay clear of the area, especially the discharge side of saw head.

7. Start engine and set engine speed at LOW idle.

8. Turn ON the saw switch.

9. Run saw with engine speed at LOW idle for 10 minutes.

SAW-D01 DIM X

10. Slowly increase engine speed to HIGH idle.

Front View of Motor

A Port M B Minimum Displacement Adjusting Screw C Setup Dimension for Minimum Displacement Adjusting Screw

b. Remove the minimum displacement adjusting screw from the side of the motor housing and measure its length. c.

Reinstall the minimum displacement adjusting screw and locknut into the motor housing and set dimension C to 9.5 mm (160cc motor) 13 mm (170cc motor) for a 110 mm screw. For a longer screw, measure the length of the screw and add the difference to dimension C. IMPORTANT! Do not set dimension C less then 9.5 mm (160cc motor) 13 mm (170cc motor).

Screw failure will occur and damage to the saw motor will result. Pump displacement will require adjustment if the max blade speed specification cannot be attained at that setting.

d. Reinstall saw motor cover.

DANGER Carry out this procedure with care. Make sure that there are no chips or blocks of wood remaining in the saw housing that could be thrown by the rotating blade.

11. Run saw with engine at HIGH idle for 10 minutes.

12. Check spindle housing temperature. Spindle bearing housing should be roughly the same as hydraulic oil temperature or less. Maximum temperature should not be higher than 82°C (180°F). If temperature is too high turn OFF the saw following STOPPING THE SAW BLADE in this section. Allow the saw spindle housing to cool then check saw drive spindle assembly end play (as per PDI), check spindle and bearing lubrication and check vent fittings for proper operation. Refer also to SAW DRIVE SPINDLE ~ CHECKING SAW DRIVE SPINDLE HOUSING TEMPERATURE in this section for more information.

Return to step 6. If spindle housing temperature is acceptable proceed to step 13.

13. Set engine speed at LOW idle. Wait for blade to slow down, then turn OFF the saw and wait for blade to come to a complete stop before turning OFF the engine.

14. Allow spindle bearings to cool before operating the saw under load.

15. Spindle bearings are now properly seated.

16. Continue with hydraulic setup and initial start procedures. Refer also to SAW DRIVE, HYDRAULIC: HYDRAULIC SETUPS AND ADJUSTMENTS and WRIST ASSEMBLY - 340º: INITIAL START-UP PROCEDURE (if applicable).

2.18

Tigercat Bunching and Felling Saws

Service and Maintenance

SCHEDULED MAINTENANCE

EVERY WEEK • Perform daily service and in addition:

EVERY DAY

• Remove drive motor guard and inspect for debris build up around motor. Remove debris and replace guard.

• Check saw tooth condition and rotate or replace teeth as necessary.

• Check for damage to saw blade.

• Inspect saw housing for wear. If a problem is found corrective action should be taken immediately.

Repair or replace excessively worn wear liners or wear pads. The wear pad at the saw blade inlet must be maintained to minimize blade and housing wear and possible circulation of large debris.

• Check spindle end play (0.003" - 0.005").

• Check tooth retaining bolt torques.

• Check saw blade bolt torques.

• Check butt plate bolt torques, where applicable.

• Lubricate clamp arms, accumulator arms, cylinders and links as applicable to saw model. See lubrication chart for number of fittings, purge* • Lubricate upper and lower saw drive spindle bearings (at operating temperature): 2-fittings, one shot of grease for every hour of operation at each fitting.

IMPORTANT! Use a manual grease gun to prevent damage to seal*.

WARNING The wear liners in the saw housing must be maintained to prevent perforation of the saw housing and possible uncontrolled discharge of debris.

EVERY 175 HOURS • Perform daily and WEEKLY service and in addition: • Lubricate spindle spline adapter. 1-fitting, eight shots*

• Lubricate wrist bearing, cylinders and gears where applicable.

• Lubricate upper and lower saw drive spindle bearings (at operating temperature):

• Lubricate tilt cylinder and boom attachment points.

Refer to MACHINE SERVICE MANUAL.

2-fittings, until grease purges from vent (relief) fittings.

CAUTION

EVERY 500 HOURS

When lubricating the upper and lower saw drive spindle bearings, Use a manual grease gun to prevent damage to seal, NEVER use a power grease gun.

• Perform daily, weekly and 175-hour service and in addition: • Check saw blade speed.

• Check all hydraulic pressures.

• Inspect saw and boom attachment for damage and repair as necessary.

WARNING Pay attention to all safety instructions outlined in section 1 of this manual.

*Use lithium-based EP2 grease containing 3 – 5 % molybdenum disulfide.

Wear safety gloves at all times when handling and working around the saw blade.

Use recommended safety stands and devices when called for.

Always block wheels or tracks of machine.

Work on solid ground.

2.19

Service and Maintenance

Tigercat Bunching and Felling Saws

LUBRICATION Refer to the SCHEDULED MAINTENANCE and the following charts and illustrations to determine frequency and location of lubrication points.

ITEM

EVERY DAY

EVERY 175 HOURS

LUBRICATION SCHEDULE FOR Tigercat® SAW MODELS DW5003, DW5502, AND DW5603

1 2 3 4 5

LUB LUB LUB LUB LUB

CLAMP ARM CLAMP ARM CYLINDER ACCUMULATING ARM ACCUMULATING ARM CYLINDER LUB SAW DRIVE UPPER SPINDLE BEARING

3 2 3† 2 1 WITH 1 VENT FITTING

6

LUB

LUB SAW DRIVE LOWER SPINDLE BEARING

1 WITH 1 VENT FITTING

7

DESCRIPTION

NUMBER OF LUB. FITTINGS

REMARKS / LUBRICANT PURGE* THE OUTER ACCUMULATING ARM PIVOT MAY BE LUBRICATED AT EITHER THE TOP OR BOTTOM FITTIMG.† LUBRICATE* AT OPERATING TEMPERATURE. USE A MANUAL GREASE GUN TO PREVENT DAMAGE TO THE SEAL. DO NOT USE POWER GREASE GUNS. DAILY: 1 SHOT FOR EVERY HOUR OF OPERATION EVERY 175: UNTIL GREASE PURGES FROM VENT FITTING

LUB SPINDLE SPLINE ADAPTER 1 8 SHOTS* *LITHIUM-BASED EP2 GREASE CONTAINING 3–5 % MOLYBDENUM DISULFIDE

LUBDW5000-5500-5600.XLSX

2.20

Tigercat Bunching and Felling Saws

3

A

3

A00371

3

Service and Maintenance

4

4

1

7 B SAWPLT

Underside of Blade

1 2 1 F A00372

power clip applied to grouped object C

D

C

D

2 5 6

E

E

2 6

A00373

5

A00374

Grease Fitting Bulkhead– Model DW5603

Grease Fitting Bulkhead– Models DW5003 and DW5502

A00370

Lubrication Points– Models DW5003, DW5502, and DW5603

A Vent Fitting, Upper Clamp Arm Bushing B Plug C Saw Motor

D Vent Fitting, Upper Spindle Bearing E Vent Fitting, Lower Spindle Bearing F Vent Fitting, Lower Clamp Arm Bushing

2.21

Service and Maintenance

Tigercat Bunching and Felling Saws

ITEM

EVERY DAY

EVERY 175 HOURS

LUBRICATION SCHEDULE FOR Tigercat® SAW MODELS DT5003 AND DT5301

1 2 3 4 5

LUB LUB LUB LUB LUB

CLAMP ARM CLAMP ARM CYLINDER ACCUMULATING ARM ACCUMULATING ARM CYLINDER LUB SAW DRIVE UPPER SPINDLE BEARING

3 2 3† 2 1 WITH 1 VENT FITTING

6

LUB

LUB SAW DRIVE LOWER SPINDLE BEARING

1 WITH 1 VENT FITTING

7 8 9 10 11 12

LUB LUB LUB LUB LUB

NUMBER OF LUB. FITTINGS

DESCRIPTION

REMARKS / LUBRICANT PURGE* THE OUTER ACCUMULATING ARM PIVOT MAY BE LUBRICATED AT EITHER THE TOP OR BOTTOM FITTIMG.† LUBRICATE* AT OPERATING TEMPERATURE. USE A MANUAL GREASE GUN TO PREVENT DAMAGE TO THE SEAL. DO NOT USE POWER GREASE GUNS. DAILY: 1 SHOT FOR EVERY HOUR OF OPERATION EVERY 175: UNTIL GREASE PURGES FROM VENT FITTING

LUB SPINDLE SPLINE ADAPTER 1 8 SHOTS* WRIST BEARING (TIGERCAT 30°) 4 PURGE* WRIST BEARING (KW) 4 PURGE* WRIST CYLINDER 2 PURGE* WRIST BEARING (340°) 3 4 SHOTS* EVERY 45° STOP-TO-STOP WRIST PINIONS (340°) 3 10 SHOTS* AT EACH FITTING *LITHIUM-BASED EP2 GREASE CONTAINING 3–5 % MOLYBDENUM DISULFIDE

LUBDT5000-5300.XLSX

12

12

11

WRIST-100

12

A

A

SAW-175A

340° Wrist Lubrication

2.22

Tigercat Bunching and Felling Saws

Service and Maintenance

power clip applied to grouped object

power clip applied to grouped object A

8

9

10 10

3 8

4 3

9

3 4

A00379

1

8

A00380

9

8

9

power clip applied to grouped object 2

1

A00378

1

C

B

D

6

7

5

F

2

SAWPLT

Underside of Blade A00381

E

A00377

Lubrication Points– Models DT5003 and DT5301

A Vent Fitting, Upper Clamp Arm Bushing B Vent Fitting, Lower Clamp Arm Bushing C Saw Motor

D Vent Fitting, Upper Spindle Bearing E Vent Fitting, Lower Spindle Bearing F Plug

2.23

Service and Maintenance

Tigercat Bunching and Felling Saws

ITEM

EVERY DAY

EVERY 175 HOURS

LUBRICATION SCHEDULE FOR Tigercat® SAW MODEL ST5401

1 2 3 4 5 6

LUB LUB LUB LUB LUB LUB

CLAMP ARMS CLAMP ARMS CYLINDER CLAMP ARMS LINK ACCUMULATING ARM ACCUMULATING ARM CYLINDER LUB SAW DRIVE UPPER SPINDLE BEARING

3 2 2 3† 2 1 WITH 1 VENT FITTING

7

LUB

LUB SAW DRIVE LOWER SPINDLE BEARING

1 WITH 1 VENT FITTING

8

LUB SPINDLE SPLINE ADAPTER 1 8 SHOTS* WRIST BEARING (30°) 4 PURGE* WRIST BEARING (110°) 4 PURGE* LUB WRIST BEARING (340°) 3 4 SHOTS* EVERY 45° STOP-TO-STOP WRIST CYLINDER (30°) 2 LUB PURGE* WRIST CYLINDERS (110°) 4 LUB WRIST PINIONS (340°) 3 10 SHOTS* AT EACH FITTING *LITHIUM-BASED EP2 GREASE CONTAINING 3–5 % MOLYBDENUM DISULFIDE

9 10 11

NUMBER OF LUB. FITTINGS

DESCRIPTION

REMARKS / LUBRICANT PURGE* THE OUTER ACCUMULATING ARM PIVOT MAY BE LUBRICATED AT EITHER THE TOP OR BOTTOM FITTIMG.† LUBRICATE* AT OPERATING TEMPERATURE. USE A MANUAL GREASE GUN TO PREVENT DAMAGE TO THE SEAL. DO NOT USE POWER GREASE GUNS. DAILY: 1 SHOT FOR EVERY HOUR OF OPERATION EVERY 175: UNTIL GREASE PURGES FROM VENT FITTING

LUBST5400.XLSX

12

12

9

WRIST-100

12

A

A

SAW-175A

340° Wrist Lubrication

2.24

Tigercat Bunching and Felling Saws

Service and Maintenance

A

SAW98

7

6

Saw Drive Spindle Bearings

1 3

A SAW97A

2 2

8

1 4 B

A

SAWPLT

Underside of Blade

4

SAW100A

5

5

1

Clamp and Accumulating Arms 9 10

9 10 9 10

9

9

10

9 10 9 SAW138

SAW98

110° Wrist Lubrication

30° Wrist Lubrication

A Lower Vent Fitting

Lubrication Points– Model ST5401 B Plug

2.25

Service and Maintenance

Tigercat Bunching and Felling Saws

ITEM

EVERY DAY

EVERY 175 HOURS

LUBRICATION SCHEDULE FOR Tigercat® SAW MODEL ST5702

1 2 3 4 5 6 7

LUB LUB LUB LUB LUB LUB LUB

CLAMP ARMS CLAMP ARMS CYLINDER CLAMP ARMS LINK ACCUMULATING ARMS ACCUMULATING ARMS CYLINDER ACCUMULATING ARMS LINK LUB SAW DRIVE UPPER SPINDLE BEARING

3 2 2 7† 2 2 1 WITH 1 VENT FITTING

8

LUB

LUB SAW DRIVE LOWER SPINDLE BEARING

1 WITH 1 VENT FITTING

9

LUB SPINDLE SPLINE ADAPTER 1 8 SHOTS* WRIST BEARING (30°) 4 PURGE*. VARY WRIST POSITION TO WRIST BEARING (110°) 4 LUB ENSURE FULL RACE LUBRICATION. WRIST BEARING (340°) 3 WRIST CYLINDER (30°) 2 LUB PURGE* WRIST CYLINDERS (110°) 4 LUB WRIST PINIONS (340°) 3 10 SHOTS* AT EACH FITTING *LITHIUM-BASED EP2 GREASE CONTAINING 3–5 % MOLYBDENUM DISULFIDE

10 11 12

NUMBER OF LUB. FITTINGS

DESCRIPTION

REMARKS / LUBRICANT

PURGE* THE OUTER ACCUMULATING ARM PIVOT MAY BE LUBRICATED AT EITHER THE TOP OR BOTTOM FITTIMG.† LUBRICATE* AT OPERATING TEMPERATURE. USE A MANUAL GREASE GUN TO PREVENT DAMAGE TO THE SEAL. DO NOT USE POWER GREASE GUNS. DAILY: 1 SHOT FOR EVERY HOUR OF OPERATION EVERY 175: UNTIL GREASE PURGES FROM VENT FITTING

LUBST5702.XLSX

10

11 10 WRIST-100

A

12 11 10

12

10

A 11 SAW138

SAW-175A

110° Wrist Lubrication

340° Wrist Lubrication

2.26

Tigercat Bunching and Felling Saws

Service and Maintenance

A

B 7

SAW-189A

A SAW-188A

7

A

8 9

B SAW190

Saw Drive Spindle Bearings

B

C SAWPLT

Underside of Blade

A 2

3

11

1 1

10

6

4 5

10

A00403

Clamp and Accumulating Arms

SAW-189

30° Wrist Lubrication A Upper Vent Fitting (Behind Cover) B Lower Vent Fitting

Lubrication Points– Model ST5702 C Plug

2.27

4

Service and Maintenance

Tigercat Bunching and Felling Saws

ITEM

EVERY DAY

EVERY 175 HOURS

LUBRICATION SCHEDULE FOR Tigercat® SAW MODEL ST5702-26

1 2 3 4 5 6 7

LUB LUB LUB LUB LUB LUB LUB

CLAMP ARMS CLAMP ARMS CYLINDER CLAMP ARMS LINK ACCUMULATING ARMS ACCUMULATING ARMS CYLINDER ACCUMULATING ARMS LINK LUB SAW DRIVE UPPER SPINDLE BEARING (REAR GREASE FITTING)

3 2 2 7† 2 2 1 WITH 1 VENT FITTING

8

LUB

LUB SAW DRIVE LOWER SPINDLE BEARING (FRONT GREASE FITTING)

1 WITH 1 VENT FITTING

9 10

LUB

11

NUMBER OF LUB. FITTINGS

DESCRIPTION

LUB SPINDLE SPLINE ADAPTER WRIST BEARING (340°)

REMARKS / LUBRICANT

PURGE* THE OUTER ACCUMULATING ARM PIVOT MAY BE LUBRICATED AT EITHER THE TOP OR BOTTOM FITTIMG.† LUBRICATE* AT OPERATING TEMPERATURE. USE A MANUAL GREASE GUN TO PREVENT DAMAGE TO THE SEAL. DO NOT USE POWER GREASE GUNS. DAILY: 1 SHOT FOR EVERY HOUR OF OPERATION EVERY 175: UNTIL GREASE PURGES FROM VENT FITTING

1 3

8 SHOTS* PURGE*. VARY WRIST POSITION TO ENSURE FULL RACE LUBRICATION. LUB WRIST PINIONS (340°) 3 10 SHOTS* AT EACH FITTING *LITHIUM-BASED EP2 GREASE CONTAINING 3–5 % MOLYBDENUM DISULFIDE

LUBST5702-26.XLSX

11

11

10

WRIST-100

11

A

A

SAW-175A

340° Wrist Lubrication

2.28

Tigercat Bunching and Felling Saws

Service and Maintenance

A

A

8

7

9 2

B

3

A

SAWPLT

Underside of Blade

1 1

6

4 5 A00403

Clamp and Accumulating Arms

SAW-192 SAW-191A

Lubrication Points– Model ST5702-26

A Upper and Lower Vent Fittings (Spindle Bearings)

B Plug

2.29

4

Service and Maintenance

Tigercat Bunching and Felling Saws

ITEM

EVERY DAY

EVERY 175 HOURS

LUBRICATION SCHEDULE FOR Tigercat® SAW MODEL SW5702

1 2 3 4 5 6 7

LUB LUB LUB LUB LUB LUB LUB

CLAMP ARMS CLAMP ARMS CYLINDER CLAMP ARMS LINK ACCUMULATING ARMS ACCUMULATING ARMS CYLINDER ACCUMULATING ARMS LINK LUB SAW DRIVE UPPER SPINDLE BEARING

3 2 2 7† 2 2 1 WITH 1 VENT FITTING

8

LUB

LUB SAW DRIVE LOWER SPINDLE BEARING

1 WITH 1 VENT FITTING

NUMBER OF LUB. FITTINGS

DESCRIPTION

REMARKS / LUBRICANT

PURGE* THE OUTER ACCUMULATING ARM PIVOT MAY BE LUBRICATED AT EITHER THE TOP OR BOTTOM FITTIMG.† LUBRICATE* AT OPERATING TEMPERATURE. USE A MANUAL GREASE GUN TO PREVENT DAMAGE TO THE SEAL. DO NOT USE POWER GREASE GUNS. DAILY: 1 SHOT FOR EVERY HOUR OF OPERATION EVERY 175: UNTIL GREASE PURGES FROM VENT FITTING

LUB SPINDLE SPLINE ADAPTER 1 8 SHOTS* *LITHIUM-BASED EP2 GREASE CONTAINING 3–5 % MOLYBDENUM DISULFIDE

9

LUBSW5700.XLSX

2

3 1

A SAW101A

1

6

9

4 A

5

A

SAWPLT

A Plug

Underside of Blade

A00403

Clamp and Accumulating Arms

2.30

4

Tigercat Bunching and Felling Saws

Service and Maintenance

A

B

7 8

A

B SAW190

B

A00366

Saw Spindle Lubrication– Model SW5702

A Upper Vent Fitting (Behind Cover) B Lower Vent Fitting

2.31

Service and Maintenance

Tigercat Bunching and Felling Saws

TORQUE CHART LOCATION Saw Blade Mounting bolts Motor Mounting bolts Mounting cap bolts Pin retaining bolts All Lower Guard/Ski Retaining bolts Retaining bolts Retaining bolts Retaining bolts Retaining bolts Retaining bolts Wrist cylinder, 30° and 110° rotation Pin retainer bolts Wrist - 30° and 110° rotation Bearing to felling head bolts Bearing to boom adapter locknuts Wrist - 340° rotation Bearing to head bolts Bearing to boom adapter bolts High torque motor to boom adapter bolts Output shaft assy to boom adapter bolts Std. torque motor to output shaft assy bolts

SAW SERIES

THREAD DIAMETER

ALL

TORQUE (LUBRICATED)

NOTES

lbf-ft

Nm

3/4"-16 UNF GR.8

280-320

380-434

Use anti-seize.

ALL ALL

3/4"-10 UNC GR.8 1/2"-13 UNC GR.8

200-220 80-85

271-298 108-115

Lubricated

As Applic.

3/4"-10 UNC GR.8 5/8"-11 UNC GR.8

200-220 160-175

271-298 217-237

Lubricated

160-175 280-310 280-310 280-310 280-310 280-310

217-237 380-420 380-420 380-420 380-420 380-420

Lubricated

280-310

380-420

Use anti-seize.

5000 5/8"-11 UNC GR.8 5300 3/4"-10 UNC GR.8 5400 3/4"-10 UNC GR.8 5500 3/4"-10 UNC GR.8 5600 3/4"-10 UNC GR.8 5702 3/4"-10 UNC GR.8 TRACK FELLER BUNCHERS ONLY 3/4"-10 UNC GR.8 1"-14 UNF GR.8 1 1/8"-12 UNF L9 3/4"-16 UNF GR.8 7/8"-14 UNC GR.8 5/8"-11 UNC GR. 8 5/8"-11 UNC GR. 8 1/2"-13 UNC GR. 8

SAW TORQUE CHART 2019.XLSX

2.32

670-690 908-936 Use anti-seize.

400 + half turn 1274-1302 Use anti-seize.

290-310 440-460 160-175 160-175 80-85

393-420 596-624 217-237 217-237 108-115

Use anti-seize.

Use anti-seize.

Use anti-seize.

Use anti-seize.

Lubricated

Tigercat Bunching and Felling Saws

Service and Maintenance

GENERAL TORQUE SPECIFICATIONS

The torque values listed below are for general use only.

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

IMPERIAL GRADE 8 BOLTS

GRADE 5 BOLTS

IMPERIAL BOLT TORQUE SPECIFICATIONS GRADE 8 BOLTS GRADE 5 BOLTS LUBRICATED lbf-ft Nm 8 - 10 11 - 13 20 - 28 27 - 38 33 - 36 45 - 49 52 - 57 71 - 77 80 - 88 109 - 119 115 - 127 156 - 172 159 - 175 216 - 237 282 - 310 393 - 420 455 - 501 617 - 679 682 - 750 925 - 1016 966 - 1062 1310 - 1441 1360 - 1496 1844 - 2027 LUBRICATED lbf-ft Nm 10 - 13 14 - 17 18 - 25 25 - 33 37 - 41 50 - 55 58 - 64 79 - 86 90 - 99 122 - 134 128 - 141 174 - 191 180 - 198 244 - 268 315 - 347 427 - 470 501 - 550 679 - 745 746 - 821 1012 - 1113 1083 - 1191 1469 - 1613 1509 - 1660 2046 - 2250 8.8

10.9

8.8

10.9

12.9

8.8

10.9

12.9

10

10

10

METRIC

10

DRY LUBRICATED COARSE THREAD lbf-ft Nm lbf-ft Nm 1/4" - 20 7- 8 10 - 11 8 - 10 11 - 13 5/16" - 18 14 - 18 19 - 24 10 - 15 13 - 20 3/8" - 16 31 - 34 42 - 46 23 - 25 31 - 34 7/16" - 14 49 - 54 66 - 73 37 - 41 50 - 55 1/2" - 13 75 - 83 102 - 112 57 - 63 77 - 85 9/16" - 12 109 - 120 148 - 162 82 - 90 111 - 122 5/8" - 11 150 - 165 204 - 223 113 - 124 152 - 168 3/4" - 10 266 - 293 360 - 397 200 - 220 271 - 298 7/8" - 9 394 - 433 535 - 586 296 - 326 402 - 441 1" - 8 591 - 649 802 - 879 443 - 489 601 - 663 1 1/8" - 7 794 - 873 1077 - 1183 596 - 656 808 - 889 1 1/4" - 7 1120 - 1232 1519 - 1670 840 - 924 1139 - 1252 FINE DRY LUBRICATED lbf-ft Nm lbf-ft Nm THREAD 1/4" - 28 9 - 10 12 - 13 9 - 10 12 - 13 5/16" - 24 17 - 22 23 - 29 16 - 20 21 - 27 3/8" - 24 35 - 39 48 - 53 26 - 29 35 - 39 7/16" - 20 55 - 61 75 - 83 41 - 45 56 - 61 1/2" - 20 85 - 94 116 - 127 64 - 70 87 - 95 9/16" - 18 121 - 133 164 - 180 91 - 100 124 - 135 5/8" - 18 170 - 187 231 - 253 128 - 141 174 - 191 3/4" - 16 297 - 327 403 - 443 223 - 245 303 - 332 7/8" - 14 434 - 477 589 - 646 326 - 359 442 - 486 1" - 12 646 - 711 876 - 965 484 - 534 657 - 724 1 1/8" - 12 891 - 980 1208 - 1328 668 - 735 906 - 996 1 1/4" - 12 1240 - 1364 1682 - 1849 931 - 1024 1262 - 1387 12.9

10

12.9

12.9

12

12

DRY lbf-ft Nm 11 - 12 15 - 16 26 - 30 35 - 40 44 -48 60 - 65 70 - 77 95 - 104 106 - 117 144 - 158 153 - 168 208 - 228 212 - 233 288 - 316 376 - 414 510 - 561 606 - 667 822 - 904 909 - 1000 1233 - 1355 1288 - 1417 1746 - 1921 1817 - 1999 2464 - 2710 DRY lbf-ft Nm 13 - 14 18 - 19 23 - 28 31 - 38 49 - 54 67 - 73 78 - 86 106 - 116 120 - 132 163 - 179 171 - 188 232 - 255 240 - 264 326 - 358 420 - 462 570 - 626 668 - 735 906 - 996 995 - 1096 1359 - 1486 1445 - 1590 1960 - 2155 2012 - 2213 2728 - 2997

10

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

12

METRIC BOLT TORQUE SPECIFICATIONS CLASS 8.8

SIZE PITCH LUBRICATED mm Nm 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 Nm lbf-ft Nm lbf-ft Nm 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 - 253 324 - 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

2.33

CLASS 12.9 LUBRICATED DRY Nm lbf-ft Nm 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

Service and Maintenance

SAW BLADE LOCK PIN WARNING Pay attention to all safety instructions outlined in section 1 of this manual.

Tigercat Bunching and Felling Saws PROCEDURE 1. Turn OFF the saw and allow saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade is stopped.

Wear safety gloves at all times when handling and working around the saw blade.

Use recommended safety stands and devices when called for.

Always block wheels or tracks of machine.

Work on solid ground.

CAUTION DO NOT use this blade lock pin for any hydraulic pressure or blade speed adjustments. The saw blade guard and locking bolt are to be used for any hydraulic pressure or blade speed adjustments. Refer to SAW BLADE GUARD AND LOCKING BOLT in this section.

The saw blade lock pin must be used for all maintenance procedures requiring access to the exposed portion of the blade and teeth, such as saw tooth replacement and saw tooth sharpening. Before using the saw blade lock pin turn OFF the engine, the saw blade must have come to a complete stop and the felling head must be supported.

For all other maintenance procedures install the saw blade guard and locking bolt. Refer to SAW BLADE GUARD AND LOCKING BOLT in this section.

SAW38

2. Park the machine on firm level ground. Block the wheels or tracks. Engage the parking brake or swing brake. Position the saw head vertically on devices strong enough to support its weight.

For in-woods maintenance, position the felling head with the base of the head supported on firm level ground. Tilt the head back slightly to allow access to the exposed portion of the blade and teeth.

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Ensure the saw blade has come to a complete stop.

STORAGE LOCATION FOR SAW BLADE LOCK PIN TIGHTEN BOLT TO SECURE LOCK PIN IN STORAGE LOCATION.

SEE SAW OPERATING AND SERVICE MANUAL FOR INSTRUCTIONS.

A B SAW145

Typical Saw Blade Lock Pin Storage Location

A Saw Blade Lock Pin B Bolt

5. Remove the saw blade lock pin from its storage location.

2.34

Tigercat Bunching and Felling Saws

Service and Maintenance

SAW BLADE GUARD AND LOCKING BOLT

A

The saw blade guard and locking bolt are to be used for maintenance procedures which do not require access to the exposed portion of the blade and teeth. The saw blade guard and locking bolt are used for any hydraulic pressure or blade speed adjustment procedures.

B

STORAGE LOCATION FOR SAW BLADE LOCK PIN TIGHTEN BOLT TO SECURE LOCK PIN IN STORAGE LOCATION.

SEE SAW OPERATING AND SERVICE MANUAL FOR INSTRUCTIONS.

Before using the saw blade guard and locking bolt turn OFF the engine, the saw blade must have come to a complete stop and the felling head must be supported.

C

For all maintenance procedures which require access to the exposed portion of the blade and teeth the saw blade lock pin must be used. Refer to SAW BLADE LOCK PIN in this section.

D SAW146

A B C D

Typical Saw Blade Lock Pin Installation

PROCEDURE

Bolt Saw Blade Lock Pin Storage Location Slotted Inspection Cover

6. Install the saw blade lock pin in the slotted inspection cover. The saw blade may need to be rotated slightly to allow the pin to engage completely.

7. Bolt the saw blade lock pin securely into position with the same bolt provided to hold the pin in its storage location.

8. Perform the maintenance required on the exposed portion of the saw blade and teeth. Refer to specific maintenance procedures in this manual for further instructions and safety information.

1. Turn OFF the saw and allow saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade is stopped.

2. Park the machine on firm level ground. Block the wheels or tracks. Engage the parking brake or swing brake. Position the saw head vertically and supported on devices strong enough to withstand the weight of the saw head.

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Ensure the saw blade has come to a complete stop.

9. Remove the saw blade lock pin from the slotted inspection cover and carefully rotate the saw blade to expose a different section of blade.

10. Install the saw blade lock pin in the slotted inspection cover, slightly rotate the blade for full engagement and fasten securely into position.

11. Perform the maintenance on this portion of the saw blade.

12. Continue to repeat steps 9, 10, and 11 until all maintenance is completed on the saw blade.

A B

SAW63

Blocking the Saw Blade

13. Remove the saw blade lock pin from the slotted inspection cover and install in the storage location.

A Locking Bolt B Saw Blade Guard

14. Bolt the saw blade lock pin securely in the storage location.

5. Install the saw blade guard and block the saw blade rotation using the locking bolt provided.

6. Perform the maintenance required. Refer to specific maintenance procedures in this manual for further instructions and safety information.

2.35

Service and Maintenance

Tigercat Bunching and Felling Saws

SAW BLADES BLADE IDENTIFICATION Saw blades can be identified by the blade part number and the blade serial number.

SERIES NUMBER The first two digits of the blade serial number represent the blade series number. The first digit is the blade kerf.

The second digit identifies the blade profile.

First Digit– Blade Kerf 1 = Wide kerf (2 5⁄16") 2 = Narrow kerf (1 7⁄8") 7 = Wide kerf shankless (2 1⁄4") Second Digit– Blade Profile 3 = Centred web 4, 5, or 6 = Offset web

A B

A00367

Locations of Blade Identification Numbers

A Serial Number B Part Number

A

B SAW74

Blade Profiles

A Centred Web: Second Digit = 3 B Offset Web: Second Digit = 4, 5, or 6

2.36

Tigercat Bunching and Felling Saws

Service and Maintenance

INSPECTING THE SAW BLADE

IMPORTANT! Do not perform any welding on the saw blade or saw teeth.

The saw blade should be inspected at the same time as the teeth. Special attention should be paid to tooth holders which hold excessively worn or damaged teeth.

Daily inspection of the blade and teeth is normally done with the blade installed on the saw and the teeth installed on the blade. As a result some surfaces are not visible for inspection. A more thorough inspection of the entire blade and/or teeth should always be done whenever a blade or tooth is removed as a result of performing any service or maintenance procedure.

1. Turn OFF the saw and allow saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade is stopped.

2. Park the machine on firm level ground. Block the wheels or tracks. Engage the parking brake or swing brake. Position the saw head vertically on devices strong enough to support its weight.

For in-woods maintenance, position the felling head with the base of the head supported on firm level ground. Tilt the head back slightly to allow access to the exposed portion of the blade and teeth.

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Ensure the saw blade has come to a complete stop.

5. If the saw you are working on is equipped with a saw blade lock pin, install the pin and make sure it is secure. Refer to SAW BLADE LOCK PIN in this section for instructions on the proper use of this safety device.

SAW-P03 SAW-D11

Inspecting the Blade for Cracks and Wear

CAUTION Wear gloves and keep fingers clear of rotating blade and pinch points. A slowly rotating blade has enough stored energy to crush and cut hands or fingers.

6. Inspect the saw blade for cracks in the areas indicated by the arrows. If any cracks are found the blade must be replaced immediately.

7. Inspect the blade for signs of excessive wear in the areas indicated by the arrows.

Where wear is observed, determine the severity using the following chart and wear location illustrations. They specify wear limits for both widekerf blades and narrow-kerf blades. These limits apply to all Tigercat series 13, 14, 24, 26, 74, 75, and 76. Inspect with special care tooth holders when excessively worn or damaged teeth are found.

If blade wear is greater than the specified limit, replace the blade immediately.

2.37

Service and Maintenance

Tigercat Bunching and Felling Saws

BLADE WEAR LIMITS SERIES NUMBER 13 14 24 26 0.190" 0.190" 0.190" 0.190" 1.40" 1.40" 1.25" 1.25" 0.5" 0.375" 0.375" 0.5" 0.80"

WEAR LOCATION A B C D

BLADE WEAR LIMITS – LOCATION C 74, 75, 76 0.25" 1.40" 0.375"

C

WEARLIMITS.XLSX

8. Inspect blade for correct blade runout. Refer to CHECK BLADE RUNOUT in this section.

SAW114

Series 13

C ♦

SAW115

C

Series 14 and 24

A

C B

A A

SAW113

Blade Wear Limits– Locations A – C

♦ Important: This face must be flat for proper tooth seating.

SAW141

1

2

D

3

Series 26

C

4

2

SAW142

Series 74

SAW140

1 2 3 4

Butt Plate Wear Tooth Saw Blade

Blade Web Wear – Location D

C

SAW194

Series 75 and 76

2.38

Tigercat Bunching and Felling Saws

Service and Maintenance

CHECKING THE BLADE RUNOUT 1. Turn OFF the saw and allow saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade is stopped.

2. Park the machine on firm level ground. Block the wheels or tracks. Engage the parking brake or swing brake. Position the saw head vertically on devices strong enough to support its weight. (When the head is vertical, the saw blade is horizontal.)

For in-woods maintenance, position the felling head with the base of the head supported on firm level ground. Tilt the head back slightly to allow access to the exposed portion of the blade and teeth.

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Ensure the saw blade has come to a complete stop.

5. If the saw you are working on is equipped with a saw blade lock pin, install the pin and make sure it is secure. Refer to SAW BLADE LOCK PIN in this section for instructions on the proper use of this safety device.

SAW-P09

Using a Dial Indicator to Measure the Blade Runout

9. In addition, use a dial indicator to measure blade runout: a. Place the dial indicator on the saw butt plate. b. Zero the dial indicator and rotate the blade by hand.

10. Runout should not exceed 0.100". If it exceeds this figure, check for: a. A bent or distorted blade b. Excessive spindle end play causing vertical blade movement. Refer to spindle end play in this section.

SAW42

Checking the Blade for Runout

CAUTION Wear gloves and keep fingers clear of rotating blade and pinch points. A slowly rotating blade has enough stored energy to crush and cut hands or fingers.

6. Grasp the blade and move it up and down.

7. Remove the saw blade lock pin.

8. Rotate the blade by hand to check that it rotates freely without runout.

2.39

Service and Maintenance

Tigercat Bunching and Felling Saws

SAW BLADE REMOVAL DANGER Observe all safety precautions outlined in this manual when performing this service procedure.

NOTE: Also see SAW BLADE REMOVAL – ALTERNATIVE METHOD FOR TRACK FELLER BUNCHERS in this section.

1. Turn OFF the saw and allow the saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade is stopped.

CAUTION Wear gloves and keep fingers clear of rotating blade and pinch points. A slowly rotating blade has enough stored energy to crush and cut hands or fingers.

5. Rotate the saw blade until two of the 1" tapped holes in the blade line up with the two holes in the base of the saw housing.

A

SAW36B

Parking a Wheeled Machine

C

D

E

SAW44

A B C D E

B

Threaded Rod for Blade Removal

Threaded Rod Nut Washer Spacer 475 mm (18 in.)

6. Using Tigercat toolkit 59495A, thread a 1"- 8 UNC nut, washer and a spacer on the end of each threaded rod.

SAW43A

Threading the Rods into the Saw Blade

SAW84A

Parking a Tracked Machine

2. Park the machine on firm level ground. Block the wheels or tracks. Engage the parking brake or swing brake. Position the saw head vertically on the ground.

7. Insert the rods into the two holes in the saw head base and thread the rods at least 50 mm (2") into the saw blade.

NOTE: The illustration above applies to saw models DT/DW5003 and DW5603. The location is similar on models DT5301, ST5401, DW5502, and series 5702.

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Ensure the saw blade has come to a complete stop.

2.40

Tigercat Bunching and Felling Saws

Service and Maintenance NOTE: The saw blade is now supported only by the two threaded rods.

12. With felling head positioned 25-50 mm (1"- 2") above supports, lower the blade onto the support stands by turning the 1" nuts counterclockwise on the threaded rods. Make sure that the threaded rods do not turn out of the saw blade when unscrewing the nuts.

SAW43B

Threaded Rod in Position to Lower (or Raise) the Blade

If the blade does not release from the saw drive spindle after 2 or 3 turns of the nuts, it may be necessary to pry the blade loose at several different places around the blade.

8. Tighten the nuts down onto the saw base taking care not to let the threaded rod turn at the same time.

SAW39

SAW38

Backing away from the Saw Blade

Supports for Blade Removal– Wheeled Machine

13. Remove the wheel or track blocks and back the machine away from the saw blade.

14. After removal, inspect the teeth and blade as described in INSPECTING SAW TEETH and INSPECTING SAW BLADE in this section. Also check end of drive spindle for burrs or other damage.

SAW84B

Supports for Blade Removal– Tracked Machine

9. Turn the battery disconnect switch on, start the engine and place the felling head onto support stands or two blocks of wood on flat ground.

NOTE: Ensure the support stands are close enough together to support the blade after removal.

10. Raise felling head and remove any guarding that may interfere with removal of the saw blade from the underside of the felling head.

11. Remove the twelve socket head blade retaining bolts and remove the flange (if equipped).

2.41

Service and Maintenance

Tigercat Bunching and Felling Saws

SAW BLADE REMOVAL – ALTERNATIVE METHOD FOR TRACK FELLER BUNCHERS

A

DANGER Observe all safety precautions outlined in this manual when performing this service procedure.

B

1. Turn OFF the saw and allow the saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade is stopped.

C SAW105

2. Park machine on flat solid ground. Open clamp arms sufficiently to allow felling head to rest in a horizontal position. Tilt felling head forward 90° and rest on the ground.

3. Block tracks to prevent machine movement.

4. Stop engine and turn OFF the battery disconnect switch.

5. Remove all blade guards and skis to gain access to saw blade.

SAW 107

A Sling B Chain Hoist C 1" Eye Bolt

7. Place a sling over the stick boom as shown. Attach a chain hoist to the end of the sling and the end of the chain to the eye bolt.

CAUTION Use a suitable lifting device when removing the bottom flange, bottom flange is heavy.

8. Remove the blade retaining bolts and remove the bottom flange if fitted.

SAW106

A

A 1" Eye Bolt

6. Install a 1" eye bolt into one of the four tapped holes in the saw blade.

2.42

Tigercat Bunching and Felling Saws

Service and Maintenance SAW BLADE INSTALLATION USING THREADED RODS 1. Clean blade mounting surfaces on both the blade and the spindle. If a flange plate or spindle pilot adapter is being used this should also be cleaned.

2. Lubricate spindle contact surfaces with anti-seize compound.

3. With the blade resting on support stands, position the felling head over the blade and align the two large holes in the felling head base with the two tapped holes in the blade.

4. Thread a 1" nut and washer on each threaded rod.

5. Insert the rods into each of the two holes and thread the rods at least 50 mm (2") into the saw blade.

SAW108

6. Raise the blade by alternately tightening the nuts.

When the blade approaches the spindle, raise the felling head and guide the blade onto the pilot of the spindle.

CAUTION Saw blade is heavy, make sure that the blade is supported by the chain hoist before prying it loose from the drive spindle hub.

9. Use the hoist to remove the saw blade from the drive spindle hub, it may be necessary to pry the blade loose at several different places around the blade.

7. Line up the 12 holes in the blade with the tapped holes in the spindle. Always use new (12) 3/4" bolts, lubricate with anti-seize compound and install the bolts hand tight.

9

5

3

1

7

12

11

8 2

SAW64

4 6

10

Blade Bolt Tightening Sequence Showing Underside of Saw Blade

8. Tighten all 12 bolts evenly and in several stages to draw the blade up the spindle pilot and seat the blade. Torque bolts in stages: 1st to 1/2 torque, 2nd to 2/3 torque, and 3rd to full torque of 380-434 N-m (280-320 lbf-ft).

SAW109

10. Place the saw blade on support stands to facilitate inspection and possible maintenance.

CAUTION

11. Check condition of saw blade and saw teeth as described in INSPECTING SAW BLADE and INSPECTING SAW TEETH in this section.

Wear gloves and keep fingers clear of rotating blade and pinch points. A slowly rotating blade has enough stored energy to crush and cut hands or fingers.

12. Check condition of drive spindle hub, remove any burrs or scoring that might interfere with reinstallation of saw blade.

9. Slowly rotate the blade by hand and check for any interference with the butt plate, saw guard or housing.

2.43

Service and Maintenance

Tigercat Bunching and Felling Saws

SAW BLADE INSTALLATION USING A CHAIN HOIST AND SLING

CAUTION

1. Clean blade mounting surfaces on both the blade and the drive spindle hub. If a flange plate or spindle pilot adapter is being used this should also be cleaned.

2. Lubricate drive spindle contact surfaces with antiseize compound.

A

Wear gloves and keep fingers clear of rotating blade and pinch points. A slowly rotating blade has enough stored energy to crush and cut hands or fingers.

7. Slowly rotate the blade by hand and check for any interference with the butt plate, saw guard or housing.

B

SAW110

A Dowel Pin B Drive Spindle Hub

3. To assist with lining up the blade and drive spindle hub, thread two dowel pins (Tigercat part number 12083A) into two of the 3/4" threaded holes in the drive spindle hub flange.

4. Use the chain hoist to lift the blade off the support stands and place into position opposite the drive spindle hub.

5. Line up the dowel pins with two holes in the saw blade and install the saw blade on the drive spindle hub. Lubricate the twelve 3/4" saw blade retaining bolts with anti-seize compound and install the bolts hand tight, always use new bolts.

9

5

3

1

7

12

11

8 2

SAW64

4 6

10

Blade Bolt Tightening Sequence Showing Underside of Saw Blade

6. Tighten all 12 bolts evenly and in several stages to draw the blade onto the spindle pilot and seat the blade. Torque bolts in stages: 1st to 1/2 torque, 2nd to 2/3 torque, and 3rd to full torque of 380-434 N-m (280-320 lbf-ft).

2.44

Tigercat Bunching and Felling Saws

Service and Maintenance

INSPECTING THE SAW TEETH WARNING Failure to replace damaged or worn teeth will result in premature blade wear, poor cutting performance, blade cracks and a safety hazard and will void the blade warranty.

A

1. Turn OFF the saw and allow saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade is stopped.

2. Park the machine on firm level ground. Block the wheels or tracks. Engage the parking brake or swing brake. Position the saw head vertically on devices strong enough to support its weight. (When the head is vertical, the saw blade is horizontal.)

For in-woods maintenance, position the felling head with the base of the head supported on firm level ground. Tilt the head back slightly to allow access to the exposed portion of the blade and teeth.

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Ensure the saw blade has come to a complete stop.

B C SAW-P08

Tooth Wear Limits

8. Check for wear of the cutting edges of the teeth. The two cutting edges of the tooth should always be: A. At the furthest distance from the blade centre.

B. The widest point between the top and bottom of the tooth.

C. The blade width (B must be greater than C).

TOOTH WEAR LIMITS – DIMENSION B

5. If the saw you are working on is equipped with a saw blade lock pin, install the pin and make sure it is secure. Refer to SAW BLADE LOCK PIN in this section for instructions on the proper use of this safety device.

Series 13, 14 new tooth = 25⁄16" or 2⅜" replace at 2⅛" Series 24, 26 new tooth = 1⅞" or 115⁄16" replace at 1¾" Series 74, 75, 76 new tooth = 2½" replace at 2¼"

6. Check that tooth mounting bolts are torqued to specifications.

Tooth retaining bolt torque with anti-seize as follows: • ½" - 20 X 21⁄4" gr 8 = 115 N-m (85 lbf-ft) • ½" - 20 X 3" gr 8 = 115 N-m (85 lbf-ft) • ⅝" - 18 X 21⁄4" gr 8 = 217 N-m (160 lbf-ft) • 1" - 14 X 4½" gr 8 = 678 N-m (500 ft-lb) IMPORTANT! If tooth mounting bolts are found to be loose all saw teeth should be removed and inspected. Inspect teeth and blade for cracks, excessive wear or other damage. Replace all cracked, worn or damaged components.

NOTE: The teeth protect the saw blade from wear. Tooth wear limits are intended to ensure that only the cutting edge of the tooth comes in contact with the tree being cut. The rest of the tooth and blade should pass within the cut made by the cutting edge in order to reduce blade wear.

NOTE: There are numerous tooth options available.

Compare new tooth thickness to guidelines above for recommended replacement for best performance, fuel efficiency and saw blade life.

A

7. Check all teeth and blade for cracks, missing carbide tips or other damage. Replace damaged teeth promptly. Refer to REPLACING SAW TEETH in this section.

SAW-123

Carbide Tip Wear Limit

A Gap Between the Carbide

2.45

Service and Maintenance

Tigercat Bunching and Felling Saws

In addition, carbide tipped teeth should be replaced when wear extends as far as the body of the tooth at the tip, regardless of cutting edge position. Also, replace the tooth when the gap between the carbide is greater than 1/16".

If the wear is not too excessive the tooth may be rotated 180° in the housing. Refer to ROTATING SAW TEETH in this section.

If excessive wear has taken place the tooth must be replaced. Refer to REPLACING SAW TEETH in this section.

2.46

Tigercat Bunching and Felling Saws

Service and Maintenance

ROTATING SAW TEETH

Tooth retaining bolt torque with anti-seize as follows:

Saw teeth can be rotated 180° to extend the service life of the teeth.

• ½" - 20 X 21⁄4" gr 8 = 115 N-m (85 lbf-ft)

Normally all teeth are rotated at the same time.

• ⅝" - 18 X 21⁄4" gr 8 = 217 N-m (160 lbf-ft)

• ½" - 20 X 3" gr 8 = 115 N-m (85 lbf-ft) • 1" - 14 X 41⁄2" gr 8 = 542 N-m (400 ft-lb) IMPORTANT! Always check cutting edge clearance and blade balance after rotating teeth.

Teeth should be rotated when any one of the following conditions exist: • Tooth corners are chipped exposing the blade to wear.

• Cutting edges are dull or worn excessively exposing the rest of the tooth and blade to wear.

• Carbide tips broken off, missing or worn as far as the tooth body.

• Visible wear appears on the tooth mounting lug.

Refer to INSPECTING THE BLADE in this section for limits on acceptable blade wear.

• Any sign of excessive wear or damage which could result in an imbalance or unsafe operation of the blade. In cases of severe damage which may present a safety hazard, replacement of the tooth is recommended.

A

B

SAW41

Rotating Worn Teeth

A New Tooth B Worn Tooth Rotated 180°

Rotate teeth 180° as shown. Refer to REPLACING SAW TEETH in this section for information about removing and installing teeth.

2.47

Service and Maintenance REPLACING SAW TEETH CAUTION Two-piece or multi-piece teeth are not recommended for use on Tigercat saw blades.

These teeth can cause damage to the tooth holder of the blade which could cause the tooth to separate creating a safety hazard.

Use only the factory recommended teeth.

Tigercat Bunching and Felling Saws SAW TOOTH INSTALLATION

IMPORTANT! Do not re-use the original bolts.

1. Thoroughly clean all mating surfaces and remove any burrs that may be present before installing teeth.

Use fine emery paper on both the tooth shank and inside the hole.

2. Apply anti-seize compound to the tooth shank and the retaining bolt threads and under the head of the bolt.

1. Turn OFF the saw and allow saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade is stopped.

A

B

C

2. Park the machine on firm level ground. Block the wheels or tracks. Engage the parking brake or swing brake. Position the saw head vertically on devices strong enough to support its weight. (When the head is vertical, the saw blade is horizontal.)

For in-woods maintenance, position the felling head with the base of the head supported on firm level ground. Tilt the head back slightly to allow access to the exposed portion of the blade and teeth.

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Ensure the saw blade has come to a complete stop.

5. If the saw you are working on is equipped with a saw blade lock pin, install the pin make sure it is secure.

Refer to SAW BLADE LOCK PIN in this section for instructions on the proper use of this safety device.

SAW41

Saw Tooth Assembly

A Saw Tooth B Tooth Shank C Saw Tooth Retaining Bolt

3. Slide the tooth into the hole in the disc, ensure that the tooth seats tightly against the shoulder of the saw blade.

4. Torque the tooth retaining bolts to the specified torque value.

NOTE: Do not use an impact wrench and do not over torque.

SAW TOOTH REMOVAL NOTE: To maintain balance, saw teeth should be replaced in pairs opposite to each other, however if the majority of the teeth are excessively worn then all of the teeth on the blade should be replaced at the same time.

Tooth retaining bolt torque with anti-seize as follows: • ½" - 20 X 2¼" gr 8 = 115 N-m (85 lbf-ft) • ½" - 20 X 3" gr 8 = 115 N-m (85 lbf-ft) • ⅝" - 18 X 2¼" gr 8 = 217 N-m (160 lbf-ft)

CAUTION

• 1" - 14 X 4½" gr 8 = 542 N-m (400 ft-lb)

Wear gloves and keep fingers clear of rotating blade and pinch points. A slowly rotating blade has enough stored energy to crush and cut hands or fingers.

1. Loosen tooth retaining bolt two or three turns.

2. Tap the bolt head until the tooth is loose.

NOTE: Do not hammer on the side of the teeth if they are to be rotated and reused.

3. Remove the bolt and the tooth.

2.48

Tigercat Bunching and Felling Saws

Service and Maintenance

SAW TOOTH REMOVAL AND INSTALLATION TOOLS

SAW186

Socket

1", 12 point, ¾" drive = part number 211238 11⁄16" (M27), 12 point, ¾" drive = part number DG060

SAW187

Wrench

1", 12 point, ¾" drive = part number 37355A 11⁄16" (M27), 12 point, ¾" drive = part number 40340A

2.49

Service and Maintenance

Tigercat Bunching and Felling Saws

SAW DRIVE SPINDLE END PLAY DEFINITION End play is a measurement of the internal axial clearance of the drive spindle bearings, that is, allowable up and down movement of the spindle. End play is determined by measuring the axial movement of the drive spindle. Correct end play adjustment will maximize the life of the saw drive components. The recommended end play is 0.003" - 0.005" measured when the components are cool to the touch 10°C to 30°C (50°F to 90°F).

A "quick" end play check can be performed by following the DAILY DRIVE SPINDLE END PLAY CHECKING PROCEDURE in this section.

DAILY SPINDLE END PLAY CHECK This procedure must be performed when the spindle housing, spindle, and bearings are cool to the touch 10°C to 30°C (50°F to 90°F).

1. Turn OFF the saw and allow the saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade is stopped.

CAUTION Wear gloves and keep fingers clear of rotating blade and pinch points. A slowly rotating blade has enough stored energy to crush and cut hands or fingers.

6. Wearing gloves, grasp the saw blade and lift up and down several times. Check for any movement. The saw blade is very heavy, do not overstrain.

NOTE: If using the saw blade lock pin, care should be taken to ensure that there is no interference between the blade lock pin and saw blade while performing this step.

7. Remove the saw blade lock pin.

8. Rotate the saw blade 1/4 turn 9. Repeat steps 5 – 6.

10. Repeat steps 7 – 9 a minimum of 2 more times to complete at least 1 full turn of the saw blade.

11. If excessive or no end play movement is detected, refer to the DETAILED DRIVE SPINDLE END PLAY CHECK and ADJUSTMENT PROCEDURE in this section.

SAW38

2. Park the machine on firm level ground. Block the wheels or tracks. Engage the parking brake or swing brake. Position the saw head vertically on devices strong enough to support its weight.

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Ensure the saw blade has come to a complete stop.

5. If the saw you are working on is equipped with a saw blade lock pin, install the pin and make sure it is secure. Refer to SAW BLADE LOCK PIN in this section for instructions on the proper use of this safety device.

2.50

Tigercat Bunching and Felling Saws

Service and Maintenance

DETAILED SPINDLE END PLAY CHECK End play is adjusted by adding or removing shims under the spindle drive cap. The thickness of the shim pack will have to be altered by the amount the dial indicator reading is outside of the correct end play range.

End play may be checked with the saw blade either installed or removed. These checks are the most accurate way to measure end play and must be used before doing any end play adjustment. These checks must be performed when the spindle housing, spindle, and bearings are cool to the touch 10°C to 30°C (50°F to 90°F).

D

CHECKING SPINDLE END PLAY WITH THE SAW BLADE INSTALLED 1. Turn OFF the saw and allow saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade is stopped.

2. Park the machine on firm level ground. Block the wheels or tracks. Engage the parking brake or swing brake. Position the saw head vertically and supported on devices strong enough to support the weight of the saw head.

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Ensure the saw blade has come to a complete stop.

5. Properly install the saw blade guard using all hardware provided. Guard must be secure.

A

C

B

SAW165

A B C D

Saw Motor Retaining Bolts

Motor Mounting Cap Retaining Bolt (x6) Saw Drive Housing Motor Mounting Cap Saw Motor Retaining Bolt (x4)

A B

6. Remove the saw motor guard and thoroughly clean the area.

7. Disconnect all hydraulic hoses from the saw motor.

Plug all hose ends and motor ports to prevent dirt from getting into the system. Label the hose ends for easy reassembly.

C

SAW162

Spline Adapter and Spindle Drive Cap

A Spline Adapter (if equipped) B Spindle Drive Cap C Saw Drive Housing

8. Remove the four saw motor retaining screws and remove the saw motor. Leave the spline adapter in the top of the spindle (if equipped).

9. Remove the six motor mounting cap retaining screws and remove the mounting cap. Note grease fitting location for reassembly.

10. If the saw you are working on is equipped with a saw blade lock pin, install the pin and make sure it is secure. Refer to SAW BLADE LOCK PIN in this section for instructions on the proper use of this safety device.

2.51

Service and Maintenance

Tigercat Bunching and Felling Saws CAUTION Wear gloves and keep fingers clear of rotating blade and pinch points. A slowly rotating blade has enough stored energy to crush and cut hands or fingers.

15. Rotate the saw blade from side to side until the indicator needle settles down. The amount shown on the dial indicator will be the end play.

16. Rotate the saw blade 1/4 turn by hand.

17. Install the saw blade guard.

18. Repeat steps 10 through 15.

SAW27

Placing a Jack beneath the Spindle

11. Position a lifting device such as a hydraulic jack on a solid surface beneath the centre of the saw blade. Raise the jack to apply an upward force to the spindle to remove all clearance from the lower saw drive bearing.

A

19. Repeat steps 16 to 18 a minimum of 2 more times to complete at least 1 full turn of the saw blade.

20. The correct reading is 0.003" - 0.005". If the reading falls outside these limits, note the amount and direction of adjustment required. Refer to END PLAY ADJUSTMENT in this section.

NOTE: Operating the saw when the endplay is outside of these limits will cause premature bearing failure and possible motor, spindle, and seal damage.

B

21. If no adjustment is required: a. Remove the end play tool. b. Install the spline adapter.

C

c.

Install motor mounting adapter. Torque bolts to 108-115 N-m (80-85 lbf-ft).

d. Install drive motor. Torque bolts to 271-298 N-m (200-220 lbf-ft). e. Reconnect hoses. f.

SAW163

Positioning a Dial Indicator

A Spindle Drive Cap B Saw Drive Housing C Indicator Probe

12. Position the magnetic base of a dial indicator on the machined surface of the saw drive housing. Place the indicator probe on the top of the drive cap and set the indicator to '0'.

13. Lower the jack allowing the spindle to drop.

14. Remove the saw blade guard and lock pin.

2.52

Install saw motor cover.

Tigercat Bunching and Felling Saws

Service and Maintenance

CHECKING SPINDLE END PLAY WITH THE SAW BLADE REMOVED

A

1. Remove the saw blade. Refer to SAW BLADE REMOVAL in this section.

B

C D

2. Remove the saw motor guard and thoroughly clean the area.

E

3. Disconnect all hydraulic hoses from the saw motor.

Plug all hose ends and motor ports to prevent dirt from getting into the system. Label the hose ends for easy reassembly.

F K G

H J I

D

A 14613A

Spindle End-Play Adjustment Tool Kit

C

B

A B C D E F G H I J K

SAW165

A B C D

Saw Motor Retaining Bolts

Motor Mounting Cap Retaining Bolt (x6) Saw Drive Housing Motor Mounting Cap Saw Motor Retaining Bolt (x4)

4. Remove the four saw motor retaining screws and remove the saw motor. Leave the spline adapter in the top of the spindle (if equipped).

5. Remove the six motor mounting cap retaining screws and remove the mounting cap. Note grease fitting location for reassembly.

Kit Component • • • • • •

Hex-Head Bolt, 5 1/2" long (x3) Hex-Head Bolt, 4 1/4" long Outer Nut End-Play Bolt Adjustment Tool Inner Nut Spindle Drive Cap Saw Drive Upper Bearing Saw Drive Lower Bearing Drive Spindle Saw Drive Housing

1. This step requires using the end play adjustment tool kit available from Tigercat: For saw models DT/DW5003, use part number 18364A, which includes the tool and all hardware.

For saw models DT5301, ST5401, DW5502, DW5603, and the 5702 series, use part number 14613A, which includes the tool and all hardware.

Position the end play tool over the drive housing and install using three 5 1/2"-long bolts. Thread the end play bolt into the end of drive spindle. It may be necessary to adjust the inner nut and outer nut to allow installation of the end play bolt. Install a single 4 1/4"-long bolt through the end play tool and into the drive cap to prevent the spindle from turning.

2. Turn the outer nut on the end play bolt clockwise to pull the spindle up and remove all clearance from the saw drive lower bearing.

2.53

Service and Maintenance

Tigercat Bunching and Felling Saws

NOTE: Do not tighten the nut excessively as this will cause bearing preload and an incorrect measurement. Tighten to snug only.

1. Remove the 4 1/4" bolt attaching the tool to the spindle drive cap.

2. Rotate the saw spindle from side to side by hand to compensate for grease build up in the bearing rollers.

3. Install the 4 1/4" bolt again.

SPINDLE END PLAY ADJUSTMENT NOTE: All steps in DETAILED DRIVE SPINDLE END PLAY CHECK must be performed first to determine the amount and direction of the required adjustment.

End play is adjusted by adding or removing shims under the spindle drive cap. The thickness of shims will have to be altered by the amount the dial indicator reading is outside of the correct end play range.

WARNING A

Pay attention to all safety instructions outlined in section 1 of this manual.

B

C

Wear safety gloves at all times when handling and working around the saw blade.

Use recommended safety stands and devices when called for.

Always block wheels or tracks of machine.

Work on solid ground.

SAW163

Positioning a Dial Indicator

A Spindle Drive Cap B Saw Drive Housing C Indicator Probe

4. Position the magnetic base of a dial indicator on the machined surface of the saw drive housing. Place the indicator probe on the top of the drive cap and set the indicator to '0'.

5. Lower the spindle by turning the outer nut counterclockwise, allowing the spindle to drop. Turn the inner nut counterclockwise to push the spindle down and properly seat the saw drive upper bearing and ensure that all end play is measured.

NOTE: Do not tighten the nut excessively as this will cause bearing preload and an incorrect measurement. Tighten to snug only.

6. Remove the 4 1/4" bolt attaching the tool to the spindle drive cap.

7. Rotate the saw spindle from side to side by hand to compensate for grease build up in the bearing rollers and take several readings around the nut.

8. The correct reading is 0.003" - 0.005". If the reading falls outside these limits, note the amount and direction of adjustment required. Refer to END PLAY ADJUSTMENT in this section.

SAW27

Placing a Jack beneath the Spindle

1. Position a lifting device such as a hydraulic jack on a solid surface beneath the centre of the saw blade. Raise the jack to apply an upward force to the spindle to remove all clearance from the lower saw drive bearing.

2. If the saw you are working on is equipped with a saw blade lock pin, install the pin and make sure it is secure. Refer to SAW BLADE LOCK PIN in this section for instructions on the proper use of this safety device.

NOTE: Operating the saw when the end play is outside of these limits will cause premature bearing failure and possible motor, spindle, and seal damage.

2.54

Tigercat Bunching and Felling Saws

Service and Maintenance 9. Rotate the spindle one full rotation and watch the pointer on the dial indicator 10. Install the saw blade lock pin again.

11. Seat the bearings by repeating the following steps a few times: a. Push up with the jack on the bottom surface at the centre of the spindle, then release the jack. b. Remove the saw blade lock pin, c.

d. Re-install the lock pin,

20320AIL

Note: Do not apply excessive force as this will brinell the bearing races and cause premature bearing failure.

Spline Adapter Removal Tool 20320A

3. Remove the spline adapter (if equipped). Tigercat special tool part number 20320A can be used to assist with removal.

4. Remove the socket head capscrews from the end of the spindle and remove the spindle drive cap.

5. Add or remove shims as necessary to correct the end play. Use at least 4 of the 0.003” thick shims in the final stack of shims to allow easier adjustment.

NOTE: Removing shims will reduce the amount of end play; adding shims will increase the amount of end play.

6. Reinstall the spindle drive cap and socket head cap screws. Torque the screws to 108-115 N-m (80-85 lbf.ft).

A

Rotate the spindle ¼ turn,

B

12. Push up with the jack to shift the spindle fully up and hold. Do not use excessive force as this will preload the bearings, resulting in an inaccurate setting.

13. Set the dial indicator to ‘0’.

14. Release the jack pressure and allow the spindle to fall fully down. Read the dial indicator for the amount of end play in the assembly and record the amount.

The correct end play reading is 0.003” – 0.005”.

15. Repeat steps 8 to 14 at least 3 times to ensure an accurate setting.

16. Install the spline adapter (if equipped). Coat the inner and outer teeth with grease.

17. Install the motor mounting adaptor with the socket head capscrews (do not use a thread-locking compound). Torque capscrews to 108-115 N-m (8085 lbf-ft).

18. Install the saw drive motor. Torque the 4 bolts to 271-298 N-m (200 to 220 lbf-ft).

19. Re-connect the hydraulic hoses to the motor.

C

20. For start-up after adjusting end play, refer to INITIAL START-UP OF A NEW SAW HEAD in this section.

SAW163

Positioning a Dial Indicator

A Spindle Drive Cap B Saw Drive Housing C Indicator Probe

7. Place the magnetic base of a dial indicator on the machined surface of the saw drive housing. Place the indicator probe on the upper surface of the spindle drive cap. Locate the probe between the mounting holes and the outside diameter of the cap.

The probe must not be in line with any holes as the spindle will be rotated.

8. Remove the saw blade lock pin.

2.55

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

Tigercat Bunching and Felling Saws

Saw Drive Spindle Assembly

Cap Screw, Motor Mounting Cap Motor Mounting Cap Spline Adapter (if equipped) Cap Screw, Spindle Drive Cap Spindle Drive Cap Shims Upper Bearing Cone Upper Bearing Cup Grease Retainer Lower Bearing Cup Lower Bearing Cone Grease Seal Seal Ring Saw Drive Spindle Bolt (2 1/4" long without Flange (P); 3 1/2" with Flange (P)) Spindle Bolting Flange (Used on All Tigercat ST and DT Heads) Grease Fitting (for Lubricating Spline Adapter) Plug

B

A

D E

A B C D E F G H I

J K L M N

O

P Q R

SAW168

2.56

Tigercat Bunching and Felling Saws

Service and Maintenance

A

B C

D

E

SAW166

A Bearing End play Adjustment Shims B Spindle Drive Cap C Motor Mounting Cap

Saw Heads without a Spline Adapter

S Saw Drive Housing E Spindle

A

B

C

D

E

F

SAW167

A Spline Adapter B Spindle Drive Cap C Bearing End play Adjustment Shims

Saw Heads with a Spline Adapter

S Motor Mounting Cap E Saw Drive Housing F Spindle

2.57

Service and Maintenance

Tigercat Bunching and Felling Saws

SAW DRIVE SPINDLE REMOVAL 1. Remove saw blade. Refer to SAW BLADE REMOVAL in this section.

A

2. Remove saw motor cover, saw motor, motor mounting cap, and spline adapter (if equipped).

B

3. Loosen the screws of the spindle drive cap half way.

4. Install the saw spindle puller onto the spindle flange on the underside of the saw head: a. Assemble the two threaded rods and fasteners onto the main structure. b. Put the main structure under the spindle flange such that one vertical bar would contact the butt plate, the other vertical bar would contact the main floor plate, and the horizontal bar would be parallel with the spindle flange. The orientation of the main structure depends on the saw model. c.

E

C

Loosely install the fine-thread end of the puller rods into the spindle flange.

d. Assemble the support bar, spacers, and fasteners onto the main structure in the correct configuration such that the horizontal bar would be parallel with the spindle flange. The configuration depends on the saw model. Two possible configurations are illustrated.

5. Tighten the puller nuts clockwise evenly to pull the spindle down until the drive cap makes contact with the inner race of the upper bearing.

6. Remove the spindle drive cap.

D SAW 51C

A B C D E

Removing the Saw Drive Spindle

Eye Bolt Saw Drive Spindle Nut Threaded Rod Spindle Bolting Flange

7. Insert an eye bolt (1/2"-13 UNC) into the tapped hole located in the top of the drive spindle and support the spindle with a suitable wire rope attached to the upper part of the felling head.

8. Continue to pull out the spindle while at the same time loosening the rope.

NOTE: The spindle is heavy, handle with a suitable lifting device to prevent personal injury and damage to the spindle.

9. Lower the spindle and remove it from saw housing.

10. Remove the spindle seal from the housing and discard. Normally the lower spindle seal is dislodged by interference with the lower bearing during removal of the spindle. If it is not dislodged it must be removed from the housing.

11. Once the spindle is free, remove the rope and eye bolt and remove the upper bearing cone.

12. Remove the lower bearing cone from the spindle.

A bearing puller is the best tool to use for removing the lower bearing cone. However if a bearing puller is not available, you may use one of the following methods depending on the saw model/series: For saw models DT5301, ST5401, DW5502, DW5603, and the 5702 series, you can use the bolts threaded in through the blade installation holes in the bottom of the spindle to push the lower bearing cone off of the spindle.

2.58

Tigercat Bunching and Felling Saws

Service and Maintenance

For saw models DT/DW5003, you can use the two 1/2" bolts through the two 1/2" tapped holes in the bottom of the spindle to push the lower bearing cone off of the spindle. Alternatively use a soft steel punch in the two 1/2" tapped holes in the bottom of the spindle to push the lower bearing cone off of the spindle. With these methods, the steel seal ring will be removed as well.

A B C G

13. Remove the steel seal ring from the spindle if it has not been removed already.

D A

14. Remove the upper bearing cup and grease retainer from the saw housing.

E

15. Remove the lower bearing cup from the saw housing.

16. Clean all components and thoroughly inspect for wear and damage. Inspect the drive spindle for cracks and the splines and threads for damage.

H

17. Clean out the inside of the saw housing and check for cracks/damage.

I F

A J

A00375

A B C D E F G H I J

2.59

Saw Drive Spindle Puller

Washer, 3/4 in.

Nut, 3/4 in.

Threaded Rod Main Structure Washer, 7/8 in.

Nut, 7/8 in.

Support Bar Spacer Spacer, 7/16-in. Thick Screw

Service and Maintenance

Tigercat Bunching and Felling Saws

SAW DRIVE SPINDLE INSTALLATION

cone is firmly up against the bearing cup.

NOTE: Always use new bearings, seals, and spindle drive cap. Refer to the illustration for correct order of parts.

1. Install the lower bearing cup into the housing, with the smaller inside diameter facing up and firmly up against the shoulder in the lower part of the saw housing.

A

2. Install the upper grease retainer into the upper part of the saw housing with the lip facing up.

B

3. Install the upper bearing cup into the saw housing with the smaller inside diameter facing down and firmly down against the upper grease retainer in the upper part of the saw housing.

C

4. Heat lower seal ring in oil to approximately 137°C (280°F) and slide the seal ring onto the spindle making sure that the 45° chamfer faces down. Allow the lower seal ring to cool to 38°C (100°F) or less.

5. Apply a thin coating of grease to the lip of the grease seal.

6. Install the grease seal onto the spindle and around the seal ring with the open side of the seal facing up.

7. Heat lower bearing cone in oil to approximately 137°C (280°F) and install onto spindle with wide side of cone facing down and pressed against the seal ring.

8. Pack the lower bearing cone with grease.

9. Place the drive spindle onto a jack and proceed to raise the spindle into the saw housing. Take care not to damage the grease seal. Carefully guide the grease seal into the small recess in the saw housing.

NOTE: The outer mounting surface of the grease seal has a special coating which acts as a lubricant during assembly and then as an adhesive to help hold the seal in place after assembly.

10. Pre-heat upper bearing cone to approximately 137°C (280°F) and install onto spindle with small end of cone facing down.

11. Select a quantity of the spindle bearing shims. Use 4 of the 0.003” thick, 3 of the 0.005” thick, one each of 0.007”, 0.048” thick and 2 each of 0.010”, 0.020” thick. Place this package of shims (total 0.142” thick) on the end of the spindle and align with the bolt holes.

12. Place the spindle drive cap on the end of the spindle and install the socket head cap screws through the holes in the cap and into the end of the spindle.

13. Pull the spindle through the housing by equally tightening the socket head cap screws and tapping the upper bearing cone down onto the spindle with a mild steel punch. While tightening the socket head cap screws, check that the lower grease seal is seating properly in the recess. Continue to tighten the socket head cap screws until the upper bearing

SAW 111

A Saw Housing B Spindle Bolting Flange C Flat-Faced Mild-Steel Punch

14. Tap around the grease seal in several places using a flat-faced mild-steel punch to make sure that the seal is seated properly in the housing and is not rubbing against the top side of the spindle flange. On the model 5000 saw use the twelve blade mounting holes. On models 5400, 5500, 5600 and 5700 saws use the two ⅜" dia. plain holes.

15. Torque the socket head cap screws in the spindle drive cap to 108-115 N-m (80-85 lbf-ft).

16. Check that the spindle drive cap is seated against the upper bearing cone inner race. There should be a zero gap between the drive cap and the bearing cone.

17. Set correct spindle end play. Allow all heated components to cool down prior to setting end play otherwise false readings will result. Refer to SPINDLE END PLAY ADJUSTMENT in this section.

18. Pack the upper bearing cone with grease.

19. Apply grease at the grease fittings to the upper and lower saw spindle bearings until the grease begins to come out of the vent fittings. Use a hand grease gun to prevent damage to the grease seal.

20. Install the saw blade as described in SAW BLADE INSTALLATION in this section.

21. For start-up after installing or servicing the spindle, bearings or adjusting endplay refer to INITIAL START-UP OF A NEW SAW HEAD in this section.

2.60

Tigercat Bunching and Felling Saws

Service and Maintenance

BUTT PLATE REPLACEMENT – MODELS DT/DW5003, DT5301, ST5401, DW5502, AND DW5603

CAUTION

NOTE: The following instructions are based on replacing the butt plate on saw head model DW5603. Although the shape of the butt plate on other models is slightly different, this replacement procedure may be used as a guide.

Do not allow the bearing housing to exceed 120°C (250°F) at any time during removal or installation of butt plate.

The replacement is a single piece comprising the butt plate and pocket floor.

WARNING

A

Observe all safety precautions outlined in this manual when performing this service procedure.

C

1. Turn OFF the saw and allow saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade is stopped.

2. Park the machine on firm level ground. Block the wheels or tracks. Engage the parking brake or swing brake. Position the saw head vertically on supports strong enough to support the weight of the saw head.

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Ensure the saw blade has come to a complete stop.

B

A00376

Plate Removal Method Reference

A Gouging B Gouging or Cutting, Depending on the Saw Model C Cutting

11. Remove the existing butt plate and pocket floor by using the method indicated in the illustration above for the 3 sections of the welded edge:

5. Ensure all hydraulic pressure in the pilot lines has been released.

a. Gouge the welds on the top and bottom surfaces.

6. If the saw you are working on is equipped with a saw blade lock pin, install the pin and make sure it is secure. Refer to SAW BLADE LOCK PIN in this section for instructions on the proper use of this safety device.

b. Gouge where practicable or cut depending on the saw model. c.

7. Remove guards and clean all debris from the saw head to minimize the chance of fire.

Cut along the inside profile of the vertical pocket side plate. Completely remove the floor from the bottom edge of the vertical pocket rear plate.

12. Clean paint, rust, and weld off all surfaces in the areas where the new butt plate will be located.

13. Position the replacement plate and tack weld.

CAUTION

14. The pocket floor portion is not horizontal: it slopes up to the rear of the saw head and fits inside the vertical pocket side plates. Trim the pocket floor portion if required to clear existing welds.

Wear gloves and keep fingers clear of rotating blade and pinch points. A slowly rotating blade has enough stored energy to crush and cut hands or fingers.

8. Measure blade to butt plate clearance, use this measurement and the butt plate position as a guide for installing the new butt plate.

9. Remove the saw blade lock pin.

10. Remove skis and underside guard. Remove saw blade. Refer to SAW BLADE REMOVAL in this section.

2.61

Service and Maintenance

Tigercat Bunching and Felling Saws B

A

B

A

C 13 6

3

12

9

1

4

7

2 5

10

8

Bottom View

Top View

11

SAW-151

A Weld Thickness – ⅜" B Do not weld in the bearing housing area.

Butt Plate Installation Welding Sequence

C Do not start or stop the weld in this segment. Maintain a continuous flow from fillet to bevel welds and from the top surface to the bottom surface.

F

A

B

C G

H I J

K

E

A00369 A00368

A B C D

Bottom View with a New Plate in Position

New One-Piece Butt Plate and Pocket Floor Tack weld both sides. ⅜" Radius: DT/DW5003 – 21" DW5502 and DW5603 – 23⅞" E New Pocket Floor Fitted inside Vertical Pocket Side Plates F Inlet Filler Plate

G 9" H DT/DW5003 and DW5603 – 12⅛" DT5301 – 1215/16" I DT/DW5003 and DW5603 – 22⅞" DT5301 – 24⅜" J ¼" K Do not weld within ¾" of the butt plate edge.

2.62

D

Tigercat Bunching and Felling Saws A

Service and Maintenance 24. If the saw you are working on is equipped with a saw blade lock pin, install the pin using all the hardware provided and make sure it is secure. Refer to SAW BLADE LOCK PIN in this section for instructions on the proper use of this safety device.

C

B

D E F

SAW118

A B C D E F

Preloading the Butt Plate

Shim Brace ¼" Fillet Weld at Each End of the Brace 1" at Each End of the Brace 1⅛ – 13/16" at the Centre of the Saw New Butt Plate

A B E

15. Position a brace 25 mm (1”) above the flat new butt plate. Attach the brace to the housing with a 1/4" fillet weld at each end. It is suggested to use a 2 x 4 x ⅜" steel tube.

16. To compensate for stresses due to welding, shim between the brace and new butt plate to preload the butt plate by 1⅛ – 13/16” at the centre of the saw as shown. More preload may be required depending on welding techniques.

17. Tack weld the shims to both the new plate and the brace.

D

SAW-154

C

SAW-153

A B C D E

Butt Plate 1/8" Maximum New Saw Tooth Saw Blade Gap between New Butt Plate and Saw blade

CAUTION

18. Weld new plate into position on bottom and top.

Weld in the sequence and direction as shown for each pass. Preheat the weld area to a minimum of 150°C (300°F). Recommended weld rod number ER8018E or wire number ER480S6.

Wear gloves and keep fingers clear of rotating blade and pinch points. A slowly rotating blade has enough stored energy to crush and cut hands or fingers.

Note: • The location of no welding in the bearing housing area.

• The transition of welding from top to bottom in weld segment 13.

19. Peen the face of each weld immediately after each pass using ¼” ball-nose pneumatic peener. This will help reduce the stress build up in the weld due to cooling and minimize distortion of the butt plate.

20. Wait until the new plate and the welds are cool to the touch. Remove the brace and shims. Grind all tack welds flush.

21. Weld the inlet filler plate as illustrated.

22. Check the new plate for flatness (maximum 1/16” butt plate variation allowed). Straighten as required.

23. Install saw blade. Refer to SAW BLADE INSTALLATION in this section.

2.63

25. Check gap between new butt plate and saw blade as follows: Blade series 13 = ⅛" Blade series 14 = ⅛ – ¼" Blade series 24, 26, 74, and 75 = ⅛ – 3/16" 26. Check that the gap between the top of the butt plate and the top of a new saw tooth is ⅛" maximum.

Service and Maintenance

B

A

SAW-152A

Tigercat Bunching and Felling Saws

D

C

SAW-153

A B C D

Gap between New Pocket Floor and Teeth – 5/16" Minimum Pocket Floor Section Saw Blade New Saw Teeth

27. Check the clearance between the saw blade teeth and the underside of the pocket floor. Clearance should be a minimum of 5/16”. Correct as required.

28. Install skis and underside guard.

29. Ensure all guards are in place. Do not operate the saw head without the guards installed.

2.64

Tigercat Bunching and Felling Saws

Service and Maintenance

BUTT PLATE REPLACEMENT – MODEL SERIES 5702

A

WARNING Observe all safety precautions outlined in this manual when performing this service procedure.

1. Turn OFF the saw and allow saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade is stopped.

2. Park the machine on firm level ground. Block the wheels or tracks. Engage the parking brake or swing brake. Position the saw head vertically on support devices strong enough to withstand the weight of the saw head.

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Ensure the saw blade has come to a complete stop.

5. Ensure all hydraulic pressure in the pilot lines has been released.

B

SAW116

Preparing the Butt Plate Mounting Surface: Bottom View with the Butt Plate Removed

A Chamfer B Butt Plate Mounting Surface

12. Clean paint, rust, weld, etc. off the butt plate mounting surface.

13. Create a 3/8" x 45° chamfer on either end of the butt plate mounting surface by grinding off old weld to lower the edge.

A

6. If the saw is equipped with a saw blade lock pin, install the pin and make sure it is secure. Refer to SAW BLADE LOCK PIN in this section for instructions on the proper use of this safety device.

B C

C

7. Remove guards and clean all debris from the saw head to minimize the chance of fire.

8. Measure blade to butt plate clearance, use this measurement and the butt plate position as a guide for installing the new butt plate.

9. Remove the saw blade lock pin.

D SAW117

10. Remove skis and underside guard. Remove saw blade. Refer to SAW BLADE REMOVAL in this section.

A B C D

CAUTION Do not allow the bearing housing to exceed 120°C (250°F) at any time during removal or installation of butt plate.

Positioning the Butt Plate: Bottom View with the Butt Plate in Place

Tack Weld Both Sides Radius 3/8" No Weld in Bearing Housing Area

14. Position new butt plate and tack weld on both sides at radius B as follows:

11. Remove existing butt plate by gouging the welds on the top and bottom surfaces.

2.65

Models ST/SW5702 = 239⁄16" Model ST5702-26 = 2615⁄16"

Service and Maintenance A

Tigercat Bunching and Felling Saws C

B

BUTT PLATE WELDING SEQUENCE – MODELS ST/SW5702 10

D E F

SAW118

A B C D E F

Preloading the Butt Plate

Shim Brace ¼" Fillet Weld at Each End of the Brace 1" at Each End of the Brace 1⅛ – 13/16" at the Centre of the Saw New Butt Plate

1

2

15. Position a brace 25 mm (1”) above the flat new butt plate. Attach the brace to the housing with a 1/4" fillet weld at each end. It is suggested to use a 2 x 4 x ⅜" steel tube.

3

4

A

16. To compensate for stresses due to welding, shim between the brace and new butt plate to preload the butt plate by 1⅛ – 13/16” at the centre of the saw as shown. More preload may be required depending on welding techniques.

Bottom View

17. Tack weld the shims to both the new plate and the brace.

18. Weld the new butt plate into position on the bottom and top according to the applicable illustrations and the following notes:

9

5

6 7

Preheat the weld area to a minimum of 200°C (400°F), interpass 175°C (350°F).

Recommended weld rod number ER8018E or wire number ER480S6.

For all models except 5702-26, weld in the sequence and direction as shown for each pass.

On model 5702-26, weld in an overall direction that passes away from the bearing housing on both sides of butt plate. To minimize distortion and residual stresses: • Alternate top and bottom welds for segments 1, • Use the back-step method, and • Peen the welds after each pass.

10

8

Top View SAW-D10 SAW119

A No Welding in the Bearing Housing Area

Segment

Weld Size

1 – 4 and 7 – 8

⅜" fillet

5–6

½" fillet and bevel

9–10

Do not start or stop the weld in this area. Maintain a continuous flow from fillet to bevel welds and from the top surface to the bottom surface.

19. Peen the face of each weld immediately after each pass using ¼" ball nose pneumatic peener. This will help reduce the stress build up in the weld due to cooling and minimize distortion of the butt plate.

2.66

Tigercat Bunching and Felling Saws

Service and Maintenance

BUTT PLATE WELDING DETAILS – MODEL ST5702‑26 A

B

B

1

11

A B E

C

C

Bottom View

B

B

33

E

22

D

33

D

E

22

1

D

SAW-154

C

SAW-153

11

A B C D E

Butt Plate 1/8" Maximum New Saw Tooth Saw Blade Gap between New Butt Plate and Saw blade

CAUTION Top View

SAW-196A

A Torque socket-head cap screws to 290-310 N-m (215-230 lbf-ft).

Tack weld 3 places on each screw and grind flush.

B No Weld – ¾" C No Weld – 7" D No Weld – 6" E Do not start weld here. Peen and blend smooth at end of weld.

Wear gloves and keep fingers clear of rotating blade and pinch points. A slowly rotating blade has enough stored energy to crush and cut hands or fingers.

24. Check gap between new butt plate and saw blade as follows: Blade series 13 = ⅛"

Segment Weld Size

Blade series 14 = ⅛ – ¼"

1

⅜" fillet

2

½" fillet, 6" long

Blade series 24, 26, 74, and 75 = ⅛ – 3/16"

3

1" transition from ½" fillet to ⅜" fillet

Blade series 76 = 5/32 – 3/16"

20. Wait until the new butt plate and its welds are cool to the touch. Remove the brace and shims. Grind all tack welds flush.

21. Check new butt plate for flatness (maximum 1/16” variation allowed). Straighten as required.

22. Install saw blade. Refer to SAW BLADE INSTALLATION in this section.

23. If the saw is equipped with a saw blade lock pin, install the pin and make sure it is secure. Refer to SAW BLADE LOCK PIN in this section for instructions on the proper use of this safety device.

2.67

25. Check that the gap between the top of the butt plate and the top of a new saw tooth is ⅛" maximum.

26. Install skis and underside guard.

27. Ensure all guards are in place. Do not operate the saw head without the guards installed.

Service and Maintenance

SAW HOUSING WEAR LINER Replaceable wear liners are fitted to the inside of the lower saw housing. These wear liners reduce the amount of housing wear generated by debris from the rotating saw blade. Each saw head model has different designs and locations for the wear liners.

Tigercat Bunching and Felling Saws 15. Install saw blade and re-check clearances.

16. Install guards and skis.

These wear liners will require periodic replacement.

Refer to the appropriate Parts Catalog pages for wear liner part numbers. The following procedure outlines the details for wear liner replacement on a 5600 series saw head. Other models will have different liners and locations, however the replacement procedure and weld details will be the same.

WARNING Observe all safety precautions outlined in this manual when performing this service procedure.

WEAR LINER REPLACEMENT PROCEDURE 1. Park the machine on level ground.

A

B

C

D

SAW179

A B C D

2. Lower the saw head until it is firmly support in preparation for blade removal.

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Ensure all hydraulic pressure in the pilot lines has been released.

5. Remove skis and lower guards.

6. Remove the saw blade, refer to SAW BLADE REMOVAL in this section.

7. Remove the damaged or worn liners by grinding the existing welds.

8. Clean the housing surfaces of weld and rust where the new liners are to be located. Make repairs to the housing if necessary.

9. Fit the new liners in the housing. Check the liners for fit prior to welding, trim liners if necessary.

10. Weld the liners in place using the weld details shown in the illustration.

11. Install the saw blade, refer to SAW BLADE INSTALLATION in this section.

12. Check the clearance between the saw teeth and the wear liner. Minimum clearance should be 8 mm (5/16"). Ensure that clearance is checked around the entire circumference of the saw housing.

13. If the clearance between the saw teeth and wear liners is less than 8 mm (5/16”), mark the areas on the wear liners and remove the saw blade.

14. Grind the wear liners as required to provide the specified clearances.

2.68

Typical Saw Housing Wear Liners – 5600 Series

1/4" 1/2" -8" 3/8" 2 Places

Tigercat Bunching and Felling Saws

Service and Maintenance

CYLINDER SEALS CLAMP ARM AND ACCUMULATING ARM CYLINDERS These cylinders have a two-piece piston.

ASSEMBLY NOTES AND TORQUES Note the direction of the wiper seal: wiping lip facing the environment; sealing lip facing the gland.

Install the spiral retaining ring ensuring that the ring is fully seated in the groove.

Install the bearing so the split is at 90° to the load.

SAW176

Piston Torque Tool– Tigercat Part Number 33891B

Gland bolt torque = 108 – 115 N-m (80 – 85 lbf-ft) lubricated.

Do not reuse the rear piston. Rear piston torque = 2372 N-m (1750 lbf-ft) lubricated.

A seal kit is available. Its items are identified in the illustration by grey shading.

C

A

SAW171 SAW170 SAW169

A B C D

E

Piston Seals Gland Seals Wiper Seal Spiral Retaining Ring

B

G

E

F

3.5 / 3.75-in. Cylinder with a Two-Piece Piston E Spherical Bearing F Gland Bolt G Piston

2.69

D

Service and Maintenance

Tigercat Bunching and Felling Saws

WRIST CYLINDERS These cylinders have a one-piece piston.

30° WRIST CYLINDER ASSEMBLY NOTES AND TORQUES Note the direction of the wiper seal: wiping lip facing the environment; sealing lip facing the gland.

Install the spiral retaining ring ensuring that the ring is fully seated in the groove.

Install the bearing so the split is at 90° to the load.

Gland bolt torque = 108 N-m (80 lbf-ft) lubricated.

Lock nut torque = 2372 N-m (1750 lbf-ft) lubricated.

A seal kit is available. Its items are identified in the illustration by grey shading.

C A

D

B

E

F

A00385 A00386 A00387

A Gland Seals B Piston Seals C Wiper Seal

5-in. Cylinder– 30° Wrist

D Spherical Bearing E Gland Bolt F Lock Nut

2.70

D

Tigercat Bunching and Felling Saws

Service and Maintenance

110° WRIST CYLINDER ASSEMBLY NOTES AND TORQUES Note the direction of the wiper seal: wiping lip facing the environment; sealing lip facing the gland.

Gland bolt torque = 678 – 746 N-m (500 – 550 lbf-ft) lubricated.

Lock nut torque = 2847 N-m (2100 lbf-ft) lubricated.

A seal kit is available. Its items are identified in the illustration by grey shading.

C A

A00382 A00383 A00384

A Piston Seals B Gland Seals C Wiper Seal

B

E

D

4.5-in. Cylinder– 110° Wrist

D Gland Bolt E Lock Nut

2.71

Service and Maintenance

SAW DRIVE DESCRIPTION The saw blade is driven by a variable-displacement hydraulic motor (axial piston, bent axis) which is mounted directly above the saw blade and coupled to the saw blade through a drive spindle.

On models ST5702 and ST5702-26 a fixed-displacement motor can be installed as an option. Unlike variabledisplacement motors, fixed-displacement motors do not require any setup or adjustments. Refer to FIXED DISPLACEMENT MOTORS in THIS SECTION for additional details.

Tigercat Bunching and Felling Saws IMPORTANT! To maximize saw motor life, do not turn off the engine until the saw blade has come to a complete stop and avoid turning off the saw switch when the blade is spinning at full speed. Idle engine down, allowing blade speed to reduce before turning off the saw switch.

For additional information on the saw pump and saw control valve, refer to the MACHINE SERVICE MANUAL.

Typically on Tigercat installations, a variabledisplacement hydraulic pump supplies oil flow to the motor via a saw control valve. The saw control valve, usually pilot operated with a built-in relief, controls the flow of hydraulic oil from the pump to the motor.

A saw switch on the control panel in the cab turns the saw on or off. The two-position switch controls the flow of electrical current to the solenoid operated saw pilot valve.

A

B

SAW MOTOR ANTI-CAVITATION CHECK VALVE The anti-cavitation check valve is installed between the pressure and return ports of the saw motor. The anti-cavitation check valve is mounted externally on saw motors for some saw head models. Other model saw heads have a different saw motor with an internal anti-cavitation check valve installed in the end plate.

On fixed-displacement motors, the anti-cavitation check valve is mounted in a manifold bolted directly to the motor at the pressure and return ports.

If the main oil flow from the pump to the motor is reduced due to engine lugging from other machine functions being used, the anti-cavitation check valve will allow the blade to free wheel until the pump flow increases to match the motor volume.

C

207-8A

Saw Motor with an External Check Valve

A Return Side B Pressure Side C External Anti-Cavitation Check Valve

If the engine stalls or the saw is turned OFF while the blade is rotating, the blade will continue to rotate and turn the motor. In this case the anti-cavitation check valve will open and allow oil to flow from the return side to the pressure side preventing cavitation damage to the hydraulic motor. The anti-cavitation check valve will continue to allow the blade to free wheel until it comes to a complete stop. Refer to STOPPING THE SAW BLADE in this section.

A

SAW-184

Schematic of a Saw Motor with an External Check Valve A External Anti-Cavitation Check Valve

2.72

Tigercat Bunching and Felling Saws

Service and Maintenance

B C

A

C

SAW-180

SAW-183

Saw Motor with an Internal Anti-Cavitation Check Valve

A A– Return Side B B– Pressure Side

C Anti-Cavitation Check Valve

A

SAW-185

Schematic of a Saw Motor with an Internal Anti-Cavitation Check Valve

A Anti-Cavitation Check Valve

2.73

Service and Maintenance

Tigercat Bunching and Felling Saws

SAW DRIVE HYDRAULIC START-UP PROCEDURE DANGER Observe all safety precautions outlined in this manual when performing this service procedure.

WARNING Carry out this procedure with care. Make sure that there are no chips or blocks of wood remaining in the saw housing that could be thrown out by the rotating blade.

When a pump or motor has been removed or replaced, it is necessary to prime the circuit and remove as much air as possible from the pump, motor and lines before start-up.

1. Park machine on firm level ground, lower felling head to the ground, engage the parking brake or swing brake and turn OFF the engine. Block the wheels or tracks. Properly install the saw blade guard using all hardware provided. Guard must be secure.

2. Fill the pump case with the recommended filtered hydraulic oil through the highest case drain port.

3. Fill the motor case through the highest case drain port. As the motor is being filled, rotate the saw blade by hand to allow better entry of the oil to the lower part of the motor.

4. With the high pressure line disconnected at the pump, fill as much of the line as possible with oil through the end of the hose. Reconnect hose and check all hose connections are tight.

5. Clear area under saw of all loose dirt, stones, wood and debris.

6. Raise saw head 6" off the ground and position wrist in the vertical plane (if applicable).

7. Warn all persons to stay clear of the area, especially the discharge side of saw head.

8. Start engine and set engine speed at LOW idle.

9. Turn ON the saw switch.

10. Operate saw with the engine speed at LOW idle for 10 minutes. During the 10 minute idle period occasionally crack open the case drain connection on the motor to allow air to escape.

2.74

Tigercat Bunching and Felling Saws

Service and Maintenance

SAW MOTOR TEST PORTS AND ADJUSTMENT LOCATIONS

I

E

B A

F H

G

C

D

AQ013-4 AQ013-5

A. Maximum displacement adjusting screw (160cc motor only). Not used in this application. The adjustment dimension on this screws is factory-set to 11 mm. The 50-mm long screw is too short to have any effect on the motor setting and is only used as a plug. Do not adjust.

B. Begin of regulation adjusting screw. Use 3 mm Allen key and 10 mm wrench.

C. Minimum displacement (saw blade speed) adjusting screw. Use 6 mm Allen key and 19 mm wrench.

D. Adjustment dimension IMPORTANT! Do not set this dimension to less than 9.5 mm (160cc motor) or 13 mm (170cc motor) for a 110 mm screw. Screw failure will occur and damage to the saw motor will result. Pump displacement will require adjustment if the max blade speed specification cannot be attained at that setting.

E. G Port = system pressure (#6 ORB). Use ¼" Allen key.

F.

B Port

G. M1 Port = begin of regulation pressure (#6 ORB).

Use ¼" Allen key.

H. A Port I.

X port

2.75

Service and Maintenance

Tigercat Bunching and Felling Saws

SET SAW MOTOR BEGIN OF REGULATION PRESSURE ALL MODELS EXCEPT ST5702-26 The following procedure is an initial setup and recommended best method for accurate setting. Always use this procedure for a new or replacement motor or if performance issues occur. When performing a quick maintenance check of the hydraulic pressures, refer to SAW CIRCUIT PRESSURE CHECK in this section.

A

1. Refer to the machine manual to determine the saw pump pressure override (POR) setting. Then match the applicable begin of regulation setting from the following table: Pump POR

B

Motor Begin of Regulation

bar

psi

bar

psi

248

3600

220

3200

275 or higher

4000 or higher

248

3600

2. Park machine on firm level ground, lower felling head to the ground, engage the parking brake or swing brake and turn OFF the engine. Block the wheels or tracks. Properly install the saw blade guard using all hardware provided. Guard must be secure.

SAW-D01

Saw Motor Front View

A M1 Port B Minimum Displacement Adjusting Screw

6. Install a 0-345 bar (0-5000 psi) pressure gauge in the M1 port on the saw motor.

3. Ensure that hydraulic oil is at operating temperature.

4. Remove saw motor cover.

A A

B

SAW63

Blocking the Saw Blade

B

A Locking Bolt B Saw Blade Guard

7. Block saw blade to prevent it from turning using the locking bolt provided.

C

8. Start engine and set engine speed at HIGH idle.

9. Adjust saw pump pressure override (POR) to 172 bar (2500 psi), measured on the gauge at motor G port.

D 207-1A

A B C D

Saw Motor

10. Slowly increase the pump POR (G-port pressure) while also reading the gauge at port M1.

Begin of regulation occurs at the point when the M1port pressure equals half of the G-port pressure.

G Port Begin of Regulation Adjusting Screw Maximum Displacement Adjusting Screw (Not Used) Motor Case Drain Connection

For example, if the factory begin of regulation is 220 bar (3200 psi), then the M1-port gauge should read 110 bar (1600 psi) when the G-port gauge reads 220 bar (3200 psi).

5. Install a 0-345 bar (0-5000 psi) pressure gauge in the G port on the saw motor.

11. Adjust the begin of regulation pressure as required: a. Loosen the begin of regulation adjusting screw jam nut.

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Tigercat Bunching and Felling Saws

Service and Maintenance MODEL ST5702-26

b. If the M1 gauge reads less than half of the G gauge, adjust the begin of regulation screw counterclockwise to increase the pressure. c.

If the M1 gauge reads more than half of the G gauge, adjust the begin of regulation screw clockwise to reduce the pressure.

d. Tighten the begin of regulation adjusting screw jam nut.

12. Re-check the pressures to ensure the setting has not changed.

13. Re-adjust the pump POR (G-port pressure) to the setting noted in the machine manual.

14. Turn OFF the saw.

15. Set engine speed at LOW idle. Turn OFF the engine.

16. Remove all pressure gauges and reinstall plugs.

The following procedure is an initial setup and recommended best method for accurate setting. Always use this procedure for a new or replacement motor or if performance issues occur. When performing a quick maintenance check of the hydraulic pressures, refer to SAW CIRCUIT PRESSURE CHECK in this section.

1. Park machine on firm level ground, lower felling head to the ground, engage the parking brake or swing brake and turn OFF the engine. Block the wheels or tracks. Properly install the saw blade guard using all hardware provided. Guard must be secure.

2. Ensure that hydraulic oil is at operating temperature.

3. Remove saw motor cover.

17. Remove the locking bolt and saw blade guard.

A

B

E

C D

SAW-197

A B C D E

170cc Saw Motor

Front M1 Port Minimum Displacement Adjusting Screw Begin of Regulation Adjusting Screw G Port

4. Install a 0-345 bar (0-5000 psi) pressure gauge in the G port on the saw motor.

5. Install a 0-345 bar (0-5000 psi) pressure gauge in the M1 port on the saw motor.

2.77

Service and Maintenance

Tigercat Bunching and Felling Saws SAW BLADE SPEED ADJUSTMENT 1. Park machine on firm level ground, lower felling head to the ground, engage the parking brake or swing brake and turn OFF the engine. Block the wheels or tracks. Properly install the saw blade guard using all hardware provided. Guard must be secure.

A

2. Ensure that hydraulic oil is at operating temperature.

3. Remove saw motor cover.

B

SAW63

Blocking the Saw Blade

A Locking Bolt B Saw Blade Guard

6. Block saw blade to prevent it from turning using the locking bolt provided.

7. Start engine and set engine speed at HIGH idle.

8. Adjust saw pump POR to 172 bar (2500 psi), measured on the gauge at motor G port.

9. Slowly increase the pump POR (G-port pressure) while also reading the gauge at port M1.

A

Begin of regulation occurs at the point when the M1port pressure equals half of the G-port pressure.

The factory begin of regulation for this model is 248 bar (3600 psi), so the M1 gauge should read 124 bar (1800 psi) when the G gauge reads 248 bar (3600 psi).

10. Adjust the begin of regulation pressure as required:

B SAW-D01

Saw Motor Front View– All Models Except ST5702-26

A Adjustment Dimension B Minimum Displacement Adjusting Screw

a. Loosen the begin of regulation adjusting screw jam nut.

A

b. If the M1 gauge reads less than 124 bar (1800 psi) when the G port is at 248 bar (3600 psi), adjust the begin of regulation screw counterclockwise to increase the pressure. c.

If the M1 gauge reads more than 124 bar (1800 psi) when the G port is at 248 bar (3600 psi), adjust the begin of regulation screw clockwise to reduce the pressure.

B

d. Tighten the begin of regulation adjusting screw jam nut.

11. Re-check the pressures to ensure the setting has not changed.

12. Re-adjust the pump POR (G-port pressure) to the setting noted in the machine manual.

13. Turn OFF the saw.

14. Set engine speed at LOW idle. Turn OFF the engine.

15. Remove all pressure gauges and reinstall plugs.

16. Remove the locking bolt and saw blade guard.

SAW-197

Saw Motor– Model ST5702-26

A Front B Minimum Displacement Adjusting Screw

2.78

Tigercat Bunching and Felling Saws

Service and Maintenance

4. Remove the minimum displacement adjusting screw from the motor housing and measure the length.

5. Reinstall the minimum displacement adjusting screw and locknut into the motor housing. Set the adjustment dimension to 9.5 mm (160cc motor) 13 mm (170cc motor) for a 110 mm screw. For a longer screw, measure the length of the screw and add the difference to the adjustment dimension.

IMPORTANT! Do not set the adjustment dimension to less than 9.5 mm (160cc motor) or 13 mm (170cc motor). Screw failure will occur and damage to the saw motor will result. Pump displacement will require adjustment if the max blade speed specification cannot be attained at that setting.

A

flow (displacement) if possible. Otherwise, turn the minimum displacement adjusting screw out (counterclockwise). b. To decrease the speed, decrease the saw pump flow (displacement).

Note: The 160cc motor also incorporates a MAX displacement adjusting screw opposite to the MIN displacement screw. On the 50-mm long adjusting screw, the adjustment dimension is factory-set to 11 mm. The MAX displacement screw is only used as a plug and requires no adjustment.

TROUBLESHOOTING BLADE SPEED To verify correct blade speed, check the following: 1. Begin of regulation pressure is set too low: Check begin of regulation pressure. Refer to SAW CIRCUIT PRESSURE CHECK in this section.

Readjust pressure if necessary, as described in SET SAW MOTOR BEGIN OF REGULATION PRESSURE in this section.

B C

2. Saw drive check valve faulty: Verify that the check valve is not leaking. Refer to TEST (EXTERNAL/INTERNAL) ANTI-CAVITATION AND MOTOR CONTROL CHECK VALVES in this section.

SAW-D22

Replace check valve as required.

A Clean-out Access, Saw Housing Top B Reflective Tape C Saw Blade

6. Remove the clean-out access cover on top of the saw housing and affix the reflective tape to the top of the blade as shown.

7. Clear area under saw of all loose dirt, stones, wood and debris.

8. Raise saw head 150mm (6") off the ground and position wrist in the vertical plane (if applicable).

9. Warn all persons to stay clear of the area, especially the discharge side of saw head.

10. Start engine and set engine speed at HIGH idle.

11. Turn ON the saw switch.

12. Using an electronic photo tachometer in conjunction with the reflective tape, measure the blade speed.

13. The required speed, per saw head series, is as follow: 5000 = 1200 rpm (± 25 rpm) 5300, 5400 = 1150 (± 25 rpm) 5500, 5600, 5700 (57" blade) = 1150 rpm (± 25 rpm) 5700 (64" blade ) = 1025 rpm (± 25 rpm) If blade speed requires adjustment, do one of the following: a. To increase the speed, increase the saw pump 2.79

3. Motor stroking piston seized in maximum displacement position: May be Indicated by failure to reach full blade speed.

Repair or replace motor as required.

4. Loss of pump flow: May be Indicated by failure to reach full blade speed.

Repair or replace the pump as required.

5. Excessive motor case drain: Verify case drain volume by performing CHECK MOTOR CASE DRAIN FLOW in this section.

Repair or replace the motor as required.

Service and Maintenance SAW CIRCUIT PRESSURE CHECK VARIABLE DISPLACEMENT MOTOR Refer to the machine service manual for pressure setting procedures.

1. Park machine on firm level ground, lower felling head to the ground, engage the parking brake or swing brake and turn OFF the engine. Block the wheels or tracks. Properly install the saw blade guard.

Tigercat Bunching and Felling Saws 8. Compare your begin of regulation reading with the specified setting for the saw head. Adjust as required. Refer to SET SAW MOTOR BEGIN OF REGULATION PRESSURE in this section for settings and complete instructions.

A

Variance from Factory Setting

Corrective Action

±7 bar (100 psi)

None required

more than 7 bar (100 psi) lower

Adjust the begin of regulation screw counterclockwise slightly to increase the pressure then re-check.

more than 7 bar (100 psi) higher

Adjust the begin of regulation screw clockwise slightly to reduce the pressure then re-check.

9. Turn OFF the saw and allow saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade has stopped.

B

10. Set the engine speed at LOW idle. Turn OFF the engine.

11. Remove pressure gauge and reinstall cap.

207-1A

A G Port B Begin of Regulation Adjusting Screw

2. Install a 0-345 bar (0-5000 psi) pressure gauge in the saw control valve gauge test port on the saw pump or the G port on the saw motor (to read system pressure).

Alternatively, depending on your machine, you may be able to view the pressure on the computer display in the cab.

FIXED DISPLACEMENT MOTOR Refer to the machine service manual for pressure setting procedures.

1. Park machine on firm level ground, lower felling head to the ground, engage the parking brake or swing brake and turn OFF the engine. Block the wheels or tracks. Properly install the saw blade guard.

2. Install a 0-345 bar (0-5000 psi) pressure gauge in the saw control valve gauge test port on the saw pump (to read system pressure).

3. Clear area under saw of all loose dirt, stones, wood and debris.

4. Raise saw head 150 mm (6") off the ground and position wrist in the vertical plane (if applicable).

5. Warn all persons to stay clear of the area, especially the discharge side of saw head.

Alternatively, depending on your machine, you may be able to view the pressure on the computer display in the cab.

3. Clear area under saw of all loose dirt, stones, wood and debris.

6. Start engine and set engine speed at HIGH idle.

4. Raise saw head 150 mm (6") off the ground and position wrist in the vertical plane (if applicable).

7. Turn the saw on and observe the pressure gauge reading as the blade increases in speed. Readings should reflect the trend outlined in the graph:

6. Start engine and set engine speed at HIGH idle.

• At the beginning, pressure peaks quickly to a level matching the pump POR setting noted in the machine manual then remains fairly stable for most of phase A.

5. Warn all persons to stay clear of the area, especially the discharge side of saw head.

7. Turn the saw on and observe the pressure gauge reading as the blade increases in speed. Readings should reflect the trend outlined in the graph: • At the beginning, pressure peaks quickly to a level matching the pump POR setting noted in the machine manual then remains stable for the duration of phase A.

• Pressure drops sharply towards the end of phase A, then remains fairly stable during the motor regulation phase (B). The begin of regulation pressure would be this new, lower pressure level noted at the start of phase B.

• Pressure drops sharply at the start of the full speed phase (B), then continues to decrease gradually as the motor nears full speed.

• Pressure drops sharply again at the start of the full speed phase (C), and continues to decrease as the motor nears full speed.

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Tigercat Bunching and Felling Saws

Service and Maintenance

8. Compare your pump POR reading with the specified setting for the saw head. Adjust as required.

Variance of up to ±7 bar (100 psi) from the factory setting is acceptable.

9. Turn OFF the saw and allow saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade has stopped.

10. Set the engine speed at LOW idle. Turn OFF the engine.

11. Remove pressure gauge and reinstall cap.

A

B

C

E

D

SAW61A

Generic Saw Blade Acceleration Time and Pressure Curve – Variable Displacement Motor

A Saw Pump POR B Motor Regulation C Blade Reaching Full Speed

D Time E Pressure

A

B

D

C

SAW-200

Generic Saw Blade Acceleration Time and Pressure Curve – Fixed Displacement Motor

A Saw Pump POR B Blade Reaching Full Speed

C Time D Pressure

2.81

Service and Maintenance

Tigercat Bunching and Felling Saws

TEST EXTERNAL ANTI-CAVITATION AND MOTOR CONTROL CHECK VALVES 1. Park machine on firm level ground, lower felling head to the ground, engage the parking brake or swing brake and turn OFF the engine. Block the wheels or tracks. Properly install the saw blade guard using all hardware provided. Guard must be secure.

A

B

A B

SAW63

Blocking the Saw Blade

A Locking Bolt B Saw Blade Guard

SAW-182

2. Block saw blade to prevent it from turning using the locking bolt provided.

A

B

C

A Motor Control Check Valve B Motor Port A

7. Oil flow from the motor return port A indicates that the motor control check valve inside the motor is leaking. No oil from either of these places indicates that the check valves are operating properly.

8. Reconnect all hoses and tubes taking care not to allow any dirt or contaminants to enter the hydraulic lines.

G

F

E

D

9. Remove the saw blade locking bolt and guard. Clean up any oil spills.

207-12A

A B C D E F G

Return Side Motor Port A Pressure Side External Anti-Cavitation Check Valve Disconnect the Steel Tube from the Motor Disconnect the Return Hose Plug the Hose End

3. On saw motors with external anti-cavitation check valve, disconnect main return hose at motor port A and plug hose as shown. Disconnect the tube from the motor as shown.

4. Start engine and move the engine speed control to 1/4 speed.

5. Turn ON the saw switch.

6. Any oil flow from the bottom of the external check valve indicates that the check valve is defective, or possible incorrect installation, replace or correct installation.

2.82

Tigercat Bunching and Felling Saws

Service and Maintenance

TEST INTERNAL ANTI-CAVITATION AND MOTOR CONTROL CHECK VALVES 1. Park machine on firm level ground, lower felling head to the ground, engage the parking brake or swing brake and turn OFF the engine. Block the wheels or tracks. Properly install the saw blade guard using all hardware provided. Guard must be secure.

A

CV

B

A B

SAW63

Blocking the Saw Blade

SAW-180

A Locking Bolt B Saw Blade Guard

2. Block saw blade to prevent it from turning using the locking bolt provided.

A

A Motor Control Check Valve B Internal Anti-Cavitation Check Valve C Motor Port A

6. Oil flow from the motor return port A indicates that the anti-cavitation check valve or the motor control check valve may be leaking. No oil from either of these places indicates that the check valves are operating properly.

7. Reconnect the hose taking care not to allow any dirt or contaminants to enter the hydraulic system.

B

SAW-180A SAW-198

A Motor Port A B Internal Anti-Cavitation Check Valve

3. On saw motors with internal anti-cavitation check valve, the pressure and return hoses are located on top of the motor. Disconnect the return hose at motor port A and plug hose.

4. Start engine and move the engine speed control to 1/4 speed.

5. Turn ON the saw switch.

2.83

8. Remove the saw blade locking bolt and guard. Clean up any oil spills.

Service and Maintenance

Tigercat Bunching and Felling Saws

CHECK MOTOR CASE DRAIN FLOW

Disconnect the hose at that location and plug the fitting. Make sure that the hose is long enough to place the end into a clean bucket. If length is going to be a problem, disconnect the existing case drain hose from the motor T port and plug the hose.

Temporarily connect a four foot length of hose in its place.

1. Park machine on firm level ground, lower felling head to the ground, engage the parking brake or swing brake and Turn OFF the engine. Block the wheels or tracks. Properly install the saw blade guard using all hardware provided. Guard must be secure.

3. Block saw blade to prevent it from turning using the locking bolt provided..

4. Place end of case drain hose into a clean bucket.

5. Start engine and set engine speed at HIGH idle.

6. Turn ON the saw switch.

7. Measure the amount of oil flowing from the hose into the bucket. Case drain leakage up to 2 gallons per minute is acceptable.

8. Turn OFF the saw and turn OFF the engine. Unblock saw blade and rotate blade ⅓ turn. Repeat steps (3) to (7) two more times after rotating the saw blade ⅓ of a turn. This will test all of the pistons in the motor's rotating group.

A B

9. If leakage is in excess of 2 gpm, repair/replace the motor.

207-1A

10. After these test have been carried out, make sure that all temporary plugs have been removed, all hoses have been reconnected and all safety guarding has been reinstalled.

Rear View of Saw Motor

A Motor Case Drain Connection – Port T B Drain Hose

B A

C D E 207-17A

Case Drain Hose Typical Bulkhead Location– Tigercat 720/720B/726 Wheeled Machines

A B C D E

Operator's Cab (Front) To Saw Motor Saw Motor Case Drain Hose Bulkhead Chassis

2. Trace the case drain hose from the motor T port to an accessible bulkhead connection on the machine, see below.

On Tigercat track machines, this connection is located on a bulkhead at the end of the stick boom.

2.84

Tigercat Bunching and Felling Saws

Service and Maintenance

CHECK SAW DRIVE HOUSING TEMPERATURE The normal temperature of the housing should be roughly the same as the hydraulic oil operating temperature or less.

The hydraulic oil operating temperature varies by machine and hydraulic oil type but should be in the range of approximately 48°C to 77°C (120°F to 170°F).

Maximum saw drive housing temperature should not be higher than 82°C (180°F). This maximum temperature may be further limited by the type of grease used, refer to manufacturer's recommendations.

If the saw drive housing temperature is too high: • Check the spindle end play. Refer to DRIVE SPINDLE END PLAY in this section.

• Check the spindle and bearings for proper lubrication.

IMPORTANT! When lubricating the upper and lower saw drive spindle bearings, use a manual grease gun to prevent damage to seal, never use a power grease gun.

• Check the vent fittings for proper operation.

• Check for signs of excessive greasing.

• Check for use of the proper type of grease* * USE LITHIUM BASED EP2 GREASE CONTAINING 3% - 5% MOLYBDENUM DISULFIDE. • Check bearings for damage.

• Check bearing seal for damage.

• Check the blade speed. Refer to SAW BLADE SPEED ADJUSTMENT and BLADE SPEED TROUBLESHOOTING in this section.

• Check the saw blade for damage.

• Check the saw drive housing for damage.

• Check the saw drive motor.

2.85

Service and Maintenance

Tigercat Bunching and Felling Saws

FIXED-DISPLACEMENT MOTORS – MODELS ST5702 AND ST5702-26

B

C

D

E

Models ST5702 and ST5702-26 felling heads may be equipped with an optional fixed-displacement motor, which is mounted directly above the saw blade and coupled to the saw blade through a drive spindle.

With fixed-displacement motors, all saw-related settings are done on the machine. Refer to MACHINE SERVICE MANUAL for instructions.

A

ANTI-CAVITATION CHECK VALVE The anti-cavitation check valve is installed between the pressure and return ports of the saw motor and is mounted in a manifold bolted directly to the motor at the pressure and return ports.

If the main oil flow from the pump to the motor is reduced due to engine lugging from other machine functions being used, the anti-cavitation check valve will allow the blade to free wheel until the pump flow increases to match the motor volume.

If the engine stalls or the saw is turned OFF while the blade is rotating, the blade will continue to rotate and turn the motor. In this case the anti-cavitation check valve will open and allow oil to flow from the return side to the pressure side preventing cavitation damage to the hydraulic motor. The anti-cavitation check valve will continue to allow the blade to free wheel until it comes to a complete stop. Refer to STOPPING THE SAW BLADE in this section.

A00339

A B C D E

Fixed-Displacement Motor– Model ST5702

Motor Manifold with Anti-Cavitation Valve Test Ports Pressure Port B Return Port A D

E

C

C

A

B

A00340

A B C D E

2.86

Fixed-Displacement Motor– Model ST5702-26

Motor Manifold with Anti-Cavitation Valve Test Ports Pressure Port B Return Port A

Tigercat Bunching and Felling Saws

Service and Maintenance

TEST MANIFOLD-MOUNTED ANTICAVITATION CHECK VALVE

A

B

C

1. Park machine on firm level ground, lower felling head to the ground, engage the parking brake or swing brake and stop engine. Block the wheels or tracks. Properly install the saw blade guard using all hardware provided. Guard must be secure.

A00342

Model ST5702– Anti-Cavitation Valve A

SAW 63

A Saw Blade Guard B Locking Bolt

A

B

B

Block Saw Blade

2. Block saw blade to prevent it from turning using the locking bolt provided.

3. Disconnect the return hose at motor return port A and plug hose.

4. Start engine and move the engine speed control to ¼ speed.

5. Turn ON the saw switch.

6. Oil flow from the motor return port A indicates that the anti-cavitation check valve may be leaking. No oil from this place indicates that the check valve is operating properly.

7. Reconnect the hose taking care not to allow any dirt or contaminants to enter the hydraulic system.

8. Remove the saw blade locking bolt and guard. Clean up any oil spills.

2.87

A00343

Model ST5702-26 – Anti-Cavitation Valve

A Manifold Plug B Anti-Cavitation Valve C Return Port A

C

Service and Maintenance

Tigercat Bunching and Felling Saws

CHECK MOTOR CASE DRAIN FLOW 1. Park machine on firm level ground, lower felling head to the ground, engage the parking brake or swing brake and Turn OFF the engine. Block the wheels or tracks. Properly install the saw blade guard using all hardware provided. Guard must be secure.

A

2. Trace the case drain hose from the motor T port to an accessible bulkhead connection on the machine, see below.

On Tigercat track machines, this connection is located on a bulkhead at the end of the stick boom.

Disconnect the hose at that location and plug the fitting. Make sure that the hose is long enough to place the end into a clean bucket. If length is going to be a problem, disconnect the existing case drain hose from the motor T port and plug the hose.

Temporarily connect a four foot length of hose in it's place.

A00339

Model ST5702– Rear View

3. Block saw blade to prevent it from turning using the locking bolt provided.

4. Place end of case drain hose into a clean bucket.

5. Start engine and set engine speed at HIGH idle.

6. Turn ON the saw switch.

7. Measure the amount of oil flowing from the hose into the bucket. Case drain leakage up to 2 gallons per minute is acceptable.

8. Turn OFF the saw and turn OFF the engine. Unblock saw blade and rotate blade ⅓ turn. Repeat steps (3) to (7) two more times after rotating the saw blade ⅓ of a turn. This will test all of the pistons in the motor's rotating group.

A

9. If leakage is in excess of 7.6 L/m (2 US gpm), repair/ replace the motor.

10. After these test have been carried out, make sure that all temporary plugs have been removed, all hoses have been reconnected and all safety guarding has been reinstalled.

A00340

Model ST5702-26 – Rear View

A Motor Case Drain Connection Port P

2.88

Tigercat Bunching and Felling Saws

Service and Maintenance

30° WRIST

A wrist bearing is installed with the outer race bolted to the back of the felling head and the inner race bolted to the boom adapter.

DESCRIPTION This wrist is designed to rotate the felling head a maximum of 30°.

NOTE: Left, right, clockwise and counterclockwise directions are always as viewed by the machine operator when seated in the cab facing forward.

One hydraulic wrist cylinder is used to provide the wrist action. The base end of the cylinder is attached to the boom adapter and the rod end is attached to the wrist adapter.

There are two grease fittings on the wrist cylinder and four on the wrist bearing. Refer to LUBRICATION POINTS in this section.

G

F

E

A

D

C A00404

A B C D

Boom Adapter Hose Guard Liner Boom Attachment Pin Tilt Link Attachment Pin

30° Wrist

E Wrist Bearing F Wrist Adapter G Wrist Cylinder

2.89

B

Service and Maintenance

Tigercat Bunching and Felling Saws

30° WRIST HYDRAULIC CIRCUIT DESCRIPTION

C

The components of this circuit are the pump, control valve and pilot manifold on the machine and one wrist cylinder on the felling head.

When a wrist clockwise or counterclockwise electrical signal is sent from a wrist button or trigger to the computer control system, the system sends an electrical signal out to the corresponding wrist solenoid on the attachment valve or on the pilot manifold. The solenoid then shifts and allows pilot pressure to shift the spool in the wrist section of the control valve When there is no wrist clockwise or counterclockwise signal, the solenoid valve is in the de-energized position preventing pilot oil flow to the wrist spool ends.

When there is a signal from the wrist clockwise or counterclockwise control via the computer control system, the solenoid valve will be placed in the energized position directing pilot oil to shift the spool in the wrist valve section. This will direct oil from the pump to the wrist cylinder.

A

B

A00335

30° Wrist Hydraulic Circuit

A Wrist CW From Machine Control Valve B Wrist CCW From Machine Control Valve C Wrist Cylinder

When the spool in the control valve shifts, oil from the pump is directed to one end of the cylinder. This rotates the felling head to either the counterclockwise or clockwise direction.

The speed of the wrist rotation can be adjusted by varying the flow out of the wrist control valve. For instructions on setting the speed, refer to the MACHINE SERVICE MANUAL. Return oil from the cylinder is directed back through the control valve where it is returned to tank.

2.90

Tigercat Bunching and Felling Saws

Service and Maintenance

110º WRIST

The wrist angle can be changed to any one of six different settings by varying the position of the cylinder rods on the boom adapter. Refer to illustrations below.

DESCRIPTION This wrist is designed to rotate the felling head in any one of six different counterclockwise and clockwise combinations to a maximum of 110°.

NOTE: Left, right, clockwise and counterclockwise directions are as viewed by the machine operator when seated in the cab facing forward.

A wrist bearing is installed with the outer race bolted to the back of the felling head and the inner race bolted to the boom adapter.

Two hydraulic wrist cylinders are used to provide the wrist action. The base ends of the cylinders are attached to the base of the felling head frame and the rod ends are attached to the boom adapter. The boom adapter incorporates six cylinder attachment holes, three on each side of the centre line.

SAW131

1

4

2

5

3

SAW130

6

Wrist Cylinder Attachment Points

There are a total of four grease fittings on the two wrist cylinders and four for the wrist bearing. Refer to LUBRICATION POINTS in this section.

SAW132

Holes 1 & 6 – 20° CCW & 90° CW

Holes 2 & 5 – 45° CCW & 45° CW

SAW133

SAW134

Holes 3 & 4 – 90° CCW & 20° CW

Holes 1 & 5 – 20° CCW & 45° CW

SAW135

SAW136

Holes 2 & 4 – 45° CCW & 20° CW

Holes 1 & 4 – 20° CCW & 20° CW

110º Wrist Angle Combinations

2.91

Service and Maintenance

Tigercat Bunching and Felling Saws

A B

C

I

D

H G

E F

A00401

A B C D E

Wrist Bearing Outer Race Wrist Bearing Inner Race Boom Adapter Hose Guard Liner Wrist Cylinders

110° Wrist

F Shims (Install to centre the cylinder rod between the boom adapter lugs.)

G Boom Attachment Pin H Tilt Link Attachment Pin I Felling Head

2.92

Tigercat Bunching and Felling Saws

Service and Maintenance

110° WRIST HYDRAULIC CIRCUIT DESCRIPTION The components of this circuit are the pump, control valve and pilot manifold on the machine and a wrist manifold and two wrist cylinders on the felling head.

C

When a wrist clockwise or counterclockwise electrical signal is sent from a wrist button or trigger to the computer control system, the system sends an electrical signal out to the corresponding wrist solenoid on the attachment valve or on the pilot manifold. The solenoid then shifts and allows pilot pressure to shift the spool in the wrist section of the control valve

D

C

When there is no wrist clockwise or counterclockwise signal, the solenoid valve is in the de-energized position preventing pilot oil flow to the wrist spool ends.

When there is a signal from the wrist clockwise or counterclockwise control via the computer control system, the solenoid valve will be placed in the energized position directing pilot oil to shift the spool in the wrist valve section. This will direct oil from the pump to the wrist cylinders.

When the spool shifts, oil from the pump is directed to the wrist manifold. The wrist manifold divides the flow of oil to the base end of one cylinder and the rod end of the other cylinder or vice-versa to rotate the felling head either clockwise or counterclockwise.

The speed of the wrist rotation can be adjusted by varying the flow out of the wrist control valve. For instructions on setting the speed, refer to the MACHINE SERVICE MANUAL. Return oil from the cylinders is directed back through the control valve where it is returned to tank.

2.93

A

B

A00336

A B C D

110º Wrist Hydraulic Circuit

Wrist CW From Machine Control Valve Wrist CCW From Machine Control Valve Wrist Cylinders Wrist Manifold

Service and Maintenance

Tigercat Bunching and Felling Saws

340° WRIST DESCRIPTION – STANDARD TORQUE This wrist is designed to rotate the felling head a full 340°, 170° each side of the vertical position.

NOTE: Left, right, clockwise and counterclockwise directions are always as viewed by the machine operator when seated in the cab facing forward.

A wrist bearing with teeth on the outer race is attached to the back of the felling head, the inner race is attached to the boom adapter.

Three hydraulic motors are mounted to three output shaft housings which are attached to the back of the boom adapter. The hydraulic motor shaft is connected to each output shaft by splines, the pinion end of the output shafts are meshed with the gear teeth on the outer race of the wrist bearing. Running all three motors simultaneously causes the pinions on the output shafts to rotate the wrist bearing outer race and rotate the felling head. To prevent the felling head from exceeding the 340° rotation, a stop at the top of the wrist bearing spacer will make contact with a stop block positioned at the bottom of the boom adapter.

NOTE: The stop block is only a guide and will not withstand full machine loading. If an application requires full rotation, Tigercat recommends removing the stop block and using caution not to over rotate and damage hoses. It is the responsibility of the operator to respect the limits of rotation and prevent component damage.

Grease fittings are provided for lubrication of the wrist bearing and each pinion. Refer to LUBRICATION POINTS in this section.

Lubrication of the output shaft bearings is accomplished by using case drain oil from the hydraulic motors. For additional information refer to WRIST HYDRAULIC CIRCUIT DESCRIPTION– 340° STANDARD TORQUE in this section.

NOTE: Depending on the machine and head, it may be possible to hit the boom or tilt cylinder with the head tilted fully back and rotated, especially if the stop has been removed. Use caution and be aware when rotating the head.

A

A

F B

A

A00388

A Wrist Motor B Manifold C Drain and Return Manifold

E

D

C

340° Wrist – Standard Torque

D Wrist Counterclockwise E Wrist Clockwise F Case Pressure Test Port (on Output Shaft Housing)

2.94

Tigercat Bunching and Felling Saws

Service and Maintenance

A WRIST-100

Wrist Bearing Lubrication Fittings

A 3 Grease Fittings Located under the Left Wrist Motor (Cover Removed for Clarity)

A

B

D

C

E

F

G B

H

F

L

K

J

SHEAR-10b

A B C D E F

Felling Head Pinion Cover / Grease Retainer Wrist Bearing Outer Race Wrist Bearing Inner Race Boom Adapter Motor Cover

340° Wrist – Standard Torque G H I J K L

2.95

Hose Guard Hose Guard Liner Hydraulic Motor Output Shaft Assembly Hose Guide Stop Block

I

Service and Maintenance

Tigercat Bunching and Felling Saws

DESCRIPTION – HIGH TORQUE This wrist is designed to rotate the felling head a full 340°, 170° each side of the vertical position.

NOTE: Left, right, clockwise and counterclockwise directions are always as viewed by the machine operator when seated in the cab facing forward A wrist bearing with teeth on the outer race is attached to the back of the felling head, the inner race is attached to the boom adapter.

Three hydraulic motors and output shaft assemblies which are attached to the back of the boom adapter. The pinion end of the output shafts are meshed with the gear teeth on the outer race of the wrist bearing. Running all three motors simultaneously causes the pinions on the output shafts to rotate the wrist bearing outer race and rotate the felling head. To prevent the felling head from exceeding the 340° rotation, a stop at the top of the wrist bearing mounting plate will make contact with a stop block positioned at the bottom of the boom adapter.

NOTE: The stop block is only a guide and will not withstand full machine loading. If an application requires full rotation, Tigercat recommends removing the stop block and using caution not to over rotate and damage hoses. It is the responsibility of the operator to respect the limits of rotation and prevent component damage.

Grease fittings are provided for lubrication of the wrist bearing and each of the three pinions. Refer to LUBRICATION POINTS in this section.

Lubrication of the output shaft bearings is accomplished by using case drain oil from the hydraulic motors. For additional information refer to WRIST HYDRAULIC CIRCUIT DESCRIPTION– 340° HIGH TORQUE in this section.

NOTE: Depending on the machine and head, it may be possible to hit the boom or tilt cylinder with the head tilted fully back and rotated, especially if the stop has been removed. Use caution and be aware when rotating the head.

A A

F B

A

C

A00389

A Wrist Motor B Wrist Control Manifold C Drain and Return Manifold

E

D

340° Wrist – High Torque

D Wrist Counterclockwise E Wrist Clockwise F Case Pressure Test Port

2.96

Tigercat Bunching and Felling Saws

Service and Maintenance

A WRIST-100

Wrist Bearing Lubrication Fittings

A 3 Grease Fittings Located under the Left Wrist Motor (Cover Removed for Clarity)

A

B

C

D

E

F

G

B

H

F

K

J

I

FC5185-101a

A B C D E F

Felling Head Pinion Cover / Grease Retainer Wrist Bearing Outer Race Wrist Bearing Inner Race Boom Adapter Motor Cover

340° Wrist – High Torque G H I J K

2.97

Hose Guard Hose Guard Liner Hydraulic Motor Hose Guide Stop Block

Service and Maintenance 340° WRIST HYDRAULIC CIRCUIT DESCRIPTION The components of this circuit are the pump, control valve and pilot manifold on the machine. Mounted to the boom adapter are three hydraulic motors, a wrist control manifold, and a drain manifold. The wrist control manifold contains four check valves, two counterbalance valves, two shuttle valves and an optional relief and external pilot connection for the float feature. Refer to WRIST CONTROL MANIFOLD in this section.

A wrist clockwise or counterclockwise electrical signal from a wrist button or trigger is sent to the computer control system. The computer control system sends an electrical signal out to the corresponding wrist solenoid on the pilot manifold, the corresponding solenoid shifts and allows pilot pressure to shift the spool in the wrist section of the control valve.

Tigercat Bunching and Felling Saws lines to prevent cavitation For lubrication purposes a small percentage of oil is allowed to leak into the case of the motors and into the output shaft housing, filling them with hydraulic oil to lubricate the bearings. A drain line connected to each of the three output shaft housings directs surplus oil back to tank.

In addition some adjustments to the wrist can be made electronically through the computer control system. Refer to WRIST ELECTRONIC ADJUSTMENT PROCEDURE in the MACHINE SERVICE MANUAL.

When there is no wrist clockwise or counterclockwise signal, the solenoid valve is in the de-energized position preventing pilot oil flow to the wrist spool ends.

When there is a signal from the wrist clockwise or counterclockwise control via the computer control system, the solenoid valve will be placed in the energized position directing pilot oil to shift the spool in the wrist valve section. This will direct oil from the pump to the wrist motors.

The speed of rotation of the wrist action is adjustable and is controlled by spool stops in the pilot end caps of the spool section of the control valve. Turn the spool stop IN to slow down and OUT to speed up.

Refer to the MACHINE SERVICE MANUAL for instructions to set speed.

The work lines each have a check valve blocking return flow to the machine control valve.

The counterbalance valves are configured in a crossported arrangement, allowing relief flow to the opposite work line and normal return flow to the return/charge line. The return/charge line is kept at positive pressure by machine supply. Anti-cavitation check valves allow flow from the return/charge line to the work lines to keep work lines at a positive pressure to prevent cavitation and drift. The counterbalance valves also incorporate check valves to allow anti-cavitation flow to the work lines.

The counterbalance valves control the relief or holding pressure of the wrist. If a load on the head overpowers the motors, the counterbalance valve on the outlet side of the motors closes to limit the pressure, metering the oil out to provide controlled falling of the head. Relief oil and charge oil flows through the check valves to the work lines, keeping positive charge pressure on the work 2.98

Tigercat Bunching and Felling Saws

Service and Maintenance

340° WRIST CONTROL MANIFOLD VA = Oil supply A-port from machine VB = Oil supply B-port from machine A1, A2, A3 = A-ports to motors B1, B2, B3 = B-ports to motors T1 = Oil return to machine (teed to saw return at stick) CV1, CV2, CV3, CV4 = check valves CBA, CBB = counter balance valves SB, SA = shuttle valves GA, GB = gauge ports F = external pilot source to pilot open counter balance valves (optional float feature) RV = relief valve (optional float feature)

F T3 CV4

CV3

GA

49352B01

B3 B2 B1

FC5185-100

WRIST-018

Wrist Control Manifold Schematic

Wrist Control Manifold

2.99

Service and Maintenance 340° WRIST TROUBLESHOOTING KNOWN SYMPTOMS OF SPECIFIC VALVES Check valves CV2 and CV4 • Loss of rotate torque/speed and/or wrist will not hold in a position when stopped if the check valve is not seating.

Check valves CV1 and CV3 • Loss of rotate control in a runaway condition when rotating, however the wrist will hold when stopped, if the check valve is not seating.

• Wrist may jerk or bang when reversing rotate direction if the check valve isn’t initially seated when rotation begins.

Tigercat Bunching and Felling Saws 340° WRIST GENERAL SETUP PROCEDURE Follow all servicing and safety recommendations in the machine and attachment operator's and service manuals.

The general setup procedure includes: 1. START-UP PROCEDURE 2. CHECK CASE PRESSURE 3. ADJUST COUNTERBALANCE VALVE (HOLDING) PRESSURE Refer to each of the above sub-procedures for detailed instructions.

Shuttle valves SA and SB • Wrist falls over with poor control if the shuttle valves are missing or damaged.

• No wrist rotation. A stuck shuttle may prevent pilot oil from shifting the counterbalance valve open preventing rotation.

Charge pressure • Charge pressure must be maintained to maintain control. Always park head in a stable position when machine is turned OFF. Do not rely on the wrist to hold as there is no charge pressure when machine is turned OFF and saw is not running.

• The high torque motors are a cam-piston design and require positive charge pressure on both work ports to maintain control. If charge pressure is low, or if case pressure is high, the pistons will come off the cam and the motor will free-wheel, with the pistons potentially striking the cam causing a rattling sound and piston/cam damage.

SERVICE HINT Wrist Motor and Output Shaft Seal (High Torque) The pinion seal of the high torque motor is installed in a bolt-on seal retaining cap on the front of the output shaft housing. Refer to WRIST ASSEMBLY - 340° – HIGH TORQUE – MOTOR AND OUTPUT SHAFT SEAL REPLACEMENT (HIGH TORQUE WRIST) in this section. Additional motor disassembly is not required unless motor damage is suspected.

2.100

Tigercat Bunching and Felling Saws

Service and Maintenance

START-UP PROCEDURE Before beginning this procedure, motor cases and output shaft housings must be filled with clean, filtered oil and bled of trapped air. Wrist bearing and pinions must be greased.

output shaft housings before operating the attachment under load. Refer to 340° WRIST GENERAL SETUP PROCEDURE – CHECK CASE PRESSURE in THIS SECTION.

When installing a wrist assembly for the first time or after performing a major service where hydraulic hoses have been disconnected, the wrist motors and output shaft housings must be filled with hydraulic oil prior to start-up.

This can be accomplished by pressurizing the hydraulic tank. Then loosen all three drain line fittings on the output shaft housings and also the case drain plugs on the three motors. Hydraulic oil under pressure from the hydraulic tank will flow backwards through the drain lines to fill the output shaft housings and motors and bleed the air from the system. When hydraulic oil appears at the fittings, tighten the fittings. Refer to MACHINE SERVICE MANUAL for HYDRAULIC TANK PRESSURIZATION procedure (if applicable).

A

B C

D

A new wrist installation must be lubricated before being used, Refer to LUBRICATION SCHEDULE in this section.

There are two 90° fittings below the lower right hand motor. The left fitting (closest to the wrist centre) is the WRIST RETURN AND MAKEUP OIL. The right fitting (furthest from the wrist centre) is the WRIST MOTOR DRAIN CONNECTION. It is very important that the WRIST RETURN AND MAKEUP OIL and WRIST MOTOR DRAIN lines be connected correctly. If these lines are connected incorrectly failure of the wrist motors and/or wrist output shaft assemblies will occur. To verify correct connection always check case pressure in the

FC5185-004

Typical Motor and Output Shaft Case Drains– Standard Torque Wrist

A B C D

Output Shaft Housing Case Drain Connection Output Shaft Motor Case Drain Plug Wrist Motor

A

A

C

B C

E

D

E

D

WRIST-019

FC5185-009

A B C D E

B

Typical Motor and Output Shaft Case Drains– High Torque Wrist

Hose Connections

A B C D E

Wrist Clockwise Connection Wrist Anticlockwise Connection Wrist Return and Makeup Oil Wrist Motor Drain Connection Float External Pilot Connection (Optional)

2.101

Motor Housing Top Bleed Port Output Shaft Housing Output Shaft Housing Case Drain Connection Motor Case Drain Plug Wrist Motor

Service and Maintenance CHECK CASE PRESSURE

Tigercat Bunching and Felling Saws 11. Remove the gauge and wipe up any spilled oil.

Checking case pressure verifies that hose connections are correct before making wrist adjustments.

1. Get the hydraulic oil up to operating temperature.

2. Park machine on firm level ground, lower felling head to the ground, engage swing brake and turn OFF the engine. Block tracks.

A

B C

D

B

E FC5185-011

A

FC5185-008

A Case Pressure Test Port– Standard Torque Wrist, Left Output Shaft Housing B Case Pressure Test Port– High Torque Wrist, Left Motor Housing

3. Connect a 0-35 bar (0-500 psi) gauge to the case pressure test port, located on the left motor output shaft housing or the left motor housing. The wrist will be operated during this procedure, place the gauge in a location where it can be read safely.

4. Start engine and set engine speed at HIGH idle.

5. Raise head slightly off the ground and tilt forward so that head is horizontal.

WARNING The felling head will be rotated side to side during this procedure. Operator must ensure that no one is near the felling head during this procedure.

FC5185-009

A B C D E

Hose Connections

Wrist Clockwise Connection Wrist Anticlockwise Connection Wrist Return and Makeup Oil Wrist Motor Drain Connection Float External Pilot Connection (Optional)

CAUTION When installing or re-installing a 340° wrist it is very important that the WRIST RETURN AND MAKEUP OIL and WRIST MOTOR DRAIN lines be connected correctly. If these lines are connected incorrectly failure of the wrist motors and/or wrist output shaft assemblies will result.

The swing brake should be applied at all times during this procedure.

6. Rotate wrist fully counterclockwise then rotate wrist fully clockwise.

7. Case pressure reading should not be higher than 1.4 bar (20 psi). If pressure is too high check wrist motor drain connection.

8. Position head vertically 150 mm (6 in.) off the ground.

9. Case pressure reading should not be higher than 1.4 bar (20 psi). If pressure reading is 4.1 bar (60 psi) or higher check the wrist return and make up oil line for correct connection. It is likely that the wrist return and make up oil have been crossed during installation. Refer to illustration for correct hose connection information. If case pressure reading is very high it may be that the case drain line is not connected, pinched, or plugged. Recheck all connections.

10. Set engine speed at LOW idle and turn OFF the engine.

2.102

Tigercat Bunching and Felling Saws

Service and Maintenance

ADJUST COUNTERBALANCE VALVE (HOLDING) PRESSURE

9. Set wrist feed reducer for one direction.

For machines with wrist control on the attachment valve (Parker) proceed to step 1.

For machines with wrist on the main valve (Linde) refer to step 13.

Refer to the MACHINE SERVICE MANUAL for additional instructions specific to the machine.

ATTACHMENT VALVE (PARKER) SET FEED REDUCERS AND ATTACHMENT PUMP PRESSURE OVERRIDE (POR) Prior to adjusting wrist manifold counterbalance valves machine wrist section feed reducers and attachment pump POR must be temporarily adjusted. Note that temporary adjustment specifications* are different for standard torque wrists and high torque wrists for proper adjustment and wrist operation.

1. Get the hydraulic oil up to operating temperature.

2. Park machine on level ground, lower the felling head to the ground, engage the swing brake and turn OFF the engine.

3. Connect a 0-350 bar (0-5000 psi) pressure gauge to the attachment control valve 'PX' test port.

4. Connect a 0-350 bar (0-5000 psi) pressure gauge to the test port for measuring attachment pump POR. Refer to the MACHINE SERVICE MANUAL for correct attachment pump POR gauge location.

5. Start the engine and set engine speed at HIGH idle.

6. Close cab door and press pilot reset switch to activate pilot system.

7. Loosen locknuts and turn feed reducer screws on the wrist section of the attachment control valve in all the way and tighten locknuts.

8. Temporarily increase the attachment pump POR setting.

With the aid of an assistant raise the boom and rotate the felling head wrist fully to one side. While holding the joystick wrist trigger switch depressed Loosen locknut and set feed reducer screw until the pressure gauge reading meets wrist feed reducer specifications* and tighten locknut. * Wrist feed reducer settings are: • Standard Torque Wrist: 210 bar (3050 psi) • High Torque Wrist: 251 bar (3650 psi) 10. Set wrist feed reducer for the other direction.

With the aid of an assistant raise the boom and rotate the felling head wrist fully to the other side.

While holding the joystick wrist trigger switch depressed Loosen locknut and set feed reducer screw until the pressure gauge reading meets wrist feed reducer specifications* and tighten locknut.

11. Reset attachment pump POR setting so that gauge reading meets attachment pump POR specifications*. * Attachment pump POR settings are: • Standard Torque Wrist 207 bar (3000 psi ) • High Torque Wrist 248 bar (3600 psi ) 12. Set engine speed at LOW idle, turn OFF the engine and remove the gauges. Proceed to step 21.

MAIN VALVE (LINDE) SET WRIST SECTION PORT RELIEFS Prior to adjusting wrist manifold counterbalance valves machine wrist section port reliefs must be temporarily adjusted. Note that temporary adjustment specifications* are different for standard torque wrists and high torque wrists for proper adjustment and wrist operation.

13. Get the hydraulic oil up to operating temperature.

Refer to the MACHINE SERVICE MANUAL for correct attachment pump POR gauge location.

NOTE: This adjustment procedure requires the wrist stop block to be installed and in good condition.

If the stop block is missing or damaged the head rotation must be firmly supported against the ground or otherwise blocked from rotating.

With the aid of an assistant raise the boom and rotate the felling head wrist fully to one side. While holding the joystick wrist trigger switch depressed, loosen the locknut on the POR adjustment screw on the attachment pump and turn the screw in until gauge reading (Main Pressure Relief Valve Setting) is: • Standard Torque Wrist: 227 bar (3300 psi) • High Torque Wrist: 276 bar (4000 psi) 2.103

14. Park machine on level ground, lower the felling head to the ground, engage the swing brake and turn OFF the engine.

15. Connect a 0-350 bar (0-5000 psi) pressure gauge to the main control valve 'xP' test port. Refer to label on machine to verify the location of the wrist section on the main valve.

16. Start the engine and set engine speed at LOW idle.

17. Close cab door and press pilot reset switch to activate pilot system.

18. Set wrist port relief for one direction.

NOTE: This adjustment procedure requires the wrist stop block to be installed and in good condition.

If the stop block is missing or damaged the head rotation must be firmly supported against the ground or otherwise blocked from rotating.

Service and Maintenance

Tigercat Bunching and Felling Saws

With the aid of an assistant raise the boom and rotate the felling head wrist fully to one side. While holding the joystick wrist trigger switch depressed.

NOTE: This adjustment procedure requires the wrist stop block to be installed and in good condition.

If the stop block is missing or damaged the head rotation must be firmly supported against the ground or otherwise blocked from rotating.

Check gauge reading and adjust port relief valve to meet wrist section port relief specifications*. Turn adjusting screw in to increase pressure or turn screw out to decrease pressure.

With the aid of an assistant raise the boom and position head tilted forward so that the wrist is in the horizontal plane. Rotate the felling head wrist fully clockwise. While holding the joystick wrist trigger switch depressed.

* Wrist section port relief settings are: • Standard Torque Wrist: 207 bar (3000 psi ) • High Torque Wrist: 248 bar (3600 psi )

Check the gauge reading at GA and adjust counterbalance valve adjusting screw CBA.

19. Set wrist port relief for the other direction.

With the aid of an assistant raise the boom and rotate the felling head wrist fully to the other side.

While holding the joystick wrist trigger switch depressed.

A

D

Check gauge reading and adjust port relief valve to meet wrist section port relief specifications*. Turn adjusting screw in to increase pressure or turn screw out to decrease pressure.

C

20. Set engine speed at LOW idle. Turn OFF the engine and remove the gauges. Proceed to next step.

SET COUNTERBALANCE VALVE PRESSURE Prior to adjusting wrist manifold counterbalance valves, machine settings must be set as outlined above.

Note that adjustment specifications* are different for standard torque wrists and high torque wrists for proper adjustment and wrist operation.

B

WRIST-018

A B C D

22. Park machine on firm level ground, lower felling head to the ground, engage swing brake and turn OFF the engine. Block tracks.

27. Adjust counterbalance valve for counterclockwise wrist rotation.

With the aid of an assistant raise the boom and position head tilted forward so that the wrist is in the horizontal plane. Rotate the felling head wrist fully counterclockwise. While holding the joystick wrist trigger switch depressed.

NOTE: The head will be moved during this procedure so gauges must be mounted so they can be read safely by an assistant.

24. Start the engine and set engine speed at LOW idle.

NOTE: Increase engine speed slightly if pressure reading on pressure gauge is erratic.

Do not rotate wrist at LOW idle with head in a vertical position. Wrist damage and loss of control may occur at LOW idle with the head in a vertical position. Always position head tilted forward so that the wrist is in the horizontal plane when engine speed is set at LOW idle.

25. Close cab door and press pilot reset switch to activate pilot system.

Wrist Control Manifold

Turn the screw clockwise so the valve just starts to crack open and relieve (pressure on gauge starts to drop), then turn screw counterclockwise until pressure on gauge is stable (stops relieving) then turn a further 1/8 turn counterclockwise.

21. Get the hydraulic oil up to operating temperature.

23. Remove right motor cover and connect two 0-350 bar (0-5000 psi) pressure gauges to upper and lower test ports on the distribution manifold.

Test Port GB Test Port GA CBB CBA

Check the gauge reading at GB and adjust counterbalance valve adjusting screw CBB. Turn the screw clockwise so the valve just starts to crack open and relieve (pressure on gauge starts to drop), then turn screw counterclockwise until pressure on gauge is stable (stops relieving) then turn a further 1/8 turn counterclockwise.

28. Check wrist for proper operation when both counterbalance valves have been adjusted.

CBA is the clockwise adjusting valve.

26. Adjust counterbalance valve for clockwise wrist rotation.

CBB is the counterclockwise adjusting valve.

2.104

Tigercat Bunching and Felling Saws

Service and Maintenance

However when troubleshooting possible problems it may be the opposite direction that needs adjustment.

For example if the head falls counterclockwise the problem is likely with CBA and if the head falls clockwise the problem is likely to be CBB. 29. Set engine speed at LOW idle, turn OFF the engine, remove the gauges and replace covers.

2.105

Service and Maintenance

Tigercat Bunching and Felling Saws

DISASSEMBLE/ASSEMBLE OUTPUT SHAFT ASSEMBLY (340° STANDARD TORQUE WRIST) DISASSEMBLY 1. Turn OFF the saw and allow saw blade to come to a complete stop. Do not exit the cab or approach the felling head until the blade is stopped.

2. Park the machine on firm level ground. Block the wheels or tracks. Engage the parking brake or swing brake. Position the felling head tilted forward 90° and resting on ground.

NOTE: Open clamp arms sufficiently to allow felling head to be resting in a horizontal position.

A

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Ensure the saw blade has come to a complete stop.

B

5. Remove protective cover to access wrist motor.

6. Before disassembly operation, remove any accumulation of dirt or debris from surrounding area.

C

7. Disconnect all hydraulic tubing from the affected wrist motor and the output shaft housing. Plug all ports and cap tubing to prevent entry of dirt.

D

8. Remove the case drain plug from the wrist motor and drain any hydraulic oil remaining in the motor, replace plug.

9. Remove the (4) bolts securing the wrist motor to the output shaft housing and remove the wrist motor from output shaft housing. Cover exposed shaft end of motor.

SAW-D18

A B C D

NOTE: The motor shaft has no support bearings and will be loose (side to side, in and out). A loose shaft is not an indication of motor failure.

10. Remove the (8) bolts securing the output shaft housing to the boom adapter and remove the output shaft from the boom adapter.

11. Remove all grease and dirt accumulation from the outside of the assembly.

12. Remove shoulder ring, retaining ring and shims from output shaft.

13. Rest housing on blocks in upright position, pinion down and press out shaft complete with sealing collar and inner race of lower bearing.

14. Remove old oil seal (Teflon ring and O-ring) from groove of housing and discard. Never reuse any part of old seal.

15. Remove wiper from collar and discard. If only replacing the seal go to step 23 16. Remove sealing collar and lower bearing inner race from shaft.

17. Press out both upper and lower bearings from housing.

18. Thoroughly clean housing and shaft.

2.106

Motor and Output Shaft

Motor Case Drain Plug Motor Securing Bolt (x4) Output Shaft Drain Connection Output Shaft Housing Securing Bolt (x8)

Tigercat Bunching and Felling Saws

Service and Maintenance A

B

C

M

J

K

L

D E

I H

F

G

A00334

A B C D E F G

Seal O-Ring Seal Teflon Ring Output Shaft Sealing Collar Wiper Lower Bearing Upper Bearing

Output Shaft Assembly H I J K L M

Motor Mount O-Ring Motor Shaft V-Cup Seal Ring Retaining Ring Shoulder Ring Shim(s) between Shoulder Ring and Inner Race Housing

ASSEMBLY 1. Lightly oil bore of housing and press a new upper bearing into the housing. Use special tool Tigercat part number 19047A. 2. Lightly oil bore of housing and press a new lower bearing into the housing. Use special tool Tigercat part number 19047A. 3. Heat sealing collar and lower bearing inner race in a bearing oven to 120°C (250°F), do not place on floor of oven. Maximum 1.5 hours.

4. Install sealing collar and lower bearing inner race onto shaft. Press both on simultaneously by supporting inner race (using a spacer - Tigercat part number 19048A) and pressing down on pinion end of shaft.

5. Clean seal groove in housing and insert new O-ring part of seal into groove. Keep inside of housing clean and free from contaminants.

SAW127

Teflon Seal Ring Installation

6. Coat the inside surface of the new Teflon seal ring with clean, filtered hydraulic oil. Collapse ring as shown, taking care not to crease or damage it. Insert pre-formed ring into groove in housing on top of O-ring. Use seal seating tool Tigercat part number 19057A or fingers to smooth out the inside diameter of the seal ring.

7. Check wiper groove in sealing collar to ensure it is clean and dry. Insert a new wiper into the groove with lip facing out, see illustration.

8. Position housing with lower bearing facing up.

Support inner race of upper bearing with special tool Tigercat part number 19049A.

2.107

Service and Maintenance

Tigercat Bunching and Felling Saws

9. Oil Teflon seal ring surface, wiper and bearings and install output shaft into housing, lightly tap into position so that sealing collar slips into the Teflon seal ring and the wiper slips into the housing.

13. Install drain tube/fittings onto output shaft housing and fill housing with clean, filtered hydraulic oil.

A

NOTE: To prevent extrusion of the wiper, carefully push it in around the edge of the collar once it starts to engage the housing. Use only enough pressure to seat the bearings. Check to ensure the shaft is installed straight, collar clears housing and wiper is evenly positioned.

10. Install shoulder ring and retaining ring on shaft (square edge of shoulder ring next to snap ring) and check shaft end play, use feeler gauge between upper bearing inner race and shoulder ring, maximum allowable end play is 0.006”-0.010". Add or remove shims between shoulder ring and inner race to achieve correct end play. Using a soft-faced hammer gently tap the end of the shaft until the shoulder ring is snug to the snap ring.

B

SAW-D19

A

11. Turn housing over. Check sealing collar for runout.

Place the base of a dial indicator on the housing and zero the dial on the sealing collar, rotate the shaft one revolution (use tool Tigercat part number 19122A), maximum allowable run-out is 0.002”.

Repeat in different locations of the sealing collar.

C

SAW-D20

A V-Cup Seal Ring B Motor Shaft C O-Ring A

B

C

D

14. Install V-cup seal over the wrist motor shaft and into the recess in the motor housing. Install a new O-ring on the wrist motor housing.

15. Install the wrist motor on the output shaft housing.

Secure in place with (4) retaining bolts, torque bolts.

NOTE: The wrist motor should easily fit onto the output shaft housing. Any interference, gap or misalignment will result in failure of the output shaft and/or the motor. Therefore fit problems must be corrected immediately.

SAW-D17

A B C D

Outer Face of Boom Adapter Output Shaft Housing Sealing Collar Wrist Bearing

12. Clean mating surfaces and install output shaft assembly onto the boom adapter. Align gear teeth of output shaft with the gear teeth on the wrist bearing.

Use special tool Tigercat part number 19056A to rotate housing to align mounting holes. Secure in place with (8) retaining bolts, torque bolts.

16. Re-connect all hydraulic tubing and replace protective cover.

17. Fill housing and motors with oil. See INITIAL STARTUP PROCEDURE in this section.

NOTE: Ensure that the sealing collar does not protrude through the outer face of the boom adapter and interfere with the wrist bearing or grease retainers.

2.108

Tigercat Bunching and Felling Saws

Service and Maintenance

REPLACE MOTOR AND OUTPUT SHAFT SEAL (340° HIGH TORQUE WRIST)

and drain any hydraulic oil remaining in the motor, replace plug.

A leak on a low-hour motor or when the seal and bearing spacer are undamaged is likely caused by incorrect preload of the bearings in the motor and pinion assembly. Refer to BEARING PRELOAD ADJUSTMENT under ASSEMBLY in DISASSEMBLE/ASSEMBLE MOTOR AND PINION ASSEMBLY (HIGH TORQUE WRIST) in this section.

9. Install an appropriate lifting strap in the lifting bracket on the motor.

REMOVAL

11. Place motor and the output shaft assembly on blocks in upright position with the pinion facing up.

1. Park machine on firm level ground, lower felling head to the ground. Position the felling head tilted forward 90° and resting on ground.

10. Remove the (8) socket head bolts securing the motor and output shaft assembly to the boom adapter. Do not remove the 12 bolts securing the motor to the output shaft housing. Remove the motor and the output shaft assembly using a suitable lifting device.

NOTE: Open clamp arms fully to allow felling head to be resting in a horizontal position. Block head to ensure it is fully supported. Engage the swing brake and block tracks.

C

A B

2. Relieve the hydraulic pressure in the lines connected to the saw head, wrist boom adaptor and tank pressure. For procedure to relieve pressure, refer to MACHINE OPERATOR'S MANUAL.

C

3. Turn OFF the engine and turn OFF the battery disconnect switch.

4. Remove protective cover to access wrist motor(s).

Motor and Output Shaft– High Torque Wrist

5. Remove any accumulation of dirt or debris from surrounding area.

6. Mark all saw head and boom adaptor hoses, tubes and fittings to identify connections.

A

E

51733B-001

B

A Seal Housing B Bolt (x10) C Jacking Screw Location

12. Remove the (10) bolts from the seal housing, take (2) bolts and install them in the provided jacking screw locations on the seal housing. Use jacking screws to evenly remove the seal housing.

13. Remove old oil seal (Teflon ring and O-ring) from groove of housing and discard. Never re-use any part of old seal.

C

14. Clean seal housing.

15. Carefully clean any dirt, debris, and grease out of output shaft housing, do not damage the bearing spacer.

D

WRIST-019

A B C D E

Typical Motor and Output Shaft– High Torque Wrist Motor and Output Shaft Assembly Securing Bolt (x8) Output Shaft Housing Case Drain Connection Motor Case Drain Plug Lifting Bracket Wrist Motor

A

WRIST-016

7. Disconnect the wrist motor hoses from the connections on the wrist motors. Cap or plug all open hydraulic ports and hose ends to prevent entry of dirt. Collect all hydraulic oil to prevent spills.

Dispose of all fluids properly.

8. Remove the case drain plug from the wrist motor 2.109

A Sealing Surface

Bearing Spacer

16. Inspect all visible components for any sign of damage. Check that the sealing surface of the bearing spacer is smooth, polished, undamaged, and has an even wear pattern.

Service and Maintenance

Tigercat Bunching and Felling Saws

INSTALLATION

6. Install the seal housing on the output shaft housing.

Keep the seal housing square to prevent seal damage.

7. Apply anti-seize to the 10 seal housing bolts.

8. Install the bolts by hand initially. Start with 2 bolts on opposite sides. Before tightening the bolts, rotate the pinion with the rotating tool to seat the seal.

Power clip applied to grouped object

3

9

8 6 2

1 G

5

7

F

4

A

10

51733-001

A00396 A00397

A B C D E F G

E

D

C

B

Bearing Spacer Seal Teflon Ring Seal O-Ring Seal Housing Seal Housing Mounting Bolt O-ring Output shaft housing

1. Clean the seal groove in seal housing.

2.

Insert the new green O-ring part of the seal into the groove.

Bolt Tightening Pattern

9. Tighten the bolts in a cross pattern using hand tools.

Torque in 2 stages, repeating the pattern at each stage: 1. 8 N-m (6 lbf-ft) 2. 15.6 N-m (11.5 lbf-ft) 10. Clean mating surfaces and install motor and output shaft assembly onto the boom adapter. Align gear teeth of output shaft with the gear teeth on the wrist bearing. Use special tool Tigercat part number 19056A to rotate housing to align mounting holes.

Secure in place with (8) retaining bolts, torque bolts.

11. Re-connect the wrist motor hoses.

12. Before moving the saw head fill housing and motors with oil, purge all air from the 3 wrist motors and 3 output shaft housings by cracking the case port connections and pressurizing the hydraulic tank.

Refer to 340° WRIST GENERAL SETUP PROCEDURE – INITIAL START-UP PROCEDURE and CHECK CASE PRESSURE in this section.

SAW127

NOTE: Motor and output shaft failure will occur if air is not purged.

Seal Teflon Ring Installation

3. Collapse the seal Teflon ring as shown, taking care not to crease or damage it. Install the Teflon ring in the groove, on top of the O-ring. Then use your fingers to smooth out the inside diameter of the Teflon ring.

13. Replace protective covers.

4. Using clean, filtered hydraulic oil, lightly oil and install the O-ring in the groove on the face of the output shaft housing.

5. Lightly oil the sealing face of the seal ring and the outer diameter of the bearing spacer.

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Tigercat Bunching and Felling Saws

Service and Maintenance

DISASSEMBLE/ASSEMBLE MOTOR AND PINION ASSEMBLY (340° HIGH TORQUE WRIST) CAUTION

4. Carefully lift the motor cover off the outer cam ring and set it aside inverted.

5. Remove the outer cam ring and piston block from the output shaft housing.

6. Remove and discard the used O-rings.

The assembly weighs over 68 kg (150 lb). Handle with a suitable lifting device. Attach to a work bench for disassembly and assembly.

OUTPUT SHAFT HOUSING DISASSEMBLY I

Injury and equipment damage may result if the assembly is mishandled or not set up safely for work.

H

DISASSEMBLY SEAL HOUSING REMOVAL

G

Refer to the removal instructions in MOTOR AND OUTPUT SHAFT SEAL REPLACEMENT (HIGH TORQUE WRIST) in this section.

A B C

MOTOR REMOVAL F D

A B E

C A00399

A B C D E F G H I

D

A00398

A B C D

Locking Ring Bearing Adjusting Nut Lower Bearing Bearing Spacer Pinion Rotating Tool 19122A Output shaft Upper Bearing Output Shaft Housing Bearing Nut Tool 38257A

7. Install bearing nut tool 38275A on the bearing adjusting nut, then install a wrench on the nut tool.

Motor Mounting Bolt Work Port R Plug Work Port L

8. While holding the output shaft in place with pinion rotating tool 19122A, turn the wrench on the bearing nut tool counterclockwise to loosen the bearing nut.

1. Remove the 12 bolts securing the motor to the output shaft housing.

2. Remove the plug from one of the motor work ports marked L and R. 3. Insert a 5 mm Allen key through the work port to retain the distributor in the motor cover before lifting it. Either port can be used subject to the best alignment of the port and inner slot. You may have to rotate the piston block (hollow splined bore) to align the distributor slots with the Allen key.

2.111

9. Remove the locking ring and the bearing nut from the output shaft.

10. Press the output shaft out of the housing.

11. Remove and discard the bearings and O-rings.

12. Thoroughly clean the output shaft housing, output shaft, and bearing spacer (especially the O-ring groove).

13. Inspect the output shaft housing, output shaft, and bearing spacer for damage to ensure they can be reused.

Service and Maintenance

Tigercat Bunching and Felling Saws LOWER BEARING CONE INSTALLATION Power clip applied to grouped object

ASSEMBLY BEARING CUP INSTALLATION

1. If an oven will be used to heat the upper bearing cone, begin preheating now.

A

WARNING Liquid nitrogen can cause rapid suffocation and severe frostbite. Handle in accordance with the manufacturer instructions to prevent serious injury or death.

B

2. Freeze the 2 roller bearing cups (outer races) in liquid nitrogen for 1 to 2 minutes.

C

I

J

A B

D E F

C A00390

G

A Output Shaft Housing B Upper Bearing Cup C Lower Bearing Cup

3. Install the bearing cups, small inside diameter first, into the bores in the output shaft housing. Rotate the chilled cup while pushing it against the housing shoulder. Continue doing this until the cup warms enough to be tight in the housing bore. Then let the housing warm to room temperature.

4. Alternatively, press the 2 unchilled cups into the output shaft housing until they are seated against the shoulder in the housing.

5. If required, tap the cups into position using only a mild steel bar tapered to the width of the thin surface of the cup.

6. When the housing is at room temperature, use a small feeler gauge (0.001 – 0.0015 in.) to check for gaps between the cup and the housing shoulder.

The feeler gauge should not slide under the cup at any point.

If a gap exists, use the press to fully seat the cup, then re-check with the feeler gauge.

H

A00391 A00392

A B C D E F G H I J

Press Ram Press Plate Press Tube Output shaft Bearing Cage Lower Bearing Cone Bearing Spacer Press Base Backup O-Ring (2.75-in. Inner Diameter) O-Ring (3.5-in. Inner Diameter)

7. Put the bearing spacer onto the output shaft such that the O-ring groove in the spacer will point away from the pinion.

8. Press the bearing spacer onto the output shaft.

9. Install the O-ring into the groove in the bearing spacer.

10. Install the backup O-ring between the shaft and the bearing spacer.

11. Apply Loctite 518 over the stamped letters on the seating surface of the lower bearing cone. Then spread the Loctite over the surface with your finger to fill the indents.

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Tigercat Bunching and Felling Saws

Service and Maintenance

12. Lubricate the O-ring, the output shaft bearing land, and the bore of the lower bearing cone.

UPPER BEARING CONE INSTALLATION

13. Press the lower bearing cone onto the output shaft to seat the cone fully against the bearing spacer.

Do not press on or damage the cage that holds the rollers.

J

Before the cone is fully seated, stop and check the O-rings in the bearing spacer to ensure they are still installed correctly.

A B I

OUTPUT SHAFT INSTALLATION 14. Attach the housing to a work bench or mount in a fixture. The setup must allow the output shaft to turn freely and provide access to both ends of the shaft.

H

C D

A G F

E

A00394

B

A B C D E F G H I J

C

Locking Ring Bearing Adjusting Nut Output Shaft Housing Lower Bearing Cone Bearing Spacer Output shaft Groove for Seal Housing O-Ring Upper Bearing Cone Groove for Motor O-Ring Bearing Nut Tool 38257A

16. Heat the upper bearing cone in an induction heater to 250°F (121°C). If an induction heater is not available, heat the cone in an oven to 250°F (121°C) for 1– 1½ hours.

A00393

A Output Shaft Housing B Output shaft Assembly C Pinion Rotating Tool 19122A

15. Use pinion rotating tool 19122A to lever the output shaft through the bottom of the housing and into the lower bearing cup. Hold the tool in place with devices such as spacers and a bottle jack . The shaft should be able to wiggle in the housing slightly.

17. Test fit the bearing adjusting nut to ensure the threads are clean.

18. Install the heated upper bearing cone onto the output shaft and into the upper bearing cup.

19. Thread the bearing adjusting nut onto the output shaft. The smooth side of the nut is to be next to the bearing cone.

20. Using bearing nut tool 38275A and a wrench, tighten the nut until it is firmly pressing on the upper bearing cone and the shaft does not move.

21. Allow the assembly to cool to room temperature.

22. Remove the pinion rotating tool that held the shaft in place.

2.113

Service and Maintenance

Tigercat Bunching and Felling Saws

BEARING PRELOAD ADJUSTMENT

31. Clean the O-ring groove on the motor cover.

23. Install the locking ring on the shaft splines: line up the dog teeth in the ring as close as possible with the slots in the shaft, then adjust the bearing nut clockwise to engage the ring.

32. Lubricate the groove and sealing surface then install the O-ring.

A

24. Preload the bearings by 0.003 – 0.005 in. as described in this step. Preload is determined by the amount of torque needed to turn the output shaft: a. Install the bearing nut tool and torque wrench onto the bearing nut. Leave the locking ring in place. b. Use the wrench to turn the output shaft smoothly at a constant speed. Record the rolling torque measured. c.

If the rolling torque is not within 120 – 180 lbf‑in (10 – 15 lbf-ft) (13.5 – 20 N-m), adjust as follows: 1. Remove the bearing nut tool and wrench, then remove the locking ring.

2. Install the bearing nut tool and torque wrench onto the bearing nut.

3. While holding the output shaft in place with the pinion rotating tool, turn the torque wrench clockwise to tighten the bearings or counterclockwise to loosen the bearings.

4. Remove the tools.

5. Install the locking ring on the shaft splines: line up the dog teeth in the ring as close as possible with the slots in the shaft, then adjust the bearing nut clockwise to engage the ring.

6. Strike both ends of the output shaft with a soft-faced hammer to reseat the bearings.

Rotate the shaft a partial turn, and repeat the hammer strikes.

d. Repeat steps a – c until the torque to rotate the output shaft is within range.

B

A00395

Motor Cover

A Work Port R B Work Port L

33. Remove the plug from one of the motor work ports marked L and R. 34. Insert a 5 mm Allen key through the work port to retain the distributor in the motor cover before inverting it. Either port can be used subject to the best alignment of the port and inner slot.

35. Install the motor cover on the outer cam ring in the correct orientation for the motor rotation direction: • Right rotation: motor ports facing AWAY from the large curve on the housing • Left rotation: motor ports facing TOWARDS the large curve on the housing Remove the 5 mm Allen key.

36. Apply Loctite 518 to the 12 counterbores in the motor cover.

37. Apply anti-seize to the threads of the 12 motor mounting bolts.

38. Install the bolts by hand then tighten lightly.

25. Invert the housing to access the pinion side.

5

26. While turning the output shaft with the pinion rotating tool, measure with a dial indicator the runout of the bearing spacer outer diameter.

If the runout is more than 0.0015 in., the bearing spacer may not be seated square on the shaft.

In that case, disassemble to remove the spacer, reinstall, then check again.

27. Invert the housing right side up again to access the motor side.

28. Lubricate the motor O-ring then install in the groove on the housing.

29. Install the motor piston block onto the output shaft splines.

3

9

8

1

2

7

10

MOTOR INSTALLATION

11

4

12

6

WRIST-101

Bolt Tightening Pattern

39. Torque the bolts in a cross pattern in 3 stages, repeating the pattern at each stage: 1. 68 N-m (50 lbf-ft) 2. 108 N-m (80 lbf-ft)

30. Install the outer cam ring and align the bolt holes.

3. 145 N-m (107 lbf-ft) 2.114

Tigercat Bunching and Felling Saws

Service and Maintenance

40. Using a small brush, grease the seal surfaces of the housing and motor ports.

41. Install the hydraulic plugs into the motor and output shaft housing ports. Leave the case port open for testing.

42. Install a case pressure tester in the open housing port.

43. Invert the motor assembly to access the pinion side.

SHAFT SEAL HOUSING ASSEMBLY AND INSTALLATION

in the groove, on top of the O-ring. Then use your fingers to smooth out the inside diameter of the Teflon ring.

47. Using clean, filtered hydraulic oil, lightly oil and install the O-ring in the groove on the output shaft housing.

48. Lightly oil the sealing face of the Teflon ring and the outer diameter of the bearing spacer.

49. Install the seal housing on the output shaft housing.

Keep the seal housing square to prevent seal damage.

50. Apply anti-seize to the 10 seal housing bolts.

51. Install the bolts by hand then tighten lightly.

3

9

8 6

Power clip applied to grouped object

2

1 5

7 4

10

G 51733-001

F

A

Bolt Tightening Pattern

52. Torque the bolts in a cross pattern in 2 stages, repeating the pattern at each stage: A00396 A00397

A B C D E F G

E

D

C

1. 8 N-m (6 lbf-ft)

B

2. 15.6 N-m (11.5 lbf-ft) 53. Attach an air hose to the case pressure tester and pressurize to 30 psi.

Bearing Spacer Seal Teflon Ring Seal O-Ring Seal Housing Seal Housing Mounting Bolt O-ring Output Shaft Housing

54. Let stand for 10 – 15 min. If the pressure drops, inspect the shaft seal and repair or replace as required.

55. When testing is complete, release the air pressure.

44. Clean the seal groove in the seal housing.

56. Remove the test apparatus.

45. Insert the new, green O-ring part of the seal into the groove.

57. Install the case drain plug.

58. Apply grease to the housing and pinion surfaces below the mounting face.

59. Using an appropriate lifting device, remove the motor assembly from the fixture or work bench.

SAW127

Seal Teflon Ring Installation

46. Collapse the seal Teflon ring as shown, taking care not to crease or damage it. Install the Teflon ring 2.115

Service and Maintenance

Tigercat Bunching and Felling Saws

RECONFIGURE MOTOR RIGHT/LEFT ORIENTATION (340° HIGHT TORQUE WRIST) High torque wrist motor and pinion assemblies have 2 configurations: either left (one installed on the left side of the wrist) or right (two installed on the right side of the wrist). Both configurations have identical parts, the only difference between them being the motor orientation.

Therefore it is possible to convert one configuration to the other as required.

1. Place the motor and output shaft assembly on blocks in upright position with the pinion facing up.

Use an appropriate lifting strap in the lifting bracket on the motor and a suitable lifting device to position the assembly.

2. Before disassembly, remove any accumulation of dirt or debris if required.

3. Remove the 12 bolts securing the motor to the output shaft housing.

WRIST-101

Left Configuration

Right Configuration

• In the left configuration, the motor ports face the large curve on the housing.

• In the right configuration, the motor ports face away from the large curve on the housing.

8. Apply Loctite 518 (or an equivalent anaerobic sealant) to the 12 counterbores in the motor cover.

9. Apply anti-seize to the 12 motor mounting bolts.

10. Install the bolts by hand then tighten lightly.

A

5

11

3

9

B 1

2

7

10

A00395

A Work Port R B Work Port L

8

Motor Cover

4. Remove the plug from one of the motor work ports marked L and R. 5. Insert a 5 mm Allen key through the work port to retain the distributor in the motor cover before lifting it. Either port can be used subject to the best alignment of the port and inner slot. You may have to rotate the piston block (hollow splined bore) to align the distributor slots with the Allen key.

4

12

6

WRIST-101

Bolt Tightening Pattern

11. Torque the bolts in a cross pattern in 3 stages, repeating the pattern at each stage: 1. 68 N-m (50 lbf-ft) 2. 108 N-m (80 lbf-ft) 3. 145 N-m (107 lbf-ft) 12. Reinstall any fittings removed during the procedure.

6. Carefully lift the motor cover, rotate it 180°, then install it on the outer cam ring and align the bolt holes.

7. Remove the 5 mm Allen key.

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Tigercat Bunching and Felling Saws

Service and Maintenance

WRIST CYCLE TIMES The following instructions give typical cycle time and is based on recommended factory settings. It should be noted that over adjusting to provide faster cycle times could increase the stress on components and the hydraulic system.

Refer to the MACHINE SERVICE MANUAL for more detailed information regarding the wrist control valve port relief pressure settings for your machine.

ADJUST OIL FLOW TO THE WRIST (CYCLE TIME)

7. Rotate the head fully clockwise while using the stopwatch to measure the time for a full clockwise rotation.

8. Rotate the head fully counterclockwise while using the stopwatch to measure the time for a full counterclockwise rotation.

9. Adjust the cycle time as required for full stop-to-stop clockwise and counterclockwise rotations. Refer to the applicable setting in the following table: Cycle Time by Wrist Type Wrist Type

Rotation Range

30°

NOTE: Constant loosening and tightening of the locknut (seal nut) on the adjusting screws will eventually cause the seal in the nut to break down and leak. Because of this it is best to keep the adjustment procedure brief.

110°

340°

DANGER

Cycle Time in Seconds

3.5 40°

3

65°

4

90°

5

110°

6 10.5 – 11.5

Refer to the MACHINE SERVICE MANUAL for adjustment instructions.

Observe all safety precautions outlined in this manual and the MACHINE SERVICE MANUAL when performing this procedure.

A stopwatch will be required for this procedure.

1. Park machine on firm level ground, lower felling head to the ground, engage swing brake and turn OFF the engine. Block tracks.

2. Properly install the saw blade guard using all hardware provided. Guard must be secure.

3. Start engine and set engine speed at HIGH idle.

4. Get the hydraulic oil up to operating temperature.

5. Raise felling head and position head so that the wrist is in the vertical plane.

WARNING The felling head will be rotated side to side during this procedure. Operator must ensure that no one is near the felling head during this procedure.

The swing brake should be applied at all times during this procedure.

6. Rotate head fully counterclockwise.

NOTE: When rotating a 30° or 110° wrist to record the time, stop the cylinder just before it gets to the end of its stroke rather than let it bottom out and impose unnecessary loads on the cylinder parts and boom structures.

When rotating the 340° wrist, stop the wrist before it hits the stop block to prevent unnecessary loads on the wrist parts and boom structures.

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Service and Maintenance

Tigercat Bunching and Felling Saws

WRIST BEARING

5. Cut the end of the seal square with a sharp knife to form a butt joint. Bond ends of seal together with a Loctite 495 adhesive.

SEAL REPLACEMENT A seal on either side of the wrist bearing is in place to prevent entry of dust and other foreign material that would cause damage to the bearing. The seal consists of a one-piece strip long enough to go all the way around the groove.

Inspect the seal for damage during maintenance of the wrist assembly.

If a seal is damaged or is coming out of the groove it should be replaced.

1. Remove the damaged seal.

6. Wipe away any excess adhesive.

7. Apply grease to wrist bearing as outlined in felling head LUBRICATION SCHEDULE in this manual.

2. Clean the groove thoroughly. Remove all traces of old adhesive, dirt and grease. Ensure that the groove is completely dry after cleaning.

3. Apply adhesive, 3M-1300 adhesive, into the groove of the wrist bearing.

4. Start inserting the seal into the groove, make sure that the end of the seal is cut square. Work around the diameter pressing the seal all the way into the groove. The seal should be even without any bumps.

A

A

B C C SAW128 SAW-D21

A Wrist Bearing Seal B Inner Race C Outer Race

Wrist Bearing Assembly

2.118

A

B

Tigercat Bunching and Felling Saws

Service and Maintenance

WRIST BEARING WEAR LIMITS

WEAR LIMITS (340° WRIST)

It is important that the wrist bearing be periodically inspected for wear. Any significant wear will be noticeable by observing the attachment’s movement. A small amount of clearance in the bearing is normal and is present in a new attachment.

RADIAL CLEARANCE NOTE: Radial clearance in a bearing can only be measured with the bearing laying flat on a table.

New bearing = 0.004” maximum

Too much clearance will affect the backlash between the ring gear and the drive pinion for the 340° wrist. If left unchecked, this will cause damage to the gear teeth.

When the bearing needs replacement = 0.083”

The main cause of wear in the ball race can be due to a lack of lubricant or not following the proper lubricating procedure. A damaged or missing peripheral seal will also contribute to early wear by allowing dirt particles to enter the ball race.

New bearing = 0.006” maximum

Regular inspection of the seal should be carried out and the proper lubricating procedure should be followed, refer to LUBRICATION SCHEDULE in this manual.

TILT CLEARANCE When the bearing needs replacement = 0.108”

WEAR LIMITS (30° AND 110° WRISTS) RADIAL CLEARANCE NOTE: Radial clearance in a bearing can only be measured with the bearing laying flat on a table.

New bearing = 0.010” maximum When the bearing needs replacement = 0.112” TILT CLEARANCE New bearing = 0.010” maximum When the bearing needs replacement = 0.112”

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Service and Maintenance

Tigercat Bunching and Felling Saws

RADIAL CLEARANCE CHECK

TILT CLEARANCE CHECK

NOTE: Radial clearance in a bearing can only be measured with the bearing laying flat on a table.

1. Position the saw or shear fully suspended on the machine’s boom.

1. Using a C-clamp, clamp the inner and outer races together.

2. Mount a dial indicator base on the outer race and the indicator on the bore of the inner race in line with the clamp. Zero the dial indicator.

3. Using a second C-clamp, snuggly clamp the inner and outer races together directly opposite (180°) the first clamp.

4. Gradually loosen the first clamp and tighten the second clamp.

5. Read and record the dial indicator reading when the races are fully tightened the opposite way.

6. Move the clamps and dial indicator 90° and repeat the procedure.

2. Set the base of the dial indicator on the boom adapter and the indicator against the rear surface of the saw or shear. This location should be on the vertical at the highest point close to the bearing as illustrated. Zero the dial indicator.

An alternative location may be at the lowest point, where the base of the dial would require support.

3. Lower the boom and apply pressure to the saw or shear.

4. Read and record the dial indicator reading.

5. Rotate the head 90° or fully in one direction, whichever is less and repeat the procedure.

6. Average both readings for the tilt clearance.

7. Average both readings for the radial clearance.

A C

A

B

B C

D

SAW161

A B C D

Inner Race Outer Race C-Clamp Dial Indicator

SAW160

A Saw Rear Surface B Boom Adapter C Dial Indicator

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Tigercat Bunching and Felling Saws

19048AIL

Service and Maintenance

19047AIL

19049AIL

A

19057AIL

C

B

19122AIL

D

19056AIL

19051AIL

F

E

G

38257A

H

A B C D

Wrist Assembly – Special Tools Available from Tigercat

Seal Ring Assembly Tool (Part # 19048A) Shaft Assembly Bearing Support Tool (Part # 19049A) Bearing Assembly Tool, Double (Part # 19047A) Rotary Seal Assembly Tool (Part # 19057A)

E F G H

2.121

Seal Ring Removal Tool (Part #19051A) Pinion Rotating Tool (Part # 19122A) Housing Alignment Tool (Part # 19056A) Bearing Nut Tool (Part # 38257A)

Service and Maintenance

Tigercat Bunching and Felling Saws

2.122